64/110kV Power Cable – 1×800mm² Copper Core XLPE Insulated Corrugated Welded Aluminium Sheathed High Voltage Underground Cable

Product Overview

The 64/110kV Power Cable with 1×800mm² copper conductor, XLPE insulation, and corrugated welded aluminium sheath is a premium high voltage underground transmission cable designed for critical power grid infrastructure. Rated at 64/110kV, this single-core cable combines high conductivity copper, solid dielectric insulation, and advanced metallic sheath technology to deliver exceptional electrical performance, mechanical protection, and long-term reliability.

The corrugated welded aluminium sheath represents a significant advancement in cable construction, offering an impermeable moisture barrier, excellent impact resistance, and enhanced flexibility for easier installation. This cable is the preferred choice for utility transmission networks, renewable energy grid connections, substation interconnections, and industrial high voltage power supplies where uninterrupted operation and low maintenance are essential.

Key Features

• High conductivity copper conductor – The 800mm² Class 2 stranded copper conductor provides superior current carrying capacity with minimal resistive losses. Copper's excellent conductivity makes this 64/110kV power cable ideal for applications where space is constrained and high power transmission is required, particularly in urban underground networks.
• XLPE solid insulation – The cross-linked polyethylene insulation offers high dielectric strength, low dielectric losses, and excellent thermal stability. This 64/110kV power cable operates continuously at 90°C conductor temperature and withstands short circuit conditions up to 250°C without compromising insulation integrity.
• Corrugated welded aluminium sheath – This distinctive construction feature provides multiple critical functions. The continuous welded aluminium tube is corrugated to enhance bending flexibility, making the 64/110kV power cable easier to install around bends and in confined cable trenches. The seamless metallic barrier prevents all water ingress into the cable core, serves as a fault current return path, and delivers robust mechanical protection against impact, compression, and rodent attack.
• Plastic outer sheath – The outer sheath, typically black high density polyethylene (HDPE) or low smoke zero halogen (LSZH) material, provides UV resistance, chemical protection, and additional mechanical defence for underground or outdoor installations of this 64/110kV power cable.
• Longitudinal and radial water blocking – In addition to the welded aluminium sheath, water swellable tapes are incorporated within the cable construction to prevent moisture migration along the cable length, ensuring reliable operation even if the outer sheath is accidentally damaged.

Applications

• This 64/110kV power cable is engineered for demanding high voltage transmission applications where reliability and performance cannot be compromised.
• Utility primary transmission networks – The 64/110kV power cable serves as underground transmission lines connecting primary substations, as urban grid infeed cables where overhead lines are not feasible, and as replacement cables for aging infrastructure requiring capacity upgrades.
• Renewable energy grid connections – Large scale solar farms and onshore wind farms require high capacity transmission cables to connect to grid substations, typically over distances of several kilometres. This 64/110kV power cable provides the necessary capacity and reliability for such renewable energy projects.
• Industrial power supply – Heavy industries such as steel manufacturing, petrochemical complexes, and data centres require dedicated high voltage feeds with guaranteed uptime. This 64/110kV power cable delivers the required capacity and durability for these critical applications.
• Infrastructure projects – Airport primary power distribution, railway traction substation feeds, and tunnel power transmission systems all demand cable types with superior fire safety and mechanical protection characteristics, making this 64/110kV power cable an excellent choice.

Construction Details

• The 64/110kV power cable follows a carefully engineered layer by layer design, each contributing to overall performance and reliability.
• Conductor – The core is formed from 800mm² copper, stranded to Class 2 configuration per IEC 60228. The stranding uses compact circular construction to minimise overall diameter while maintaining flexibility. Copper purity exceeds 99.95 percent, ensuring maximum conductivity and corrosion resistance for this 64/110kV power cable.
• Conductor screen – An extruded semi-conductive layer is applied directly over the conductor. This layer eliminates voids between the conductor surface and the insulation, ensuring uniform electrical stress distribution and preventing partial discharge within the 64/110kV power cable.
• XLPE insulation – The insulation is extruded and chemically cross-linked to achieve required thermal and mechanical properties. For this 64/110kV power cable with 800mm² conductor, nominal insulation thickness is approximately 16 to 18 millimetres, depending on the specific design and standard requirements.
• Insulation screen – Another extruded semi-conductive layer surrounds the insulation. Together with the conductor screen, this layer confines the electrical field within the insulation. Copper tape or copper wire provides electrical contact for the metallic sheath of this 64/110kV power cable.
• Welded aluminium sheath – The corrugated welded aluminium sheath is formed by longitudinally folding an aluminium strip around the cable core and welding the seam closed. The sheath is then corrugated to improve flexibility. Typical aluminium sheath thickness for this 64/110kV power cable ranges from 1.2 to 2.0 millimetres, depending on mechanical and fault current requirements.
• Anti-corrosion coating – A thin bitumen or polymeric coating is applied over the aluminium sheath to protect against corrosion, particularly where the 64/110kV power cable may be exposed to aggressive soil conditions or moisture.
• Plastic outer sheath – The final layer is an extruded plastic sheath, typically black high density polyethylene (HDPE). Sheath thickness ranges from 3.0 to 4.0 millimetres, providing mechanical protection and chemical resistance for this 64/110kV power cable. For fire sensitive installations, an LSZH sheath can be supplied.

Technical Specifications

Why Choose Welded Aluminium Sheath Construction for Your 64/110kV Power Cable

• The corrugated welded aluminium sheath offers significant advantages over alternative metallic screen constructions such as copper wire screens or lead sheaths for this 64/110kV power cable.
• Superior water blocking – The continuous welded tube creates a completely impermeable metallic barrier. Unlike wire screens, which contain voids that allow water migration, the sealed aluminium tube in this 64/110kV power cable prevents all moisture ingress.
• Excellent mechanical protection – The corrugated structure provides high resistance to impact, compression, and longitudinal stress. This 64/110kV power cable can withstand significant mechanical loads without damage to insulation or conductor.
• Flexibility for installation – Corrugations allow the 64/110kV power cable to bend more easily than a smooth tube of equivalent wall thickness, reducing bending radius and easing installation around bends and obstacles.
• Lightweight compared to lead – Aluminium has approximately one third the density of lead, making this 64/110kV power cable significantly lighter and easier to handle while providing equivalent or superior mechanical protection.
• Fault current capacity – The aluminium sheath provides a low resistance path for fault currents, typically capable of carrying 40 to 60 kiloamperes for 1 second, sufficient for most transmission system requirements.
• Recyclable and environmentally sound – Aluminium is fully recyclable and presents no environmental hazards associated with lead sheathed cables, making this 64/110kV power cable a more sustainable choice.

Installation Guidelines for 64/110kV Power Cable

• Proper installation practices are essential to realize this 64/110kV power cable's design life of more than 30 years.
• Trench preparation requires a clean, level bed of compacted sand or fine soil free from sharp stones and debris. The 64/110kV power cable should be installed with adequate sand covering before backfilling.
• Pulling tension must be monitored continuously during installation using a dynamometer, ensuring the maximum recommended value for this 64/110kV power cable is not exceeded. Cable rollers should be placed at intervals of 3 to 5 metres for straight runs and closer spacing for curved sections.
• Bending radii must be respected. When installing this 64/110kV power cable around bends, the minimum radius should be maintained to prevent buckling of the corrugated sheath or stress on insulation.
• Jointing and termination of this 64/110kV power cable require trained personnel and approved accessories specifically designed for welded aluminium sheath cables. The sheath must be carefully prepared to ensure proper electrical connection and sealing.
• After installation, acceptance testing for this 64/110kV power cable should include insulation resistance measurement, high voltage withstand test, partial discharge measurement, and sheath integrity testing.

Why Choose This 64/110kV Power Cable

• The copper conductor provides superior conductivity and mechanical robustness compared to aluminium alternatives, resulting in lower power losses and longer service life for this 64/110kV power cable.
• XLPE insulation eliminates the need for oil or gas pressure systems, making this 64/110kV power cable easier to install and maintain while eliminating environmental risks associated with fluid filled cables.
• The corrugated welded aluminium sheath ensures reliable operation even in flooded conditions, making this 64/110kV power cable suitable for river crossings, coastal areas, and high water table regions.
• High fault current capacity of the metallic screen provides safety and protection for connected transmission equipment, enhancing overall grid reliability.
• With proven performance in utility, renewable, and industrial applications worldwide, this 64/110kV power cable represents a dependable choice for critical high voltage transmission infrastructure.