As a seasoned B2B supplier with over 20 years of specialized expertise in high-voltage cable manufacturing equipment, we understand that your success depends on production lines that deliver consistent dielectric performance, minimal scrap, high throughput, and maximum flexibility. Our Baicheng 110kV Catenary Continuous Vulcanization (CCV) Line represents the pinnacle of triple extrusion technology for XLPE-insulated power cables rated up to 110kV.
This advanced half-catenary CCV system performs simultaneous one-pass extrusion of the inner semiconductor (conductor screen), XLPE insulation, and outer semiconductor (insulation screen) layers through a precision triple crosshead. The result: homogeneous insulation free of micro-voids, exceptional layer bonding, superior concentricity, and outstanding electrical properties that meet the most stringent international standards for underground, submarine, and overhead transmission applications.
Core Competitive Advantages
Our 110kV triple extrusion CCV line goes far beyond standard configurations to deliver measurable ROI through:
- True One-Step Triple Extrusion Process — Eliminates multi-pass interface contamination, ensures perfect layer adhesion, and produces cables with minimal eccentricity and excellent long-term reliability up to 110kV.
- Optimized Half-Catenary CCV Design — Heating section ≈54 m (9 tubes), pre-cooling ≈12 m (2 tubes), cooling ≈84 m (14 tubes) for stable thermal profiling and high-quality crosslinking.
- High-Output Capability — Line speeds up to 30 m/min (with optional high-output packages reaching higher velocities), supporting conductor sizes Cu 25–1000 mm² / Al 35–1000 mm² and insulation thickness 3.4–15.0 mm.
- Advanced Dual-Rotation & Surface Stabilization Technology — Integrated dual rotating caterpillars (pre- and post-CV tube) effectively counteract the “pear-drop” effect in the viscous insulation zone. Combined with controlled-temperature gas circulation at the crosshead exit, this delivers superior roundness, reduced torsional stress on Milliken or taped conductors, and significantly lower scrap rates.
- Siemens TIA Portal Control System — High-resolution HMI touch-screen interface with robust anti-interference design, real-time cable position monitoring, automatic capstan speed adjustment, and precise CV tube temperature control for stable, repeatable production.
- Clean-Run & Long-Run Performance — Nitrogen-protected environment and optimized material handling minimize contamination and enable longer continuous production runs, reducing joints and material waste.
- Full Customization & Upgrade Readiness — Customer-specific modifications including speed adjustment via CV tube temperature control, extruder configurations, quick conductor splicing packages, and future-proof upgrades for even higher voltages or outputs.
Comprehensive Technical Specifications
| المعلمة | مواصفة |
|---|
| Voltage Class | 10–110 kV (XLPE) |
| Conductor Cross Section | Cu: 25–1000 mm² / Al: 35–1000 mm² |
| Max. Cable Diameter | 80 mm |
| Max. Cable Weight | 14.5 kg/m |
| Conductor Screen Thickness | 0.5–2.0 mm |
| XLPE Insulation Thickness | 3.4–15.0 mm |
| Insulation Screen Thickness | 0.5–2.0 mm |
| Line Speed | 0–30 m/min (higher with optional packages) |
| Line Configuration | Half-catenary |
| Cross-linking Section | ≈54 m / 9 sections |
| Pre-cooling Section | 12 m / 2 sections |
| Cooling Section | 84 m / 14 sections |
| Extruder Arrangement | Φ80 (screen) + Φ175 (XLPE) + Φ100 (screen) |
| Installed Power | 1000 kVA |
| Utilities | Water, compressed air, high-purity nitrogen (99.5%) |
Higher-output configurations (up to 500 kV, 3250 mm² conductors, 145 mm diameter, 45 m/min) available upon request.
Key Line Components & Engineering Highlights
- Extruder Group & Precision Triple Crosshead — Three dedicated extruders connected to a single three-layer crosshead for uniform melt flow, easy centering, and rapid changeover.
- Pay-off Stand, Accumulator & Tension Control — Precision conductor handling with minimal damage and stable tension.
- Dual-Rotation Haul-off Caterpillars & Capstans — Independently frequency-controlled motors for haul-off and rotation, ensuring gentle handling of heavy conductors.
- Cooling & Take-up Systems — Multi-section cooling tubes and robust take-up stands for continuous, high-quality production.
- Complete Utilities Package — Nitrogen storage (≥6 m³ × 2), circulating water cooling, and compressed air systems engineered for safety, efficiency, and low consumption.
Pay-off Stand MV/HV CCV Line for High Voltage Cables
Accumulator MV/HV CCV Line for High Voltage Cables
Lower Pull-Out Capstan MV/HV CCV Line for High Voltage Cables
Accumulator & Upper Auxiliary Caterpillar MV/HV CCV Line for High Voltage Cables
Accumulator & Upper Auxiliary Caterpillar MV/HV CCV Line for High Voltage Cables
Lower Pull-Out Caterpillar MV/HV CCV Line for High Voltage Cables
Proven Value for Cable Manufacturers
Operators worldwide report higher productivity, lower scrap rates, superior cable roundness (critical for jointing and installation), reduced material consumption, ، و minimal maintenance. Whether producing standard MV/HV cables or specialized designs for demanding environments, this line provides the technical foundation for long-term manufacturing leadership and competitive advantage.
Ready to transform your high-voltage cable production?
Our engineering team is prepared to deliver a fully customized technical proposal, detailed line layout, ROI analysis, or factory demonstration tailored to your exact requirements.
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Contact us today for complete specifications, quotation, and technical consultation. Let us help you achieve reliable quality, customized solutions, and sustained success through long-term partnership.
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