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Among the technology developments enabling • Larger turbines unit power to reduce the number of
LCE reduction several independent studies have turbines and associated array cables
shown that use of array cables operating at 66 kV
Offshore wind applications require high reliability cables
instead of 33 kV presents considerable
with easy installation at a competitive cost. Prysmian’s
advantages on typical offshore wind farm
aim is to provide the offshore wind industry a proven
systems.
cable design with a long-standing track record of
The main cost reduction drivers for using 66 kV, operating systems as well as with the lowest impact for
instead of 33 kV whilst maintaining the same the installation teams.
Prysmian Group carried out a comparison among Current rating for the three cable designs has
three 66 kV submarine array cables with 800 been calculated under the same ambient
mm2 aluminum conductors in order to assess the conditions:
different designs available for this market.
Where
• Dry design is a cable with an extruded lead sheath over insulation
• Semi-wet/Semi-dry design is a cable with a PE sheath over a non-fully impervious metallic screen
(e.g. metal tapes or thermoglued foils)
• Wet design is a cable without any polymeric sheath over a non-fully impervious metallic screen
(e.g. metal tapes)
Insulation material of 66 kV cables operates at higher The technical features of these cables are
electric stress than 33 kV cables, requiring rigorous outstanding, with no equal among any other
cable design and insulation material selection. cable insulation types at this voltage level.
Therefore, Prysmian’s 66 kV array cable is based on Prysmian EPR insulated cables are compatible
wet design EPR insulation, with 50 years successful with Prysmian’s full range of accessories
operational experience up to 72.5 kV, which is a reliable including Click-Fit®, ElaspeedTM and hang-off
and cost effective solution for offshore cable systems. systems.
EPR insulated cables
Background
EPR insulated cables are covered by the IEC standards Utilising the natural qualities of EPR, Prysmian
and by many National Standards worldwide, with Group strove to enhance its performance and
successful operational experience in several countries achieved the development of a suitable compound
at voltages up to 150 kV. for wet-design cables.
Natural rubber-based compounds were the only Use of EPR insulated cables reached its peak during
polymeric materials used as cables electrical insulation the seventies and eighties following the failures in
from the middle of the 18th century until 1930s, when service caused by water treeing phenomenon in the
the first suitable synthetic materials became available. first generation of polyethylene insulated cables.
During the following years, new technologies boosted Utilities have been using EPR insulated cables for
the development of new rubber based insulations with submarine and land cables up to 170 kV for more
better characteristics for the cable industry. than 40 years.
In the early sixties the inventions of Carl Ziegler and Nowadays the use of EPR insulated cables is preferred
Giulio Natta (who were awarded the Nobel Prize) for applications requiring superior mechanical and
enabled the manufacture of Ethylene Propylene Rubber thermal performances including industrial, oil and
(EPR). A few years after this breakthrough, the first gas, nuclear, submarine, and renewables systems.
EPR insulated cables appeared in the market and
since that time they have achieved an excellent track Most premoulded type accessories for EHVAC and
record in terms of operational reliability. HVDC cable systems are also made of EPR.
H
include fillers and other additives to optimise electrical H H H H H H H H C H H
H
performance. The polymer chains in the compound are
H
Ethylene Unit Propylene Unit
H
chemically cross-linked in the same way as XLPE.
C
H
A3 - Structure of EPDM Typical Diene Unit
Prysmian EPR insulation compound, although being based
on a proprietary formulation, can be duly fingerprinted to ensure its compliance with the qualified compound.
Diameter expansion of 150 kV EPR and XLPE insulated cables
Performance
Cable performance under current overload 8
The major cable problem resulting from current relies for its strength and its ability to maintain its XLPE
overload (generally due to emergency operation, original shape on its crystalline structure. When the
EPR
fault or short circuit) is that the heat generated can temperature exceeds 90 °C XLPE begins to undergo
damage the cable and reduce its life. EPR and XLPE “crystalline melting” which makes the compound
have the same nominal conductor operating soften, deforming more easily and reduces its
6
temperature, i.e. 90 °C, but can withstand different tendency to return to original shape. XLPE is thus far
overload current because of the differing high more likely to incur damage when temperatures
Diameter Expansion %
temperature properties of the compounds. are elevated above standard operating conditions.
EPR is a highly amorphous compound with little The lower level of expansion of EPR reduces risks
crystal structure, and its physical properties are little associated to physical stress in the cable, against
affected by temperature increases up to 130 °C. external restraints, or other cable system 4
XLPE has a lower crosslink density than EPR and components.
0
0 20 40 60 80 100 120 140
Temperature °C
AC over-voltage testing however gives a different part of the cable that will fail at a lower stress).
picture for the breakdown levels as RMS voltages are
usually considered. The test parameter “b” is used to describe the amount
of scatter of results (Weibull theory) with high scatter
The breakdown test is generally carried out on a giving a lower value. The band of scatter for XLPE has
standard test cable, 20 m long with a 70 mm2 a median of 10 compared to 14 for EPR and the
conductor and rated at 12/20 kV. Once again XLPE is consequence of this can be seen in the next chart.
seen to have higher breakdown stresses than EPR,
60-70 kV rms/mm compared to 50-55 kV rms/mm, but The graph plots breakdown voltage against a
XLPE exhibits far greater scattering of results. coefficient proportional to the square of the conductor 70
that of EPR because of the wider spread of results (in installed cable and the bigger the cables installed, the
a larger cable it is more likely that there will be some greater the reliability of EPR compared with XLPE. 50
30
20
10
10 100 1.000 10.000 100.000 1.000.000
Geometric Factor Ø
( Ø = (R2l)/(R02l0); R = conductor radius; l = sample length )
Dielectric losses
XLPE is well known to be a compound which kV the effect on current rating is negligible (less
exhibits an extremely low dielectric loss and the than 0.3% of current rating difference on a
more pure the polymer, the lower the losses. EPR typical 66 kV array cable when considering either
has a somewhat higher dielectric loss, but at 66 XLPE or EPR).
Installation
The first stage in using a cable is obviously internal switchgear. Increased flexibility of the
installation, and a primary reason for the move cable core could be a significant advantage to the
from paper to elastomeric insulated cables is jointing and termination operations where careful
ease of installation and handling. alignment is necessary in a limited space.
The use of an appropriate elastomeric insulation The reduced external bending forces in an EPR
removes the necessity for a metal sheath, thus insulated cable also reduce the internal stresses
considerably simplifying cable installation. between insulation and screen which, in extreme
cases, could cause problems with the formation
EPR has the advantage of an elastic modulus of voids.
lower than XLPE which makes it easier to install,
particularly if the operation has to be undertaken Joints and terminations are generally the same
in restricted spaces (such as underground as those used for installation of XLPE cables,
passages, ducts or offshore structures), or into hence minimising the need for jointer training.
350
250
150
100
50
0
1.0 10.0 100.0
Bending radius [m]
1
Dynamic cables
Example of 46 kV submarine dynamic cable The submarine cables intended for these
applications, require superior fatigue resistance
and better mechanical performance. 1. Click-Fit® Connector type CFC(O)-72 (Compact)
It is designed to connect extruded high voltage
Prysmian Group has gained significant experience cables with Switchgears (GIS) and Transformers.
with dynamic cables to connect Oil & Gas floating This connector can be installed in any position,
platforms, based on EPR insulation. regardless of the orientation of the system’s
configuration. The epoxy socket insulators can be
pre-installed in the factory, thus avoiding
offshore oil or gas treatment.
2
The economical exploitation of oil fields in deep water
is generally achieved by means of floating platforms. 2. Click-Fit® Joint type CFJ-72
This straight joint type is designed to connect two
Floating structures are not yet widespread in offshore extruded high voltage cables. It can be installed in
wind farms but several concepts and some pilot any position, regardless of the orientation of the
projects have been deployed in recent years. system’s configuration. After completion of the
installation, the cables need to be fixed with clamps.
These early applications are encouraging the study
Different cable and joint clamps are available on
of larger full scale floating offshore wind turbines.
request.
Accessories
Prysmian EPR insulated cables are compatible ways of factory prepared (identical) cable ends.
with Prysmian’s full range of accessories
including Click-Fit®. To minimize offshore installation times, cable
ends can be prepared onshore and then installed 3. Click-Fit® Branch (Y) joint type CFYJ-72
All products within the Click-Fit® range - including and clamped inside the offshore turbine. It is designed to connect three extruded high voltage
outdoor terminations, joints, Y (branch) joints 3
cables, such as inter array subsea cables, to the
and GIS/Transformer connectors - are based on The 66 kV Turbine Click-Fit® cable connections tower cable. Y-joints can be installed in any position,
the Click-Fit® “Plug&Power” concept for high can be divided into three main groups of dry-type regardless of the orientation of the system’s
voltage extruded cable accessories that enables accessories: Click-Fit® Connector type CFC(O)-72 configuration. After completing the installation, the
optimum ease and speed of assembly, maximum (Compact), Click-Fit® Joint type CFJ-72 and cable needs to be fixed with clamps. Different cable
reliability and maintenance-free operation, by Click-Fit® Branch (Y) joint type CFYJ-72. and joint clamps are available on request.
More than 40 years of experience
The application of EPR has varied widely, from In the last 50 years more than 200 submarine cable
industrial locations where flexibility is the key, to circuits have been installed worldwide with excellent
wet-design submarine cables where reliability and operational results.
performance are the key criteria.
The only 72.5 kV class wet design systems with
Prysmian Group experience with EPR insulated more than 40 years operational experience are EPR
cables dates back to the early sixties. insulated.
Prysmian service experience with submarine wet design EPR insulated cables
2001 - 150 kV (dry design)
150 Venezia - Murano –
Mestre
120
More than 40 years of experience
Voltage class Number of projects*
Nominal Voltage kV
90
0 - 10 kV more than 30
1972 - 60 kV 1986 - 69 kV
10 - 20 kV more than 70
Channel crossing in Venice Calcasieu lake
60
islands link crossing
1988 - 69 kV 20 - 30 kV more than 55
Indian river
crossing
30 - 40 kV more than 25
1972 - 30 kV
Ibiza – Formentera
islands link up to 60 kV and above 8
30
* @ 2016
1967/1968 - 20 kV
Sardinia - S. Stefano
islands link
0
1965 1970 1975 1980 1985 1990 1995 2000 2005 2010 2015
Construction Year Construction Year
Carbon Trust 66 kV qualification project
An outstanding track record Prysmian Group has
successfully type tested its
“wet-design” cable system with 800 mm2 aluminium
conductors and integrated optical element.
Historical Milestones 66 kV cable system in
accordance with CIGRE and The solution includes factory, field joints and plug-in
• “Sardinia - S. Stefano” islands link - ENEL, Italy (1967/1968) - 20 kV, 3x50 mm 2
IEC test protocols, as part terminations (using proprietary Click-FitTM technology)
First EPR supply (wet design) of the Carbon Trust’s and combines the use of state-of-the-art EPR
Offshore Wind Accelerator insulation - a material with excellent performance in
• “Ibiza - Formentera” islands link - GESA, Spain (1972) - 30 kV, 3x50 mm2 (OWA) programme. direct contact with water, with the cost effectiveness
First 30 kV (wet design) of a lighter and lead-free design.
The Carbon Trust is an
• “Channel crossing in Venice” - FF.SS., Italy (1973) - 60 kV, 1x120 mm2 independent UK company The qualification process was carried out in Prysmian
First 60 kV (wet design) with a mission to accelerate laboratories in the UK and in Italy. 66 kV copper
the move to a sustainable, designs are also available from Prysmian; however
• “Calcasieu lake crossing” - Jefferson Davis Elec. Corp, USA (1986) - 69 kV, 1x350 MCM for this Carbon Trust type test Prysmian considers
low-carbon economy. The OWA is Carbon Trust’s
First 69 kV (wet design) an aluminium design more onerous, especially with
flagship collaborative R&D programme, involving nine
• “Venezia - Murano – Mestre” - ENEL, Italy (2001) - 150 kV, 1x1000 mm2 offshore wind developers and supported by the UK respect to the flexible factory joints.
First 150 kV (dry design) Department of Energy and Climate Change (DECC) and
the Scottish Government, which aims to reduce the cost Although the qualified cable technology is innovative
of offshore wind through innovation, developing in its application, Prysmian has experience of over
Other key projects innovative concepts into commercial solutions. 40 years with such “wet design” EPR insulated
cables up to 72.5 kV in a wide range of applications.
• “Lanzarote – Fuerteventura” - Unelco Endesa, Spain - 60 kV 3x300 mm2 + 48 F.O. To encourage an accelerated development of a
competitive 66 kV cable system market, the OWA This success in the qualification of its 66 kV system
• “Nantucket Island I & II” - New England Power Co., USA - 46 kV, 3x500 MCM+48 F.O. will provide the necessary confidence to offshore
supported selected cable manufacturers, including
Prysmian, with the testing and certification of their 66 wind developers to reap the benefits by raising their
• “Indian river crossing” - City of Vero Beach – Florida, USA - 69 kV, 1x750 MCM inter-array system voltage to achieve significant
kV cable system designs.
• Tidal overall cost reductions and a higher competitiveness
“Minas Basin” - ITT TELECOM/FORCE, Canada - 34.5 kV 3x120+1x4 pilot cable + 12 F.O. Prysmian has type tested a 3-core, 66 kV EPR insulated of offshore wind energy systems.
2
1
1 Factory Joint
2 Repair Joint
Linking power grids
to sustainability
Prysmian Group
Via Chiese 6, 20126, Milan, Italy
www.prysmiangroup.com