Giant MV Cable YJV22 3x400mm² 8.7/15kV Armored XLPE Power Cable

Cable Designation & Meaning

Construction: XLPE insulated, steel-tape armoured, PVC sheathed, three-core medium-voltage power cable.

Applicable Standards

• GB/T 12706.2-2020 / IEC 60502-2 — Power cables with extruded insulation and their accessories for rated voltages from 6 kV up to 30 kV
• GB/T 3956 / IEC 60228 — Conductors (Class 2 stranded circular)
• GB/T 2951 / IEC 60811 — Insulating and sheathing materials — Common test methods
• GB/T 3048 — Test methods for electric cables
• GB/T 18380 / IEC 60332 — Flame retardant tests (Category C or B available)

YJV22-3×400 mm² 8.7/10 kV (and 8.7/15 kV) — Cable Specification & Engineering Data 

1. Product Overview & Rating Summary. YJV22-3×400 is a maximum-size medium-voltage (MV) power cable rated 8.7/10 kV (Um = 12 kV) at 50 Hz, built around three 400 mm² compacted-stranded copper conductors, each with a triple-extruded semi-conducting screen / XLPE insulation / semi-conducting screen system, a lapped copper-tape screen, and an overall double-galvanised-steel-tape armour (type 22) with a black PVC outer jacket. The same construction is also manufactured in the 8.7/15 kV grade (Um = 17.5 kV) with thicker 5.5 mm XLPE insulation. The cable is designed for 10 kV primary distribution feeders serving 40000–63000 kVA distribution transformers and medium-voltage motors in the 10000–16000 kW range. Finished diameter is about 125 mm (10 kV) and nominal mass about 34500 kg/km (≈ 3450 kg per 100 m). With all three cores loaded, the cable carries about 745 A in free air at 25 °C (engineering estimate).

2. Layer-by-Layer Construction (Conductor to Outer Jacket).

3. Electrical Characteristics. Each 400 mm² conductor is held to a maximum DC resistance of 0.0470 Ω/km at 20 °C, rising to about 0.065 Ω/km at the 90 °C operating point. Every length survives the routine 21.5 kV AC power-frequency proof held for five minutes (30.5 kV for the 15 kV grade). Partial discharge at 1.5 U0 must not exceed 20 pC. Dissipation factor tan δ ≤ 0.001 at U0. Insulation resistance ≥ 1000 MΩ·km, typical capacitance ≈ 0.72 μF/km. Impulse withstand (BIL) is 75 kV for the 10 kV grade and 95 kV for the 15 kV grade. With all three cores energised, reference loading is about 745 A in free air at 25 °C, about 740 A direct-buried.

Insulation Data

Electrical Parameters

Reference values: 400 mm² at 565 A, 3-phase 10 kV → max balanced load ≈ 9.80 MVA. Voltage drop at 565 A ≈ 3.4 V/km per core (≈0.034% per 100 m).

Temperature Characteristics

4. Thermal Response & Flame Behaviour. XLPE insulation sustains a 90 °C continuous conductor temperature, with short-circuit capability up to 250 °C for ≤ 5 s. The cable is rated for service ambients between −20 and +50 °C. PVC jacket provides flame-retardant performance per GB/T 18380.34 class A. Short-circuit rating at 250 °C for 1 s is about 57.6 kA for the 400 mm² copper conductor. Thermal resistance of reference burial soil is 1.2 K·m/W.

Fire Performance (YJV22 — Standard)

5. Installation Practice & Handling. Bends must not fall below 15 times the actual outer diameter — about 1875 mm for this size. The steel armour must be earthed at both ends; the copper-tape screen must be bonded per MV practice (both ends, or cross-bonded for longer routes). MV heat-shrink or cold-shrink termination kits are mandatory — do not treat this as an LV cable. Laying temperature must not fall below 0 °C; reels must be pre-heated in cold weather. At about 3450 kg per 100 m, the cable requires extra-heavy-duty drum jacks, winches and rated pulling gear.

Mechanical & Installation Parameters

6. Typical Service Applications. This YJV22-3×400 MV cable is used in 10 kV / 15 kV primary distribution networks serving very heavy industrial and utility loads: 40000–63000 kVA distribution transformer primary feeds, substation 10 kV outgoing main feeders to very heavy industrial plants, 10 kV motor branch feeds for MV motors in the 10000–16000 kW range (very large pump stations, compressor stations, mill drives, crushers, rolling-mill main drives), steel-mill / cement-plant / paper-mill / chemical-plant 10 kV power distribution mains, high-rise commercial and hospital 10 kV main risers, very large data-centre and district-cooling 10 kV switchboard feeders, mining and quarry 10 kV heavy-duty power supply lines, direct-buried urban 10 kV primary network feeders, PV / wind-farm 10 kV collection mains, and any circuit where mechanical protection against crush or impact is required. Approved installation methods include direct burial, cable tray, concrete duct, and indoor MV cable trench.

7. Testing & Quality Assurance Regime. Routine tests on every length include conductor DC resistance ≤ 0.0470 Ω/km at 20 °C, the 21.5 kV AC / 5 min withstand (30.5 kV for 15 kV grade), partial discharge ≤ 20 pC at 1.5 U0, tan δ ≤ 0.001, insulation resistance ≥ 1000 MΩ·km, conductor continuity across all three cores, steel-armour and copper-screen continuity, and dimensional inspection. Sample and type tests comprise impulse withstand at ±75 kV (or ±95 kV for 15 kV), heating-cycle load-loss test, bending at 15 × OD, short-circuit to 250 °C, flame spread GB/T 18380.34 class A, and voltage re-test after thermal ageing. A factory test certificate accompanies each drum.

Cable Parameters

Cable Test Parameters

Cable Cross Section Structure

Cable Construction Description

8. Standards & Conformity. Design and production are governed by GB/T 12706.2-2020 (IEC 60502-2) for extruded-solid-insulation power cables from 1.8/3 kV to 26/35 kV. Conductors satisfy GB/T 3956 Class 2. Flame performance follows GB/T 18380.34. Surface marking complies with GB/T 6995. Cables can also be supplied to IEC 60502-2, BS 6622 or NFC 32-322 requirements on request.

9. Packaging, Storage & Logistics. Standard delivery is 500 m or 1000 m per wooden-steel drum, with bespoke cut lengths available on request. Each drum carries type, voltage, size, supplier identity, production year and sequential metre marking per GB/T 6995. Storage should be in dry, covered premises at −20 to +40 °C, shielded from direct sunlight and moisture; drum end seals must remain intact until installation. MV cable terminations and joints should be scheduled immediately after laying to avoid prolonged exposure of cut ends.

10. Procurement Specification. State "YJV22-8.7/10 kV-3×400" (or "YJV22-8.7/15 kV-3×400" for the thicker-insulation grade) together with the required length or drum arrangement. Always order the matching MV termination kits (indoor/outdoor / separable connectors) and field-joint kits at both ends. Always request the factory test certificate, which must include the partial-discharge and impulse-withstand reports, to confirm the actual diameter, weight and conductor resistances for the production batch.

11. Cable Industry FAQ.

• Q1: How does 400 mm² differ from 300 mm² in 10 kV service? 400 mm² raises the reference ampacity from about 645 A to about 745 A, and the short-circuit rating from about 43.2 kA to about 57.6 kA. It is the maximum standard feeder size for 40000–63000 kVA transformers and MV motors in the 10000–16000 kW range, whereas 300 mm² serves 25000–40000 kVA transformers and motors up to about 10000 kW.
• Q2: What does the "22" in YJV22 mean? The first "2" = double-steel-tape armour; the second "2" = PVC outer jacket. YJV22 is therefore a Cu conductor / XLPE insulation / double-steel-tape armour / PVC jacket MV cable. Without the "22" suffix, YJV would be unarmoured.
• Q3: When do I choose 8.7/10 kV vs 8.7/15 kV? Choose 8.7/10 kV for nominal 10 kV distribution networks (Um = 12 kV). Choose 8.7/15 kV for nominal 15 kV networks (Um = 17.5 kV) or where the system may be up-rated — the thicker 5.5 mm XLPE gives a larger safety margin.
• Q4: Why is there no separate neutral core? At MV distribution voltages, three-phase currents are balanced and the system is typically solidly or resistance-earthed; the copper-tape screen provides the earth path. A separate neutral is not required in standard 3-core MV construction.
• Q5: Why is the triple-extrusion process important? Conductor screen, XLPE insulation and insulation screen are co-extruded in one pass to avoid air gaps and contamination at the interfaces. Even tiny voids cause partial discharge at MV voltages and lead to early insulation failure.
• Q6: Why is there a copper-tape screen? The copper tape (0.1 × 25 mm lapped) provides an equipotential outer surface around each core, equalises the electric field, and carries capacitive and fault currents to earth.
• Q7: Can this cable be directly buried? Yes — the double-steel-tape armour provides crush protection, and the PVC jacket is moisture-resistant. Direct burial depth and covering must follow the local MV cable installation code.
• Q8: What is partial discharge and why is it tested? Partial discharge (PD) is tiny electrical sparks inside the insulation caused by voids or contaminants. At 1.5 U0, PD must be ≤ 20 pC. High PD values predict early insulation failure and are the most sensitive factory-quality indicator.
• Q9: Why is the routine test 21.5 kV and not 10 kV? Routine tests apply a power-frequency withstand voltage higher than the rated voltage (typically 2.5 U0 = 21.75 kV, rounded to 21.5 kV) to catch manufacturing defects before site installation.
• Q10: Can the steel armour be used as the earth? The steel armour provides mechanical protection but is not sized or certified as the primary fault-current earth conductor. The copper-tape screen and dedicated earthing conductors carry fault currents; the armour must be bonded to earth for safety.
• Q11: What service life can be expected? When installed, terminated and operated within the stated temperature, voltage and current ratings, XLPE-insulated MV cables are designed for a service life of around 30 years in fixed installation. The dominant failure mode is moisture or PD at terminations, so professional jointing is critical.