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MODELLING OF XLPE NANOCOMPOSITE POWER CABLE USING COMSOL MULTIPHYSICS

NIROSHINI A/P SUKUMARAN

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MODELLING OF XLPE NANOCOMPOSITE POWER CABLE USING COMSOL MULTIPHYSICS

NIROSHINI A/P SUKUMARAN

A project report submitted in partial fulfilment of the requirements for the award of the degree of

Master of Engineering (Electrical Power)

Faculty of Electrical Engineering Universiti Teknologi Malaysia

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iii

This project report is dedicated to my beloved mother and father. I give my deepest expression of love and appreciation for the encouragement and support

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iv

ACKNOWLEDGEMENT

First and foremost, I would like to express my deepest sincere gratitude to my supervisor Dr. Mohd Hafizi Bin Ahmad for his patience in guidance, motivation, encouragement, enthusiasm and his immerse knowledge on master project. To Dr. Zuraimy B. Adzis and Dr. Mona Riza Bt. Mohd Esa, I thank you for your idea and insightful comment during seminar sessions which are useful in improving master project.

A special thanks and gratitude to my superior in YTL Power Services, Mr. Raman Subramaniam for your moral support, advise and intellectual support in my master program.

Finally, and above all, I cannot begin to express my unfailing gratitude and love to close friends and my family especially my parent, R.Sukumaran and B.Kathiyane who has prayed, supported and understood me throughout this process and has constantly encouraged me when the tasks seemed challenging and insuperable.

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v

ABSTRAK

Laporan ini membentangkan pemodelan kabel polyethylene (XLPE) bersalut nano terlindung dengan kehadiran lompang menggunakan menggunakan perisian COMSOL Multiphysics. Lompang sama ada dengan medium udara atau air adalah salah satu faktor yang menyebabkan degradasi penebat kabel. Kehadiran lompang di dalam kabel berlaku semasa proses penghubung silang di mana penembusan wap air berlaku. Dengan menggunakan perisian COMSOL Multiphysics mungkin menjadi kaedah terbaik untuk menyiasat taburan medan elektrik dan pengagihan medan potensial lompang dalam kabel. Kaedah elemen terhingga adalah salah satu daripada kaedah berangka terkini yang digunakan untuk menganalisis elektrik dan pengagihan medan potensi lompang dalam kabel kuasa. COMSOL Multiphysics adalah salah satu alat berkuasa yang melaksanakan kaedah unsur terhingga dengan menyelesaikan persamaan Poisson. Dalam laporan ini, perbandingan kedua-dua jenis bahan kabel XLPE seperti kabel XLPE tulen dan kabel bertebat nano yang dibuat dalam penyiasatan elektrik dan pengagihan medan potensi lompang dalam kabel dengan menganalisis dan membandingkan corak graf dihasilkan oleh dua jenis bahan penebat kabel. Keputusan yang diperolehi daripada simulasi COMSOL menunjukkan medan elektrik dipengaruhi oleh jenis lompang, lokasi lompang dan kehadiran zarah nano di dalam penebat XLPE.

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vi

ABSTRACT

This report presents modelling of a nano-insulated cross-linked polyethylene (XLPE) cable with the presence of voids using COMSOL Multiphysics software. Void either with the medium of air or water is one of the factor that causes degradation of the power cable insulation. The void that presence in the power cable is occur during cross linking process where the penetration of water steam happened. Using COMSOL Multiphysics software might be the best method in investigating the electric field distribution and potential field distribution of the void in the power cable. Finite element method is one of the latest numerical methods use in analyze the electrical and potential field distribution of the voids in the power cable. COMSOL Multiphysics is one the powerful tools that implement the finite element method by resolving Poisson’s equation. In this report, comparison of both type of the XLPE cable materials such as pure XLPE cable and nano-insulated cable are made in investigating the electrical and potential field distribution of the voids in the cable by analyze and compare the graph pattern generated by two types of the cable insulation material. Simulation results indicate that the electric field distribution is influenced by the type of the void, void position and presence of nanoparticle in the XLPE insulation.

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vii

TABLE OF CONTENTS

CHAPTER TITLE PAGE

DECLARATION ii

DEDICATION iii

ACKNOWLEDGEMENT iv

ABSTRAK v

ABSTRACT vi

TABLE OF CONTENTS vii

LIST OF TABLES xi

LIST OF FIGURES xii

LIST OF ABBREVIATIONS xiv

LIST OF APPENDICES xvi

1 INTRODUCTION 1 1.1 Introduction 1 1.2 Background of Study 2 1.3 Problem Statement 4 1.4 Objectives 5 1.5 Scope of Study 5 1.6 Project Methodology 6

1.7 Project Report Structure 7

2 LITERATURE REVIEW 9

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viii modelling of the XLPE power cable

2.1.1 Theoretical Approach 11

2.1.2 Parametric Analysis 11

2.1.3 Finite Element Method (FEM) 16

2.1.3.1 Maxwell Software 16

2.1.3.2 Static Regime Modelling 18

2.1.3.3 COMSOL Multiphysics 20

2.2 Summary of research on techniques used 22

2.3 Direction of further research 23

3 RESEARCH METHODOLOGY 24

3.1 Introduction 24

3.2 General Development and Implementation of 27

Electrostatic Model

3.2.1 Geometrical Parameter of the XLPE 27

Power Cable

3.2.2 XLPE Power Cable Material and 28

Properties

3.2.3 Electrostatic Model 29

3.3 COMSOL Multiphysics Software Flowchart 31

4 RESULTS & DISCUSSION 34

4.1 XLPE power cable without the existence of 35

void

4.1.1 2D Pure XLPE power cable without the 35

presence of void

4.1.2 3D Pure XLPE power cable without the 37

presence of void

4.1.3 2D Nanocomposite XLPE power cable 39

without the presence of void

4.2 XLPE power cable with the existence of air- 41

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ix

4.2.1 2D Pure XLPE power cable with the 41

presence of air-filled void

4.2.2 3D Pure XLPE power cable with the 43

presence of air-filled void

4.2.3 Nanocomposite XLPE power cable 45

with the presence of air-filled void

4.3 XLPE power cable with the existence of water- 46 filled void

4.3.1 2D Pure XLPE power cable with the 47

presence of water-filled void

4.3.2 3D Pure XLPE power cable with the 48

presence of water-filled void

4.3.3 Nanocomposite XLPE power cable 50

with the presence of water-filled void

4.4 XLPE power cable with the existence of air-filled 52 void at different location

4.4.1 2D Pure XLPE power cable with the 53

presence of air-filled void located further away from the conductor

4.4.2 3D Pure XLPE power cable with the 54

presence of air-filled void located further away from the conductor

4.4.3 Nanocomposite XLPE power cable with 56

the presence of air-filled void located further away from the conductor

4.5 XLPE power cable with the existence of water 58 filled void at different location

4.5.1 2D Pure XLPE power cable with the 59

presence of air-filled void located further away from the conductor

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presence of air-filled void located further away from the conductor

4.5.3 Nanocomposite XLPE power cable with 62

the presence of air-filled void located further away from the conductor

4.6 Summary: Comparison between the pure XLPE 64

power cable and nano-insulated XLPE power cable

4.6.1 Comparison between the pure XLPE 64

power cable and nano-insulated XLPE power cable without the presence of void

4.6.2 Comparison between the pure XLPE 65

power cable and nano-insulated XLPE power cable without the presence of void

5 CONCLUSIONS & RECOMMENDATION 67

5.1 Project Conclusions 67

5.2 Problem encounter 68

5.3 Recommendation for Future Works 69

REFERENCES 70

Appendices A-C 74

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xi

LIST OF TABLES

TABLE NO. TITLE PAGE

2.0 Electric field stress on the different type of nano- 21

filler

2.1 Summary of gaps of the technique used 22

3.0 Research Design 26

3.1 Geometrical Parameter of the XLPE Power Cable 28

3.2 XLPE Power Cable Material with Its Respective 28

Properties

4.1 Electric Field Distribution on the XLPE Power Cable 65

without void

4.2 Electric Field Distribution on the XLPE Power Cable 66

with void

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xii

LIST OF FIGURES

FIGURE. NO TITLE PAGE

1.0 Development of the cable insulation material 3

over the years

2.0 Techniques of analyzing the electric field and 10

potential field distribution of cavities in the XLPE cable

2.1 Frequency of damage in PE versus electric field 12

based on variation on void height

2.2 Frequency of damage in PE versus electric field 13

based on variation of temperature

2.3 Frequency of damage in PE versus electric field 14

based on variation of conductivity of material

2.4 Frequency of damage in PE versus electric field 15

based on variation of void radius

2.5 Electric field distribution across the cable 17

2.6 Electric field distribution of a different void shape 18

2.7 Overview of the zone that consists of the 19

voids

2.8 Simulation from COMSOL Multiphysics of 21

XLPE with 5% wt of (a)nanoclay

(b)nanosilica, (c) nanocarbonate

3.1 Project methodology flowchart 26

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3.3 COMSOL Multiphysics flowchart 32

4.1 Electric field distribution and electric potential 36

in the pure XLPE cable.

4.2 Electric field distribution in the pure XLPE 36

cable

4.3 Electric field distribution and electric 37

potential in the 3D pure XLPE cable.

4.4 Electric field distribution in the 3D pure XLPE 38

cable

4.5 Electric field distribution and electric 40

potential in the 2D nanocomposite XLPE cable.

4.6 Electric field distribution in the 2D 40

nanocomposite XLPE cable

4.7 Electrical field distribution and potential field 42

distribution in the 2D pure XLPE cable with the presence of air-filled void

4.8 Electrical field distribution in the 2D pure 42

XLPE cable with the presence of air-filled void

4.9 Electrical field distribution and potential field 43

distribution in the 3D pure XLPE cable with the presence of air-filled void

4.10 Electrical field distribution in the 3D pure 44

XLPE cable with the presence of air-filled void

4.11 Electrical field distribution and potential field 45

distribution in the nanocomposite XLPE cable with the presence of air-filled void

4.12 Electrical field distribution in the 46

nanocomposite XLPE cable with the presence of air-filled void

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4.13 Electrical field distribution and potential field 47 distribution in the 2D pure XLPE cable with

the presence of water- filled void

4.14 Electrical field distribution in the 2D pure 48

XLPE cable with the presence of water-filled void

4.15 Electrical field distribution and potential field 49

distribution in the 3D pure XLPE cable with the presence of water- filled void

4.16 Electrical field distribution in the 3D pure 49

XLPE cable with the presence of water-filled void

4.17 Electrical field distribution and potential field 51

distribution in the nanocomposite XLPE cable with the presence of water- filled void

4.18 Electrical field distribution in the 51

nanocomposite XLPE cable with the presence of water-filled void

4.19 Electrical field distribution and potential field 53

2D pure XLPE cable with the presence of air- filled void further away from conductor

4.20 Electrical field distribution in the 2D XLPE 54

cable with the presence of air-filled void further away from conductor

4.21 Electrical field distribution and potential field 55

distribution in the 3D pure XLPE cable with the presence of air- filled void further away from conductor

4.22 Electrical field distribution in the 3D pure 55

XLPE cable with the presence of air-filled void further away from conductor

4.23 Electrical field distribution and potential field 57

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distribution in the nanocomposite XLPE cable with the presence of air- filled void further away from conductor

4.24 Electrical field distribution in the 57

nanocomposite XLPE cable with the

presence of air-filled void further away from conductor

4.25 Electrical field distribution and potential field 59

distribution in the 2D pure XLPE cable with the presence of water- filled void further away from conductor

4.26 Electrical field distribution in the 2D Pure 60

XLPE cable with the presence of water-filled void further away from conductor

4.27 Electrical field distribution and potential field 61

distribution in the 3D pure XLPE cable with the presence of water- filled void further away from conductor

4.28 Electrical field distribution in the 3D pure 61

XLPE cable with the presence of water-filled void further away from conductor

4.29 Electrical field distribution and potential field 63

distribution in the nanocomposite with the presence of water- filled void further away from conductor

4.30 Electrical field distribution in the 63

nanocomposite XLPE Cable with the presence of water-filled void further away from conductor

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xiv

LIST OF ABBREVIATIONS

XLPE - Cross-linked Polyethylene

HVDC - High Voltage Direct Current

DC - Direct Current

FEM - Finite Element Method

PVC - Polyvinylchloride

PE - Polyethylene

2D - Two Dimensional

3D - Three Dimensional

m - Meter

V/m - Volt per meter

SiO2 - Silicon Dioxide

E - Electric Field

V - Potential

Ɛ - Relative Permittivity

Ɛr - Relative Permittivity of the Insulating Material

Ɛ0 - Free Space Permittivity

D - Electric Displacement of the Conductor

E - Electric Field of Cavity

r - Radius of the Conductor

rc - Cavity Radius

rz - Radius of the Area Influenced

𝜀 - Permittivity of the Cavity

𝜀 - Permittivity of the XLPE

n - Normal Component

𝜌 - Free Space Charge

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xvi

LIST OF APPENDICES

APPENDIX TITLE PAGE

A Project schedule semester 1 74

B Project schedule semester 2 75

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CHAPTER 1

INTRODUCTION

1.1 Introduction

Electricity is useful and important for everyone where it used to power up most of the electrical equipment such as mobile phone, computer, lighting, and others essential appliances. Without electricity, it may interrupt and give rise to certain problem such as industry may have stop production, people have to stay in dark and others inconvenience of the lifestyle.

According to the recent development either in technology or lifestyle, the demand of the electricity keeps increasing over the years. The increase in the demand of the electricity have been a huge concern to the energy utilities where they must make sure sufficient of supply is available in the system. Apart from that, energy utilities have to ensure that the electricity supply is always reliable and stable. In order to ensure the stability of the electricity supply to the consumer, power cable is one of the main component in the power system need to be taken care properly. Any damage occurred on the power cable will cause power interruption. Most of the damage occurred on the power cable is due to damage in the power cable insulation.

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2 Therefore, good quality of the power cable insulation will ensure the power system in the stable condition. Electric power cable has evolved by time to time to tally with the present technology. Evolvement of power cable from PVC type to the addition of the nano filler in the power cable insulation at current technology.

Addition of nano filler in the power cable have improved the electrical characteristics of the power cable where it reduces the risk of partial discharge [1].

1.2 Background of Study

Power cable is one of the essential component in the power system especially used in the overhead line and underground lines. Most of the power cable expensive to be replaced in term of the installation cost. Therefore, it is important to have a good cable insulation where can be used for many years without cause any power interruption due to failure of the cable. The condition of the insulation system is determining the cable lifetime due to insulation system continuously encounter stresses such as thermal, electrical, mechanical, chemical and environmental stresses. Presence of the voids [2] might cause degradation of the cable insulation which leads the failure of the cable. Cable insulation material is the most important component need to be considered properly in order to ensure no failure happened.

The development of the cable insulation material from the PVC in the year 1913 introduced by Friedrich to present where the nanocomposite XLPE cable introduced by the Lewis in year 1994. For the past few decades since year 1955 introduced by Gilbert, cross-linked polyethylene (XLPE) cable is widely used in the transmission and distribution industry due to its outstanding features such as good dielectric strength, resist to solvent, dielectric permittivity is low and low loss factor as well, good dimensional stability and behavior of the thermo-mechanical.

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3 There is drawback in the usage of the XLPE power cable due to the formation of the space charge and treeing which decreases the service time of the power cable. Formation of the space charge [3] due to penetration of the water steam during cross-linking process and wrong extrusion. These leads to the formation of the voids in the power cables which enhance the partial discharge [1] to be occurred.

Figure 1.0 Development of the cable insulation material over the years.

In the year 1994, Lewis had introduced nanometric dielectric which drawn interest to many researchers on this nanocomposite material as this material able to act as barrier in the formation of the space charge and treeing which eventually improve the quality of the cable insulation where the lifetime of the cable can be prolonged. Nano filler [4] that infused in the XLPE cable have excellent characteristics than the pure XLPE cable where it improves breakdown strength and high resistance to the water and electrical trees. Besides that, nanocomposite cable has potential in reducing the space charge formation in the power cable. Improvement in the XLPE cable insulation material able to prevent the failure of the cable where the risk of the partial discharge able to be reduced.

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4 1.3 Problem Statement

High voltage power cable is one of the essential component in the power system which continuously exposed to variety of stresses such as thermal stress, electric stress, chemical stress, environmental stress and other stress that act on the cable insulation. These stresses that act on the cable which will eventually degrade the properties of the insulation. The lifetime of the power cable depends on the cable

insulation. It is important to have a good insulation for the cable to avoid any damage occurred which might interrupt the power system.

One of the major problem that causes the degradation of the power cable insulation is the presence of the voids. The voids can have medium of either air or water that can leads to shorten the lifetime of the power cable. Phenomenon that causes the presence of the voids in the power cable is due to penetration of the water steam during process of the cross-link. Besides that, mistake can also happen during operation of the cross link and wrong extrusion. Usually the size of the voids appear in the cable is about 1 μm to 20 μm. Apart than that, the position of the voids exists in the cable also give impact to the lifetime of the power cable as the voids near to the conductor have high electrical field distribution compare to the voids located further away from the conductor which enhance the partial discharge occurred.

Besides that, cable insulation material also play an important role in preventing the presence of the voids in the cable. Over the years, the cable insulation material had been developed from the PVC material to the XLPE material which show significance improvement in the quality of the cable insulation where the cable is long lasting. Depends on the material of the cable insulation, the voids present encounter different temperature and pressure on it. Proper design of the cable insulation material is needed to ensure the cable can be used for many years which is

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5 cost efficient for the power utility company. In this project, nano-insulated XLPE

power cable with the presence of the voids with different feature would be analyzed.

1.4 Objectives:

By referring to the problem statement mentioned above, this research was conducted with several meaningful objectives below:

1. To simulate the electric field distribution and potential field distribution in the

nanocomposite XLPE power cable having void using COMSOL Multiphysics.

2. To analyse the simulation result by considering various factors such as void

position, void size and others.

3. To compare the simulation result with the pure XLPE power cable.

1.5 Scope of Study

By referring to the objectives mentioned above, the limitation and assumption applied in this project is clearly elaborated as the followings:

1. This work focused on the XLPE power cable model only. Based on existing

research, the study of the pure XLPE power cable with the presence of voids was investigated for the electrical field distribution and potential field distribution. It is proven that the voids near to the conductor have high electrical field than the voids further away from the conductor.

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2. The focus of this study was on electrical field distribution and potential field

distribution based on respective void feature only. Void feature considered in this paper is the void position and type of the void in the XLPE power cable.

3. This work also focused on comparison of the results obtained from the pure

XLPE power cable and nano-insulated XLPE power cable by considering the presence of voids with different void feature.

1.6 Project Methodology

By referring to the objectives mentioned earlier, the following work methodologies have been planned:

1. A literature review on the technique used in analyzing the electric field and

potential field distribution in the void presence in the XLPE cable using finite element method was carried out. Topic related article can be extracted from the conference papers, journal papers, online articles and electronic books from internet or digital library in UTM. Suitable application within each reference was gained.

2. A critical and strategic literature review of electric field and potential field

distribution in the void presence in the XLPE cable using finite element method was performed. In order to propose algorithm, the existing flowchart and formulation have been analyzed. By having in depth literature review, it provides a good theoretical understanding about XLPE cable with the presence of void design considerations need to be taken in order to develop the algorithm.

3. A new modelling of a nano-insulated XLPE power cable with the presence of

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4. Verification of proposed modelling of a nano-insulated XLPE power cable

with the presence of the voids will be performed by comparing the result output against FEMM software output which is available.

1.7 Project Report Structure

Chapter 1 describes the introduction of the XLPE power cable insulation that used in the power system. It includes the problem statement, objectives, the scope of this project work and the methodology used to apply in accomplishing this project report. Briefly explanation on this chapter will gauge the reader have a clearer picture on the overview of the project.

Chapter 2 presents the literature review on the techniques used to investigate the electrical field distribution and potential field distribution of the voids presence in the XLPE power cable. The data of the literature review was collected from the journal which extracted from the UTM digital library such as IEEE, Scopus, science

direct and others relevant journal. All the journal collected based on the project background which is related to the XLPE power cable insulation having cavities.

In Chapter 3, the mathematical modelling of the electrical field and potential field distribution of the XLPE power cable with the presence of the voids is described in detail. First and foremost, it will cover Poisson’s equation in the modelling. In addition, this chapter will also cover the implementation of the mathematical modelling in the COMSOL Multiphysics software.

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8 Chapter 4 starts with the validation of result simulated from the pure XLPE power cable containing voids and the simulation result of the nano-insulated XLPE power cable with the presence of voids will be presented and discuss upon.

Chapter 5 draws the conclusions for the work undertaken are presented and few possible suggestions for future work are highlighted as well.

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73 32. Blackburn TR, Liu Z, Morrow R, Phung BT. Partial discharges development in a void and its effect on the material surface. Proceedings of the 6th International Conference on Properties and Applications of Dielectric Materials. China. 2000; 2: 280-285.

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