The 6th International Conference on Renewable Power Generation (RPG)

19–20 October 2017

Application status of XLPE insulated submarine cable used in offshore wind farm in
China
Hongliang Zhang1, Jianmin Zhang1, Lewis Duan2, Shuhong Xie3, Jianlin Xue1
1
Zhongtian Technology Submarine Cable Co., Ltd, Nantong, People’s Republic of China
2
ZTT International Co., Ltd, Nantong, People’s Republic of China
3
Zhongtian Technology Group Co., Ltd, Nantong, People’s Republic of China
E-mail: zhanghongliang@chinaztt.com

Published in The Journal of Engineering; Received on 5th October 2017; Accepted on 1st November 2017

Abstract: The application of cross-linked polyethylene (XLPE)-insulated submarine cable used in offshore wind farms in China is discussed.
Different from onshore wind farms, the cable connects fans of offshore wind farms and transmits electric energy to booster stations installed
under water. Therefore, to a certain extent, a mass of offshore wind farm construction in China promoted the development of XLPE-insulated
submarine cable. The aim of the application of XLPE-insulated submarine cable for China’s offshore wind power, first summarised the struc-
tural characteristics of three-core AC submarine cable and introduced results of product structure improvement, production equipment upgrad-
ing and performance stability verification in the process of cable voltage levels of 35 to 110 and 220 kV. The product features and insulation
structure design method of flexible DC submarine cable have been analysed. Finally, according to the trend of a large capacity and high seas
construction for offshore wind farms, the application of XLPE-insulated submarine cable will focus on wet-type structure interconnecting sub-
marine cable and high-voltage flexible direct current submarine cable in the future.

1 Introduction cable in the construction of offshore wind power in China in com-

Currently, offshore wind power generation is one of the main con-
cerns of international green energy development. Compared with
onshore wind power with years of operating experience, offshore
wind power has more resources, and is conducive to increasing
the capacity of the generating units. According to the statistical as-
sessment of the Chinese Academy of Meteorological Sciences,
wind energy reserves that can be developed in China is about
2.5 × 108 kW, while the offshore wind energy resources can reach
7.5 × 108 kW [1]. In terms of wind field characteristics, the turbu-
lence intensity of offshore wind resources is relatively small and
can reduce the fan fatigue, and the wind shear becomes small,
which can reduce the height of the wind turbine tower construction.
In addition, the development of offshore wind power also avoids
land acquisition and noise pollution and other issues, which is
an important part of China’s future development of ocean
economy [1].
Affected by the geographical conditions, offshore wind power
is different from land wind power construction. Due to the com-
plexity of the underwater conditions, the basic construction of the
offshore wind turbine should take into consideration the seabed
geological structure, offshore distance, wind and wave levels,
the current situation and many other effects [2]. In addition, the
ocean wind turbine interconnection and further integration after
a boost to a higher-voltage level grid are required to use a submar-
ine cable, therefore, the submarine cable is also an integral part of
the offshore wind power construction. With the development of
polymer materials and cable production equipments, the design
and production technology of cross-linked polyethylene
(XLPE)-insulated power cable have highly advanced. At
present, XLPE-insulated submarine cable has completely
replaced the original oil–paper insulation in the field of domestic
submarine transmission [3]. This paper introduced the application
status and development prospects of XLPE-insulated submarine
bination with the landmark project of domestic offshore wind
power.
2 Application of XLPE-insulated medium-voltage AC
submarine cables in offshore wind farm
XLPE-insulated medium-voltage cable is used to interconnect the
sea fans in the offshore wind farm, which is also known as the inter-
connecting cable.
‘East China Sea Bridge 100 MW offshore wind farm’, which of-
ficially started construction in September 2008, is China’s first off-
shore wind power project. The project installed 34 single capacities
of 3 MW offshore wind turbines in the East China Sea Bridge 1 km
east of the sea, the farthest offshore distance is 13 km, using AC
transmission and network [4].
During the designing period of the project, there was no domes-
tic HVAC submarine cable, besides the capacity of whole wind
farm was only 100 MW, so 35 kV XLPE Insulated medium-
voltage submarine cable was chosen to integrate wind turbines
to 110 kV Booster station on land. Thirty-five kilovolt cables
comprising of copper conductors of three-core XLPE-insulated
lead-sheathed steel wire armoured polypropylene fibre optical
composite cables, power cable and communication cable in
cable structures, achieve electric power transmission and commu-
nication measurement at the same time [5]. Fig. 1 shows the struc-
tural diagram of 35 kV optical fibre composite with a three-core
submarine cable.
Thirty-five kilovolt optical fibre composite, three-core submarine
cable contains three power cores, according to engineering require-
ments, equipped with optical fibre unit and fibre optic unit number.
Taking into account the special environment of the cable, requiring
the power core and fibre optic cable core in the vertical and radial
cables have a good waterproof performance, on the one hand to
ensure that the product is running well, while reducing the length

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Attribution License (http://creativecommons.org/licenses/by/3.0/) doi: 10.1049/joe.2017.0421
 Fig. 2 Hierarchical structure diagram of 110 kV three-core XLPE-insulated
Fig. 1 Hierarchical structure diagram of 35 kV three-core XLPE-insulated optical fibre composite submarine cable for Zhuhai Guishan project
optical fibre composite submarine cable

three-core XLPE-insulated optical fibre composite submarine

of loss of damage when the cable was damaged, at this point on the
requirements common to the voltage level and specifications of the
submarine cable.
Another typical 35 kV submarine cable project in China was
Longyuan Rudong 150 MW offshore wind power demonstration
one; a 35 kV submarine cable was used to interconnect offshore
wind turbines together and transmitted power to the land booster
station. That was the first intertidal offshore wind power project
in China, and all the turbines were connected to the power gener-
ation plant in September 2012 [6]. In the territory of China,
coastal wind resources in Jiangsu, Shanghai and Shandong and
other coastal areas, mostly intertidal zone waters, there was no pre-
cedent to carry out offshore wind farm construction in the intertidal
zone before. Therefore, Longyuan Rudong 150 MW offshore wind
power demonstration project exhibited significance in infrastructure
construction and submarine cable selection, both during manufac-
ture and laying.
3 Breakthrough on independent XLPE-insulated AC
three-core submarine cable used in offshore wind farms
With the development of China’s offshore wind power to large-
capacity turbines and long-distance wind farms, the medium-
voltage transmission method has been unable to meet the
requirements of large-capacity power integration to the land
after the booster-station delivery, hence, the domestic cable man-
ufacturers started to develop independent high-voltage submar-
ine cable.
cable, and the main performance indicators are shown in Table 1.
As shown in Fig. 2, compared with the medium-voltage three-
core submarine cable, AC 110 kV three-core submarine cable for
Zhuhai Guishan project carried out a series of structural optimisa-
tion. First of all, the high-voltage submarine cable that had a
thicker XLPE insulation is considered, and the production process
of the insulation layer was to squeeze the extrusion pressure of
the machine which was significantly higher than that of the
medium-voltage submarine cable. Therefore, the outer layer of
the conductor was tightly wrapped around a layer of semi-
conductive tape, and together with the extruded semi-conductive
shielding material to form the conductor shield. Second, semi-
conductive polyethylene (PE) was chosen as the sheath material
for electric power core outside the lead sheath, and also for
optical fibre unit, the outer jacket also used the same material,
and the potential difference could be effectively eliminated
among the fibre unit, metal shield and armour. In addition, due to
the large size of the high-voltage power core, there would be a
larger gap in the cable after cabling. Therefore, the preformed
packing strip was used to fill the cable as shown in Fig. 2. The pre-
formed packing strip was designed according to the size and shape
of the power core.
Due to the size and weight of the high-voltage cable core, the
main difficulty in the production of high-voltage three-core submar-
ine cable was the large-length cabling. Take 110 kV three-core sub-
marine cable used in Zhuhai Guishan project for example, the
section of the copper conductor was 500 mm2; in the completion

3.1 Application of AC 110 kV three-core submarine cable Table 1 Main performance of 110 kV three-core XLPE-insulated
submarine cable for Zhuhai Guishan project
In April 2013, the South China Sea Wind Power Joint Development
Co, Ltd presided over the development of Zhuhai Guishan 198 MW Items Data Unit
wind farm project officially issued AC 110 kV three-core optical
fibre composite submarine cable tender notice. Zhuhai Guishan approximate outer diameter 193 mm
wind farm was located in the Pearl River estuary of the approximate weight (in air) 76 kg/m
Lingdingyang bay, and planned to install 66 offshore wind turbines 20°C DC resistance of conductor ≤0.0366 Ω/km
with single capacity of 3 MW, while constructing a wind farm 90°C AC resistance of conductor ≤0.0488 Ω/km
booster station on the Guishan island, Dongao island, by the capacitance 0.170 μF/km
Dawan island network project. Before the offshore wind power inductance 0.406 mH/km
project was built in Zhuhai Guishan, high-voltage three-core sub- maximum allowable working temperature on 90 °C
marine cable was subject to the design and tooling equipment, conductor
and monopolised by foreign manufacturers [7]. This project maximum allowable temperature on conductor for 250 °C
opened the era of independent high-voltage three-core submarine short circuit
cable in China. reference capacity (air temperature 40°C, not 590 A
The structure of AC 110 kV three-core optical fibre composite exposed to direct sunlight)
short-circuit current on conductor 78.8 kA/1 s
submarine cable was generally the same as the medium-voltage
short-circuit current on metal shield 20.3 kA/1 s
cable that had been used; the model was HYJQF41-F 64/110
maximum allowable tension 210 kN
3×500+24B1+4B4+4A1a; single-mode optical fibre and simultan-
maximum allowable pressure 20 kN/m
eous monitoring multimode fibre are applied in the same optical minimum bending radius for installation 4000 mm
fibre unit. Fig. 2 is a hierarchical structure diagram of AC 110 kV

J. Eng., 2017, Vol. 2017, Iss. 13, pp. 702–707 This is an open access article published by the IET under the Creative Commons
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of the insulation layer, lead sheath and PE sheath production, the Table 2 Main performance of 220 kV three-core XLPE-insulated
theoretical outside diameter and unit weight of the power core submarine cable for Xiangshui project
were ∼80 mm and 16 kg/m, respectively. If the continuous produc-
tion length is 20 km, the installation of each power core disk Items Data Unit
required a carrying capacity of 32 ton, so the ordinary planetary
cabling machine could not meet high-voltage three-core submarine approximate outer diameter 247 mm
cable for long-term continuous needs. approximate weight (in air) 110 kg/m
20°C DC resistance of conductor ≤0.0366 Ω/km
A Vertical cable twisting equipment was transformed to twist
90°C AC resistance of conductor ≤0.0488 Ω/km
three single cable cores together, it has three turntables which
capacitance 0.131 μF/km
could bear the weight of 350 tons. Fig. 3 is the vertical cabling
inductance 0.460 mH/km
machine with an automatic tray.
maximum allowable working temperature on 90 °C
As shown in Fig. 3, the vertical cable machine was equipped conductor
with a plurality of thread-cutting discs in addition to the maximum allowable temperature on conductor 250 °C
three large-scale automatic turntables, and is used for the simul- for short circuit
taneous cabling of the optical fibre unit and the forming filler reference capacity (air temperature 40°C, not 760 A
bar. After completion of the high-voltage power cores and fibre exposed to direct sunlight)
unit twisted together, the product flow to the cable machine in short-circuit current on conductor 72.1 kA/1 s
series with the wire armour, asphalt coating and the outer layer short-circuit current on metal shield 34.2 kA/1 s
of the interlocking production line, then stockpiled maximum allowable tension 275 kN
synchronously. maximum allowable pressure 20 kN/m
The successful development of the three-core high-voltage sub- minimum bending radius for installation 4400 Mm
marine cable had importance in economic and social value for
not only reflected in the technical progress, but also reduced the
use of the same transmission capacity of single-core high-voltage
submarine cable production costs, laying costs and operation and in Xiangshui County of Guandong Saltery; Sanwei saltworks
maintenance costs. outer sea, offshore distance of about 10 km, selected the first
domestic 220 kV three-core submarine cable, which was
produced by Zhongtian Technology Submarine Cable Co,
3.2 Era ushered in AC 220 kV three-core high-voltage cable
Ltd [8].
After the first 110 kV three-core submarine cable successfully For the structural design and process control of 220 kV three-
detected by the national testing organisation, and completion of core submarine cable used in Xiangshui offshore wind farm for ref-
large length production, CNPEC Rudong 150 MW offshore wind erence experiences of the 110 kV three-core submarine cable, the
farm, Huaneng Rudong 300 MW offshore wind farm were sub- model used was HYJQF41-F 127/220 3×500+2×(34B1+2A1b),
sequently built in China, all chose domestic 110 kV three-core sub- the product structure was the same as the 110 kV three-core sub-
marine cable connected offshore booster station to the grid on land. marine cable for Zhuhai Guishan project; the main performance
With the production and application of high-voltage three-core sub- was shown in Table 2.
marine cable experience accumulated, and increasing offshore wind Xiangshui offshore wind farm project is currently the only one
farm design capacity, the first 220 kV three-core submarine cable running offshore wind farm project, which made use of 220 kV
was put into operation in 2015. three-core submarine cable as the main circuit that had the largest
Investment was made by the Three Gorges group of Jiangsu size and heaviest weight in the domestic product; the development
offshore; Xiangshui 202 MW offshore wind farm was located process in addition to ensuring electrical performance meets the
standards and requirements of the project. In order to ensure that
the product in the production and laying process of mechanical
stress would not lead to wire and light unit quality damage,
bending tensile test was carried out while 220 kV three-core sub-
marine cable was developed.
The bending tensile test was used to simulate the situation of sub-
marine cable withstanding the tension during progress of construc-
tion, and the test device diagram is shown in Fig. 4.
Two-hundred and twenty kilovolt three-core submarine cable
bending tensile test in accordance with GB/T 32346.1-2015GB/T
32346.1-2015 ‘Rated voltage 220 kV (Um = 252 kV) XLPE insu-
lated large length AC submarine cables and accessories part 1:

Fig. 3 Vertical cabling machine with automatic turntable Fig. 4 Schematic diagram of bending test

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test methods and requirements’ [9], according to the installation of
Fig. 4, the test needed to complete the winding, straightening,
winding process on a turning wheel in a submarine cable sample
of not <30 m. The sample shall be subjected to three cycles.
During the test, the tension applied to the submarine cable was
121 kN according to the recommended calculation method in the
standard. Before the test, two optical fibres were chosen randomly
from the sample and connected to the CD500 type fibre optic
tester after the ring is connected. The fibre performance changed
to determine whether the fibre suffered from destructive stress
during the sample withstanding the force or not. Fig. 5 shows add-
itional attenuation situation of the fibre under 1330 nm wavelength
during bending tensile test.
According to the results of the bending tensile test, the additional Fig. 6 Hierarchical structure diagram of ±160 kV XLPE-insulated optical
fibre composite submarine DC cable
attenuation of composite fibre unit in 220 kV three-core submarine
cable was <0.05 dB, which meet the requirement of the test. This
type of cable had passed the type test of the third-party testing
agency, the main facilities of Jiangsu Xiangshui wind power
project achieved power generation in October 2016, and now is
running well.

4 Attempt of XLPE-insulated DC submarine cable in

offshore wind power construction
The wide use of voltage source commutation (VSC) technology
enabled the rapid development of XLPE insulated DC cable. Due
to the advantages of small line loss, stable system, flexible power
control, reliable operation, easy construction and expansion of cap-
acity, flexible DC transmission technology had gradually replaced Fig. 7 Insulation field distribution of ±160 kV DC cable under no load
the traditional DC transmission technology and high-voltage AC
transmission technology to become the best choice of long-
distance, high-capacity transmission [10] (Figs. 6 and 7).
In 2013, China Southern Power Grid Company set up a demon-
stration project of ±160 kV/200 MW multi-terminal flexible DC
transmission in Shantou, Guangdong, based on the ‘National 863
Program’ project ‘Research and development of flexible DC trans-
mission access technology for large wind farms’ that was the first
three-terminal flexible HVDC project all over the world, which
built 10.6 km DC submarine cable, 9.5 km DC land cable and
20.6 km DC overhead line connecting QingNiu, QingAo and
SuLiu converter stations. This project also was the first domestic in-
dependent designing and manufacturing of high-voltage DC cable.
The fibre composite DC submarine cable used copper core, XLPE
insulated, lead sheath, thick round steel wire armoured, polypropyl-
ene fibre as outer layer and composite 36 core fibre. Fig. 8 and Fig. 8 Insulation field distribution of ±160 kV DC cable under rated load
Table 3, respectively, were structure diagram and the main perform-
ance of ±160 kV XLPE-insulated optical fibre composite submarine
DC cable. Table 3 Main performance parameters of ±160 kV XLPE-insulated
optical fibre composite submarine cable

Items Data Unit

approximate outer diameter 111.4 mm

approximate weight (in air) 28.6 kg/m
20°C DC resistance of conductor ≤0.0366 Ω/km
70°C AC resistance of conductor ≤0.0438 Ω/km
capacitance 0.172 μF/km
maximum allowable working temperature on 70 °C
conductor
maximum allowable temperature on 160 °C
conductor for short circuit
reference capacity (air temperature 40°C, not 905 A
exposed to direct sunlight)
short-circuit current on conductor 15.6 kA/1 s
short-circuit current on metal shield 30.4 kA/1 s
maximum allowable tension 126 kN
maximum allowable pressure 15 kN/m
minimum bending radius for installation 2280 mm
Fig. 5 Optical wire supplementary deterioration while bending test

J. Eng., 2017, Vol. 2017, Iss. 13, pp. 702–707 This is an open access article published by the IET under the Creative Commons
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 As shown in Fig. 4, compared with high-voltage AC submarine
cable, the biggest feature of the DC cable was that it has only a
power core, greatly saving the cost of manufacturing. In addition,
in the case that the conveying capacity was about 200 MW,
NanAo flexible DC cable project used ±160 kV DC submarine
cable, the diameter and unit weight were greatly reduced, compared
to 110 kV three-core submarine cable of Zhuhai Guishan wind
power project and 220 kV three-core AC submarine cable of
Jiangsu Xiang shui offshore wind power project, it was convenient
for long-term transporting and laying.
In addition to the differences in structure, the insulation design of
the DC cable was more complex than that of AC cable. For
XLPE-insulated DC cable, the DC transmission will cause the accu-
mulation of space charge in the insulation layer, which may cause
electrical field distortion of the insulation layer, resulting in de-
crease in electrical performance [11]. In addition, the DC cable in-
sulation layer showed the resistive distribution of the electric field,
which was not only related to the structure and size of the insulated
wire core, but also related to the temperature distribution of the in-
sulation layer. Therefore, the DC cable insulation structure design
needed to consider the electric field and thermal field coupling
problem [12].
Currently, the finite-element analysis method was used to solve
the multi-physics coupling problem of DC cable insulation.
Taking ±160 kV-1 × 500 mm2 DC cable of NanAO flexible DC
cable project as an example, the finite-element analysis software
was used to carry out simulating analysis of electric field distribu-
tion of the submarine cable under no load and rated load.
From the finite-element simulation results above, the maximum
electric field strength of insulation was 13.5 kV/mm on the outer
surface of the conductor screen, and the minimum electric field dis-
tributed on the inner surface of the insulation screen was 7.6 V/mm
when ±160 kV DC cable under no-load operating; the maximum
electric field strength of the insulation was 12.2 kV/mm on the
outer surface of the conductor screen, and the minimum electric
field distributed on the inner surface of the insulation screen was
8.5 V/mm when ±160 kV DC cable under rated-load (625 A) oper-
ating, at this stage, the corresponding conductor operating tempera-
ture was 53°C, less than the maximum operating temperature of 70°
C of DC cable [13]. It was shown that as the load increases, the elec-
tric field distribution was removed and the electric field of the insu-
lation screen increased. It could be seen that under the same
insulation structure, size and voltage, the distribution of electric
field of insulation was obviously different with different load con-
ditions. Therefore, it was necessary to repeatedly verify the choice
of insulation thickness by combining the actual operating condi-
tions and load of the cable in the project when designing the insu-
lation structure of DC cable.
5 Development trend of XLPE-insulated submarine cable in
offshore wind farms
5.1 Interconnecting submarine cable to develop 66 kV and
wet-type structure
With the capacity increase of offshore wind turbines, some projects
with a stand-alone capacity of 9 MW offshore wind turbine were
being built according to some relevant reports. Therefore, 35 kV
AC submarine cable used in interconnecting has been already sig-
nificantly insufficient; the development of submarine cable with a
higher voltage level would be an inevitable trend. Sequentially,
with the increasing of interconnecting cable voltage and the aware-
ness of environmental protection enhanced, lead used as a metal
screen would not be able to meet short-circuit current capacity or
environmental requirements. To solve the problems above, copper
wires would be used as a metal screen instead of lead, the metal
screen twisted by copper wires could not ensure a good water-
resistance performance as lead sheath, therefore, that caused a
higher demand of submarine cable under long-term work, this
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Fig. 9 Hierarchical structure diagram of wet-type submarine cable
type of cable was known as a wet-type submarine cable for now.
Fig. 9 shows a typical structure of wet-type submarine cable.
As shown in Fig. 9, compared with the split-phase lead sheath
submarine cable, water-resistance performance of the submarine
cable mainly depended on the semi-conductive PE sheath. In con-
trast to this, compared with lead plus PE sheath, a single layer of
the water resistance of the wet-type submarine cable is still relative-
ly poor. Therefore, water-tree-retardant insulation material usually
used to ensure electrical performance of non-lead sheath submarine
cable under long-term underwater operation [14], but the operation
experience of non-lead submarine cable was short-lived for the
moment, especially if the voltage levels of interconnecting cable
increased to 66 kV, it was uncertain whether the existed
water-tree-retardant insulation material could meet the require-
ments. Currently, the relevant international institutions are studying
the underwater operating test standards of wet-type submarine
cable, used for evaluating the long-term operation of such products.
The related research work is still in progress, the wet-type submar-
ine cable would be a great development direction in the future.
5.2 Application proportion expected increase of HVDC
submarine cable
According to the statistics of relevant departments, at present, the
total resources of offshore wind energy could be developed as
7.5 × 108 kW in China, and more than 60% of that has a long dis-
tance over 50 km. Using the HVAC cable as the main circuit, in
addition to increasing the cost of manufacturing and laying, also
caused significant power loss. In comparison, VSC-HVDC trans-
mission technology has obvious advantages in terms of cost and re-
ducing loss, although the investment on construction of converter
equipment in the early investment was higher, but for long-term
plan, the construction of long-distance offshore wind farm would
be more inclined to HVDC submarine cable [15].
Currently, the voltage of XLPE-insulated flexible DC cable had
reached ±525 kV, and with the strategic direction of building a
global energy internet proposed in China, the State Grid
Corporation had set up the project to integrate domestic cable and
accessory manufacturers to develop ±500 kV flexible DC cable
system, intended for the construction of offshore power intercon-
nection, so ultra-high-voltage flexible DC cable product develop-
ment and application would be the focus of national power
construction in the next few years.
6 Conclusion
This paper introduced the application of XLPE-insulated submarine
cable in offshore wind farm with the representative offshore wind
power project in China, mainly introduced the key problems and
work on the development of HVAC three-core submarine cable
and HVDC flexible cable, then described in detail the improvement
of technology and equipment of HVAC three-core submarine cable,
the typical mechanical performance test method of large-size
HVAC submarine cable and the design process with finite-element
J. Eng., 2017, Vol. 2017, Iss. 13, pp. 702–707
doi: 10.1049/joe.2017.0421
analysis method for HVDC flexible cable insulation structure. In
addition, after analysing the research progress of the submarine
cable technology, combined with the development trend of the off-
shore wind power at home and abroad, the paper put forward the
development direction of XLPE-insulated cable to the wet-type
structure interconnecting cable and HVDC flexible accessing tech-
nology in offshore wind power area.
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