HVDC SUBMARINE POWER CABLES SYSTEMS
STATE OF THE ART AND FUTURE DEVELOPMENTS
DIEGO VALENZA and GEFW CPOLLINI
Pirelli Cavi S.p.A.- Divisione Italia
Vide Sarca, 222 20126 Milano, Italy
~-
ABSTRACT The paper begins with an introduction on
the reasons that lead to the use of HVDC submarine
cable links. The main aspects for the choice of direct
current are presented as well as the advantages
deriving from the utilization of submarine cables.
The second part is dedicated to a discussion on the
various type of insulation that could be used in power
cables and their possibile application to I-IVDC
submarine cables.
In the following there is a description of the main
characteristics and technical details of some particular
project that at present time (1995) are in progress.
Two projects are briefly presented :
- Spain-Morocco, a 26 km long interconnection for the
transmission, in a first phase, of 700 MW from Spain
to Morocco at 400 kV a.c. by means of three cables,
plus one spare, of the fluid filled type. The cables are
designed for a future change to d.c. 450 kV, allowing a
transmission of 500 MW each (i.e. 2 GW total). One of
the peculiarities of the link is the maximum water
depth of 615 m (world record for submarine power
cables at the time of installation).
- Italy-Greece, a 160 km long interconnection for the
transmission of 500 MW (bi-directional) by means of
one paper insulated mass impregnated cable having
1250 sqmm conductor size and insulated for a rated
voltage of 400 kV. This link (the installation of which
will be posterior to the Spain-Morocco) will attain the
world record for the maximum water depth for
submarine power cables: 1000 m.
The last part deals with the future developments
expected in this field, in terms of conductor size and
voltage, that means an increase in transmissible
capacity.
1. INTRODUCTION
Without dealing with excessively technical detail our
intention at the present conference is to focus the main
features of respectively :
+ The why of HV submarine cables
+ The when of HVDC snbmarine-cables
+ how far is the research and the state of the art with
HVDC submarine-cables
IEEE Catalogue No. 95TH8130
0-780.3-2981-3/95/$4.00@1995IEEE
+ what shall we be expecting in the near f u m e as far
as the DC cables are concerned
The concept of submarine cable power transmission is
well recognized, since it has been alive for many years
so far, giving the possibility of finding solutions which
would be very difficult otherwise. Considerable
advantages can be found which can be surpassed with
difficulty by any other transmission system:
- electrical feeding of islands
- interconnections between non syncronized Hv
networks through sea paths
- transfer of cheap power generated on natural or
artificial islands to the mainland
- crossing of sea inlets, rivers and lakes
- connection to or between offshore oil platforms
The present state of the art of submarine power cables
shows that submarine systems have transmission
characteristics as noteworthy as those of land cables
and overhead lines as well. Different technologies
allow cables to be manufactured for AC and DC
applications. How they differ for can be shown as
follows:
HVAC IIVDC
CABLES CABLES
Theoretical 60-90 km * unlimited
length
Additional Yes no
losses
Inverter/Convert no Required
er
Network Required no
Syncronicity
In spite of the lower prices and the higher voltage rates
of the AC submarine links, if the required length for
the project is more than the figure indicated, then the
only solution available is that of using an HVDC cable.
Moreover, taking into account that the SCOF cables,
commonly used for both AC and DC links, have an
intrinsic length limitation due to pressurized oil
presence, MIND insulation is the only way to date of
carrying out long links. Extruded insulation, widely
283
used for AC cables, has never been tested on field for
HVDC cables, but only laboratory tests have been
performed with no very encouragmg results.
out that each manufacturer does not engage only in
supplying systems or just cables, eventually exploiting
these opportunities to boost the research and
development department, but moves also forward
loohng for opportunities the only goal of which is to
conduct feasibility studies for potential projects still far
from being finalized. It was following the above path

I
53 100
Theoretical Cable Link

Figure 1
1
m 4 I
that the Hawaii deep water cable program was
developed (1600 sqmm SCOF cable at 2000 m water
depth) as well as the Iceland-United Kingdom long link
feasibility study (1400-1600 sqmm MIND cable 1000
km long).
The projects described in this paper are given
lierebelow in chronological order of commissioning.
The reasons supporting the development of HVDC
projects can be outlined as follows: 1) SPAIN - MOROCCO

1. very long transmission links (no inductive and 2) ITACY - GREECE

capacitive reactance limitations, no dielectric
losses)
2. the possibility of increasing the power flow without
increasing the short circuit current levels 3. SPAIN -MOROCCO
3. the need to control power flow from one network to
another
4. interconnection of networks having different
frequency or, anyway, non - syncronous

The state of the art is a concept that has to be strictly

related to the art itself and can be exposed only from a
comparative point of view.

1 YEARS I kV I MW I Insulation I Approx. I

I I
‘50 I 100 I 20 I 7.0 I loo
Figure 2
‘60 1 200 I 200 I 11.8 I 120
‘70 250 500 16.0 130 Conceived for the first time during the 1980’s it
‘80 400 500 17.5 200 represents a premiere for more than one reason. It will
‘90 450 600 19.0 250
~
be the first potential intercontinental link from both
I >2000 I 500 I 7-800 I 19-20 I >500 I energy and cultural perspective allowing a continuous
flux between two mainlands which have always been
radically different. Technically speaking there is a
What emerges from a glance at the above table is that peculiarity regarding the m,ucimum water depth along
the operating characteristics have been increasing the route, 615 m, which has never been reached except
gradually every decade, making the projects which in phase of simulation (HAWAII). The
were once unthinkable come true. interconnection, initially to be operated in AC, should
By way of example, the insulation thickness is acquire, in a second stage, the configuration of HVDC
noteworthy, representing the trend of manufacturing link, according to the system study of the customer.
technology both in the paper lapping process under The reasons that gave origin to the idea of this
conditioning control and in the impregnation process. interconnection are more concrete and mainly
P<aticular emphasis is necessary for the materials imputable to Morocco’s energy requirement due to the
composing the cables, even where they remain slow but ever growing industrial and economic
substantially the same they have assumed better development. The European interconnection, with its
characteristics in reliability and resistance. The continuous development, would actually allow the
extreme depths of water achieved in cable laying is a transmission of European energy to Morocco via Spain.
further substantial evidence of the mechanical stress Internal consumption is forecasted to grow by 7% for
now withstood by the cable itself. the years to come making the need for new capacity
urgent.
The submarine link which is the subject of this paper
2. HVDC SUBMARINE LINKS will be initially operated at 400 kV AC, being
composed of 4 cables, 3 per circuit plus 1 spare. The
Before introducing our company’s present involvement AC power to be transmitted is 700 MW.
in HVDC submarine pro-jects it is important to point

284
Due to the high cost of converter stations the
customer's intention was to split the investment
required, whilst still owning a potential HVDC link.
Should the customer decide to set the converters to
activity, a 4 cables DC link will be available, operated
at +450 kV carrying 500x4 = 2000 MW.
The SCOF (self contained oil filled) cable insulation
type has been selected since it is able to support both
AC and DC systems.
The oil feeding system is realized with pumping
stations whose working pressure is 16 bar. It is worth
noticing that as the oil pressure is related to the
maximum water depth, when such depths are reached
it is necessary to dedicate maximum care to the
analysis of the technical features of the cable project.
required. The repair joint is one of the major delicate
points bf the testing process, because it has to show the
ability of the manufacturer to implement an industrial
cycle on any site, giving the cable the same industrial
mechanical and electrical properties as such cycle.
All the tests carried out on the subject cable covered
both a.c. and d.c. operation.
The mechanical behaviour of the copper used for the
conductor and for the armour as well as all the other
layers composing the cable is such to allow a
distribution of the pulling tension during laying about
20% on the conductor and 80% on the armour.
The use of conductive armour reduces the return
current losses, obtaining a result (in terms of total
losses) similar to increase the conductor cross section

I I= I

Figure 3
A special fluid having density similar to the sea water much beyond the nominal 800 sqmm. During the
is purposely chosen when dealing with high depths due operation of the cable in DC the double armour will
to the huge hydropressureacting on the cables. merely lave a function of mechanical protection.

The route length of the link is about 26 km, therefore

the total length of submarine cable is 4x26=104 kin.

As far as the cable protection is concerned, the use of a SPAIN-MOROCCO

special armour type is worthy of note. The armour is
composed of two layers of flat copper wires applied in 0.F.SUBMARINE CABLE 400 kV, 1x800 mm
opposite directions in order to reduce any torsional
effect during the cable laying.
Due to the presence of the double amour the necessity
arises of a turntable for the cable storage on the ship as
well as for its laying. The combination conductor-
armour was the subject of a special study. A detailed
analysis had to be undertaken on the tension
distribution between armour and conductor, as
specified below.

Total weight of cable in air 56 kglm

Total weight of cable in water 40 kg/m

The type test was accomplished in accordance with

Electra <andIEC specifications. The pulling tension for
the bending test was equal to 24.6 plus 30% margin
plus 4 tons of sea bottom tension
( T, +
= 24.6.1.3 4 = 36 tons).
Please note that the above tension level had to be
applied to test the repair joint as well, in order to
ensure that the reconstruction of the cable is as

285
 -
5. TTALY GREECE
I
Figure 5
ENEL and PPC, the public utilities of Italy and Greece
respectively, performed some studies on the direct
interconnection between the two countries during the
1970’s. It was in 1983 that the European Community
showed its interest in the project. In 1990 the feasibility
study was positively performed by ENEL and PPC.
Among the benefits deriving from the interconnection
of the two power networks :
- emergency assistance by making capacity reserves
-
mutually available
increased flexibility and more opportunities for
energy exchanges
- it provides the first direct interconnection between
Greece and Western Europe
- it provides electricity transactions between Western
Europe and Greece thus reducing overall marginal
costs.
The envisaged configuration of the interconnection
project through the Otranto Channel and the CO&
Straits, to be operated in DC, with a transmission
capacity of 500 MW consists o f :
A Overhead lines : approx. 130 km o€ AC and approx.
30 km DC in Italy; approx. 140 km of AC and
approx. 110 km DC in Greece.
- Converter stations : revertible, one in Italy and in one
in Greece.
- Submarine Cables : approx. 160 km.
- Telecommunication equipment for remote control of
the DC connection.
- CONSTRUCTION FEATURES
The submarine part of the link is composed of a 160
km length cable which will be laid up to 1000 m water
depth. Due to the long length a mass impregnated cable
has to be used. A double counter helical armour is
necessary due to the extreme depth of the water. The
cable nominal voltage is +_ 400 kV and its cross section
is 1250 sqmm. On the Italian shore the submarine
cable is jointed with a 2000 sqmm MIND land cable
0.5 km long, and afterward, before the outdoor
termination, there is a transition joint with a 1200
sqmm SCOF cable, The electrical scheme envisages a
monopole with sea return through the two sea
electrodes: the cathode in Italy and the anode in
286
Greece. This link is designed to allow an upgrade in
the future thus doubling the current capacity,
transforming it into a bipolar scheme by installing a
second pole, the mirror image of the present one.
Total weight of cable in air 45 kg/m
Total weight of cable in water 34 kg/m
The total cable weight and the relevant volume requires
the necessity of a double campaign and a flexible sea
joint for the cable laying.
The bending test was performed by applying
T, = 34.1.3 + 4 = 48 tons
For the cablelaying a special 50 tons capstan has been
envisaged as a counterpoise for the cable tension.
The double armour, the main duty of which is to
protect the cable during the laying operations, is made
of galvanized flat steel wires. The external water
pressure on cable may assume a critical level at such
depths. The cable successfully passed laboratory tests
withstanding outer pressure of about 12.2 lo6 Pa for
1 month under thermal cycles without any deformation.
ITALY-GREECE
/’
2 8
3 9
4 10
5 11
6 12
1 - Conductor 7 - Metallic Reinforcement
2 - Conductor Screen 8 - Bedding
3 -Insulation Imp. Paper 9 - Inner Armour
-
4 Core Screening 10 - Bedding
5 - Lead AUoy Sheath 11 - Outer Armour
6 - High Density PE Sheath 12 - Serving ,
Figure 6
- LABORATORY TESTS
The peculiarities of the project required a preliminary
qualification program for cable and installation
equipment and procedures lasting approx. 20 months.
All type of cables included in the link have been
mechanically and electrically tested to ascertain their
reliability. It is worth noticing that all the electrical
tests have been not only carried out according to
CIGRE specifications but further tests have been
performed among which :
- PE sheath impulse withstand test
- Polarity reversal ageing test
Particular focus has been given to the terminals which
were submitted to a specific testing program.
The sea tests have a dominant role among the several
sigruficant tests the equipment had to withstand. The
sea trial was performed close to the actual cable route
using 2.5 km of cable specifically manufactured.
- 1st phase : A cable length of 200 m was embedded at
low water depth (20-30 m) with a jetting
machine.
- 2nd phase : A cable length of 2,500 m was installed
at a depth of 150 m. A portion 500 m long
of this length included the joint for low
water depth and the factory joint was then
embedded.
- 3rd phase : The cable length including a flush flexible
joint suitable for extreme water depth was
installed at 1000 m depth and then
recovered.
- 4th phase : the cable was offloaded and submitted to a
d.c. voltage test at 600 kV. The test was
successfully whitstood.
The results of the above tests were thoroughly
successful.
The project as well as the tests were developed in
accordance with specific procedures under total quality
assurance system.
6. FUTURE DEVELOPMENTS
The present paper has shown the state of the art of
HVDC submarine cable technology. The performances
achieved so far can be improved by acting on the
following elements.
A further increase in the cable cross-section would be
a fundamental improvement, and 2500-3000 sqmm
seems to be achievable, with an increase of
transmissible load. This improvement is related to the
development of stranding machines capable of
assembling a sufficient number of strips in several
layers in a single step and the capability of of handling
the cable as far as weights, diameters, bending radii
and pitches are concerned.
The cable operating voltage could realistically rise up
to 500-600 kV for paper insulated cables and to 800-
1000 kV for SCOF cables. The increase in insulation
thickness and in operating electrical stress produce the
same effect of permitting a higher voltage level. When
increasing the insulation thickness a problem occurs,
that is the difficulty in ensuring a good impregnation of
the inner layers of insulating paper. A possible solution
is the increase the fluidity of the compound (by
elevating the temperature, provided that this does not
287
affect paper characteristics), to increase the pressure
during impregnation or the extension of impregnation
time.
The electrical stress increase can be achieved by using
new insulating materials, presently in phase of research
( polypropylene laminated paper, etc. ).
It is attainable an increase in nominal temperature
because SOLID cables can reach an operating
temperature of 50 OC max. whilst it is thinkable to
increase it to 6OoCby using non-draining impregnating
compound. Even if it has already been successfully
tested, it needs further development.
The last field is the development of new construction
technologies, which would allow to reduce the cable
weight acting on the armour’s materials, replacing
copper or steel wires with lighter materials equally
protective and having similar or higher tensile
strengths (e.g. pultruded profiles).
7. CONCLUSIONS
Submarine cable technology has been involved in a
continuous development allowing power supply
Authorities to establish power transmission links where
it was technically impossible some years ago, mainly
due to long distances or extreme water depths. Many
renewable sources around the world will surely
incentive the technology of submarine cable links,
driving the development toward higher capacities to
be transmitted and longer distance to be covered.
8. REFERENCES
(1) G. BAZZI - D. VALENZA - P. BARONI: HVDC
Submarine Cable Systems-EECPS ‘89.
(2) G.BAZZI - D. VALENZA: Recent Developments in
HVAC and HVDC Submarine Power Cables, CEPSI
1992.
(3) T.JHAMMONS - A. OLSEN -
T. GUDMUNDSSON: Feasibility of IcelanWnited
Kingdom HVDC Submarine Cable Link, IEEE
Winter Meeting 1989.
(4) Electra N. 28: Progress Report of Study Committee
14 (AC/DC Converting Plant).
(5) C.CARCAN0 - P.0LIVA - J. VOJATZAKIS:
Improvement of the reliability of the European
Electrical System, UNPEDE 1995.