MV CCV Line for Medium Voltage Cable Manufacturer

MV CCV Line for Medium Voltage Cable

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35kV Cable Extrusion Line, Triple Extrusion

This MV CCV line is typically designed for triple extrusion of XLPE insulated medium voltage cables for use at voltages ranging from 6kV to 35kV. By absorbing world's advanced catenary continuous vulcanization (CCV) technology, Baicheng Miracle has developed and manufactured this three-layer extrusion dry cure cross-linking line in-house, which was the first in the domestic market.

Our independently developed three-layer crosshead has obtained national patent, due to its great convenience and ease of alignment. Furthermore, the patented control technology in catenary line is characterized by high resistance against interference, ensuring an exceptional stability.

Medium voltage cables manufactured by this extrusion line are supplied in diverse sizes, diameters, lengths, layer thickness and other technical specifications. Depending on applications, the produced XLPE insulated power cables can be laid directly in the ground or buried in underground ducts, also suitable for submerged under water and working on overhead transmission systems.

Features

Triple extrusion process for XLPE insulated cables of voltages up to 35kV;
Capable of manufacturing power cables used for a variety of applications;
Computer control, touch screen operation, Siemens TIA Portal software, and high-resolution HMI interface;
Triple crosshead provides great convenience and ease of alignment;
Customer-specific modified versions are available, which deviate from the standard version in speed adjustment by control of CV tube temperature;

MV Cable Triple Extrusion Line (6 Sections)

Voltage class	XLPE: 6-35kV
Conductor size	Cu: 25-630mm² Al: 35-800mm²
Max. cable weight	10kg/m
Max. cable diameter	70mm
Cable construction	Conductor screen (inner semiconductor layer) 0.5-2mm	Insulation 3.4-12mm	Insulation screen (outer semiconductor layer) 0.5-2mm
Line speed	0-30m/min
Line execution	Half catenary
Length of cross-linking section	Approx. 41m/6 sections (6 tubes)
Length of pre-cooling section	12m/2 sections (2 tubes)
Length of cooling section	54m/9 sections (9 tubes)
Arrangement of extruders	Φ65 extruder for conductor screen Φ150 extruder for cross-linked polyethylene (XIPE) Φ90 extruder for insulation screen
Electricity	Installation capacity 750kVA	380V ±10% 50Hz±1%	3 phase 4 wire
Water	Water pressure 0.2-0.6MPa	Water consumption 15m³/h (circulating water from reservoir)
Compressed air	0.6-0.8MPa	Air consumption 0.8m³/min
Nitrogen	Pressure 2.0-2.5MPa	Purity 99.5%	Consumption 1-2m³/h
Nitrogen storage tank	≥6m3 (1 pc)

MV Cable Triple Extrusion Line (9 Sections)

Voltage class	XLPE: 6-35kV
Conductor size	Cu: 25-630mm² Al: 35-800mm²
Max. cable weight	10kg/m
Max. cable diameter	70mm
Cable construction	Conductor screen (inner semiconductor layer) 0.5-2mm	Insulation 3.4-12mm	Insulation screen (outer semiconductor layer) 0.5-2mm
Line speed	0-30m/min
Line execution	Half catenary
Length of cross-linking section	Approx. 54m/9 sections (9 tubes)
Length of pre-cooling section	12m/2 sections (2 tubes)
Length of cooling section	90m/15 sections (15 tubes)
Arrangement of extruders	Φ80 extruder for conductor screen Φ175 extruder for cross-linked polyethylene (XIPE) Φ100 extruder for insulation screen
Electricity	Installation capacity 1050kVA	380V ±10% 50Hz±1%	3 phase 4 wire
Water	Water pressure 0.2-0.6MPa	Water consumption 15m³/h (circulating water from reservoir)
Compressed air	0.6-0.8MPa	Air consumption 0.8m³/min
Nitrogen	Pressure 2.0-2.5MPa	Purity 99.5%	Consumption 1-2m³/h
Nitrogen storage tank	≥6m3 (1 pc)×2

Extruder & Crosshead

Extruder

Three-layer Crosshead

Triple extrusion lines have three extruders connected to one common three-layer crosshead for the simultaneous extrusion of conductor screen layer, insulation layer and insulation screen layer.

Technical Data of Extruders

65/20D Extruder

Max. screw speed: 46.5rpm
Gear reduction ratio: 32:1
Extrusion output: 35kg/h
Used for extruding conductor screen layer (inner semiconductor layer)

90/20D Extruder

Max. screw speed: 41.5rpm
Gear reduction ratio: 36:1
Extrusion output: 60kg/h
Used for extruding insulation screen layer (outer semiconductor layer)

150/25D Extruder

Max. screw speed: 40rpm
Gear reduction ratio: 37.5:1
Extrusion output: 250kg/h
Used for extruding insulation layer

Technical Data of Three-layer Crosshead

Technical Parameters

Conductor diameter: 6-34mm
Max. cable diameter: 70mm
Extrusion thickness:
First layer: 0.5-2.0mm
Second layer: 2.0-12mm
Third layer: 0.5-2.0mm
Heating method: oil or water heating

Features

Designed with circulating distribution flow channel and restrictor ring, the length of flow distributors and crosshead is greatly shortened in contrast to other three-layer crosshead, thus reducing its weight;
Easy to disassemble for convenient cleaning;
Providing great convenience and ease of alignment during extrusion process;

Control System

Highly resistant to interference, minimum fluctuation of cables in tube, ensuring stable running and easy to maintain;
Control system is placed at the middle part of heating zone, it can protect cables from contacting the tube wall during heating process;
When the control receives the signal of cable position, the rotation speed of lower capstan (pulling) will be adjusted accordantly;

Details

Portal Upper Beam Travelling Pay-Off Stand

Features

Gantry structure with mechatronic design, achieving reciprocating motion while keeping the alignment of center line when paying off;
Shaftless pay-off reel moves up and down between two posts, driven by AC motor;
Dancer is adopted for speed control;
Pay-off stand can achieve rotation in both positive and negative directions;
Touch screen allows operator to input technical parameters easily and conveniently;
The pay-off stand is independently controlled;

Specifications

Drum diameter: 1600-2500mm (GB4004-84, PN Type)
Drum width: 1180-1900mm
Drum weight: Max.16t
Pay off tension: 5000N
Main drive: 5.5kW DC motor, 4 quadrant, Parker 590P (original Eurotherm)
Dancer: used for speed control, keeping the cable aligned with center line when paying off

Horizontal Accumulator

Specifications

Accumulation length: 120m
Pulley diameter: 1600mm
Tension control: Siemens 200 Smart PLC Parker 590P Drive (original Eurotherm), 300-3200N adjustable
Traction wheel speed: 0-2m/min

Capstan

Lower Pull-Out Caterpillar

Lower Pull-Out Capstan

Features

Used for pulling cable conductors from lower level to desired height;
Belt wrap capstan (or caterpillar capstan) operates synchronously in CCV line;
Conductor positioning unit ensures the cable conductors of different sizes placed in alignment with the center of the crosshead;
Transmission unit adopts fixed base, spiral bevel gear reducer and DC motor;

Specifications

Pulling method: belt wrap capstan
Capstan wheel diameter: 2000mm
Adjusting range: 0-30m/min (four gear shifts)
Pulling force: max. 30kN
Belt contact length: 3m or above
Cable diameter: up to 100mm
Speed sensor equipped with line speed meter
Main drive: 11kW DC motor, Parker 590P drive

Belt-type Twister with Angle Adjustment

Specifications

Twister weight: 650kg
Overall dimensions: 1525mm×975mm×1243mm
26 grooved passive wheels are mounted on both sides. The distance between wheel sets on both sides is adjustable ranging from 2 to 200mm. The wheel sets move on both sides.
The rollers on both sides can be adjusted by ±50mm, which is calibrated by the caliper. Max. wire diameter passing through is 70mm.
The center height is 1m. (If the height is not consistent with the outlet of end seal, cut off the footing to change the center height.)
The twister comes with a welded machine body, a passive transmission mechanism, and a semi-enclosed stainless steel cover.
It’s installed between the end seal and pull-out capstan.
Belt width: 150mm, thickness: 20mm

Accumulator & Upper Auxiliary Caterpillar

Accumulator
End Seal
Extruder
Lower Capstan
Pay off Stand
Upper Capstan
35kV Cable Extrusion Line