Borlink

High productivity XLPE

for power cables

About Borealis
and Borouge
Borealis is a leading provider of innovative solutions in the
fields of polyolefins, base chemicals and fertilizers. With
headquarters in Vienna, Austria, the company currently
has around 6,500 employees and operates in over 120
countries. Borealis generated EUR 7.7 billion in sales
revenue and a net profit of EUR 988 million in 2015. The
International Petroleum Investment Company (IPIC) of Abu
Dhabi owns 64% of the company, with the remaining 36%
belonging to OMV, an international, integrated oil and gas
company based in Vienna. Borealis provides services and
products to customers around the world in collaboration
with Borouge, a joint venture with the Abu Dhabi National
Oil Company (ADNOC).
Building on its proprietary Borstar and Borlink
technologies and more than 50 years of experience in
polyolefins, Borealis and Borouge support key industries
with a wide range of applications in the areas of energy,
automotive, pipes, consumer products, healthcare, and
advanced packaging.
The Borouge 3 plant expansion will make Borouge the
worlds largest integrated polyolefins complex. Once fully
ramped up in 2016, the additional 2.5 million tonnes of
polyolefins capacity will yield a total Borouge capacity of
4.5 million tonnes, and a combined Borealis and Borouge
capacity of 8 million tonnes.
Borstar is a registered trademark of the Borealis Group. Borlink, Visico, Ambicat, Casico and Water for the World are
trademarks of the Borealis Group.
Borlink High productivity XLPE for power cables
Contents
04 The challenge of growing energy demand
04 High productivity XLPE cable insulation
solutions
05 The reaction power of Borlink
Borealis offers a wide range of base chemicals, including
melamine, phenol, acetone, ethylene, propylene, butadiene 06 Benefits of Borlink LS4201
and pygas, servicing a wide range of industries.
07 Better scorch resistance
Borealis also creates real value for the agricultural industry,
selling approximately 5 million tonnes of fertilizers. Technical
nitrogen and melamine products complement the portfolio 08 Reduced degassing burden
with applications ranging from mono-nitrogen oxide (NOx )
abatement to glues and laminates in the wood working 09 Superior extrusion properties
industry.
10 Excellent electrical performance
Borealis and Borouge aim to proactively benefit society
by taking on real societal challenges and offering real 12 Borlink power cable product recommendations
solutions. Both companies are committed to the principles
of Responsible Care, an initiative to improve safety
13 Sources for further information
performance within the chemical industry, and work to solve
the worlds water and sanitation challenges through product
innovation and their Water for the World programme.
For more information visit:
www.borealisgroup.com
www.borouge.com
www.waterfortheworld.net
Polyolefins, Stenungsund High Pressure plant, Sweden
3

The challenge of
growing energy demand
Growth in demand for energy, already at unprecedented
levels, is set to continue at an even faster pace in the
foreseeable future. In addition, new energy sources
(mostly renewables) need integration into the existing grid
or even new grid options. This poses major challenges for
each segment of the electricity value chain: generation,
transmission, distribution and end use, and particularly for
cable makers who supply the vital links throughout
the chain.
High productivity
XLPE cable
insulation solutions
XLPE insulation compounds are predominantly used
for power cable production. They are based on high
pressure low-density polyethylene (LDPE) polymers.
The compounds contain stabilising and crosslinking
packages to facilitate cable production in a Continuous
Vulcanisation (CV) process. The production system for
manufacturing power cables is designed and optimised
around a number of processes (extrusion, cross-linking,
cooling, degassing, finishing).
Building on the advantages of XLPE insulation to aid
cable makers in meeting the productivity challenge,
Borealis has developed market leading solutions based
4 Borlink High productivity XLPE for power cables
This rising need for energy gives rise to a rapid increase in
demand for cables. More cables are required to expand,
strengthen and build electricity networks while maintaining
safety and uninterrupted power supply reliability. However,
in order to produce more cables quickly, simply and cost-
effectively, cable makers face the challenge of increasing
the productivity of existing plants, at the same time
retaining the highest level of cable quality.
on a unique polymer family that delivers more reaction
power than the classic base polymer for XLPE. These are
the Borlink polymers based on Supercure technology.
Figure 1: Schematic illustration of the Borlink Supercure base resin. The red
structures represent the double bonds that amplify reactivity.
The reactivity of the base polymers is dependent on the
level of reactive double bonds within the polymer chain.
A standard LD polymer has a low level of reactive double
bonds.
Borlink Supercure polymers incorporate highly
reactive double bonds using a special comonomer in
the polymerisation. The nature of the double bonds
serves to amplify the normal reactivity of classic XLPEs.
The advantage of this technology is that the level and
consistency of the amplification (double bonds) can be
controlled without affecting other properties, such as
polymer extrusion properties.
The reaction power
of Borlink
Supercure technology delivers a variety of valuable
advantages
Borlink polymers based on Supercure technology are
designed to enhance production efficiency and help
manufacturers maximise asset utilisation and increase
production capacity.
Using Borlink LS4201, a larger process window can be
utilised to permit longer running times and reduce the
amount of degassing required.
Borlink LS4201
Equivalent line speeds with existing conditions
Much higher scorch safety
Much reduced degassing burden (time/temperature)
Table 1: Benefits of Supercure based compounds when compared with classic
materials for MV and HV cables
5
Benefits of Borlink
LS4201
Borlink LS4201
Within some configurations of cable manufacture the
CV line is not a limitation. In these instances higher
productivity comes from increased run length (lower
scorch propensity) and a lower degassing burden
Better scorch resistance
The conclusion might be drawn that a more reactive
polymer would have increased sensitivity to scorch during
at higher temperatures. Thus the compound based on
Supercure technology shows a higher resistance to scorch
extrusion. However, this is not the case as the onset of the than classic insulation, offering a lower risk of downtime
crosslinking of the Borlink Supercure technology occurs and a more productive solution.
Cleanliness Borlink LS4201
100
This feature of the Borlink Supercure technology concept
1.5
Borlink LE4201
has been demonstrated both in laboratory experiments
(Monsanto & Carrot Scorch tests and die extrusion tests)
1
Rheology Treeing
80
and full-scale cable production. Figure 3 shows the results

Volume fraction of scorch [%]

0.5 of 5 hour die extrusion tests, using a scorch accelerating
(lower initial levels of crosslinking by-products). 60
die. It clearly indicates that Borlink LS4201 can be
0 extruded at a higher temperature compared to classic
The much improved scorch safety can either be used 40 insulation while exhibiting the same level of scorch risk.
to permit longer run times or higher melt temperatures Alternatively, operating at a lower temperature reduces
(potentially higher line speed). Throughput Scorch resistance the risk of scorch.
20

A lower degassing burden, in practical terms, leads

to reduced heat treatment time or temperature, which Degassing
0
132 134 136 138 140 142 144
provides higher production flexibility and faster response Melt temperature [C]

to the market demand. Figure 2: Property chart for Borlink LS4201 Figure 3: Die extrusion test for scorch insulations (often referred to as the
carrot test lower results show better scorch)

6 Borlink High productivity XLPE for power cables 7

Reduced degassing Superior extrusion
burden properties
Degassing is a vital process for HV and many MV cable The polymer compound based on Supercure technology
designs. In this process cable cores are held at elevated Borlink LS4201 improves the productivity of cable has been modified only with regard to peroxide reactivity.
temperatures to speed up the desorption of by-products makers by reducing the degassing burden which Therefore the extrusion properties of LS4201 remain
from the crosslinking process. The most important target accounts for a major part of cable manufacturing unchanged compared to the classic LE4201 types.
is the reduction of methane content. The degassing time (figure 4). This has been verified by both extrusion bleeding tests
burden is directly related to the level of by-products left and practical experience.
in the cable after it exits the CV tube and to the size of
the cable core. The standard temperature profiles for extruder and
CV tube provide good extrusion properties for LS4201.

Stranding Degassing Testing

LS4201 displays stable output and temperature
Extrusion Finishing
characteristics on a range of extrusion equipment.
Borlink

This characteristic is especially useful with cable designs Figure 6: Extrusion performance of Borlink LS4201 on common
using strippable screens where the semicon surface extruder sizes

temperature often limits practical line speed. In these

instances, throughputs can be obtained approaching
Standard

those experienced with bonded constructions.

0 2 4 6 8 10 12 14 16 18 20 22
Days

Figure 4: Reduced production cycle for large HV cables manufactured with Borlink LS4201 compared with the classic Borlink LE4201

100
Time to reach 0.5 wt % by products [%]

80

60

40

20

0
Classic Borlink LE4201S High productivity Borlink LS4201S
Insulation material

Figure 5: Relative comparison between Classic Borlink LE4201S and

High productivity Borlink LS4201S on the time needed to reach 0.5 wt%
of by-products remaining in the cable with degassing at 70C

Medium Voltage cable

8 Borlink High productivity XLPE for power cables 9

 3. High Voltage cable type approval tests

Excellent electrical
HV cables manufactured using Borlink compounds based on Table 3 shows details of the 170 kV type test carried out at
Supercure technology have been qualified to the IEC60840 an independent SATS accredited laboratory.
protocol at 90 kV, 132 kV and 170 kV.

performance 8 kV/mm max stress, 5.5 kV/mm mean stress

Description Requirements Results

Loss factor [Tan ] (IEC 60840 Test no. 12.3.5)

Voltage kV 87 87
1. Model cable test Temperature C 95100 97

The cables were produced and tested at the Borealis Tan 1010-4 Pass
Innovation Centre according to: Heating cycle voltage test (IEC 60840 Test no. 12.3.6)

Voltage during cycling phase earth kV 174 174

Test method Evaluation
No of cycles (8/16) Max. temperature C 20, 95100 20, 95100
Applied voltage: 9kV/50Hz AC breakdown strength Test requirement No b.d or flashover Pass
Water: inside and outside Number and length of bow-tie trees Impulse withstand test (IEC 60840 Test no. 12.3.7)
Inner temperature: 85C Number and length of vented trees Conductor temperature kV 95100 97
Outer temperature: 70C Impulse rise/fall time s 15/4060 2.6/51
Ageing time: 1,000 hours (42 days) Peak voltage, 10 pos/10 neg C 750 750

Test requirement No b.d or flashover Pass

AC voltage withstand test (IEC 60840 Test no. 12.3.7)

Borlink LE4201 Borlink LS4201
Test voltage, duration kV, min 218.15 218.15
Initial AC breakdown strength [kV/mm] 94102 >105
Test requirement No b.d or flashover Pass
Aged in water (1,000h at 9kV & 80C) breakdown strength [kV/mm] 38 41
Table 3: Type approval of cable at 170 kV to IEC60840
Table 2: Typical model cable breakdown strengths when using standard performance semicon screens

2. Medium Voltage cable long-term wet ageing tests 99

W/rr
90
To confirm good dielectric properties for Medium Voltage
cables, long-term wet ageing tests were carried out following 70

well-established CENELEC protocols. The good wet ageing 50

Occurrence CDF (%)

for full sized cables has been retained while the cable 30

manufacturing productivity improves.

Borlink LS4201R
10
Minimum requirement
within CENELEC HD620

Eta Beta r2 n/s

53.51 8.336 0.920 35/0
19.35 5.605 0.871 6/0
1
1 10 100
Units

Figure 7: 3,000 hour wet ageing test for a 20kV MV cable aged at a
frequency of 500Hz, conductor temperature 40C, voltage 3Uo

10 Borlink High productivity XLPE for power cables 11

Borlink power cable
product recommendations
The below represents Borealis standard recommendations.
However, Borealis technical representatives can
recommend optimal solutions based on particular needs.
Borlink
MV
Sources for further
information
1) R. N. Hampton et al, Critical issues for the HV & EHV cables of today 9) P. Huotari, Advanced technology for HV & EHV Cable Insulation,
and tomorrow, Jicable 2003, p. 111. Wire Ind., September 2002.
2) H. BrakelmannStudie Netzverstrkungs-Trassen zur bertragung 10) D. Wald & W. Weissenberg, Entgasen von VPE-Kabeln
von Windenergie: Freileitung oder Kabel?, Bundesverband Ein notwendiges bel?, EW 11, p. 16.
Windenergie e.v. Oktober 2004. 11) A. Smedberg, J-O Bostrm, D. Wald, R. Peters: Comparison of
3) Borealis Compounds for Extra High Voltage cables brochure. different analytical test methods to monitor crosslinking by-products
4) D. Wald, A. Smedberg, Kritische Untersuchungen und Entwicklung in XLPE insulated cables, 7th International Conference on Insulated
fr Hoch- und Hchstspannungskabel, Power Cables (JiCable 07), Versaille, June 2428, 2007, p. 280285.
9. Symposium Energieinnovation, Graz 2005. 12) C. Andersson, M. Jakobsson, A. Smedberg, J-O Bostrm:
5) Faremo et al, Improved productivity for power cable manufacture, Distribution of peroxide by-products along degassed XLPE HV
CIGRE 2006, B1-109. cables, 8th International Conference on Insulated Power Cables
6) Gorham & Partners, Undergrounding a success story already in (JiCable 11), June 1923, 2011, p. 567571.
Europe potentially worldwide, Report to ICF Congress 1995. 13) A. Smedberg, J-O Bostrm, Methoden zur Messung von
7) T. Tanaka & A. Greenwood, Advanced power cable technology; Spaltprodukten fr Hochspannungskabel, VDI-Tagung
HV EHV CRC Press 1983. Kabelextrusion, Nrnberg, Dec 23, 2009, p. 3548.
8) A. Smedberg et al, What is crosslinked polyethylene?,
ICSD 2004 Toulouse, p. 415418.

Conductor screen LE0592 LE0592S LE0500

Insulation LS4201R LS4201S LS4201EHV

Insulation screen LE0592

LE0520 (Strippable) LE0592S LE0500

Figure 8: Recommended Borlink solutions

12 Borlink High productivity XLPE for power cables 13

Borealis and Borouge
Dedicated to Wire &
Cable Solutions
Borealis and Borouge are the worlds leading providers of to extending that leadership position and our role as
innovative, value creating plastics solutions for the wire reliable partners for the long-term a commitment not
and cable industry. Our solutions are customer-driven and only supported by our forward thinking in innovative
designed to satisfy the industrys continuously evolving solutions, but also confirmed by ongoing investments
demands for higher technical performance. Consequently, for our customers continued success.
they can be found in the most challenging EHV and
Putting customers needs at the centre of our planning is
HV cable applications, as well as MV and LV energy
reflected in Borealis largest investment in Europe to date,
transmission and distribution cables, building wires,
the new 350,000 t/y high-pressure, low-density PE plant
and communications cables.
in Stenungsund, Sweden, was inaugurated in June 2010,
In answer to the need for production, installation and further strengthening Borealis capabilities to meet the
cable-system lifetime enhancements, we create the needs of the growing wire and cable markets. Furthermore,
innovation links that secure world-class, step-change Borouges expansion of Borstar and Borlink capacity
solutions and benefit the whole wire and cable value chain. in Abu Dhabi, UAE, allows us to satisfy growing customer
Through the introduction of unique polymer technologies, demand for wire and cable products in the Middle East
which include Borlink, Visico/Ambicat, Borstar, and and Asia Pacific markets and other emerging markets.
Casico, we continue to pioneer the development of
Through ongoing research and development, investment
advanced insulation and jacketing systems for both energy
in the future and a dedicated team with solid industry
and communication cables.
knowledge, we aim to remain fully responsive to our
Built on more than 50 years experience, Borealis and customers needs throughout the world.
Borouge have a well-established track record in serving
customers needs with the consistently high quality
products expected of global leaders. We are committed

Disclaimer The information contained herein is to our knowledge accurate and reliable as of the date of publication. Borealis and Borouge extend no
warranties and make no representations as to the accuracy or completeness of the information contained herein, and assume no responsibility regarding
the consequences of its use or for any errors. It is the customers responsibility to inspect and test our products in order to satisfy himself as to the
suitability of the products for the customers particular purpose. The customer is also responsible for the appropriate, safe and legal use, processing and
handling of our products. Nothing herein shall constitute any warranty (express or implied, of merchantability, fitness for a particular purpose, compliance
with performance indicators, conformity to samples or models, non-infringement or otherwise), nor is protection from any law or patent to be inferred.
Insofar as products supplied by Borealis and Borouge are used in conjunction with third-party materials, it is the responsibility of the customer to obtain
all necessary information relating to the third-party materials and ensure that Borealis and Borouge products, when used together with these materials,
are suitable for the customers particular purpose. No liability can be accepted in respect of the use of Borealis and Borouge products in conjunction
with other materials. The information contained herein relates exclusively to our products when not used in conjunction with any third-party materials.
Borstar is a registered trademark of the Borealis Group. Borlink, Visico, Ambicat, Casico and Water for the World are trademarks of the Borealis Group.

14 Borlink High productivity XLPE for power cables

 2016 Borealis AG . 2016 Borouge Pte Ltd
WC BROCH 091 GB 2016 03 BB

For more information visit:

www.borealisgroup.com www.borouge.com