Prysmian is world leader in the energy and telecom cables and systems industry.
With almost 150 years of experience, sales of over € 15 billion, around 30.000 employees in 50 countries and 108 plants, the company is strongly positioned in high-tech markets and offers the widest possible range of products, services, technologies and know-how.
YEARS OF EXPERIENCE
R&D CENTRES
AROUND THE WORLD
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.
AS A COMPANY, WE CAN PLAY A CRUCIAL ROLE IN THE GLOBAL ENERGY TRANSITION.
MORE EFFICIENT, RELIABLE, ECO-FRIENDLY POWER TRANSMISSION.
Prysmian 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.
Calculated in ambient conditions with soil thermal resistivity of 0.8 mK/W, ambient temperature of 18°C, burial depth of 1.5m and cables installed in bundle
525 kV 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 wind farms. 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 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.
Prysmian wanted to take things a step further, 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 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 cross-linking by-products (such as methane, cumyl alcohol, acetophenone, etc.). These by-products should be removed, after the cross-linking 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.
High transmission power, longer transmission lengths with lower system losses
Insulation and accessories tested
up to 600 kV DC
Underground and submarine cable systems fully qualified up to 525 kV in accordance with CIGRE Technical Brochure 852
Using the technological platform used for XLPE AC and DC cables
Further optimization
of 320 kV voltage class
Higher operating temperatures
than classic paper cables
Higher electrical strength
than state-of-the-art 320 kV extruded systems
Very low electrical conductivity and high thermal stability
An extruded layer of red or black colored high density polyethylene compound is provided over the metallic sheath. An extruded black semi conductive layer can
be applied over the outer sheath for after installation tests. Flame retardant and low smoke versions are available.
The smooth metallic sheath is constituted by
The smooth metallic sheath is constituted by
a longitudinally welded aluminum tape (WAS) applied over the outer semiconductive layer and water barrier, to provide water tightness, mechanical protection and to carry fault currents.
Water-swellable
tapes and extruded semi-conducting screen layer, to have a smooth electrical interface with insulation.
Low peroxide XLPE
Water-swellable tapes and extruded semi-conducting screen layer, to have a smooth electrical interface with insulation.
Up to 4 integrated fiber optic elements for monitoring purposes, able to accommodate both multi-mode and single-mode fibers.
Bare copper wires filled with water swellable tapes, with nominal cross-section area up 3. to 4000 mm2. Aluminum is also available.
Indicative diameter
140 mm
Indicative cable weight
40 kg/m
Ohmic resistance
0.0060 Ω/km
Coaxial inductance
0.14 mH/km
Capacitance
0.24 μF/km
Two layers of polypropylene strings, to protect against abrasion and reduce cable friction.
Up to 4 integrated fiber optic elements for monitoring purposes, able to accommodate both multi-mode and single-mode fibers.
Single or double layer
of galvanized steel round wires, flushed with bitumen as further anti-corrosion protection. Double steel layer
or Composite armour designs for high depth applications are also available.
An extruded layer of insulating polyethylene compound; to avoid any electrical breakdown by induced over-voltages, the metallic sheath
is short-circuited with
the armour wires at intermediate distances. Semiconductive polyethylene is also available.
The insulated core has
a lead alloy sheath applied over the longitudinal water barrier.
Water-swellable
tapes and extruded semi-conducting screen layer, to have a smooth electrical interface with insulation.
Low peroxide XLPE.
Water-swellable
tapes and extruded semi-conducting screen layer, to have a smooth electrical interface with insulation.
Bare copper wires filled with sea-grade water blocking compound, with nominal cross-section area up to 3500 mm2. Aluminum is also available.
Indicative diameter
160 mm
Indicative cable weight
65 kg/m
Ohmic resistance
0.0072 Ω/km
Coaxial inductance
0.15 mH/km
Capacitance
0.22 μF/km
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 cross-linking 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.
High transmittable power, help avoiding hotspot issues along the route, easier to switch to aluminum conductors
Lower environmental impact
and carbon footprint
Insulation and accessories tested
up to 600 kV DC
Underground cable systems fully qualified up to 525 kV in accordance with CIGRE Technical Brochure 852
Full compatibility with existing HVDC cable accessories
P-laser cables in construction phase
for >1000 km 320 kV and 525 kV HVDC projects
Higher operating temperatures up to 90°C
Higher electrical strength, capable to better withstand polarity reversals and transient overvoltages
Reduction of CO2 emissions by up to 30% and 100% eco-friendly and fully recyclable materials*
An extruded layer of red or black colored high density polyethylene compound is provided over the metallic sheath. An extruded black semi conductive layer can
be applied over the outer sheath for after installation tests. Flame retardant and low smoke versions are available.
The smooth metallic sheath is constituted by
The smooth metallic sheath is constituted by
a longitudinally welded aluminum tape (WAS) applied over the outer semiconductive layer and water barrier, to provide water tightness, mechanical protection and to carry fault currents.
Water-swellable
tapes and extruded semi-conducting screen layer, to have a smooth electrical interface with insulation.
Low peroxide XLPE
Water-swellable tapes and extruded semi-conducting screen layer, to have a smooth electrical interface with insulation.
Up to 4 integrated fiber optic elements for monitoring purposes, able to accommodate both multi-mode and single-mode fibers.
Bare copper wires filled with water swellable tapes, with nominal cross-section area up 3. to 4000 mm2. Aluminum is also available.
Indicative diameter
155 mm
Indicative cable weight
25 kg/m
Ohmic resistance
0.0081 Ω/km
Coaxial inductance
0.13 mH/km
Capacitance
0.25 μF/km
Two layers of polypropylene strings, to protect against abrasion and reduce cable friction.
Up to 4 integrated fiber optic elements for monitoring purposes, able to accommodate both multi-mode and single-mode fibers.
Single or double layer
of galvanized steel round wires, flushed with bitumen as further anti-corrosion protection. Double steel layer
or Composite armour designs for high depth applications are also available.
An extruded layer of insulating polyethylene compound; to avoid any electrical breakdown by induced over-voltages, the metallic sheath
is short-circuited with
the armour wires at intermediate distances. Semiconductive polyethylene is also available.
The insulated core has
a lead alloy sheath applied over the longitudinal water barrier.
Water-swellable
tapes and extruded semi-conducting screen layer, to have a smooth electrical interface with insulation.
Low peroxide XLPE.
Water-swellable
tapes and extruded semi-conducting screen layer, to have a smooth electrical interface with insulation.
Bare copper wires filled with sea-grade water blocking compound, with nominal cross-section area up to 3500 mm2. Aluminum is also available.
Indicative diameter
160 mm
Indicative cable weight
50 kg/m
Ohmic resistance
0.0119 Ω/km
Coaxial inductance
0.15 mH/km
Capacitance
0.22 μF/km
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.
Largest track record and high reliability for 525 kV voltage level
Field proven designs for high depth applications
Competing solution for low transmission loss applications
Operating temperature up to 60°C
High electrical strength, capable to withstand polarity reversals and transient over voltages
Laboratory and Field proven
capability for high water depths
Two layers of polypropylene strings, to protect against abrasion and reduce cable friction.
Double layer of composite wires, specially designed for high depth applications, combining light weight features
with high tensile strength performances. Steel wires or single layers designs are also available.
One layer of steel tapes, to allow for proper thermal expansion and contraction of the MIND insulation.
An extruded layer
of semiconductive polyethylene compound, to avoid any electrical breakdown by induced over-voltages. Insulating polyethylene is also available for metallic armours.
The insulated core has
a lead alloy sheath applied over the longitudinal water barrier.
Carbon black and metallized paper layers.
High density wood pulp paper tapes, impregnated with fully degasified special viscous compound.
Carbon black paper layers.
Aluminum keystone conductors, with nominal cross-section area up
to 2500 mm2. Copper
is also available.
Indicative diameter
135 mm
Indicative cable weight
30 kg/m
Ohmic resistance
0.0247 Ω/km
Coaxial inductance
0.16 mH/km
Capacitance
0.33 μF/km
Insulation: MIND
Power transmitted: 1,000 MW
1,500 KM of Prysmian submarine cables
2,200 KM max water depth
Insulation: P-LASER
Power transmitted: 2,000 MW
270 KM Prysmian cable route
550 KM of Prysmian HVDC underground cables
Insulation: XLPE
Power transmitted: 2,000 MW
580 KM Prysmian cable route
1,200 KM of Prysmian HVDC underground cables
Insulation: P-LASER
Power transmitted: 2,000 MW
300 KM Prysmian cable route
640 KM of Prysmian HVDC underground cables
XLPE (submarine cable)
P-Laser (land cables)
Power transmitted: 2,000 MW
328 KM of Prysmian HVDC submarine cables
24 KM of Prysmian HVDC land cables
XLPE (submarine cable)
P-Laser (land cables)
Power transmitted: 2,000 MW
310 KM of Prysmian HVDC submarine cables
410 KM of Prysmian HVDC land cables
Insulation: MIND
Power transmitted: 1,400 MW
1,250 KM of Prysmian submarine cables 135 KM of Prysmian land cables
lnsulation: XLPE (submarine and land cables) P-Laser (land cables)
Power transmitted: 2,000 MW
352 KM of Prysmian HVDC submarine cables
36 KM of Prysmian HVDC land cables
Insulation: MIND
Power transmitted: 1,400 MW
950 KM of Prysmian submarine cables
1500 KM of Prysmian land cables
