20kv 35kv SIP-3 Self-Supporting Insulated Wire Cable Aluminum Alloy XLPE for Overhead Available Sizes 1X35 1X50 1X70 1X95 1X120

Structural Integration: Combines Power Conductor, insulation, and mechanical support into a single unit, eliminating:

Separate messenger wires (reducing material costs by 35%)

Spacer hardware (simplifying inventory management)

Additional installation steps (cutting project timelines by 40%)

Layer Configuration: From core to exterior:

Self-Supporting Mechanism: The 6201-T81 aluminum alloy conductor provides 180MPa tensile strength, enabling 100-meter spans with <2.5m sag at 90°C. This exceeds the capabilities of traditional Insulated Conductors by 60% in span length.

Aerodynamic Profile: 18–28mm outer diameter (depending on size) reduces wind load by 25% compared to conductor-messenger combinations, minimizing stress on utility poles during storms with winds up to 120kph.

Alloy Composition: Aluminum with magnesium and silicon additives (Mg: 0.5–0.9%, Si: 0.7–1.1%) creates a heat-treatable alloy that, when processed to T81 temper, delivers:

52% IACS conductivity (optimal for high-voltage applications)

180MPa tensile strength (30% higher than 1350-H19 aluminum)

Superior creep resistance (critical for maintaining tension in long spans)

Strand Configuration: Each conductor comprises 19 strands (for 35–70mm²) or 37 strands (for 95–120mm²) of 1.2–2.0mm diameter, twisted at 16× lay length. This stranding:

Enhances Flexibility (bend radius 12× outer diameter) for installation around obstacles

Reduces "skin effect" by 20% at 50–60Hz compared to solid conductors

Improves resistance to fatigue from wind-induced vibration

Size-Specific Performance:

1X35mm²: 130A continuous at 90°C, 1.2kg/m weight

1X50mm²: 165A continuous at 90°C, 1.6kg/m weight

1X70mm²: 205A continuous at 90°C, 2.0kg/m weight

1X95mm²: 250A continuous at 90°C, 2.4kg/m weight

1X120mm²: 290A continuous at 90°C, 2.8kg/m weight

XLPE Cross-Linking: Peroxide cross-linking creates a three-dimensional polymer network that:

Withstands 35kV AC without breakdown (10kV/mm dielectric strength)

Operates continuously at 90°C (130°C short-term overload)

Resists water treeing (a common failure mode in humid environments)

Temperature Performance: -40°C to 90°C continuous operation, with:

No embrittlement at low temperatures (passes -40°C impact test)

No insulation flow at high temperatures (maintains dimensional stability)

Consistent dielectric properties across the entire range

Semi-Conductive Screens: Inner and outer semi-conductive layers:

Ensure uniform electric field distribution around the conductor

Eliminate partial discharge (a major cause of insulation degradation)

Bond chemically to XLPE for seamless layer transitions

Weather Protection: 1.2mm PE jacket with 2.0% carbon black content:

Blocks 99% of UV radiation (retaining 90% tensile strength after 20,000 hours of sunlight)

Resists ozone degradation (critical in industrial areas)

Withstands salt spray (up to 5% NaCl concentration for coastal applications)

Voltage Ratings:

20kV: 11.5kV phase-to-ground, 20kV phase-to-phase

35kV: 20.2kV phase-to-ground, 35kV phase-to-phase

Current-Carrying Capacity:

Dielectric Loss: <0.001 at 50Hz, minimizing energy waste in long-distance transmission.

Partial Discharge: <10pC at 1.73× rated voltage, ensuring long-term insulation integrity.

Short-Circuit Withstand: 25kA for 2 seconds, providing ample time for protective relays to clear faults.

Primary distribution from substations to industrial areas

Rural electrification projects requiring long spans

Urban network modernization where space is limited

Industrial park high-voltage feeders

Tensile Strength: 180MPa for the aluminum alloy conductor, with:

1X35mm²: 6.3kN breaking force

1X50mm²: 9.0kN breaking force

1X70mm²: 12.6kN breaking force

1X95mm²: 17.1kN breaking force

1X120mm²: 21.6kN breaking force

Span Capability: 100-meter maximum span with:

<2.5m sag at 90°C (1X120mm²)

<3.0m sag at 90°C (1X35mm²)

River crossings

Valley spans

Highway intersections

Protected environmental areas

Wind and Ice Loading: Withstands:

120kph wind speeds (equivalent to category 1 hurricane)

10mm radial ice accumulation (adding 1.8–3.2kg/m depending on size)

Combined wind-ice loads per IEC 60826

Impact Resistance: Survives 100J impact (10kg weight dropped from 1m) without conductor damage, ensuring durability during installation and storm events.

Handling Advantages: Despite its high-voltage capabilities, the cable remains manageable:

1.2–2.8kg/m weight (60% lighter than copper alternatives)

Flexible stranding allows bending to 12× outer diameter

Available on 500-meter reels (reducing splice requirements)

Installation Sequence: Simplified 5-step process:

Termination Systems: Compatible with:

Outdoor Cable terminations (20kV/35kV rated)

Polymer insulators (reducing weight on poles)

Load-break elbows (for sectionalizing)

Junction boxes (for tap-offs to lower voltage)

Specialized Equipment: Requires only:

Tension-controlled winch (5kN capacity)

Cable stripper for multi-layer insulation

Crimping tools for Aluminum Alloy Conductors

Dynamometer for tension verification

Crew Requirements: 3-person crew can install:

300 meters of 1X35mm² per day

200 meters of 1X120mm² per day

IEC 60502-2: Specification for Power Cables with rated voltages from 6kV to 30kV

ASTM B800: Standard for 6201 aluminum alloy Electrical Conductors

IEC 60826: Calculation of load capacity of Overhead Lines

ANSI/ICEA S-97-682: Specifications for high-voltage aerial cables

EN 50182: European standard for overhead Power Cables

Urban Networks: Ideal for cities where:

Limited right-of-way requires long spans

Aesthetic concerns favor single-cable solutions

Reliability is critical (minimizing outage costs)

Space constraints limit pole installation

Rural Electrification: Transforms connectivity in remote areas by:

Spanning rivers and valleys without intermediate poles

Reducing infrastructure requirements in low-population areas

Withstanding extreme weather with minimal maintenance

Lowering total project costs by 35% compared to traditional systems

Industrial Feeders: Powers manufacturing facilities requiring:

High reliability (minimizing production downtime)

Long runs between substations and plant entrances

Resistance to industrial contaminants

Ability to handle load fluctuations

Specialized Environments: Thrives in challenging locations:

Coastal areas (salt spray resistance)

Desert regions (extreme temperature tolerance)

Forested areas (reduced clearance requirements)

Protected habitats (minimizing pole footprint)

Initial Cost Savings:

35% lower material costs than conductor-messenger combinations

40% reduced installation labor

60% fewer poles required for 100-meter spans

Lifecycle Savings: 30-year service life minimizes:

Replacement frequency (once vs. 2–3 times for 12-year cables)

Maintenance costs (inspection every 5 years vs. annual for bare conductors)

Downtime costs (estimated at $10,000/hour for industrial feeders)

Energy Efficiency: 52% IACS conductivity reduces line losses by 8% compared to lower-grade aluminum, saving:

1X35mm²: ~5,200kWh annually per 100 meters

1X120mm²: ~18,500kWh annually per 100 meters

Environmental Benefits: Reduced pole requirements save 10–15 trees per kilometer, while longer spans minimize habitat disruption.

Service Life: 30 years under normal conditions, with:

25-year expectancy in coastal/salt environments

20-year expectancy in heavy industrial areas

Inspection Requirements:

Visual inspection every 5 years (looking for:

UV degradation of jacket

Damaged dampers

Proper tension retention

Hardware corrosion)

Thermal imaging every 10 years (identifying hot spots at terminations)

No periodic cleaning or treatment required

Repair Capabilities:

Damaged sections can be spliced using 20kV/35kV rated joints

Jacket repairs possible with heat-shrink sleeves

Partial replacement feasible without full span removal

Repair costs 60% lower than full span replacement

End-of-Life Management:

Aluminum alloy retains 90% of material value for recycling

Insulation layers can be separated for material recovery

Complies with WEEE and RoHS directives for responsible disposal