As the world transitions towards widespread electrification and the adoption of renewable energy sources, the reliability and longevity of cable systems become paramount. The backbone of modern infrastructure, these systems power industries, deliver clean energy to households, and support the expanding urban landscape. Uninterrupted performance is essential for maintaining the safety and efficiency of energy grids, especially with growing demand and increasingly unpredictable environmental conditions.
High-quality cable jacketing materials play a pivotal role in safeguarding cable systems. They act as the first line of defence, protecting against moisture, chemical exposure, fire and physical abrasion while ensuring mechanical integrity. Superior jacketing materials preserve the cables’ structural properties amid varied environmental challenges – they not only guarantee reliability but also extend the lifespan of the systems, contributing to long-term and sustainability.
Challenges in Cable Installations
Cables installations in harsh environments are often subjected to extreme temperatures, chemical exposure, moisture ingress, and mechanical stress. These conditions can lead to premature wear and tear, compromising the performance and lifespan of the cables. Areas with high ultraviolet (UV) exposure or chemically aggressive environments are particularly problematic which can result in degradation of jacketing materials. Selecting the appropriate jacketing material is critical to address these challenges effectively.
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Advantages of HDPE and MDPE for Cable Jacketing
High-density polyethylene (HDPE) and medium-density polyethylene (MDPE) are pre-compounded thermoplastic materials known for their exceptional durability and resilience. HDPE boasts high-tensile strength, excellent resistance to abrasions, and superior resistance to chemicals and UV radiation. MDPE offers a balance of rigidity and flexibility, making it ideal for installations where mechanical stress and bending are involved. Both materials are hydrophobic, which reduces water ingress – a critical factor in humid or moisture-laden environments.
Proper UV performance over the lifetime of a cable can only be achieved with pre-compounded virgin polymers with high-quality carbon black particles, ensuring good dispersion. This is evidenced by mechanical performance studies showing the superiority of pre-compounded jacketing materials over in-line mixing at the production line.
Optimising Medium Voltage Cables with Water Tree Retardant (WTR) XLPE
Water Tree Retardant Cross-Linked Polyethylene (WTR XLPE) is a specialised insulation material designed to resist water trees – microscopic channels that develop within the insulation when exposed to moisture and electrical stress. These water trees can significantly weaken the dielectric strength of the cable, reducing its performance and lifespan. HDPE and MDPE jacketing materials provide excellent moisture barriers and mechanical protection, effectively mitigating the water treeing effect and prolonging the cable’s operation life.
Graph 2 below shows this combination of using HDPE or MDPE jacketing with WTR XLPE insulation effectively mitigates the water treeing effect, representing a robust solution for optimising cable longevity and efficiency.
Studies have shown that moisture migration in power cable systems can reduce the electrical breakdown strength by 50% over a period of 10 years. Using HDPE or MDPE jacketing ensures stable retention of physical properties in combination with a high-quality water barrier, maintaining the reliability of the cable in challenging environments. Graph 3 shows the electrical breakdown strength of a medium voltage (MV) cable that has been in service for 10 years with two different types of jacketing materials. After 10 years, both medium voltage cables were taken out of service to undergo an electrical breakdown test.
Emerging Requirements for Critical Installations
As urbanisation accelerates, more metro lines are being constructed in Asia, increasing the need for dependable cable jacketing solutions in critical areas such as tunnels and metro systems. ST-12 jacketing materials are preferred for these environments due to their high mechanical strength, durability, and compliance with stringent flame tests. These properties ensure robust performance, reduced smoke release, and enhanced fire safety, making them ideal for modern infrastructure.
DYM Solution Co. Ltd, Borouge’s affiliate company in South Korea, meets this demand with its fully qualified ST-12 solution, DYM-8867, specially designed for high and medium voltage cable jacketing. Combining mechanical resilience with superior fire resistance, DYM-8867 delivers reliability and safety tailored for use in metro systems and tunnels.
Latest Trends in Cable Jacketing
The trend of using HDPE and MDPE as jacketing materials for power cables is rapidly growing in India. These materials are highly valued for their moisture resistance, mechanical durability, and ability to enhance cable lifespan, making them ideal for the country’s expanding infrastructure projects. While India is quickly embracing these solutions, Europe has already fully adopted HDPE and MDPE for cable jacketing, setting a benchmark for global implementation.
For low voltage utility cables, MDPE stands out as an excellent option due to its flexibility and superior water barring properties, providing an optimal balance of performance and practicality. Semi-conductive jacketing is another major trend, particularly for High Voltage (HV) and Extra High Voltage (EHV) cables. These jackets are essential in controlling electrical fields and maintaining cable integrity, ensuring high performance and longevity. DYM-710 is a specialised semi-conductive jacketing grade designed for this application.
Together, HDPE, MDPE, and semi-conductive jacketing materials are setting new benchmarks for reliability in power cable systems worldwide.
Also Read: Engineering Safer Cables for India’s Infrastructure Growth: Vikas Ecotech’s Flame-Retardant Solutions in Action
Setting New Standards: Borouge’s HDPE and MDPE Solutions
In the realm of cable jacketing materials, Borouge stands out as a leader with a commitment to quality and innovation. Borouge’s pre-compounded HDPE and MDPE materials are engineered to meet the demanding requirements of modern cable installations. Their products have set new benchmarks for reliability and performance, safeguarding infrastructure against the harshest environmental conditions.
Borouge’s focus on research and development has led to the creation of advanced jacketing materials that not only comply with international standards but often exceed them. By investing in state-of-the-art manufacturing processes and maintaining stringent quality controls, Borouge ensures that every product delivered is of the highest quality, capable of withstanding the challenges posed by extreme applications.
As the world embraces electrification and renewable energy, the importance of reliable cable systems cannot be overstated. High-quality jacketing materials like HDPE and MDPE play a crucial role in maintaining the integrity and longevity of these systems. Companies like Borouge lead the industry by providing innovative and durable solutions that ensure the continued safety and efficiency of our energy infrastructure.
