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Text Content

Linking the
sustainable future

TABLE OF CONTENTS

Connecting the world.
Today and in the future. 525 kV cable technology,
a step further XLPE technology P-Laser technology Mass Impregnated
non drained technology Milestone projects Contact us

ADDITIONAL DOCUMENTS

A-Nord project

Sued Link project

SuedOst Link
project




525 KV HVDC

NEW CABLE SYSTEMS
FOR THE ENERGY TRANSITION


525 KV HVDC

NEW CABLE SYSTEMS
FOR THE ENERGY TRANSITION


CONNECTING THE WORLD.
TODAY AND IN THE FUTURE.



Prysmian Group is world leader in the energy and telecom cables and systems
industry.

150
YEARS OF
EXPERIENCE
With almost 150 years of experience, sales of over €16 billion, about 30,000
employees in 50 countries and 108 plants, the Group is strongly positioned in
high-tech markets and offers the widest possible range of products, services,
technologies and know-how.
26
R&D CENTRES
AROUND
THE WORLD


AS A COMPANY, WE CAN PLAY A CRUCIAL ROLE
IN THE GLOBAL ENERGY TRANSITION

We operate in the business of high voltage underground and submarine cables and
systems for power transmission and distribution, special cables for applications
in many different industries and medium and low voltage cables for the
construction and infrastructure sectors.
We manufacture cables and accessories for voice, video and data transmission for
the telecom industry, offering a comprehensive range of optical fibres, optical
and copper cables and connectivity systems.



SUSTAINABILITY IS IN OUR DNA

Prysmian’s ambition is to act as an enabler to accelerate the energy transition,
while also creating business value, by supporting the development of greener and
smarter power grids with innovative cable technologies to cover longer distances
and sea depths, ensuring higher performance, reliability and sustainability.
This ambition is demonstrated by our everyday business activities to provide
clean energy where it is needed, all over the world. Interconnectors between
countries are another key part of the energy transition: as the backbone of
power grids, cables are, and will be an essential part of this development,
supporting the implementation of larger, more integrated, efficient and
sustainable power transmission systems.




525 KV CABLE TECHNOLOGY, A STEP FURTHER


MORE EFFICIENT, RELIABLE, ECO-FRIENDLY
POWER TRANSMISSION

Prysmian Group launched the new 525 kV HVDC cable technology, making a
significant step forward towards more efficient, reliable and eco-friendly power
transmission.

525 kV extruded land cable systems are qualified with two different insulation
materials, P-Laser and XLPE. They are both designed to operate at very high
electrical stresses and are tested with large conductor cross-sections to
maximize power transmission over long distances with minimized land use. For
example, the ±525 kV technology uses less cable to transmit the same power
compared to classic 380 kV AC systems. This is reflected in less construction
efforts when installing the cables and narrower trench widths. P-Laser also
benefits from a higher operating temperature than classic HVDC systems at 320
kV, further increasing its power transmission capacity.

525kV systems are effective solutions able to connect power generation areas
such as wind generation-rich regions to major consumption centers, typically
located far from renewable energy sources, reducing the required land usage and
ensuring lower environmental impact.

525 kV XLPE submarine cable systems are also successfully developed and tested
according to International Standards.
This breakthrough innovation will enable a massive increase in the transmission
capacity of Bipole systems of up to 2.5 GW, which is almost twice the value
achieved with 320 kV DC systems currently in service. This is key to connecting
huge amounts of green energy to the grid such as next generation offshore
windfarms. The pace at which renewable power needs to be connected each year has
to increase to meet challenging targets set worldwide to lower carbon emissions:
increasing the power each link can transmit is the only way to deploy the needed
energy infrastructure in time. The company leveraged on extensive and in-depth
knowledge of materials and manufacturing processes, successfully optimizing the
industrial process while keeping reliability and guaranteeing strict
technological parameters. An entire system of submarine cable and accessories -
including flexible factory joints, rigid repair joints and sea-land joints -
with the best dielectric properties was successfully developed and is now
available on the market.


A CONTINUOUS EFFORT TOWARDS THE ENERGY TRANSITION

Prysmian Group wanted to take things a stepfurther confirming its role and
commitment in the development of power grid infrastructure, empowering its
customers in the continuous effort towards the energy transition to reach the EU
2050 goal of having 300 GW of offshore wind power and also reducing
infrastructure costs for the benefit of energy bills and final consumers.


XLPE TECHNOLOGY

XLPE insulation technology is based on polyethylene and requires a cross-linking
process, which is essential for stabilizing the insulation material. This
process determines the presence in the insulation of crosslinking by-products
(such as methane, cumyl alcohol,acetophenone, etc.). These by-products should be
removed, after the crosslinking with a specific thermal treatment process, known
as “degassing”.

The degassing operation decreases the amount of residual by-products present in
the cable. Electrical and thermomechanical working performance should be
selected accordingly, to guarantee reliable system operations at the
ever-increasing voltage levels.

The newly developed XLPE material presents higher cleanliness and lower
electrical conductivity, allowing for an increase of the maximum allowable
electrical stresses in the insulation (if compared to the previous XLPE
materials), meaning that the conductivity is more stable between cold and hot
conditions. As a result, it is possible to reach cable voltage levels up to 600
kV, while reducing thicknesses at standard voltages with lighter and less
expensive cables.


XLPE LAND

Read
Datasheet
Indicative diameter
140 mm
Dimensional data for 3000 mm2 copper

Indicative cable weight
40 kg/m
Ohmic resistance
0.0060 Ω/km
Dimensional data for 3000 mm2 copper

Coaxial inductance
0.14 mH/km
Capacitance
0.24 μF/km


XLPE SUBMARINE

Indicative diameter
160 mm
Dimensional data for 2500 mm2 copper

Indicative cable weight
65 kg/m
Ohmic resistance
0.0072 Ω/km
Dimensional data for 2500 mm2 copper

Coaxial inductance
0.15 mH/km
Capacitance
0.22 μF/km
Read
Datasheet

The energy transition from fossil fuels to renewable power sources is already
underway and the independence from energy imports has become even more
important. It is taking place mainly in the power sector, where renewable energy
now accounts for 26% of electricity generation worldwide. Given the existential
threat posed by continued use of fossil fuels, the European Union has taken the
global lead in fighting climate change and in reducing energy dependency by
setting ambitious targets already significantly before 2030. The European
Commission’s European Green Deal is asking member states to become carbon
neutral by 2050. This can only be achieved by an integrated energy market that
is both, digitalized and interconnected, powered by renewable sources.


By the end of 2022, Germany will shut down the last three of its 17 nuclear
power plants, and, as of now, will close all of its coal-fired electricity
plants by 2030 as part of its shift to a fossil fuel-free economy by 2050.
Europe’s industrial powerhouse intends to rely on renewables such as wind,
solar, biomass, and hydropower to make up 65% of the energy mix by 2030.
Therefore, Germany is making a massive investment in renewable energy, including
investment in its electricity grid to bring it up to the task of transporting
wind energy generated in the north to where it is needed in the southern
regions. Given the country’s status as Europe’s biggest economy, Germany’s
transition is decisive for the EU’s overall ability to implement a more
sustainable, secure, and independent economy.


‍Cables are the backbone of Europe’s energy transition and energy security. A
flexible electricity grid and interconnectors capable of shifting power across
borders are needed to transport wind, solar, and hydro power safely, rapidly and
at a lower cost. Prysmian Group supports Europe’s national Transmission System
Operators (TSOs) and plans to build up this smarter and more robust grid with
intelligent solutions both in terms of products and systems.



P-LASER TECHNOLOGY

P-Laser cable technology is based on a High-Performance Thermoplastic Elastomer
(HPTE) insulation, an in-house developed insulation material based on
polypropylene. The excellent electrical properties of polypropylene are well
known; however, intensive R&D work was needed to achieve a combination of
excellent values of flexibility and thermomechanical properties. Compared to
XLPE, HPTE does not require any crosslinking process and therefore does not
require the time and energy consuming degassing process. Being intrinsically
free of any cross-linking by products, P-Laser insulation performances are
outstanding, and it can safely withstand demanding electrical stresses such as
polarity reversals and transient overvoltages.

HPTE is designed for operation at 90°C. This allows, in comparison to operation
at 70°C, to either transmit more power or to reduce the cable cross section and
thus investment costs. Also, this feature can be used to operate the link at
increased safety margins.

P-Laser is fully recyclable, a key advantage for the end of life stage of
obsolete HVDC links. As the production process with P-Laser has a low energy
consumption, it has an overall reduced carbon footprint compared to XLPE up to
30%. P-Laser technology is fully compatible with existing cable accessories and
can be integrated in networks using different insulation technologies.


P-LASER LAND

Read
Datasheet
Indicative diameter
155 mm
Dimensional data for 3500 mm2 aluminum

Indicative cable weight
25 kg/m
Ohmic resistance
0.0081 Ω/km
Dimensional data for 3500 mm2 aluminum

Coaxial inductance
0.13 mH/km
Capacitance
0.25 μF/km


P-LASER SUBMARINE

Indicative diameter
160 mm
Dimensional data for 2500 mm2 aluminum

Indicative cable weight
50 kg/m
Ohmic resistance
0.0119 Ω/km
Dimensional data for 2500 mm2 aluminum

Coaxial inductance
0.15 mH/km
Capacitance
0.22 μF/km
Read
Datasheet

Prysmian is the leading cable supplier to German energy utilities, with
approximately 1,900 local employees and 6 manufacturing plants: Nordenham,
Schwerin, Berlin, Neustadt near Coburg, Nuremburg and Wuppertal.‍


‍Prysmian’s 4 R&D centres in Germany mean it can work closely together with
local customers. The German HDVC cables projects were awarded by European grid
operators TenneT, TransnetBW and Amprion to Prysmian in 2020, which makes
Prysmian the only cable manufacturer involved in all three German HVDC cable
projects.


Six offshore wind farms now operating in Germany’s North Sea are being powered
by HVDC submarine cables installed by Prysmian: BorWin2, BorWin3, DolWin3,
HelWin1, HelWin2, and SylWin1. A seventh, DolWin5, is currently under
construction.


‍These are some of the windfarms generating the electricity that will be
transported by the three German HVDC cable projects in order to supply
sustainable energy to cities and factories in Germany’s industrial south.



MASS IMPREGNATED NON DRAINED TECHNOLOGY

Mass Impregnated Non Drained (MIND) cables are suitable for voltages of up to
600 kV DC. The insulation consists of high-density paper tapes impregnated with
a high-viscosity compound which does not require fluid pressure feeding, thus
allowing cables to be installed in HVDC links in very long lengths, up to
several hundreds of kilometers. Nevertheless, they have intrinsic limitations in
power given by kraft paper’s electrical and thermal performances.

Research and development work on materials and technologies carried out by
Prysmian over the years has led to a product that can operate up to 60°C and has
the longest track record of operation at 525 kV voltage level. MIND cables are
still of interest for all applications where thermal performances are limited by
other factors or aren’t the main design driver, such as limitation of
transmission losses, environmental constraints, or high depth applications.

Prysmian’s special armour design enables record installation depths exceeding
2200 m, using special armour design features also developed by Prysmian. MIND
cables are the only technology installed and in operation at 1600 m. For high
depth applications ,mechanical constraints reduce the cross-section disadvantage
with extruded cables.

The thin insulation package typically used in MIND cables is beneficial in
reducing the cable weight and pulling tensions during installation. This doesn’t
affect the current rating, as thermal conditions at high depths are more
favorable thanks to lower temperatures and large distances between pole cables,
not installed in bundle.


MIND SUBMARINE

Read
Datasheet
Indicative diameter
135 mm
Dimensional data for 1200 mm2 aluminum

Indicative cable weight
30 kg/m
Ohmic resistance
0.0247 Ω/km
Dimensional data for 1200 mm2 aluminum

Coaxial inductance
0.16 mH/km
Capacitance
0.33 μF/km


MILESTONE PROJECTS


Go To Page - Prysmian sets up the organisation for the development of the 3
German power transmission cable projects


CONTACT US

From products and projects, to services, sustainability, safety and supply
chain. Our expert team is on hand to help with any questions you may have
regarding anything that has been discussed here.

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Linking
the future


PRYSMIAN GROUP


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