As key tools in
bulk power transmission, submarine power cables tend to operate at high voltage in order to minimize
resistive losses between the endpoints. Unlike
overhead powerlines, many submarine power cables tend to operate with DC current.
Electrical phases must endure
close proximity inside the cable, increasing
parasitic capacitance. It is more economical to use AC only with lines shorter than 100 km in length, in which case losses at the
landing point grid interfaces dominate. When the reasons for high voltage transmission, the preference for AC, and for capacitive currents are combined, one can understand why there are no underwater high electric power cables longer than 1000 km (see the table in "Operational submarine power cables" section below).
Conductor As indicated above, submarine power cables transport
electric current at
high voltage. The electric core is a concentric assembly of inner
conductor,
electric insulation, and protective layers (resembling the design of a
coaxial cable). Modern three-core cables (e.g. for the connection of
offshore wind turbines) often carry
optical fibers for data transmission or temperature measurement, in addition to the electrical conductors. The
conductor is made from
copper or aluminum wires, the latter material having a small but increasing market share. Conductor sizes ≤ 1200 mm2 are most common, but sizes ≥ 2400 mm2 have been made occasionally. For voltages ≥ 12 kV the conductors are round so that the insulation is exposed to a uniform
electric field gradient. The conductor can be stranded from individual round wires or can be a single solid wire. In some designs, profiled wires (keystone wires) are laid up to form a round conductor with very small interstices between the wires.
Insulation Three different types of
electric insulation around the conductor are mainly used today.
Cross-linked polyethylene (XLPE) is used up to 420 kV system voltage. It is produced by
extrusion, with an insulation thickness of up to about 30 mm; 36 kV class cables have only 5.5 – 8 mm insulation thickness. Certain formulations of XLPE insulation can also be used for DC. Low-pressure oil-filled cables have an insulation lapped from paper strips. The entire cable core is impregnated with a low-
viscosity insulation fluid (
mineral oil or synthetic). A central oil channel in the conductor facilitates oil flow in cables up to 525 kV for when the cable gets warm but rarely used in submarine cables due to
oil pollution risk with cable damage. Mass-impregnated cables have also a paper-lapped insulation but the impregnation compound is highly viscous and does not exit when the cable is damaged. Mass-impregnated insulation can be used for massive
HVDC cables up to 525 kV.
Armoring Cables ≥ 52 kV are equipped with an extruded lead sheath to prevent water intrusion. No other materials have been accepted so far. The lead alloy is extruded onto the insulation in long lengths (over 50 km is possible). In this stage the product is called cable core. In single-core cables the core is surrounded by concentric armoring. In three-core cables, three cable cores are laid-up in a spiral configuration before the armoring is applied. The armoring consists most often of steel wires, soaked in bitumen for corrosion protection. Since the alternating magnetic field in AC cables causes losses in the armoring, those cables are sometimes equipped with non-magnetic metallic materials (stainless steel, copper, brass). ==Operational submarine power cables==