Water Tree Retardant

Several countries have been using water tree-retardant, crosslinked polyethylene (TR-XLPE)
as the preferred medium voltage (5-46 kV) insulation for primary distribution cables. Other
countries are actively engaged in moving to this technology that has laid to rest the concerns
of water tree degradation of regular cross-linked polyethylene (XLPE). With proven improved
performance the Dow TR-XLPE system is suitable for Indian utilities.
M.S. Chavan, Ramachandran

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E
lectric utilities worldwide demand cable was manufactured in 1968. The key
underground distribution cables with advantage was higher rated conductor
longer life to increase reliability, temperature of 90C and an emergency
minimize service interruptions and lower rating of up to 130C, providing higher
overall lifetime costs for the distribution ampacity and lower dielectric losses. As with
systems. all innovations, unforeseen problems
For the past 25 years, the North American appeared when the use became wide spread.
utility industry (with TR-XLPE) and Germany There were growing concerns of cable failure
(with copolymer insulation), have been and was traced back to the cause of water
successful in using advanced performance treeing in 1972. It was discovered that
XLPE insulations on wet designs for unprotected cable cores (no outer jacket),
underground distribution systems. Since moisture ingression into the insulation,

T
then, other countries such as Philippines, combined with taped semiconductive shield
Newzealand, Australia, South Korea and interface imperfections that created high
The goal of many more have moved to using water tree- electrical stress points, led to water tree
TR-XLPE retardant, crosslinked polyethylene (TR-XLPE) initiation and growth. To resolve this problem
as the preferred medium voltage (5-46 kV) various measures were introduced such as
insulation is to
insulation for primary distribution cables. reduction of void sizes and moisture in the
effectively Other countries are actively engaged in insulation by using true triple extrusion dry
combine the moving to this technology. This technology curing process, use of extruded
has laid to rest the concerns of water tree semiconductive materials with drastically
excellent degradation of regular crosslinked reduced levels of ionic species. One of the
electrical polyethylene (XLPE). This improved primary solutions was the development of
performance, has been confirmed by water tree retardant (TR) XLPE insulation in
properties (high extensive field aging cable data. 1982.
ACBD, low This initial article touches upon history of
developments in cable manufacturing and Water Treeing Phenomenon
dielectric losses) compounds, water treeing, importance of The electrical degradation process of
and toughness of tree retardant TR-XLPE cable performance treeing in polymers occurs in the presence
differentiation and the value-added of electrical stress and moisture. This is
XLPE with ability
attributes for utilities in terms of total owning acknowledged as a leading cause of non-
to prevent the costs through the life of distribution cable mechanical insulation degradation and cable
growth of water systems. failure.
The water-treeing process may be
trees under Historical Developments considered to occur in three phases (Figure
electrical stress, Crosslinked polyethylene, XLPE, was 1):
invented in year 1963 and the first ever XLPE Initiation is due to uneven stress at
when the
insulation comes
in contact with
moisture.

Figure-1: Water treeing phenomenon

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 Water Tree Retardant

interface and or contamination (micron Tree Retardant Xlpe Enhanced Cable

level) in insulation. (Tr-Xlpe) Insulation Performance
Growth continues in the presence The goal of TR-XLPE insulation is Over a period, moisture in the
of moisture (in ppm levels) under to effectively combine the excellent ground will slowly diffuse through the
electrical stress, with the water tree electrical properties (high ACBD, low jacket or conductors (due to poor cable
growing along electrical field, dielectric losses) and toughness of manufacturing or terminations process)
contributing to lowering the electrical XLPE with ability to prevent the through semiconductive screens and
strength of the insulation / cable. When growth of water trees under electrical into the insulation. Since moisture
the water tree gets long enough, with stress, when the insulation comes in ingress into the cable is inevitable in
the electrical strength of the insulation contact with moisture. Such a most installations, compound suppliers
being quite low, any surge due to performance has to be established continuously work to minimize
switching or lightening can lead to through material tests, accelerated contaminants and imperfections that
bridging, formation of electrical tree, cable (wet) aging tests and of course, can serve as water tree initiation sites.
leading to rapid cable failure. ultimately, proven in the field. The The water tree retardant XLPE, TR-XLPE,
propensity for water tree growth can was developed to resist the water tree
Type of Water Trees be studied using the ASTM D6097-97 growth. To evaluate the effectiveness of
Vented Water Trees (Figure 2) Test. This material test allows these efforts, a variety of testing
Permanent structures that grow from comparison of materials under protocols have been designed to
semicons surface into polymeric controlled conditions. (Figure 4) rapidly screen new cable compounds,
insulations, generally continue growing
and can bridge the insulation. Vented
water trees can grow from either the
conductor or the insulation screen into
the insulation.

Figure-2: Vented Water tree

Bowtie Water Trees (Figure 3) Figure-4: Accelerated material water tree growth rate test ASTM D6097- 97
Permanent structures that grow within
the body of polymer insulation. They are It is clear that TR-XLPE material has manufacturing and cable constructions.
generally limited in size. The term bowtie significantly reduced tree growth rate Accelerated Water Treeing test (AWTT)
is derived from the shape of the tree. and the trees have a constrained is a widely accepted test in North
geometry. The most predominant America. Details of the test are found in
commercial TR-XLPE uses a proprietary, the ANSI / ICEA S-649-2004.. Typical
non-fugitive, additive in the XLPE results of one year wet aging done
during the compounding process that under accelerated conditions (water in
effectively renders the moisture to be conductors and in the aging tube, 3
non-effective in growing water trees. times the rated voltage stress, 90C
The effectiveness of TR-XLPE has conductor temperature in air) at Wuhan
been documented both in laboratory High Voltage Research Institute, China
cable aging studies as well as historical are shown in Figure 5. It is evident that
field performance. TR-XLPE has significantly higher ACBD
Figure-3: Bowtie Water tree (AC Breakdown Strength) over the one-

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 Water Tree Retardant

year test, than XLPE, while poor quality from field measurements, it was
XLPE did not meet the standard possible to estimate the moisture
requirements, with all cables failing content in PILC cables; identify the
within 150 days of aging. deterioration of XLPE power cables
due to presence of water trees; and
Proven and Field Experience also identify the influence of
While laboratory accelerated accessories in the cable system.
testing of cables provide a window
to the potential performance of Conclusion
cables under field operation, there is The Longer Life XLPE systems
Figure-6: Lower life cycle cost with
no substitute for actual field (TR-XLPE) allows for cost effective
TR-XLPE Insulation
evaluation. Excellent field means to improve system reliability.
performance can be reflected in very TR-XLPE meets and exceeds the
low non-mechanical cable failure Potential For Water Treeing current IS 798 Part II requirements and
rates as well as maintaining a high in Indian MV Underground allows for simpler cable systems.
level of electrical strength over time. Cables This system has been globally
Review of available literature It should be noted that utilities in proven and in use for more than 25
demonstrates very low failure rates general do not always track their years.
for TR-XLPE. Such examples include cable performance and failure Based on industry experience, the
field aging tests from Alabama Power, statistics. While utilities are always expected life of primary cable systems
Wisconsin Public Service, Oncor anxious to improve their system with Dow TR-XLPE is at least 40 years,
Services and CenterPoint Energy. reliability; a strong statistical database thus ensuring significant value to the
is not readily utility in enhanced reliability and lower
available. There life cycle costs.
have been cases The enhanced performance
of water treeing TR-XLPE insulated cables meet the
formation in the predominant global accelerated wet
cables installed aging standards such as ANSI/ICEA
underground for S-94-649-2004, AEIC CS8-07, CENELEC.
the last 3-18 years, With the growing need for reliable
as per CPRI News electric power distribution and
APR-JUNE 2008 increasing use of underground cables,
From the analysis Indian utilities will be well served to
of voluminous adopt this enhanced performance
data obtained TR-XLPE system that has a proven
Figure-5: WUHVRI AWTT testing data
from laboratory track record of over 25 years. 
studies as well as

Milind S Chavan is the End Use Marketing Leader for India, Middle East & Africa for Dow
Lower Life Cycle Cost Wire & Cable. He holds Bachelor of Engineering degree in Electronics & Telecommunication
Based on the laboratory testing and from Amravati University and Masters of Engineering in Electronics from Government College
field aged cable analysis for more than of Engineering, Aurangabad, Maharashtra. He closely interact with power and Telecom utilities
25 years it is predicated that the cables to promote the Dows new technological products & solutions to help utilities on life cycle
Milind S cost reduction and enhancing the reliability & longevity of underground system. He published
made with TR-XLPE insulation shall several papers at various conferences on Telecom & Power.
Chavan
have the life expectancy of more than
Ramachandran is the Global Director of End Use Marketing for Dow's Wire and Cable
40 years as against 20-25 years for the
business unit. He holds undergraduate degrees in Chemistry and Metallurgical Engineering
cable made with XLPE insulation. The from Indian Institute of Science, Bangalore, MS in Materials Science and Engineering from
Figure 6 demonstrates the typical life Columbia University, New York and an MBA from SUNY, Buffalo, New York. His role and focus
cycle cost comparison for the cables is to understand the critical needs and issues of cable end users such as electric utilities to
help drive Dow product development and offer solutions and support. He is a Senior Member
with XLPE & TR-XLPE insulation. There is Ramachandran
of IEEE, member of CIGRE and the current Chair of A 14 D, Power Cable Standards Group of
huge saving potential for the cables the Insulated Conductors Committee of IEEE. He has been recently named a co-editor of the
manufactured with TR-XLPE insulation High Voltage Magazine of the Wuhan High Voltage Research Institute. He holds several
patents and authored more than 20 papers.
over the cable life cycle.

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