HIGH VOLTAGE CABLES

FOR
DIRECT CURRENT
TRANSMISSION

Eindhoven, 27 March 2006

Presentation is based on answering to four main questions:

1. Why Cables for HVDC Transmission ?

2. Which are the main characteristics of an HVDC

Cable system ?

3. How is an HVDC Cable made ?

4. Which are the critical issues to be considered in

HVDC cable design ?

And will finish with few remarkable examples.

Eindhoven, 27 March 2006 Property of Prysmian

1st question: Why Cables for HVDC Transmission?

Firsts of all, Cables are used when Overhead Lines (that are simple and
cheap but with a significant impact on ambient) cannot be built for
environmental reasons or when power shall be transmitted underwater
(through sea, lakes or rivers).

In first case we have the so called Underground High Voltage Cable

systems, in the second case Submarine Cable systems.

Eindhoven, 27 March 2006 Property of Prysmian

In general the power is transmitted using Alternating Current (AC) by simply
connecting the two networks.

The two networks must be SYNCHRONOUS: same frequency, same phasing

(different voltages can be managed with transformers).

Rigid Connection:
Disturbances are also transmitted between the two networks. Power flow control
is difficult, lead by impedance of transmission lines (mainly reactances).

Eindhoven, 27 March 2006 Property of Prysmian

 Cables are
cylindrical
capacitors

A cable under AC voltage is subject to a capacitive current that is proportional to

the frequency f[Hz], to the voltage V[V], to the unitary capacitance C [μF/km]
and to the cable length L[km]: I = 2·π· f · C · V · L
Cables for HV-AC transmission typically have a capacitance of the order of
0,2-0,3 [μF/km] therefore require capacitive currents of 10 to 25 [A/km],
depending on system voltage and frequency.

For short lengths (few kilometers) this is not a problem, but for long lengths,
e.g. above 60-80 km the capacitive current become similar in magnitude (even if
in quadrature) to the active current that the cable is asked to transmit: losses
are very much increased and consequently actual cable rating is reduced.

Eindhoven, 27 March 2006 Property of Prysmian

With DC transmission, the things for the cable system are much simpler: f = 0;
Consequently, capacitive current and main effects relevant to reactances are
eliminated. Only conductor resistance plays the major role.

2
Transmission (Joule) losses are: W [W] = R · L · I (+ W Earth Return )

and Voltage Drop: ΔV [V] = R · L · I (+ ΔV Earth Return )

Practically, there are no limits for the Transmission Length, quite independently
from transmission Voltage and Power.

Eindhoven, 27 March 2006 Property of Prysmian

However, systems are operated in AC; therefore DC transmission requires
Converter Stations at both ends to convert AC to DC at sending point and DC
to AC at receiving end.

The two networks are not required to be syncronised; they can have different
frequency and voltage. The power flow is simply controlled by voltage drop.

The system, overall, acts like a Generating Power Station that is injecting
power into the receiving network.
P
Flexible Connection G
AC Network
345 kV, 60 Hz

Eindhoven, 27 March 2006 Property of Prysmian

 i

+ P
HVDC CABLE Conventional High-Power Converters use
Tyristors (controlled Diodes): the current
GROUND RETURN must flow in one direction only.
i

Therefore, when the power flow is reversed, also the polarity on the HVDC
cable is reversed: here is a simple example:

A + B
Transferring power from side A to B, +
i

clockwise direction of current, cable _

is at positive voltage (+) i

_
Transferring power from side B to A, A B
to keep same direction of current, i _
cable is at negative voltage (-) +
i

Eindhoven, 27 March 2006 Property of Prysmian

 TYPICAL HVDC BIPOLE WITH EMERGENCY ELECTRODES
CONFIGURATIONS
P/2 + HV
+
(Cook-Strait;
MONOPOLE 2.v Vancouver 1;
Skagerrak;
( Majority of CABLE i − Haenam-Cheju)
P/2 _ HV
Old Systems:
SA.CO.I; + P
ITA-GREECE; SEA RETURN BIPOLE WITH METALLIC RETURN
Fennoskan; i +
Baltic Cable ) P/2 + HV
Cathode Anode (Hokkaido-
v 2.v Honshu 2;
v Gotland 2)
HV
MONOPOLE (WITH METALLIC RETURN) P/2 _
CABLE
(Hokkaido- i BIPOLE WITHOUT METALLIC RETURN
Honshu 1; + P P/2
Moyle;
(Cross
SVE-POL; M.V. RETURN CABLE + HV Channel;
Basslink)
Nor-Ned)
Laid Separated _ HV
or bundled P/2

Eindhoven, 27 March 2006 Property of Prysmian

2nd question: Which are the main characteristics
of an HVDC Cable system ?
In general, an HVDC system can be composed by various sections, sometime
including OHL lines, land and submarine cable. Here is an example for the
Basslink Interconnection (Tasmania-Victoria, AUS):

Eindhoven, 27 March 2006 Property of Prysmian

The HVDC Cable system is typically made by:

Intermediate Joints

End Terminations
Cable

Eindhoven, 27 March 2006 Property of Prysmian

In the Land (Underground) sections, Installation is generally done from large
drums, in excavated trenches, being the cable directly buried or pulled in
plastic pipes.

Unloading Lay in
from Drum Trench

Pulling
Winch

Eindhoven, 27 March 2006 Property of Prysmian

For Submarine Cables, the Installation is done by laying the cable on the sea
bottom by using suitable Ships, that can accomodate large quantity of cable
on board, stored on rotating platforms.
GIULIO VERNE SHIP FEATURES:
•Length Overall 133 m
•Moulded Breadth 30 m
•Draft 8.5 m
•Tonnage (tons) 10617
•Dynamic Positioning Control
•Propulsion Power 5,710 kW
•Capstan 6 m 50 tons
•Turntable capacity 7,000 tons

Eindhoven, 27 March 2006 Property of Prysmian

Very often, the cable is protected on the sea bottom against possible
damages caused by fishing tools and anchors by various methods.

Jetting Machine
for Burial

Cast Iron
Shells

Sand/Cement
Bags

Concrete Block
Mattresses

Eindhoven, 27 March 2006 Property of Prysmian

3rd question: How is an HVDC cable made ?
Cables used for HVDC transmission are mainly of three types:
• MI: Insulated with special paper, impregnated with high viscosity compound
• SCFF: Insulated with special paper, impregnated with low viscosity oil
• Extruded: Insulated with extruded polyethylene-based compound
Mass Impregnated Self-Contained Fluid Filled Extruded

Eindhoven, 27 March 2006 Property of Prysmian

Mass Impregnated Cables are the most used; they are in service for more
than 40 years and have been proven to be highly reliable. At present used for
Voltages up to 500 kV DC. Conductor sizes up to 2500 mm2.

Copper conductor
Semiconducting paper tapes

Insulation of paper tapes impregnated with viscous compound

Semiconducting paper tapes
Lead alloy sheath
Polyethylene jacket
Metallic tape reinforcement
Syntetic tape or yarn bedding

Single or double layer of steel armour (flat or round wires)

Polypropylene yarn serving

Typical Weight = 30 to 60 kg/m

Typical Diameter = 110 to 140 mm

Eindhoven, 27 March 2006 Property of Prysmian

Typical Manufacturing Flow Diagram of a Mass Impregnated Cables. Lengths
of up to 30-50 km of cable can be lapped and impregnated, without need of
intermediate joints. For very long lengths, factory joints are included.
CONDUCTOR STRANDING

TURNTABLE

IMPREGNATION VESSEL PAPER LAPPING MACHINE

LEAD EXTRUDER

TURNTABLES

PE SHEATH EXTRUDER
ARMOURING MACHINE

TURNTABLE

Eindhoven, 27 March 2006 Property of Prysmian

Self Contained Fluid-Filled Cables are used for very high voltages (they are
qualified for 600 kV DC) and for short connections, where there are no
hydraulic limitations in order to feed the cable during thermal transients; at
present used for Voltages up to 500 kV DC. Conductor sizes up to 3000 mm2.
Conductor of copper or aluminium wires or segmental strips
Semiconducting paper tapes
Insulation of wood-pulp paper tapes impregnated with low
viscosity oil
Semiconducting paper tapes and textile tapes
Lead alloy sheath
Metallic tape reinforcement
Polyethylene jacket
Syntetic tape or yarn beddings

Single or double layer of steel armour (flat or round wires);

sometime copper if foreseen for both AC and DC use, in order
to reduce losses in AC due to induced current
Polypropylene yarn serving

Typical Weight = 40 to 80 kg/m

Typical Diameter = 110 to 160 mm

Eindhoven, 27 March 2006 Property of Prysmian

Extruded Cables for HVDC applications are still under development; at present
they are used for relatively low voltages (up to 150 kV DC), mainly associated
with Voltage Source Converters, that permit to reverse the power flow without
reversing the polarity on the cable.

In fact, an Extruded Insulation

(generally PE based) can be Conductor

subjected to an uneven distribution Semiconducting compound

of the charges, that can migrate XLPE extruded insulation

inside the insulation due to the Semiconducting compound

effect of the electrical field. Lead alloy sheath

Polyethylene jacket

It is therefore possible to have an Syntetic tape or yarn beddings

accumulation of charges in Steel armour

localised areas inside the insulation Polypropylene yarn serving

(space charges) that, in particular

during rapid polarity reversals, can Typ. Weight = 20 to 35 kg/m

give rise to localised high stress Typ. Diameter= 90 to 120 mm

and bring to accelerated ageing of

the insulation.

Eindhoven, 27 March 2006 Property of Prysmian

 4th question: Which are the critical issues to be
considered in HVDC cable design ?
In AC, and in general for rapid applications or changes of the voltage, the
electrical stress is led by a capacitive distribution. The insulation can be
supposed as divided in concentric capacitors, all in series. It results:
E [kV/mm]
Ei V
E (r ) =
⎛ re ⎞
r ⋅ ln⎜ ⎟
Ee ⎝ ri ⎠
V
Insulation
Being therefore:

r [mm] Ei > Ee
Typical value for EHV (AC) Cables
Conductor
are:
Ei = 10 to 14 kV/mm
Ee = 5 to 7 kV/mm

Eindhoven, 27 March 2006 Property of Prysmian

 V [kV]
In DC the things are a bit more complicated.
V

Let’s suppose from time t0 a DC

voltage V is applied across insulation: t0 t
In the first period, the stress distribution is capacitive, but after some time,
under static conditions the charges can move and the stress distribution
becomes resistive.

E [kV/mm]
The resistive distribution is led by the insulation
Resistive
Stress
‘conductivity’ ơ , that is not similar to the capacitive
Inner one (led by ‘permittivity’ε), because ơ varies, as a
Insul. Outer function of the stress E and temperature θ:
αθ + βE
Insul.

Capacitive
σ = σ0
Stress
Where stress is higher, insulation conductivity is
better (lower resistance) and the charges are moved
r [mm] away from the high stress zone to the low one.
Eindhoven, 27 March 2006 Property of Prysmian
 If we now circulate a current I in the conductor, then Joule losses W in the
form of heat are produced.
W
Outer
The heat must cross the insulation to be Insulation

dispersed outside, thus causing a θI

temperature drop Δθ across the insulation. Temp. Drop
Δθ
The inner part of the insulation is hotter than I
the external one, therefore the conductivity
is futher increase by the temperature effect, Conductor

and consequently θC
E [kV/mm]
the charges are
futher moved
αθ + βE
Resistive Stress,

σ = σ0
COLD
Inner Ee away from the
Insul. inner to the outer
insulation layer. Typically α= 0,1 ; Β= 0,03
Ei
Outer In conclusion, depending on stresses and
Resistive Stress,
HOT (Loaded
Insul. temperatures, there could be a stress
Cable)
inversion, with outer stress on insulation
r [mm] higher than the inner one: Ee > Ei

Eindhoven, 27 March 2006 Property of Prysmian

 Another cause of electrical stress is when an impulse voltage Vp arrives from
the OHL line or is generated internally due to equipment manouvre or
malfunctioning (switching surge). The worst case is when the impulse is of
opposite polarity with respect to the cable charging voltage Vo.

In this case the Electrical stress on the cable E is calculated as due to the
whole voltage variation, and subtracting the pre-existing resistive stress at
nominal voltage:
V E (Vp) = ECAPACITIVE (Vo+Vp) – ERESISTIVE (Vo)
Vp
+ 900 kV

Vo+Vp
1300 kV
t

Vo
- 400 kV

Eindhoven, 27 March 2006 Property of Prysmian

 Then, we have seen that Electrical design and Thermal design of the cable
are very much related. Other important aspects to be considered in the cable
system design are the following:
Maximum conductor temperature
This is related to the insulation performance and
expected cable life (in general 30 to 40 years). The
calculations must take into account installation
configuration and environmental parameters, like
thermal properties of the surrounding ground and of
the trench backfill, temperatures, etc.

Mechanical design
The cable shall be capable to
withstand the pulling forces during
installation, bending stresses, the
fatigue due to dynamic thermo-
mechanical forces (e.g.in unfilled
pipes), etc.

Eindhoven, 27 March 2006 Property of Prysmian

 Mechanical aspects are very important
in submarine cable systems, where
special tests are carried out to
simulate the cable installation from
the ship and cable recovery from the
bottom and repairing operations. The
picture shows the bending/pulling line
capable of a pulling force up to 200
ton (2 MN).

Gauge
For cables impregnated
with low viscosity oil,
Valve
Expansion
hydraulical aspects
Tank
have to properly be
taken into account
Electromagnetic Field calculations are sometime
required to comply with Country regulations or
laws (more frequently for AC transmission
rather than for DC).

Eindhoven, 27 March 2006 Property of Prysmian

The final performance of the cable and its accessories, based on the sound
design, manufacturing technology and materials used is checked with Type
Tests carried out on a miniature circuit including all the parts that will
constitute the real cable system: cable, joints and terminations.

Tests are very severe, including thermal daily cycles, polarity reversals and
impulse. They are recommended by CIGRE and last several weeks.
Eindhoven, 27 March 2006 Property of Prysmian
 SOME EXAMPLES OF SUBMARINE

PROJECTS

Eindhoven, 27 March 2006 Property of Prysmian

 Basslink (Victoria-Tasmania)

Loy Yang /
Victoria

Georgetown /
Tasmania

Eindhoven, 27 March 2006 Property of Prysmian

Eindhoven, 27 March 2006 Property of Prysmian
 Basslink: Installation

Eindhoven, 27 March 2006 Property of Prysmian

 Italy - Greece
‹ POWER 500 MW

‹ VOLTAGE 400 kV DC

‹ ROUTE LENGTHS:
- Submarine 163 km
- Land 43+1 km
‹ WATER DEPTH 1000 m

‹ IN SERVICE FROM 2000

‹ NR. OF CABLES 1 HV

‹ CABLE TYPE Paper, MI

‹ HVDC CABLE SIZE 1250 mm2

‹ SEA ELECTRODES

Eindhoven, 27 March 2006 Property of Prysmian

 Neptune: New Jersey – Long Island (NY)

‹ POWER 660 (750) MW

‹ VOLTAGE 500 kV DC

‹ ROUTE LENGTHS:
- Submarine 82 km
- Land 20 km
‹ NR. OF CABLES 1 HV + 1 MR

‹ HVDC CABLE SIZE 2100 mm2

‹ MET.RETURN SIZE 2000 mm2

‹ CABLE TYPE Paper, MI

‹ RFS July 2007

‹ 345 & 230 kV XLPE AC Systems

Eindhoven, 27 March 2006 Property of Prysmian