WO2021073272A1 - Radiation-resistant small-cross-section high-voltage direct-current cable for nuclear power plant and manufacturing method therefor - Google Patents

Radiation-resistant small-cross-section high-voltage direct-current cable for nuclear power plant and manufacturing method therefor Download PDF

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WO2021073272A1
WO2021073272A1 PCT/CN2020/111930 CN2020111930W WO2021073272A1 WO 2021073272 A1 WO2021073272 A1 WO 2021073272A1 CN 2020111930 W CN2020111930 W CN 2020111930W WO 2021073272 A1 WO2021073272 A1 WO 2021073272A1
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zone
semi
cable
conductive shielding
metal
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PCT/CN2020/111930
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French (fr)
Chinese (zh)
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金华东
狄洪杰
梁福才
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江苏上上电缆集团有限公司
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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
    • 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
    • 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
    • H01B13/06—Insulating conductors or cables
    • H01B13/14—Insulating conductors or cables by extrusion
    • 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
    • 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
    • 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
    • H01B7/18—Protection against damage caused by wear, mechanical force or pressure; Sheaths; Armouring
    • 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
    • H01B7/18—Protection against damage caused by wear, mechanical force or pressure; Sheaths; Armouring
    • H01B7/182—Protection against damage caused by wear, mechanical force or pressure; Sheaths; Armouring comprising synthetic filaments
    • H01B7/1825—Protection against damage caused by wear, mechanical force or pressure; Sheaths; Armouring comprising synthetic filaments forming part of a high tensile strength core
    • 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
    • H01B7/18—Protection against damage caused by wear, mechanical force or pressure; Sheaths; Armouring
    • H01B7/22—Metal wires or tapes, e.g. made of steel
    • H01B7/221—Longitudinally placed metal wires or tapes
    • H01B7/223—Longitudinally placed metal wires or tapes forming part of a high tensile strength core
    • 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
    • H01B7/28—Protection against damage caused by moisture, corrosion, chemical attack or weather
    • 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
    • H01B7/29—Protection against damage caused by extremes of temperature or by flame
    • H01B7/295—Protection against damage caused by extremes of temperature or by flame using material resistant to flame
    • 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

Definitions

  • the technical solution belongs to the technical field of cables for nuclear power plants, and specifically relates to a radiation-resistant small-section high-voltage direct current cable for nuclear power plants and a manufacturing method thereof.
  • the working conditions in the containment of third- and fourth-generation nuclear power plants are more severe than those of previous second-generation power plants, and the working conditions after a nuclear safety accident are even worse.
  • high-dose irradiation, high temperature, high pressure, high acid and high alkali solution, etc. in this environment, the cable needs to perform its specific function.
  • the cable due to the unpredictable time of the accident, the cable also needs to have the ability to simulate thermal aging and radiation aging. That is, no matter in normal operating conditions or accident conditions, the cables can normally transmit current and signals during the 60-year life of the nuclear power plant.
  • the power input is in the form of high-voltage direct current.
  • Laying and using in the congested and narrow space of nuclear power plant not only requires the cable to have low-smoke, halogen-free and flame-retardant properties, but also requires the cable to have aging resistance, radiation resistance, high temperature resistance, high pressure resistance, good flexibility, small outer diameter, high voltage output, etc.
  • a method for manufacturing a radiation-resistant small cross-section high-voltage DC cable for nuclear power plants The nominal cross-section of the cable conductor ranges from 4 to 10 mm 2.
  • the structure of the cable is: the structure of the cable is: from the inside to the outside, the conductor and the inner half are in order.
  • the manufacturing steps of the cable include:
  • Bundle a high-strength aramid filament and multiple metal monofilaments made of tin-plated copper to form a conductor;
  • the metal monofilament is divided into multiple layers from the inside to the outside; two adjacent metal monofilaments in each metal monofilament are closely attached to each other; in two adjacent metal monofilaments, the inner and outer metal monofilaments are closely attached ;
  • the stranding direction of the metal monofilament is left, and the stranding pitch of the metal monofilament is not more than 16 times the outer diameter after the stranding;
  • the semi-conductive shielding material and insulating material are wrapped around the conductor by double-layer extrusion and cooled to form an inner semi-conductive shielding layer and insulating layer;
  • the semi-conductive shielding material is a semi-conductive insulating shielding material, and the insulating material is a resistive material. Fire ethylene propylene rubber insulation material;
  • the temperature zone of the extruder is: zone one 68 ⁇ 73°C, zone two 76 ⁇ 81°C, zone three 88 ⁇ 94°C, zone four 96 ⁇ 100 °C;
  • the temperature zone of the extruder is: 60 ⁇ 70°C in the first zone, 65 ⁇ 75°C in the second zone, 70 ⁇ 80°C in the third zone, 75 ⁇ 85°C in the fourth zone;
  • the first zone of the rubber extruder is the feeding section, the second and third zones are the plasticizing section, and the fourth zone is the homogenizing section;
  • the temperature zone of the extruder's nose is: 80 ⁇ 90°C in the first zone, 75 ⁇ 85°C in the second zone; among them, the first zone is the nose section and the second zone is the neck section;
  • the saturated steam pressure is maintained at 1.5 ⁇ 1.7MPa, and the water level is controlled between 20% ⁇ 30%;
  • the semi-conductive shielding tape is wrapped around the insulating layer to form an outer semi-conductive shielding layer by overlapping wrapping, the wrapping overlap rate is not less than 15%, and the thickness of the semi-conductive shielding tape is 0.12mm ⁇ 0.15mm;
  • the polyimide film is wrapped around the metal mesh by overlapping wrapping, the wrapping overlap rate is not less than 25%, and the thickness of the polyimide film is 0.025mm ⁇ 0.05mm;
  • Adopt continuous vulcanization method to uniformly and tightly squeeze the low-smoke halogen-free flame-retardant sheath material outside the cable core and cool it;
  • the sheath material is a thermosetting, low-smoke, halogen-free, flame-retardant EVA mixture, and its oxygen index is not less than 30%; a sheath die sleeve is equipped on the extruder machine-reading head; the diameter of the sheath die sleeve is larger than the outer diameter of the cable core; When the material reaches the direction of discharging, the temperature distribution of each zone of the extruder is: zone 1 50 ⁇ 60°C, zone 2 55 ⁇ 65°C, zone 3 60 ⁇ 70°C, zone 4 65 ⁇ 75°C, among which, zone 1 is In the feeding section, the second and third zones are the plasticizing section, and the fourth zone is the homogenizing section;
  • the temperature zone of the extruder head is: 65 ⁇ 80°C in the first zone, 70 ⁇ 90°C in the second zone, 70 ⁇ 80°C in the third zone; among them, the first zone is the head section and the second zone. It is the neck section of the machine, and the three zones are the die mouth section;
  • the saturated steam pressure is maintained at 1.4 ⁇ 1.6MPa, and the water level is controlled at 20% ⁇ 25%.
  • the temperature zone of the extruder's body is: zone one 70°C, zone two 78°C, zone three 91°C, zone four 98°C;
  • the temperature zone of the extruder's body is: 65°C in the first zone, 70°C in the second zone, 75°C in the third zone, and 80°C in the fourth zone;
  • the temperature zone of the extruder's head is: 85°C in the first zone, and two Zone 80°C;
  • the saturated steam pressure is maintained at 1.6MPa during insulation extrusion;
  • the temperature zone of the rubber extruder is: 55°C in the first zone, 60°C in the second zone, 65°C in the third zone, and 70°C in the fourth zone; °C, 80°C in the second zone and 75°C in the third zone; the saturated steam pressure is maintained at 1.5MP during sheath extrusion.
  • the semi-conductive shielding tape is prefabricated from a semi-conductive shielding material, and the nominal thickness of the semi-conductive shielding tape is 0.12 mm.
  • the tin-plated metal wire is braided outside the outer semiconductive shielding layer to form a metal mesh; the braiding coverage is not less than 80%; the nominal diameter of the tin-plated metal wire is 0.12 mm to 0.20 mm.
  • the best braided wire for tinned metal wire is 0.15mm.
  • the copper metal tape is wrapped over the outer semiconductive shielding layer, and the wrapping overlap rate is not less than 15%; the nominal thickness of the copper metal tape is 0.1mm-0.12mm.
  • the thickness of the polyimide film is 0.025 mm.
  • the core diameter of the sheath mold sleeve the outer diameter of the cable core + 0.5 mm.
  • a radiation-resistant high-voltage DC cable with a small cross-section for nuclear power plants which is made by the above method;
  • the nominal cross-section range of cable conductor is 4 ⁇ 10mm 2 .
  • the structure of the cable is: from the inside to the outside, it is a conductor, an inner semi-conductive shielding layer, an insulating layer, an outer semi-conductive shielding layer, a metal shielding layer, a polyimide film layer and a sheath;
  • the structure of the conductor is as follows: a high-strength aramid filament (breaking strength not less than 1269N) and a plurality of tinned copper monofilament bundles constitute the conductor; the aramid filament is at the axis of the conductor; the monofilament is self-contained It is divided into multiple layers from the inside to the outside; the bundle direction of the monofilament is left; the bundle pitch of the monofilament is not more than 16 times the bundled outer diameter;
  • the inner semi-conductive shielding layer and the insulating layer are composed of a double-layer co-extruded semi-conductive shielding material and insulating material;
  • the outer semi-conductive shielding layer is composed of overlapping wrapped semi-conductive shielding tape, and the wrapping overlap rate is not less than 15%; the thickness of the semi-conductive shielding tape is 0.12mm ⁇ 0.15mm;
  • the polyimide film layer is composed of overlapping and wrapping polyimide films; the thickness of the polyimide film is 0.025mm ⁇ 0.05mm, and the wrapping overlap rate is not less than 25%.
  • a radiation-resistant, small-section, high-voltage DC cable for nuclear power plants Its structure is as follows: a high-strength aramid wire and multiple tin-plated copper metal monofilaments are bundled to form a conductor; the conductor is extruded with semi-conductive shielding material and insulation Material; the insulating layer is wrapped with a semi-conductive shielding tape to form the wire core; the wire core is wrapped with a metal shielding layer (wire braided mesh or wrapped metal tape) and polyimide film to form a cable core; the cable core is wrapped with low-smoke and halogen-free Flame-retardant materials constitute the cable sheath.
  • Polyimide film has the characteristics of high insulation performance, high temperature resistance, radiation resistance, and aging resistance, which improves the service life of the cable.
  • the polyimide film has a thickness of 0.025 mm, and the wrapping overlap rate is not less than 25%.
  • Semi-conductive shielding material and insulating material are tightly packed on the surface of the conductor.
  • the semi-conductive shielding material is XPB-30A.
  • the material of the insulation layer is ethylene-propylene rubber insulation, with a life span of 60 years, nuclear radiation resistance, low smoke, halogen-free, non-toxic, flame retardant and thermosetting properties.
  • the insulating layer is wrapped with a layer of semi-conductive shielding tape by overlapping wrapping.
  • the requirements of the semi-conductive shielding material are: certain conductivity, aging resistance, low smoke, halogen-free, flame retardant and other characteristics.
  • the outer semi-conductive shielding layer adopts a metal shielding layer (tinned metal wire is woven into a metal mesh, and the material of the metal woven mesh is required to be: high conductivity, corrosion resistance, high mechanical strength and tensile strength).
  • a polyimide film is used as an auxiliary insulating layer to wrap the polyimide film outside the woven wire mesh by overlapping wrapping.
  • the polyimide film material is: high temperature resistance above 600°C, long-term use temperature range -200 ⁇ 300°C, high insulation performance.
  • the main function of this layer is to assist the outer sheath layer to resist high-dose gamma and beta radiation together, and to retain a certain insulation resistance and ensure the normal transmission of current under high temperature and high pressure accident conditions.
  • the sheath is uniformly and tightly squeezed out of the cable core; the sheath material of the sheath is: nuclear radiation resistance, low smoke, halogen-free, non-toxic, oil-resistant, flame-retardant and thermosetting.
  • the sheath can further block the transmission of harsh environments such as high temperature, high pressure, high dose gamma and beta rays to the insulation.
  • the cable can be used on some inspection equipment of third and fourth generation nuclear power plants. It is suitable for EPR, AP1000, CAP1600, Hualong No. 1 nuclear power plant containment, outside the containment, and conventional islands. Use of specific inspection equipment in the area.
  • the present invention proposes a manufacturing method dedicated to the cable.
  • a method for manufacturing the above-mentioned cable for a nuclear power plant the steps include:
  • the three-layer structure of the inner and outer semi-conductive shielding layer and insulating layer of the cable generally adopts single-layer extrusion or three-layer co-extrusion.
  • this cable adopts double-layer co-extrusion + wrapping technology
  • the semi-conductive shielding layer can homogenize the electric field strength
  • the insulating layer plays an effective electrical isolation role to ensure the good running performance of the cable.
  • the insulating layer can meet the following properties:
  • the semi-conductive shielding tape is wrapped around the insulation by overlapping wrapping, and the wrapping overlap rate is not less than 15%.
  • the thickness of the semi-conductive shielding material is 0.12mm ⁇ 0.15mm. This layer of semi-conductive shielding can also homogenize the electric field strength and ensure the distribution of the electric field strength of the cable.
  • the high-voltage resistance and partial discharge performance of the cable are greatly improved compared with the original performance after the semi-conductive shielding material is overlapped and wrapped around the insulation.
  • the partial discharge of the cable has dropped significantly, from 50pC to 20pC.
  • the ability of the cable to pass the DC withstand voltage is improved, and the cable can withstand the 60kV DC withstand voltage test for 15 minutes without breakdown after adding overlapping wrapping semi-conductive shielding materials.
  • the mechanical properties of the cable tensile strength ⁇ 9.0MPa, elongation at break ⁇ 200%; flame-retardant performance: meet the requirements of GB/T18380.12 for a single cable to be flame-retardant.
  • the cable prepared by this method can meet the design requirements, and at the same time, the pass rate can reach more than 99%.
  • Figure 1 is a schematic diagram of a radial cross-section of the cable of this embodiment
  • a radiation-resistant small cross-section high-voltage DC cable for nuclear power plants a high-strength aramid wire and multiple tin-plated copper metal monofilaments are bundled to form a conductor; the conductor is wrapped with semi-conductive shielding materials and insulating materials Form the core; the insulating surface wraps the semi-conductive shielding material to form the outer semi-conductive shielding layer; the outer semi-conductive shielding layer uses high-speed braiding equipment to weave the metal wire into a metal mesh to wrap the surface of the core; the polyimide is wrapped by wrapping The film is wrapped on the surface of the metal mesh to form the cable core; the cable core is wrapped with a low-smoke, halogen-free flame-retardant sheath material;
  • the lay length of the tin-plated copper metal monofilament bundle is not more than 16 times the outer diameter of the conductor after the bundle, and a high-strength aramid wire improves the tensile strength of the conductor.
  • the insulating layer and the inner and outer semi-conductive shielding layers can ensure the ability of the cable to withstand high voltage shocks.
  • the insulated wire core is wrapped with metal wire woven mesh and polyimide film, which can lead the cable to a larger short-circuit current protection system in the event of a fault.
  • the polyimide film has high insulation performance, high temperature resistance, radiation resistance, The characteristics of aging resistance improve the service life of the cable.
  • the sheath material requirements for cables are: nuclear radiation resistance, low smoke, halogen-free, non-toxic, oil-resistant, flame-retardant and thermosetting. The sheath is evenly and tightly squeezed out of the cable core.
  • the insulating material uses ethylene-propylene rubber insulating material
  • the inner and outer semi-conductive shielding layers are used as auxiliary insulating layers
  • the sheath material is a thermosetting EVA mixture.
  • the manufacturing steps of the cable include:
  • Bundle a high-strength aramid filament and multiple metal monofilaments made of tin-plated copper to form a conductor;
  • the metal monofilament is divided into multiple layers from the inside to the outside; two adjacent metal monofilaments in each metal monofilament are closely attached to each other; in two adjacent metal monofilaments, the inner and outer metal monofilaments are closely attached ;
  • the stranding direction of the metal monofilament is left, and the stranding pitch of the metal monofilament is not more than 16 times the outer diameter after the stranding;
  • the semi-conductive shielding material and insulating material are wrapped around the conductor by a double-layer extrusion method, and cooled to form an inner semi-conductive shielding layer and an insulating layer;
  • the semi-conductive shielding material is a semi-conductive insulating shielding material XPB -30A
  • the insulating material is flame-retardant ethylene propylene rubber insulating material
  • the temperature zone of the extruder is: zone one 68 ⁇ 73°C, zone two 76 ⁇ 81°C, zone three 88 ⁇ 94°C, zone four 96 ⁇ 100 °C;
  • the temperature zone of the extruder is: 60 ⁇ 70°C in the first zone, 65 ⁇ 75°C in the second zone, 70 ⁇ 80°C in the third zone, 75 ⁇ 85°C in the fourth zone;
  • the first zone of the rubber extruder is the feeding section, the second and third zones are the plasticizing section, and the fourth zone is the homogenizing section;
  • the temperature zone of the extruder's nose is: 80 ⁇ 90°C in the first zone, 75 ⁇ 85°C in the second zone; among them, the first zone is the nose section and the second zone is the neck section;
  • the saturated steam pressure is maintained at 1.5 ⁇ 1.7MPa, and the water level is controlled between 20% ⁇ 30%;
  • the semi-conductive shielding tape is wrapped around the insulating layer to form an outer semi-conductive shielding layer by overlapping wrapping, the wrapping overlap rate is not less than 15%, and the thickness of the semi-conductive shielding tape is 0.12mm ⁇ 0.15mm;
  • the polyimide film is wrapped around the metal mesh by overlapping wrapping, the wrapping overlap rate is not less than 25%, and the thickness of the polyimide film is 0.025mm ⁇ 0.05mm;
  • Adopt continuous vulcanization method to uniformly and tightly squeeze the low-smoke halogen-free flame-retardant sheath material outside the cable core and cool it;
  • the sheath material is a thermosetting, low-smoke, halogen-free, flame-retardant EVA mixture, and its oxygen index is not less than 30%; a sheath die sleeve is equipped on the extruder machine-reading head; the diameter of the sheath die sleeve is larger than the outer diameter of the cable core; When the material reaches the direction of discharging, the temperature distribution of each zone of the extruder is: zone 1 50 ⁇ 60°C, zone 2 55 ⁇ 65°C, zone 3 60 ⁇ 70°C, zone 4 65 ⁇ 75°C, among which, zone 1 is In the feeding section, the second and third zones are the plasticizing section, and the fourth zone is the homogenizing section;
  • the temperature zone of the extruder head is: 65 ⁇ 80°C in the first zone, 70 ⁇ 90°C in the second zone, 70 ⁇ 80°C in the third zone; among them, the first zone is the head section and the second zone. It is the neck section of the machine, and the three zones are the die mouth section;
  • the saturated steam pressure is maintained at 1.4 ⁇ 1.6MPa, and the water level is controlled at 20% ⁇ 25%.
  • the bundled equipment is a fully automatic stranding machine from Niehofer, Germany.
  • the conductor structure is completed by a total of 3 layers of bundles. It is arranged in a 1+6+12 structure, and one is placed in the center. 6320 high-strength aramid yarns, 3 to 4 metal wires are placed in 18 holes in the outer layer to be bundled, the bundle direction is left, the bundle pitch is 40 ⁇ 3mm, the traction grade is 8, and the bundle is bundled.
  • the pitch is not more than 16 times the outer diameter after beaming.
  • Extrusion adopts the German Trest continuous vulcanization production line.
  • the temperature zone of the extruder is: 60 ⁇ 70°C in the first zone, 65 ⁇ 75°C in the second zone, 70 ⁇ 80°C in the third zone, and 75 in the fourth zone. ⁇ 85°C;
  • the temperature zone of the extruder's head is: 80 ⁇ 90°C in the first zone, 75 ⁇ 85°C in the second zone; the saturated steam pressure is maintained at 1.5 ⁇ 1.7MPa during insulation extrusion;
  • the traction speed is 18-22m/min, and the eccentricity is not more than 20%.
  • the semi-conductive shielding tape is wrapped on the surface of the insulating layer by overlapping wrapping, and the wrapping overlap rate is not less than 15%.
  • the thickness of the semi-conductive shielding tape is 0.12mm ⁇ 0.15mm.
  • the tinned metal wire is woven into a metal mesh by weaving and covers the surface of the core.
  • the braiding coverage is not less than 80%.
  • the nominal diameter of tinned metal wire is 0.12mm ⁇ 0.20mm.
  • the polyimide film is wrapped around the metal mesh by overlapping wrapping, and the wrapping overlap rate is not less than 25%.
  • the thickness of the polyimide film is 0.025mm ⁇ 0.05mm.
  • a layer of low-smoke halogen-free flame-retardant sheath is uniformly and tightly extruded outside the cable core by continuous vulcanization, and cooled:
  • Zone 1 50 ⁇ 60°C, Zone 2 55 ⁇ 65°C, Zone 3 60 ⁇ 70°C, Zone 4 65 ⁇ 75°C, of which: 1 Zone is the feeding section, Zone 2 and Zone 3 are the plasticization section, and Zone 4 is the homogenization section;
  • the temperature zone of the extruder head is: 65 ⁇ 80°C in the first zone, 70 ⁇ 90°C in the second zone, 70 ⁇ 80°C in the third zone;
  • the saturated steam pressure is maintained at 1.4 ⁇ 1.6MPa, and the water level is controlled at 20% ⁇ 25%.
  • the sheath traction speed is 15m/min, and the eccentricity is not more than 20%.
  • step 3 the semi-conductive shielding material is extruded outside the surface of the insulated core by means of extrusion, with a nominal thickness of 1.0 mm.
  • Example 1 The difference from Example 1 is only in the step 4): the copper metal tape is wrapped on the surface of the insulated wire core by overlapping wrapping, and the wrapping overlap rate is not less than 15%.
  • the nominal thickness of copper metal strip is controlled within 0.1mm ⁇ 0.12mm.
  • Example 1 has the highest yield rate of cables, reaching 99.3%, Example 2 reaching 98.7%, and Example 3 reaching 98.9%. It can be seen from this result that for the outer semi-conductive shielding layer, the process of wrapping the semi-conductive shielding tape in Example 1 is 0.6% higher than the process of extruding the semi-conductive shielding material in Example 2. And Example 3 also adopts the process of wrapping semi-conductive shielding tape, and its yield rate is also higher than that of Example 2.
  • Example 1 the main difference is the metal braid and the metal belt. From the bending performance of the cable, the structure of Example 1 is naturally due to the structure of Example 3. Since the cable structure has inner and outer semi-conductive shielding layers, and a metal wire mesh with a suitable structure, its shielding performance can meet the requirements of use.
  • the cable was prepared using the method of Example 1 for testing.
  • the tinned metal wire braided wire is 0.15mm
  • the thickness of the polyimide film is 0.025mm
  • the nominal thickness of the semi-conductive shielding tape is 0.12mm.
  • the temperature zone of the extruder's body is: zone one 70°C, zone two 78°C, zone three 91°C, zone four 98°C;
  • the temperature zone of the extruder's body is: 65°C in the first zone, 70°C in the second zone, 75°C in the third zone, and 80°C in the fourth zone;
  • the temperature zone of the extruder's head is: 85°C in the first zone, and two Zone 80°C;
  • the saturated steam pressure is maintained at 1.6MPa during insulation extrusion;
  • Step 6) Parameters:
  • the temperature zone of the extruder's body is: 55°C in the first zone, 60°C in the second zone, 65°C in the third zone, and 70°C in the fourth zone;
  • the extruder's head temperature zone is: 75°C in the first zone,
  • the second zone is 80°C and the third zone is 75°C;
  • the saturated steam pressure is maintained at 1.5MP when the jacket is extruded.
  • the finished cables passed the AC withstand voltage test of 21kV*5 minutes and the DC withstand voltage test of 60kV*15 minutes.
  • the finished cable's gamma-ray radiation dose has reached 1000kGy
  • the finished cable After a third-party type test, the finished cable has a heat-resistant aging life of more than 60 years.
  • the finished cable meets the vertical burning test of a single cable specified in GB/T18380.12.

Abstract

A manufacturing method for a radiation-resistant small-cross-section high-voltage direct-current cable for a nuclear power plant, the nominal cross-sectional area range of a conductor of the cable is 4 to 10 mm 2. The cable has a structure comprising: a conductor, an inner semi-conductive shielding layer, an insulation layer, an outer semi-conductive shielding layer, a metal shielding layer, a polyimide film layer and a sheath in sequence from inside to outside. The manufacturing steps of the cable comprise: (1) manufacturing a conductor; (2) wrapping a semi-conductive shielding material and an insulation material outside the conductor in a double-layer extruding manner; (4) wrapping a metal shielding layer outside an outer semi-conductive shielding layer; (5) wrapping a polyimide film outside a metal mesh in an overlapping wrapping manner; and (6) evenly and tightly extruding a low-smoke zero-halogen flame-retardant sheath material outside a cable core in a continuous vulcanization manner, and cooling same, the sheath material being a thermosetting low-smoke zero-halogen flame-retardant EVA mixture, and the oxygen index thereof being not less than 30%. The cable manufactured by using the method can meet design requirements and has a high pass rate.

Description

一种核电站用耐辐射的小截面高压直流电缆及其制造方法Radiation-resistant small-section high-voltage DC cable for nuclear power station and manufacturing method thereof 技术领域Technical field
本技术方案属于核电站用电缆技术领域，具体是一种核电站用耐辐射的小截面高压直流电缆及其制造方法。The technical solution belongs to the technical field of cables for nuclear power plants, and specifically relates to a radiation-resistant small-section high-voltage direct current cable for nuclear power plants and a manufacturing method thereof.
背景技术Background technique
日本福岛核电站事件以后，国内、外核电站的建设更专注安全冗余的保障，更安全、环保的三代、四代核电技术得到广泛的运用，核电站用电缆、核电站配套设备用电缆迎来了新的发展。After the Fukushima nuclear power plant incident in Japan, the construction of domestic and foreign nuclear power plants has focused more on the guarantee of safety and redundancy. The safer and more environmentally friendly third- and fourth-generation nuclear power technologies have been widely used. The cables for nuclear power plants and the cables for nuclear power plants have ushered in new developments. development of.
三代、四代核电站安全壳内工况较以往二代电站更为严酷，发生核安全事故后的工况更是无比恶劣。比如高剂量辐照、高温、高压、高酸高碱溶液等，在此环境中电缆需要执行其特定的功能。同时，由于事故的发生时间不可预估，让电缆还需要具备通过模拟热老化和辐照老化的能力。即无论在正常工况还是在事故工况下，核电站60年寿期内电缆都能正常传输电流和信号。The working conditions in the containment of third- and fourth-generation nuclear power plants are more severe than those of previous second-generation power plants, and the working conditions after a nuclear safety accident are even worse. For example, high-dose irradiation, high temperature, high pressure, high acid and high alkali solution, etc., in this environment, the cable needs to perform its specific function. At the same time, due to the unpredictable time of the accident, the cable also needs to have the ability to simulate thermal aging and radiation aging. That is, no matter in normal operating conditions or accident conditions, the cables can normally transmit current and signals during the 60-year life of the nuclear power plant.
此外，对于核电站中某些特殊的检查设备，其动力输入为高压直流形式。在核电站拥挤狭小空间内敷设使用，不仅要求电缆具备低烟无卤阻燃特性，还需要电缆具备耐老化、耐辐照、耐高温、耐高压、柔软度好、外径小、高电压输出等特点。In addition, for some special inspection equipment in nuclear power plants, the power input is in the form of high-voltage direct current. Laying and using in the congested and narrow space of nuclear power plant not only requires the cable to have low-smoke, halogen-free and flame-retardant properties, but also requires the cable to have aging resistance, radiation resistance, high temperature resistance, high pressure resistance, good flexibility, small outer diameter, high voltage output, etc. Features.
发明内容Summary of the invention
为了解决现有技术中存在的上述问题，本技术方案提出：In order to solve the above-mentioned problems in the prior art, this technical solution proposes:
一种核电站用耐辐射的小截面高压直流电缆的制造方法，电缆导体标称截面范围为4～10mm 2，所述电缆的结构为：电缆的结构为：自内而外依次是导体、内半导电屏蔽层、绝缘层、外半导电屏蔽层、金属屏蔽层、聚酰亚胺薄膜层和护套； A method for manufacturing a radiation-resistant small cross-section high-voltage DC cable for nuclear power plants. The nominal cross-section of the cable conductor ranges from 4 to 10 mm 2. The structure of the cable is: the structure of the cable is: from the inside to the outside, the conductor and the inner half are in order. Conductive shielding layer, insulating layer, outer semi-conductive shielding layer, metal shielding layer, polyimide film layer and sheath;
所述电缆的制造步骤包括：The manufacturing steps of the cable include:
1)制造导体：1) Manufacturing conductor:
选择镀锡铜作为导体材质；Choose tinned copper as the conductor material;
把一根高强度的芳纶丝和多根镀锡铜材质的金属单丝束合构成导体；Bundle a high-strength aramid filament and multiple metal monofilaments made of tin-plated copper to form a conductor;
金属单丝自内而外分为多层；每层金属单丝中的相邻两根金属单丝相互紧密贴合；相邻两层金属单丝中，内、外层金属单丝紧密贴合；金属单丝的束合方向为左向，金属单丝的束合节距不大于束合后外径的16倍；The metal monofilament is divided into multiple layers from the inside to the outside; two adjacent metal monofilaments in each metal monofilament are closely attached to each other; in two adjacent metal monofilaments, the inner and outer metal monofilaments are closely attached ; The stranding direction of the metal monofilament is left, and the stranding pitch of the metal monofilament is not more than 16 times the outer diameter after the stranding;
2)采用双层挤包的方式把半导电屏蔽料和绝缘料包裹在导体外，并冷却，构成内半导电屏蔽层和绝缘层；半导电屏蔽料为半导电绝缘屏蔽料，绝缘料是阻燃乙丙橡胶绝缘料；2) The semi-conductive shielding material and insulating material are wrapped around the conductor by double-layer extrusion and cooled to form an inner semi-conductive shielding layer and insulating layer; the semi-conductive shielding material is a semi-conductive insulating shielding material, and the insulating material is a resistive material. Fire ethylene propylene rubber insulation material;
对于半导电屏蔽料：自进料到出料方向，挤橡机的机身温区为：一区68～73℃、二区76～81℃、三区88～94℃、四区96～100℃；For semi-conductive shielding material: from the feeding direction to the discharging direction, the temperature zone of the extruder is: zone one 68～73℃, zone two 76～81℃, zone three 88～94℃, zone four 96～100 ℃;
对于绝缘料：自进料到出料方向，挤橡机的机身温区为：一区60～70℃、二区65～75℃、三区70～80℃、四区75～85℃；For insulating materials: from the feeding direction to the discharging direction, the temperature zone of the extruder is: 60～70℃ in the first zone, 65～75℃ in the second zone, 70～80℃ in the third zone, 75～85℃ in the fourth zone;
挤橡机的一区为入料段，二区、三区为塑化段，四区为均化段；The first zone of the rubber extruder is the feeding section, the second and third zones are the plasticizing section, and the fourth zone is the homogenizing section;
自进料到出料方向，挤橡机的机头温区为：一区80～90℃、二区75～85℃；其中，一区为机头段、二区为机颈段；From the feeding direction to the discharging direction, the temperature zone of the extruder's nose is: 80～90℃ in the first zone, 75～85℃ in the second zone; among them, the first zone is the nose section and the second zone is the neck section;
绝缘料挤出时，饱和蒸汽压力保持在1.5～1.7MPa，水位控制在20％～30％之间；When insulating material is extruded, the saturated steam pressure is maintained at 1.5～1.7MPa, and the water level is controlled between 20%～30%;
3)采用重叠绕包的方式将半导电屏蔽材带包在绝缘层外构成外半导电屏蔽层，绕包重叠率不小于15％，半导电屏蔽带厚度是0.12mm～0.15mm；3) The semi-conductive shielding tape is wrapped around the insulating layer to form an outer semi-conductive shielding layer by overlapping wrapping, the wrapping overlap rate is not less than 15%, and the thickness of the semi-conductive shielding tape is 0.12mm～0.15mm;
4)在外半导电屏蔽层外包裹金属屏蔽层；4) Wrap the metal shielding layer on the outer semi-conductive shielding layer;
5)采用重叠绕包的方式将聚酰亚胺薄膜绕包在金属网外，绕包重叠率不小于25％，聚酰亚胺薄膜厚度采用0.025mm～0.05mm；5) The polyimide film is wrapped around the metal mesh by overlapping wrapping, the wrapping overlap rate is not less than 25%, and the thickness of the polyimide film is 0.025mm～0.05mm;
6)采用连续硫化方式在缆芯外均匀紧密挤包低烟无卤阻燃护套料，并冷却；6) Adopt continuous vulcanization method to uniformly and tightly squeeze the low-smoke halogen-free flame-retardant sheath material outside the cable core and cool it;
护套料是热固性低烟无卤阻燃EVA混合物，其氧指数不小于30％；在挤胶机读机头上配护套模套；护套模套的孔径大于缆芯外径；自进料到出料方向，挤胶机的机身各区温度分布为：一区50～60℃、二区55～65℃、三区60～70℃、四区65～75℃，其中，一区为入料段，二区和三区为塑化段，四区为均化段；The sheath material is a thermosetting, low-smoke, halogen-free, flame-retardant EVA mixture, and its oxygen index is not less than 30%; a sheath die sleeve is equipped on the extruder machine-reading head; the diameter of the sheath die sleeve is larger than the outer diameter of the cable core; When the material reaches the direction of discharging, the temperature distribution of each zone of the extruder is: zone 1 50～60℃, zone 2 55～65℃, zone 3 60～70℃, zone 4 65～75℃, among which, zone 1 is In the feeding section, the second and third zones are the plasticizing section, and the fourth zone is the homogenizing section;
自进料到出料方向，挤橡机的机头温区为：一区65～80℃、二区70～90℃、三区70～80℃；其中，一区为机头段、二区为机颈段、三区为模口段；From the feeding direction to the discharging direction, the temperature zone of the extruder head is: 65～80℃ in the first zone, 70～90℃ in the second zone, 70～80℃ in the third zone; among them, the first zone is the head section and the second zone. It is the neck section of the machine, and the three zones are the die mouth section;
挤出时饱和蒸汽压力保持在1.4～1.6MPa，水位控制在20％～25％之间。During extrusion, the saturated steam pressure is maintained at 1.4～1.6MPa, and the water level is controlled at 20%～25%.
较优方案为：The better solution is:
所述步骤2)中：In the step 2):
对于半导电屏蔽料：挤橡机的机身温区为：一区70℃、二区78℃、三区91℃、四区98℃；For semi-conductive shielding materials: the temperature zone of the extruder's body is: zone one 70°C, zone two 78°C, zone three 91°C, zone four 98°C;
对于绝缘料：挤橡机的机身温区为：一区65℃、二区70℃、三区75℃、四区80℃；挤橡机的机头温区为：一区85℃、二区80℃；绝缘挤出时饱和蒸汽压力保持在1.6MPa；For insulating materials: the temperature zone of the extruder's body is: 65°C in the first zone, 70°C in the second zone, 75°C in the third zone, and 80°C in the fourth zone; the temperature zone of the extruder's head is: 85°C in the first zone, and two Zone 80℃; the saturated steam pressure is maintained at 1.6MPa during insulation extrusion;
所述步骤6)中：挤橡机的机身温区为：一区55℃、二区60℃、三区65℃、四区70℃；挤橡机的机头温区为：一区75℃、二区80℃、三区75℃；护套挤出时饱和蒸汽压力保持在1.5MP。In the step 6): the temperature zone of the rubber extruder is: 55°C in the first zone, 60°C in the second zone, 65°C in the third zone, and 70°C in the fourth zone; ℃, 80℃ in the second zone and 75℃ in the third zone; the saturated steam pressure is maintained at 1.5MP during sheath extrusion.
所述步骤3)中：半导电屏蔽带是由半导电屏蔽料预制得到，半导电屏蔽带标称厚度是0.12mm。In the step 3): the semi-conductive shielding tape is prefabricated from a semi-conductive shielding material, and the nominal thickness of the semi-conductive shielding tape is 0.12 mm.
所述步骤4)中，在外半导电屏蔽层外编织镀锡金属丝成金属网；编织覆盖率不小于80％；镀锡金属丝标称直径采用0.12mm～0.20mm。最优为镀锡金属丝编织丝采用0.15mm。In the step 4), the tin-plated metal wire is braided outside the outer semiconductive shielding layer to form a metal mesh; the braiding coverage is not less than 80%; the nominal diameter of the tin-plated metal wire is 0.12 mm to 0.20 mm. The best braided wire for tinned metal wire is 0.15mm.
也可以说所述步骤4)中，在外半导电屏蔽层外重叠绕包铜金属带，绕包重叠率不小于15％；铜金属带标称厚度采用0.1mm～0.12mm。It can also be said that in the step 4), the copper metal tape is wrapped over the outer semiconductive shielding layer, and the wrapping overlap rate is not less than 15%; the nominal thickness of the copper metal tape is 0.1mm-0.12mm.
所述步骤5)中：聚酰亚胺薄膜厚度采用0.025mm。In the step 5): the thickness of the polyimide film is 0.025 mm.
所述步骤6)中，护套模套的模芯孔径＝缆芯外径+0.5mm。In the step 6), the core diameter of the sheath mold sleeve = the outer diameter of the cable core + 0.5 mm.
一种核电站用耐辐射的小截面高压直流电缆，是由上述方法制得；A radiation-resistant high-voltage DC cable with a small cross-section for nuclear power plants, which is made by the above method;
电缆导体标称截面范围为4～10mm 2。 The nominal cross-section range of cable conductor is 4～10mm 2 .
电缆的结构为：自内而外依次是导体、内半导电屏蔽层、绝缘层、外半导电屏蔽层、金属屏蔽层、聚酰亚胺薄膜层和护套；The structure of the cable is: from the inside to the outside, it is a conductor, an inner semi-conductive shielding layer, an insulating layer, an outer semi-conductive shielding layer, a metal shielding layer, a polyimide film layer and a sheath;
所述导体的结构为：由一根高强度的芳纶丝(断裂强力不小于1269N)和多根镀锡铜材质的单丝束合构成导体；芳纶丝在导体的轴线位置；单丝自内而外分 为多层；单丝的束合方向为左向；单丝的束合节距不大于束合后外径的16倍；The structure of the conductor is as follows: a high-strength aramid filament (breaking strength not less than 1269N) and a plurality of tinned copper monofilament bundles constitute the conductor; the aramid filament is at the axis of the conductor; the monofilament is self-contained It is divided into multiple layers from the inside to the outside; the bundle direction of the monofilament is left; the bundle pitch of the monofilament is not more than 16 times the bundled outer diameter;
所述内半导电屏蔽层和绝缘层是由双层共挤的半导电屏蔽料和绝缘料构成；The inner semi-conductive shielding layer and the insulating layer are composed of a double-layer co-extruded semi-conductive shielding material and insulating material;
所述外半导电屏蔽层是由重叠绕包半导电屏蔽带构成，绕包的重叠率不小于15％；所述半导电屏蔽带的厚度是0.12mm～0.15mm；The outer semi-conductive shielding layer is composed of overlapping wrapped semi-conductive shielding tape, and the wrapping overlap rate is not less than 15%; the thickness of the semi-conductive shielding tape is 0.12mm～0.15mm;
聚酰亚胺薄膜层是重叠绕包聚酰亚胺薄膜构成；聚酰亚胺薄膜的厚度是0.025mm～0.05mm，绕包重叠率不小于25％。The polyimide film layer is composed of overlapping and wrapping polyimide films; the thickness of the polyimide film is 0.025mm～0.05mm, and the wrapping overlap rate is not less than 25%.
本技术方案的设计原理说明如下：The design principle of this technical solution is explained as follows:
一种核电站用耐辐射的小截面高压直流电缆，其结构为：由一根高强度的芳纶丝和多根镀锡铜金属单丝束合构成导体；导体外挤包半导电屏蔽材料和绝缘料；绝缘层外包裹半导电屏蔽带构成线芯；线芯外包裹金属屏蔽层(金属丝编织网或绕包金属带)和聚酰亚胺薄膜构成缆芯；缆芯外包裹低烟无卤阻燃型材料构成电缆护套。聚酰亚胺薄膜具有较高的绝缘性能、耐高温、耐辐射、耐老化等特点，提高了电缆使用寿命要求。所述聚酰亚胺薄膜采用0.025mm厚度，绕包重叠率不小于25％。A radiation-resistant, small-section, high-voltage DC cable for nuclear power plants. Its structure is as follows: a high-strength aramid wire and multiple tin-plated copper metal monofilaments are bundled to form a conductor; the conductor is extruded with semi-conductive shielding material and insulation Material; the insulating layer is wrapped with a semi-conductive shielding tape to form the wire core; the wire core is wrapped with a metal shielding layer (wire braided mesh or wrapped metal tape) and polyimide film to form a cable core; the cable core is wrapped with low-smoke and halogen-free Flame-retardant materials constitute the cable sheath. Polyimide film has the characteristics of high insulation performance, high temperature resistance, radiation resistance, and aging resistance, which improves the service life of the cable. The polyimide film has a thickness of 0.025 mm, and the wrapping overlap rate is not less than 25%.
半导电屏蔽材料和绝缘料紧密挤包在导体表面。半导电屏蔽料为XPB-30A。绝缘层材料为乙丙橡皮绝缘，具有60年寿命、耐核辐射、低烟性、无卤性、无毒性、阻燃性和热固性。Semi-conductive shielding material and insulating material are tightly packed on the surface of the conductor. The semi-conductive shielding material is XPB-30A. The material of the insulation layer is ethylene-propylene rubber insulation, with a life span of 60 years, nuclear radiation resistance, low smoke, halogen-free, non-toxic, flame retardant and thermosetting properties.
绝缘层外采用重叠绕包的方式包裹一层半导电屏蔽带，半导电屏蔽材料要求为：具有一定的导电性、耐老化，具有低烟、无卤、阻燃等特性。The insulating layer is wrapped with a layer of semi-conductive shielding tape by overlapping wrapping. The requirements of the semi-conductive shielding material are: certain conductivity, aging resistance, low smoke, halogen-free, flame retardant and other characteristics.
外半导电屏蔽层外采用金属屏蔽层(镀锡金属丝编织成金属网，金属编织网材料要求为：高导电性、耐腐蚀性、较高的机械强度和和抗拉强度)。The outer semi-conductive shielding layer adopts a metal shielding layer (tinned metal wire is woven into a metal mesh, and the material of the metal woven mesh is required to be: high conductivity, corrosion resistance, high mechanical strength and tensile strength).
金属丝编织网外采用重叠绕包的方式包裹聚酰亚胺薄膜作为辅助绝缘层。聚酰亚胺薄膜材料为：耐高温600℃以上，长期使用温度范围-200～300℃，高绝缘性能。该层的主要作用是辅助外护套层共同抵御高剂量γ、β射线辐照，在高温、高压事故条件下仍旧能保留一定绝缘电阻并保证电流正常传输。A polyimide film is used as an auxiliary insulating layer to wrap the polyimide film outside the woven wire mesh by overlapping wrapping. The polyimide film material is: high temperature resistance above 600℃, long-term use temperature range -200～300℃, high insulation performance. The main function of this layer is to assist the outer sheath layer to resist high-dose gamma and beta radiation together, and to retain a certain insulation resistance and ensure the normal transmission of current under high temperature and high pressure accident conditions.
护套均匀紧密挤包在缆芯外；护套的护套料为：耐核辐射、低烟性、无卤性、无毒性、耐油性、阻燃型和热固性。护套能进一步阻挡高温、高压、高剂量γ、β射线等恶劣环境传输至绝缘。The sheath is uniformly and tightly squeezed out of the cable core; the sheath material of the sheath is: nuclear radiation resistance, low smoke, halogen-free, non-toxic, oil-resistant, flame-retardant and thermosetting. The sheath can further block the transmission of harsh environments such as high temperature, high pressure, high dose gamma and beta rays to the insulation.
本电缆通过材料和结构的特定设计，可以使得电缆能够配套三代、四代核电站某些检查设备上使用，适用于EPR、AP1000、CAP1600、华龙一号等核电站安全壳内、安全壳外、常规岛区域内特定的检查设备使用。Through the specific design of materials and structure, the cable can be used on some inspection equipment of third and fourth generation nuclear power plants. It is suitable for EPR, AP1000, CAP1600, Hualong No. 1 nuclear power plant containment, outside the containment, and conventional islands. Use of specific inspection equipment in the area.
上述电缆在实际生产中遇到了问题：The above cables encountered problems in actual production:
由于电缆截面较小，绝缘挤包过程非常容易拉断，故采用新的导体结构设计。Due to the small cross-section of the cable, the insulation extrusion process is very easy to break, so a new conductor structure design is adopted.
采用传统生产方法或经验在如此小截面的电缆上实现三层共挤存在不可实现性，故采用两层共挤工艺，再采用绕包的方式实现绝缘屏蔽的功能。这是传统生产工艺无法生产出的新型电缆，电缆的结构也不符合常规要求。为此，本发明提出了专用于该电缆的制造方法。Using traditional production methods or experience to achieve three-layer co-extrusion on such a small cross-section cable is impossible to achieve, so the two-layer co-extrusion process is adopted, and then the wrapping method is used to achieve the function of insulation and shielding. This is a new type of cable that cannot be produced by the traditional production process, and the structure of the cable does not meet the conventional requirements. To this end, the present invention proposes a manufacturing method dedicated to the cable.
一种上述核电站用电缆制造方法，步骤包括：A method for manufacturing the above-mentioned cable for a nuclear power plant, the steps include:
1)选择一根高强度的芳纶丝和多根镀锡铜金属单丝作为导体材质；把一根高强度的芳纶丝和多根镀锡铜材质的金属单丝束合构成导体：所述金属单丝自内而外分为多层；每层金属单丝中的相邻两根金属单丝相互紧密贴合；相邻两层金属单丝中，内、外层金属单丝紧密贴合；金属单丝的束合方向为左向；金属单丝的束合节距不大于束合后外径的16倍；并由一根高强度的芳纶丝补充提高导体 的抗拉强度。1) Choose a high-strength aramid wire and multiple tinned copper metal monofilaments as the conductor material; combine a high-strength aramid wire and multiple tinned copper metal monofilaments to form a conductor: The metal monofilament is divided into multiple layers from the inside to the outside; two adjacent metal monofilaments in each layer of metal monofilament are closely attached to each other; in two adjacent layers of metal monofilament, the inner and outer metal monofilaments are closely attached The bonding direction of the metal monofilament is left; the bonding pitch of the metal monofilament is not more than 16 times the outer diameter after bonding; and a high-strength aramid filament is supplemented to improve the tensile strength of the conductor.
2)采用双层共挤的挤包方式把半导电屏蔽料和绝缘料包裹在导体表面，并冷却：2) Use the double-layer co-extrusion method to wrap the semi-conductive shielding material and insulating material on the surface of the conductor, and cool it down:
现有电缆常用的生产工艺中，对于形如本电缆内、外半导电屏蔽层以及绝缘层的三层结构，一般都采用单层挤出或三层共挤挤出方式。而本电缆采用双层共挤+绕包的技术，半导电屏蔽层能均化电场强度，绝缘层起到有效的电气隔离作用，保障电缆的良好运行性能。In the conventional cable production process, the three-layer structure of the inner and outer semi-conductive shielding layer and insulating layer of the cable generally adopts single-layer extrusion or three-layer co-extrusion. However, this cable adopts double-layer co-extrusion + wrapping technology, the semi-conductive shielding layer can homogenize the electric field strength, and the insulating layer plays an effective electrical isolation role to ensure the good running performance of the cable.
绝缘层可满足以下性能：The insulating layer can meet the following properties:
机械性能：抗张强度≥7.0MPa，断裂伸长率≥200％Mechanical properties: tensile strength ≥7.0MPa, elongation at break ≥200%
阻燃性能：满足GB/T18380.12的线芯单根阻燃的要求Flame retardant performance: meet the requirements of GB/T18380.12 for single core flame retardant
电性能：20℃绝缘电阻常数≥10000MΩ.kmElectrical performance: 20℃ insulation resistance constant ≥10000MΩ.km
3)采用重叠绕包的方式将半导电屏蔽带绕包在绝缘外，绕包重叠率不小于15％。半导电屏蔽材料厚度采用0.12mm～0.15mm。该层半导电屏蔽同样能均化电场强度，保障电缆场强分布。3) The semi-conductive shielding tape is wrapped around the insulation by overlapping wrapping, and the wrapping overlap rate is not less than 15%. The thickness of the semi-conductive shielding material is 0.12mm～0.15mm. This layer of semi-conductive shielding can also homogenize the electric field strength and ensure the distribution of the electric field strength of the cable.
采用在绝缘外重叠绕包半导电屏蔽材料后电缆耐高电压性能、局部放电性能相比于原始性能得到了极大的提升。电缆局部放电量下降明显，由50pC下降到20pC。电缆通过直流耐压的能力得到提高，增加重叠绕包半导电屏蔽材料后电缆能承受60kV直流耐压试验15分钟不击穿。The high-voltage resistance and partial discharge performance of the cable are greatly improved compared with the original performance after the semi-conductive shielding material is overlapped and wrapped around the insulation. The partial discharge of the cable has dropped significantly, from 50pC to 20pC. The ability of the cable to pass the DC withstand voltage is improved, and the cable can withstand the 60kV DC withstand voltage test for 15 minutes without breakdown after adding overlapping wrapping semi-conductive shielding materials.
本电缆的机械性能：抗张强度≥9.0MPa，断裂伸长率≥200％；阻燃性能：满足GB/T18380.12的电缆单根阻燃的要求。采用本方法制得的电缆，能满足设计要求，同时，合格率达到99％以上。The mechanical properties of the cable: tensile strength ≥9.0MPa, elongation at break ≥200%; flame-retardant performance: meet the requirements of GB/T18380.12 for a single cable to be flame-retardant. The cable prepared by this method can meet the design requirements, and at the same time, the pass rate can reach more than 99%.
附图说明Description of the drawings
图1是本实施例电缆的径向截面示意图，Figure 1 is a schematic diagram of a radial cross-section of the cable of this embodiment,
图中：高强度芳纶1、镀锡铜金属单丝2、内半导电屏蔽层3、绝缘层4、外半导电屏蔽层5、镀锡金属编织网6、聚酰亚胺薄膜层7、护套8。In the picture: high-strength aramid 1, tinned copper metal monofilament 2, inner semi-conductive shielding layer 3, insulating layer 4, outer semi-conductive shielding layer 5, tinned metal woven mesh 6, polyimide film layer 7, Sheath 8.
具体实施方式Detailed ways
下面结合具体实施例对本技术方案进一步说明如下：The technical solution is further described below in conjunction with specific embodiments as follows:
如图1，一种核电站用耐辐射的小截面高压直流电缆：由一根高强度的芳纶丝和多根镀锡铜金属单丝束合构成导体；导体外包裹半导电屏蔽材料和绝缘材料构成线芯；绝缘表面绕包半导电屏蔽材料构成外半导电屏蔽层；外半导电屏蔽层外采用高速编织设备将金属丝编织成金属网包裹在线芯表面；采用绕包方式把聚酰亚胺薄膜包裹在金属网表面构成缆芯；缆芯外包裹低烟无卤阻燃护套材料；As shown in Figure 1, a radiation-resistant small cross-section high-voltage DC cable for nuclear power plants: a high-strength aramid wire and multiple tin-plated copper metal monofilaments are bundled to form a conductor; the conductor is wrapped with semi-conductive shielding materials and insulating materials Form the core; the insulating surface wraps the semi-conductive shielding material to form the outer semi-conductive shielding layer; the outer semi-conductive shielding layer uses high-speed braiding equipment to weave the metal wire into a metal mesh to wrap the surface of the core; the polyimide is wrapped by wrapping The film is wrapped on the surface of the metal mesh to form the cable core; the cable core is wrapped with a low-smoke, halogen-free flame-retardant sheath material;
镀锡铜金属单丝束合的绞距不大于束合后导体外径的16倍，由一根高强度的芳纶丝提高导体的抗拉强度。所述绝缘层和内外半导电屏蔽层，可保证电缆耐高电压冲击的能力。绝缘线芯外包裹金属丝编织网和聚酰亚胺薄膜，可以使电缆在故障下导出较大的短路电流保护系统，同时聚酰亚胺薄膜具有较高的绝缘性能、耐高温、耐辐射、耐老化等特点，提高了电缆使用寿命要求。电缆使用的护套材料要求为：耐核辐射、低烟性、无卤性、无毒性、耐油性、阻燃型和热固性。护套均匀紧密挤包在缆芯外。The lay length of the tin-plated copper metal monofilament bundle is not more than 16 times the outer diameter of the conductor after the bundle, and a high-strength aramid wire improves the tensile strength of the conductor. The insulating layer and the inner and outer semi-conductive shielding layers can ensure the ability of the cable to withstand high voltage shocks. The insulated wire core is wrapped with metal wire woven mesh and polyimide film, which can lead the cable to a larger short-circuit current protection system in the event of a fault. At the same time, the polyimide film has high insulation performance, high temperature resistance, radiation resistance, The characteristics of aging resistance improve the service life of the cable. The sheath material requirements for cables are: nuclear radiation resistance, low smoke, halogen-free, non-toxic, oil-resistant, flame-retardant and thermosetting. The sheath is evenly and tightly squeezed out of the cable core.
具体来说，绝缘料采用乙丙橡胶绝缘料，内、外半导电屏蔽层作为辅助绝缘层，护套料是热固性EVA混合物。Specifically, the insulating material uses ethylene-propylene rubber insulating material, the inner and outer semi-conductive shielding layers are used as auxiliary insulating layers, and the sheath material is a thermosetting EVA mixture.
上述电缆的制造方法说明如下：The manufacturing method of the above-mentioned cable is explained as follows:
所述电缆的制造步骤包括：The manufacturing steps of the cable include:
1)制造导体：1) Manufacturing conductor:
选择镀锡铜作为导体材质；Choose tinned copper as the conductor material;
把一根高强度的芳纶丝和多根镀锡铜材质的金属单丝束合构成导体；Bundle a high-strength aramid filament and multiple metal monofilaments made of tin-plated copper to form a conductor;
金属单丝自内而外分为多层；每层金属单丝中的相邻两根金属单丝相互紧密贴合；相邻两层金属单丝中，内、外层金属单丝紧密贴合；金属单丝的束合方向为左向，金属单丝的束合节距不大于束合后外径的16倍；The metal monofilament is divided into multiple layers from the inside to the outside; two adjacent metal monofilaments in each metal monofilament are closely attached to each other; in two adjacent metal monofilaments, the inner and outer metal monofilaments are closely attached ; The stranding direction of the metal monofilament is left, and the stranding pitch of the metal monofilament is not more than 16 times the outer diameter after the stranding;
2)采用双层挤包的方式把半导电屏蔽料和绝缘料包裹在导体外，并冷却，构成内半导电屏蔽层和绝缘层；本例中，半导电屏蔽料为半导电绝缘屏蔽料XPB-30A，绝缘料是阻燃乙丙橡胶绝缘料；2) The semi-conductive shielding material and insulating material are wrapped around the conductor by a double-layer extrusion method, and cooled to form an inner semi-conductive shielding layer and an insulating layer; in this example, the semi-conductive shielding material is a semi-conductive insulating shielding material XPB -30A, the insulating material is flame-retardant ethylene propylene rubber insulating material;
对于半导电屏蔽料：自进料到出料方向，挤橡机的机身温区为：一区68～73℃、二区76～81℃、三区88～94℃、四区96～100℃；For semi-conductive shielding material: from the feeding direction to the discharging direction, the temperature zone of the extruder is: zone one 68～73℃, zone two 76～81℃, zone three 88～94℃, zone four 96～100 ℃;
对于绝缘料：自进料到出料方向，挤橡机的机身温区为：一区60～70℃、二区65～75℃、三区70～80℃、四区75～85℃；For insulating materials: from the feeding direction to the discharging direction, the temperature zone of the extruder is: 60～70℃ in the first zone, 65～75℃ in the second zone, 70～80℃ in the third zone, 75～85℃ in the fourth zone;
挤橡机的一区为入料段，二区、三区为塑化段，四区为均化段；The first zone of the rubber extruder is the feeding section, the second and third zones are the plasticizing section, and the fourth zone is the homogenizing section;
自进料到出料方向，挤橡机的机头温区为：一区80～90℃、二区75～85℃；其中，一区为机头段、二区为机颈段；From the feeding direction to the discharging direction, the temperature zone of the extruder's nose is: 80～90℃ in the first zone, 75～85℃ in the second zone; among them, the first zone is the nose section and the second zone is the neck section;
绝缘料挤出时，饱和蒸汽压力保持在1.5～1.7MPa，水位控制在20％～30％之间；When insulating material is extruded, the saturated steam pressure is maintained at 1.5～1.7MPa, and the water level is controlled between 20%～30%;
3)采用重叠绕包的方式将半导电屏蔽材带包在绝缘层外构成外半导电屏蔽层，绕包重叠率不小于15％，半导电屏蔽带厚度是0.12mm～0.15mm；3) The semi-conductive shielding tape is wrapped around the insulating layer to form an outer semi-conductive shielding layer by overlapping wrapping, the wrapping overlap rate is not less than 15%, and the thickness of the semi-conductive shielding tape is 0.12mm～0.15mm;
4)在外半导电屏蔽层外包裹金属屏蔽层；4) Wrap the metal shielding layer on the outer semi-conductive shielding layer;
5)采用重叠绕包的方式将聚酰亚胺薄膜绕包在金属网外，绕包重叠率不小于25％，聚酰亚胺薄膜厚度采用0.025mm～0.05mm；5) The polyimide film is wrapped around the metal mesh by overlapping wrapping, the wrapping overlap rate is not less than 25%, and the thickness of the polyimide film is 0.025mm～0.05mm;
6)采用连续硫化方式在缆芯外均匀紧密挤包低烟无卤阻燃护套料，并冷却；6) Adopt continuous vulcanization method to uniformly and tightly squeeze the low-smoke halogen-free flame-retardant sheath material outside the cable core and cool it;
护套料是热固性低烟无卤阻燃EVA混合物，其氧指数不小于30％；在挤胶机读机头上配护套模套；护套模套的孔径大于缆芯外径；自进料到出料方向，挤胶机的机身各区温度分布为：一区50～60℃、二区55～65℃、三区60～70℃、四区65～75℃，其中，一区为入料段，二区和三区为塑化段，四区为均化段；The sheath material is a thermosetting, low-smoke, halogen-free, flame-retardant EVA mixture, and its oxygen index is not less than 30%; a sheath die sleeve is equipped on the extruder machine-reading head; the diameter of the sheath die sleeve is larger than the outer diameter of the cable core; When the material reaches the direction of discharging, the temperature distribution of each zone of the extruder is: zone 1 50～60℃, zone 2 55～65℃, zone 3 60～70℃, zone 4 65～75℃, among which, zone 1 is In the feeding section, the second and third zones are the plasticizing section, and the fourth zone is the homogenizing section;
自进料到出料方向，挤橡机的机头温区为：一区65～80℃、二区70～90℃、三区70～80℃；其中，一区为机头段、二区为机颈段、三区为模口段；From the feeding direction to the discharging direction, the temperature zone of the extruder head is: 65～80℃ in the first zone, 70～90℃ in the second zone, 70～80℃ in the third zone; among them, the first zone is the head section and the second zone. It is the neck section of the machine, and the three zones are the die mouth section;
挤出时饱和蒸汽压力保持在1.4～1.6MPa，水位控制在20％～25％之间。During extrusion, the saturated steam pressure is maintained at 1.4～1.6MPa, and the water level is controlled at 20%～25%.
例1：example 1:
1)选择一根高强度的芳纶丝和多根镀锡铜金属单丝作为导体材质；把一根高强度的芳纶丝和多根镀锡铜材质的金属单丝束合构成导体：所述金属单丝自内而外分为多层；每层金属单丝中的相邻两根金属单丝相互紧密贴合；相邻两层金属单丝中，内、外层金属单丝紧密贴合；金属单丝的束合方向为左向；金属单丝的束合节距不大于束合后外径的16倍；由一根高强度的芳纶丝提高导体的抗拉强度。1) Choose a high-strength aramid wire and multiple tinned copper metal monofilaments as the conductor material; combine a high-strength aramid wire and multiple tinned copper metal monofilaments to form a conductor: The metal monofilament is divided into multiple layers from the inside to the outside; two adjacent metal monofilaments in each layer of metal monofilament are closely attached to each other; in two adjacent layers of metal monofilament, the inner and outer metal monofilaments are closely attached The bonding direction of the metal monofilament is left; the bonding pitch of the metal monofilament is not more than 16 times the outer diameter after bonding; a high-strength aramid filament improves the tensile strength of the conductor.
以导体径向截面积为4mm 2来说明，束合的设备为德国尼霍夫公司全自动束绞机，导体结构共由3层束合完成，采用1+6+12结构排列，中心放置一根6320的高强度芳纶丝，外层18孔放置3～4根不等的金属丝进行束合、束合方向为左 向，束合节距40±3mm，牵引级数为8，束合节距不大于束合后外径的16倍。 Take the conductor radial cross-sectional area of 4mm 2 to illustrate. The bundled equipment is a fully automatic stranding machine from Niehofer, Germany. The conductor structure is completed by a total of 3 layers of bundles. It is arranged in a 1+6+12 structure, and one is placed in the center. 6320 high-strength aramid yarns, 3 to 4 metal wires are placed in 18 holes in the outer layer to be bundled, the bundle direction is left, the bundle pitch is 40±3mm, the traction grade is 8, and the bundle is bundled. The pitch is not more than 16 times the outer diameter after beaming.
2)采用挤包方式把内半导电屏蔽料和乙丙橡皮绝缘料包裹在导体外，2) Wrap the inner semi-conductive shielding material and the ethylene-propylene rubber insulating material outside the conductor by squeezing,
挤出采用德国特勒斯特连续硫化生产线，挤包时，挤橡机的机身温区为：一区60～70℃、二区65～75℃、三区70～80℃、四区75～85℃；挤橡机的机头温区为：一区80～90℃、二区75～85℃；绝缘挤出时饱和蒸汽压力保持在1.5～1.7MPa；Extrusion adopts the German Trest continuous vulcanization production line. When extruding the bag, the temperature zone of the extruder is: 60～70℃ in the first zone, 65～75℃ in the second zone, 70～80℃ in the third zone, and 75 in the fourth zone. ～85℃; The temperature zone of the extruder's head is: 80～90℃ in the first zone, 75～85℃ in the second zone; the saturated steam pressure is maintained at 1.5～1.7MPa during insulation extrusion;
牵引速度为18～22m/min，偏心度不大于20％。The traction speed is 18-22m/min, and the eccentricity is not more than 20%.
3)采用重叠绕包的方式将半导电屏蔽带绕包在绝缘层表面，绕包重叠率不小于15％。半导电屏蔽带厚度0.12mm～0.15mm。3) The semi-conductive shielding tape is wrapped on the surface of the insulating layer by overlapping wrapping, and the wrapping overlap rate is not less than 15%. The thickness of the semi-conductive shielding tape is 0.12mm～0.15mm.
4)采用编织的方式将镀锡金属丝编织成金属网，并覆盖在线芯表面。编织覆盖率不小于80％。镀锡金属丝标称直径采用0.12mm～0.20mm。4) The tinned metal wire is woven into a metal mesh by weaving and covers the surface of the core. The braiding coverage is not less than 80%. The nominal diameter of tinned metal wire is 0.12mm～0.20mm.
5)采用重叠绕包的方式将聚酰亚胺薄膜绕包在金属网外，绕包重叠率不小于25％。聚酰亚胺薄膜厚度采用0.025mm～0.05mm。5) The polyimide film is wrapped around the metal mesh by overlapping wrapping, and the wrapping overlap rate is not less than 25%. The thickness of the polyimide film is 0.025mm～0.05mm.
6)采用连续硫化方式在缆芯外均匀紧密挤包一层低烟无卤阻燃护套，并冷却：6) A layer of low-smoke halogen-free flame-retardant sheath is uniformly and tightly extruded outside the cable core by continuous vulcanization, and cooled:
护套采用挤胶机并在机头上配护套模套；护套模套的模芯孔径＝缆芯外径+0.5mm。The sheath adopts an extruder and is equipped with a sheath die sleeve on the machine head; the core diameter of the sheath die sleeve = the outer diameter of the cable core + 0.5mm.
自进料到出料方向，挤胶机的机身各区温度分布为：一区50～60℃、二区55～65℃、三区60～70℃、四区65～75℃，其中：一区为入料段，二区和三区为塑化段，四区为均化段；From the feeding direction to the discharging direction, the temperature distribution of each zone of the extruder is: Zone 1 50～60℃, Zone 2 55～65℃, Zone 3 60～70℃, Zone 4 65～75℃, of which: 1 Zone is the feeding section, Zone 2 and Zone 3 are the plasticization section, and Zone 4 is the homogenization section;
自进料到出料方向，挤橡机的机头温区为：一区65～80℃、二区70～90℃、三区70～80℃；From the feeding direction to the discharging direction, the temperature zone of the extruder head is: 65～80℃ in the first zone, 70～90℃ in the second zone, 70～80℃ in the third zone;
挤出时饱和蒸汽压力保持在1.4～1.6MPa，水位控制在20％～25％之间。During extrusion, the saturated steam pressure is maintained at 1.4～1.6MPa, and the water level is controlled at 20%～25%.
护套牵引速度为15m/min，偏心度不大于20％。The sheath traction speed is 15m/min, and the eccentricity is not more than 20%.
例2：Example 2:
与例1的不同之处仅在于步骤3)中：采用挤包的方式将半导电屏蔽材料挤包在绝缘线芯表面外，标称厚度为1.0mm。The difference from Example 1 is only in step 3): the semi-conductive shielding material is extruded outside the surface of the insulated core by means of extrusion, with a nominal thickness of 1.0 mm.
例3：Example 3:
与例1的不同之处仅在于所述步骤4)中：采用重叠绕包的方式铜金属带绕包在绝缘线芯表面，绕包重叠率不小于15％。铜金属带标称厚度控制在0.1mm～0.12mm。The difference from Example 1 is only in the step 4): the copper metal tape is wrapped on the surface of the insulated wire core by overlapping wrapping, and the wrapping overlap rate is not less than 15%. The nominal thickness of copper metal strip is controlled within 0.1mm～0.12mm.
其中，例1制得电缆良品率最高，达到99.3％，例2达到98.7％，例3达到98.9％。由该结果可知，对于外半导电屏蔽层，例1采用绕包半导电屏蔽带的工艺较之例2挤包半导电屏蔽料的工艺，电缆的良品率高出0.6个百分点。而例3同样采用采用绕包半导电屏蔽带的工艺，其良品率也高于例2工艺。Among them, Example 1 has the highest yield rate of cables, reaching 99.3%, Example 2 reaching 98.7%, and Example 3 reaching 98.9%. It can be seen from this result that for the outer semi-conductive shielding layer, the process of wrapping the semi-conductive shielding tape in Example 1 is 0.6% higher than the process of extruding the semi-conductive shielding material in Example 2. And Example 3 also adopts the process of wrapping semi-conductive shielding tape, and its yield rate is also higher than that of Example 2.
对于例1和3，区别主要是金属编织和金属带，从电缆的弯曲性能看，例1的结构天然由于例3结构。由于本电缆结构中有内、外半导电屏蔽层，再由合适结构的金属丝网，其屏蔽性能可以达到使用要求。For Examples 1 and 3, the main difference is the metal braid and the metal belt. From the bending performance of the cable, the structure of Example 1 is naturally due to the structure of Example 3. Since the cable structure has inner and outer semi-conductive shielding layers, and a metal wire mesh with a suitable structure, its shielding performance can meet the requirements of use.
采用例1的方法制得电缆进行检测。该电缆中，镀锡金属丝编织丝采用0.15mm，聚酰亚胺薄膜厚度采用0.025mm，半导电屏蔽带标称厚度是0.12mm。The cable was prepared using the method of Example 1 for testing. In this cable, the tinned metal wire braided wire is 0.15mm, the thickness of the polyimide film is 0.025mm, and the nominal thickness of the semi-conductive shielding tape is 0.12mm.
步骤2)参数：Step 2) Parameters:
对于半导电屏蔽料：挤橡机的机身温区为：一区70℃、二区78℃、三区91℃、四区98℃；For semi-conductive shielding materials: the temperature zone of the extruder's body is: zone one 70°C, zone two 78°C, zone three 91°C, zone four 98°C;
对于绝缘料：挤橡机的机身温区为：一区65℃、二区70℃、三区75℃、四 区80℃；挤橡机的机头温区为：一区85℃、二区80℃；绝缘挤出时饱和蒸汽压力保持在1.6MPa；For insulating materials: the temperature zone of the extruder's body is: 65°C in the first zone, 70°C in the second zone, 75°C in the third zone, and 80°C in the fourth zone; the temperature zone of the extruder's head is: 85°C in the first zone, and two Zone 80℃; the saturated steam pressure is maintained at 1.6MPa during insulation extrusion;
步骤6)参数：挤橡机的机身温区为：一区55℃、二区60℃、三区65℃、四区70℃；挤橡机的机头温区为：一区75℃、二区80℃、三区75℃；护套挤出时饱和蒸汽压力保持在1.5MP。Step 6) Parameters: The temperature zone of the extruder's body is: 55°C in the first zone, 60°C in the second zone, 65°C in the third zone, and 70°C in the fourth zone; the extruder's head temperature zone is: 75°C in the first zone, The second zone is 80°C and the third zone is 75°C; the saturated steam pressure is maintained at 1.5MP when the jacket is extruded.
检测结果显示：The test results show:
1)良好的低烟无卤性能1) Good low-smoke and halogen-free performance
经第三方型式检测，成品电缆分别通过GB/T 17651《在特定条件下电缆燃烧的烟密度测定》、GB/T 17650《取自电缆材料燃烧时析出气体的试验方法》。After a third-party type test, the finished cables have passed GB/T 17651 "Determination of Smoke Density of Cable Burning under Specific Conditions" and GB/T 17650 "Test Method for Gas Extracted from the Combustion of Cable Materials".
2)良好的电气性能2) Good electrical performance
经第三方型式检测，成品电缆分别通过21kV*5分钟的交流耐压试验、通过60kV*15分钟的直流耐压试验。After a third-party type test, the finished cables passed the AC withstand voltage test of 21kV*5 minutes and the DC withstand voltage test of 60kV*15 minutes.
3)耐核辐射性能3) Nuclear radiation resistance
经第三方型式检测，成品电缆耐γ射线辐照剂量达到了1000kGyAfter a third-party type inspection, the finished cable's gamma-ray radiation dose has reached 1000kGy
4)耐热老化性能4) Heat aging resistance
经第三方型式检测，成品电缆耐热老化寿命超过60年。After a third-party type test, the finished cable has a heat-resistant aging life of more than 60 years.
5)阻燃性能5) Flame retardant properties
经第三方型式检测，成品电缆满足GB/T18380.12规定的单根电缆垂直燃烧试验。After a third-party type test, the finished cable meets the vertical burning test of a single cable specified in GB/T18380.12.

Claims (9)

  1. 一种核电站用耐辐射的小截面高压直流电缆的制造方法，其特征是电缆的导体标称截面积范围为4～10mm 2，所述电缆的结构为：自内而外依次是导体、内半导电屏蔽层、绝缘层、外半导电屏蔽层、金属屏蔽层、聚酰亚胺薄膜层和护套； A method for manufacturing a radiation-resistant small cross-section high-voltage DC cable for nuclear power plants, which is characterized in that the nominal cross-sectional area of the conductor of the cable is 4-10mm 2 , and the structure of the cable is: from the inside to the outside, the conductor and the inner half are in order. Conductive shielding layer, insulating layer, outer semi-conductive shielding layer, metal shielding layer, polyimide film layer and sheath;
    所述电缆的制造步骤包括：The manufacturing steps of the cable include:
    1)制造导体：1) Manufacturing conductor:
    选择镀锡铜作为导体材质；Choose tinned copper as the conductor material;
    把一根高强度的芳纶丝和多根镀锡铜材质的金属单丝束合构成导体；Bundle a high-strength aramid filament and multiple metal monofilaments made of tin-plated copper to form a conductor;
    金属单丝自内而外分为多层；每层金属单丝中的相邻两根金属单丝相互紧密贴合；相邻两层金属单丝中，内、外层金属单丝紧密贴合；金属单丝的束合方向为左向，金属单丝的束合节距不大于束合后外径的16倍；The metal monofilament is divided into multiple layers from the inside to the outside; two adjacent metal monofilaments in each metal monofilament are closely attached to each other; in two adjacent metal monofilaments, the inner and outer metal monofilaments are closely attached ; The stranding direction of the metal monofilament is left, and the stranding pitch of the metal monofilament is not more than 16 times the outer diameter after the stranding;
    2)采用双层挤包的方式把半导电屏蔽料和绝缘料包裹在导体外，并冷却，构成内半导电屏蔽层和绝缘层；半导电屏蔽料为半导电绝缘屏蔽料，绝缘料是阻燃乙丙橡胶绝缘料；2) The semi-conductive shielding material and insulating material are wrapped around the conductor by double-layer extrusion and cooled to form an inner semi-conductive shielding layer and insulating layer; the semi-conductive shielding material is a semi-conductive insulating shielding material, and the insulating material is a resistive material. Fire ethylene propylene rubber insulation material;
    对于半导电屏蔽料：自进料到出料方向，挤橡机的机身温区为：一区68～73℃、二区76～81℃、三区88～94℃、四区96～100℃；For semi-conductive shielding material: from the feeding direction to the discharging direction, the temperature zone of the extruder is: zone one 68～73℃, zone two 76～81℃, zone three 88～94℃, zone four 96～100 ℃;
    对于绝缘料：自进料到出料方向，挤橡机的机身温区为：一区60～70℃、二区65～75℃、三区70～80℃、四区75～85℃；For insulating materials: from the feeding direction to the discharging direction, the temperature zone of the extruder is: 60～70℃ in the first zone, 65～75℃ in the second zone, 70～80℃ in the third zone, 75～85℃ in the fourth zone;
    挤橡机的一区为入料段，二区、三区为塑化段，四区为均化段；The first zone of the rubber extruder is the feeding section, the second and third zones are the plasticizing section, and the fourth zone is the homogenizing section;
    自进料到出料方向，挤橡机的机头温区为：一区80～90℃、二区75～85℃；其中，一区为机头段、二区为机颈段；From the feeding direction to the discharging direction, the temperature zone of the extruder's nose is: 80～90℃ in the first zone, 75～85℃ in the second zone; among them, the first zone is the nose section and the second zone is the neck section;
    绝缘料挤出时，饱和蒸汽压力保持在1.5～1.7MPa，水位控制在20％～30％之间；When insulating material is extruded, the saturated steam pressure is maintained at 1.5～1.7MPa, and the water level is controlled between 20%～30%;
    3)采用重叠绕包的方式将半导电屏蔽材带包在绝缘层外构成外半导电屏蔽层，绕包重叠率不小于15％，半导电屏蔽带厚度是0.12mm～0.15mm；3) The semi-conductive shielding tape is wrapped around the insulating layer to form an outer semi-conductive shielding layer by overlapping wrapping, the wrapping overlap rate is not less than 15%, and the thickness of the semi-conductive shielding tape is 0.12mm～0.15mm;
    4)在外半导电屏蔽层外包裹金属屏蔽层；4) Wrap the metal shielding layer on the outer semi-conductive shielding layer;
    5)采用重叠绕包的方式将聚酰亚胺薄膜绕包在金属网外，绕包重叠率不小于25％，聚酰亚胺薄膜厚度采用0.025mm～0.05mm；5) The polyimide film is wrapped around the metal mesh by overlapping wrapping, the wrapping overlap rate is not less than 25%, and the thickness of the polyimide film is 0.025mm～0.05mm;
    6)采用连续硫化方式在缆芯外均匀紧密挤包低烟无卤阻燃护套料，并冷却；6) Adopt continuous vulcanization method to uniformly and tightly squeeze the low-smoke halogen-free flame-retardant sheath material outside the cable core and cool it;
    护套料是热固性低烟无卤阻燃EVA混合物，其氧指数不小于30％；The sheath material is a thermosetting, low-smoke, halogen-free, flame-retardant EVA mixture, and its oxygen index is not less than 30%;
    在挤胶机读机头上配护套模套；护套模套的孔径大于缆芯外径；自进料到出料方向，挤胶机的机身各区温度分布为：一区50～60℃、二区55～65℃、三区60～70℃、四区65～75℃，其中，一区为入料段，二区和三区为塑化段，四区为均化段；Equipped with a sheath die sleeve on the reading head of the extruder; the diameter of the sheath die sleeve is larger than the outer diameter of the cable core; from the feeding to the discharging direction, the temperature distribution of each zone of the extruder is: 50-60 in one zone ℃, 55～65℃ in the second zone, 60～70℃ in the third zone, 65～75℃ in the fourth zone, among them, the first zone is the feed section, the second and third zones are the plasticization section, and the fourth zone is the homogenization section;
    自进料到出料方向，挤橡机的机头温区为：一区65～80℃、二区70～90℃、三区70～80℃；其中，一区为机头段、二区为机颈段、三区为模口段；From the feeding direction to the discharging direction, the temperature zone of the extruder head is: 65～80℃ in the first zone, 70～90℃ in the second zone, 70～80℃ in the third zone; among them, the first zone is the head section and the second zone. It is the neck section of the machine, and the three zones are the die mouth section;
    挤出时饱和蒸汽压力保持在1.4～1.6MPa，水位控制在20％～25％之间。During extrusion, the saturated steam pressure is maintained at 1.4～1.6MPa, and the water level is controlled at 20%～25%.
  2. 根据权利要求1所述的核电站用耐辐射的小截面高压直流电缆的制造方法，其特征是所述步骤2)中：The method for manufacturing a radiation-resistant small cross-section high-voltage DC cable for nuclear power plants according to claim 1, characterized in that in step 2):
    对于半导电屏蔽料：挤橡机的机身温区为：一区70℃、二区78℃、三区91℃、四区98℃；For semi-conductive shielding materials: the temperature zone of the extruder's body is: zone one 70°C, zone two 78°C, zone three 91°C, zone four 98°C;
    对于绝缘料：挤橡机的机身温区为：一区65℃、二区70℃、三区75℃、四 区80℃；挤橡机的机头温区为：一区85℃、二区80℃；绝缘挤出时饱和蒸汽压力保持在1.6MPa；For insulating materials: the temperature zone of the extruder's body is: 65°C in the first zone, 70°C in the second zone, 75°C in the third zone, and 80°C in the fourth zone; the temperature zone of the extruder's head is: 85°C in the first zone, and two Zone 80℃; the saturated steam pressure is maintained at 1.6MPa during insulation extrusion;
    所述步骤6)中：挤橡机的机身温区为：一区55℃、二区60℃、三区65℃、四区70℃；挤橡机的机头温区为：一区75℃、二区80℃、三区75℃；护套挤出时饱和蒸汽压力保持在1.5MP。In the step 6): the temperature zone of the rubber extruder is: 55°C in the first zone, 60°C in the second zone, 65°C in the third zone, and 70°C in the fourth zone; ℃, 80℃ in the second zone and 75℃ in the third zone; the saturated steam pressure is maintained at 1.5MP during sheath extrusion.
  3. 根据权利要求1所述的核电站用耐辐射的小截面高压直流电缆的制造方法，其特征是所述步骤3)中：半导电屏蔽带是由半导电屏蔽料预制得到，半导电屏蔽带标称厚度是0.12mm。The method for manufacturing a radiation-resistant small cross-section high-voltage DC cable for nuclear power plants according to claim 1, characterized in that in step 3): the semi-conductive shielding tape is prefabricated from a semi-conductive shielding material, and the semi-conductive shielding tape is nominally The thickness is 0.12mm.
  4. 根据权利要求1所述的核电站用耐辐射的小截面高压直流电缆的制造方法，其特征是所述步骤4)中，在外半导电屏蔽层外编织镀锡金属丝成金属网；编织覆盖率不小于80％；镀锡金属丝标称直径采用0.12mm～0.20mm。The method for manufacturing a radiation-resistant small cross-section high-voltage DC cable for nuclear power plants according to claim 1, characterized in that in step 4), tinned metal wires are braided outside the outer semi-conductive shielding layer to form a metal mesh; the braiding coverage is not Less than 80%; the nominal diameter of tinned metal wire is 0.12mm～0.20mm.
  5. 根据权利要求1所述的核电站用耐辐射的小截面高压直流电缆的制造方法，其特征是所述步骤4)中，在外半导电屏蔽层外重叠绕包铜金属带，绕包重叠率不小于15％；铜金属带标称厚度采用0.1mm～0.12mm。The method for manufacturing a radiation-resistant small cross-section high-voltage DC cable for nuclear power plants according to claim 1, characterized in that in step 4), the copper metal tape is overlapped on the outer semiconductive shielding layer, and the overlap rate of the wrapping is not less than 15%; the nominal thickness of the copper metal strip is 0.1mm～0.12mm.
  6. 根据权利要求4所述的核电站用耐辐射的小截面高压直流电缆的制造方法，其特征是所述步骤4)中：镀锡金属丝编织丝采用0.15mm。The method for manufacturing a radiation-resistant small-section high-voltage DC cable for nuclear power plants according to claim 4, characterized in that in the step 4): the tinned metal wire braided wire is 0.15 mm.
  7. 根据权利要求1所述的核电站用耐辐射的小截面高压直流电缆的制造方法，其特征是所述步骤5)中：聚酰亚胺薄膜厚度采用0.025mm。The method for manufacturing a radiation-resistant small cross-section high-voltage DC cable for nuclear power plants according to claim 1, characterized in that in step 5): the thickness of the polyimide film is 0.025 mm.
  8. 根据权利要求1所述的核电站用耐辐射的小截面高压直流电缆的制造方法，其特征是所述步骤6)中，护套模套的模芯孔径＝缆芯外径+0.5mm。The method for manufacturing a radiation-resistant small cross-section high-voltage DC cable for nuclear power plants according to claim 1, characterized in that in step 6), the core diameter of the sheath mold sleeve = the outer diameter of the cable core + 0.5 mm.
  9. 一种核电站用耐辐射的小截面高压直流电缆，其特征是由权利要求1～8任一方法制得；A radiation-resistant small-section high-voltage DC cable for nuclear power plants, which is characterized by being produced by any method of claims 1-8;
    导体标称截面范围为4～10mm 2 The nominal cross-section range of the conductor is 4～10mm 2
    电缆的结构为：自内而外依次是导体、内半导电屏蔽层、绝缘层、外半导电屏蔽层、金属屏蔽层、聚酰亚胺薄膜层和护套；The structure of the cable is: from the inside to the outside, it is a conductor, an inner semi-conductive shielding layer, an insulating layer, an outer semi-conductive shielding layer, a metal shielding layer, a polyimide film layer and a sheath;
    所述导体的结构为：由一根高强度的芳纶丝和多根镀锡铜材质的单丝束合构成导体；芳纶丝在导体的轴线位置；单丝自内而外分为多层；单丝的束合方向为左向；单丝的束合节距不大于束合后外径的16倍；The structure of the conductor is as follows: a high-strength aramid filament and a plurality of tinned copper monofilaments are bundled to form the conductor; the aramid filament is at the axis of the conductor; the monofilament is divided into multiple layers from the inside to the outside ; The bundled direction of the monofilament is left; the bundled pitch of the monofilament is not more than 16 times of the bundled outer diameter;
    所述芳纶丝的断裂强力不小于1269N；The breaking strength of the aramid yarn is not less than 1269N;
    所述内半导电屏蔽层和绝缘层是由双层共挤的半导电屏蔽料和绝缘料构成；The inner semi-conductive shielding layer and the insulating layer are composed of a double-layer co-extruded semi-conductive shielding material and insulating material;
    所述外半导电屏蔽层是由重叠绕包半导电屏蔽带构成，绕包的重叠率不小于15％；所述半导电屏蔽带的厚度是0.12mm～0.15mm；The outer semi-conductive shielding layer is composed of overlapping wrapped semi-conductive shielding tape, and the wrapping overlap rate is not less than 15%; the thickness of the semi-conductive shielding tape is 0.12mm～0.15mm;
    聚酰亚胺薄膜层是重叠绕包聚酰亚胺薄膜构成；聚酰亚胺薄膜的厚度是0.025mm～0.05mm，绕包重叠率不小于25％。The polyimide film layer is composed of overlapping and wrapping polyimide films; the thickness of the polyimide film is 0.025mm～0.05mm, and the wrapping overlap rate is not less than 25%.
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