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 150
and systems industry. YEARS OF
EXPERIENCE
With almost 150 years of experience,
sales of over €16 billion, around 30.000
employees in 50 countries and 108 26
plants, the Group is strongly positioned R&D CENTRES
in high-tech markets and offers the AROUND
widest possible range of products, THE WORLD
services, technologies and know-how.

PRYSMIAN GROUP | 525 kV HVDC

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.

3
 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.

Power transmission as a function of technology

2800

2600

2000

1800
525 kV suitable for
1600 connections above 2GW

1400

1200
Power [MW]

320 kV suitable for

1000 connections up to 1.3 GW

800
1000 1200 1400 1600 1800 2000 2200 2400 2600

Copper Cross-section [mm2] 320 kV extruded - 70°C 525 kV extruded - 70°C

525 kV paper - 60°C 525 kV extruded - 90°C

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

PRYSMIAN GROUP | 525 kV HVDC

 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.

Prysmian Group wanted

A CONTINUOUS to take things a step
EFFORT TOWARDS further confirming its
THE ENERGY role and commitment
TRANSITION in the development of
power grid infrastructure,
empowering its customers in the continuous effort

2.5 GW
towards the energy transition to reach the EU 2050
goal of having 300 GW of offshore wind power and also

up to reducing infrastructure costs for the benefit of energy

bills and final consumers.
TRANSMISSION
CAPACITY

5
 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 cross-
linking 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.

MAIN XLPE TECHNOLOGY

ADVANTAGES: PERFORMANCES:

High transmission power, longer Higher operating temperatures

transmission lengths with lower than classic paper cables
system losses
Higher electrical strength
Insulation and accessories tested than state-of-the-art 320 kV
up to 600 kV DC extruded systems

Underground and submarine Very low electrical conductivity

cable systems fully qualified up to and high thermal stability
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

PRYSMIAN GROUP | 525 kV HVDC

XLPE DATASHEET | Land CONDUCTOR
Bare copper wires filled with water
swellable tapes, with nominal
cross-section area up to 4000 mm².
Aluminum is also available.
INNER SEMI-CONDUCTIVE LAYER
Water-swellable tapes and extruded semi-
conducting screen layer, to have a smooth
electrical interface with insulation. INTEGRATED FO CABLE
Up to 4 integrated fiber optic
elements for monitoring purposes,
INSULATION able to accommodate both
Low peroxide XLPE. multi-mode and single-mode fibers.

METALLIC SHEATH
The smooth metallic sheath is
OUTER SEMI-CONDUCTIVE LAYER constituted by a longitudinally
Water-swellable tapes and welded aluminum tape
extruded semi-conducting screen (WAS) applied over the outer
layer, to have a smooth electrical semiconductive layer and
interface with insulation. water barrier, to provide water
tightness, mechanical protection
and to carry fault currents.

OUTER SHEATH
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.

Dimensional data for 3000 mm2 copper Electrical data for 3000 mm2 copper

Indicative diameter 140 mm Ohmic resistance 0.0060 Ω/km

Indicative cable weight 40 kg/m Coaxial inductance 0.14 mH/km

Capacitance 0.24 µF/km

7
 XLPE DATASHEET | Submarine

CONDUCTOR
Bare copper wires filled with
sea-grade water blocking compound,
INNER SEMI-CONDUCTIVE LAYER with nominal cross-section area
Water-swellable tapes and extruded up to 3500 mm².
semi-conducting screen layer, to have Aluminum is also available.
a smooth electrical interface with insulation.

INSULATION
Low peroxide XLPE.

METALLIC SHEATH
OUTER SEMI-CONDUCTIVE LAYER The insulated core has a
Water-swellable tapes and extruded semi- lead alloy sheath applied
conducting screen layer, to have a smooth over the longitudinal
electrical interface with insulation. water barrier.

ARMOUR
ANTI-CORROSION SHEATH
Single or double layer of galvanized
An extruded layer of insulating
steel round wires, flushed with
polyethylene compound; to avoid
bitumen as further anti-corrosion
any electrical breakdown by induced
protection. Double steel layer or
over-voltages, the metallic sheath is
Composite armour designs for high
short-circuited with the armour wires at
depth applications are also available.
intermediate distances. Semiconductive
polyethylene is also available.

INTEGRATED FO CABLE
Up to 4 integrated fiber optic SERVING
elements for monitoring purposes, Two layers of polypropylene strings,
able to accommodate both to protect against abrasion and
multi-mode and single-mode fibers. reduce cable friction.

Dimensional data for 2500 mm2 copper Electrical data for 2500 mm2 copper

Indicative diameter 160 mm Ohmic resistance 0.0072 Ω/km

Indicative cable weight 65 kg/m Coaxial inductance 0.15 mH/km

Capacitance 0.22 µF/km

PRYSMIAN GROUP | 525 kV HVDC

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.
MAIN P-LASER TECHNOLOGY
ADVANTAGES:
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
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.
PLaser is fully recyclable, a key advantage for the end
of life stage of obsolete HVDC links. As the production
process with PLaser 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.
PERFORMANCES:
High operating temperature
up to 90°C
High 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*
*Refers to the end-of-life phase
of Life Cycle Assessment (LCA)
evaluation
9
 P-LASER DATASHEET | Land
INNER SEMI-CONDUCTIVE LAYER
Water-swellable tapes and extruded semi-
conducting screen layer, to have a smooth
electrical interface with insulation.
OUTER SEMI-CONDUCTIVE LAYER
Water-swellable tapes and extruded semi-
conducting screen layer, to have a smooth
electrical interface with insulation.
OUTER SHEATH
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.
Dimensional data for 3500 mm2 aluminum
Indicative diameter 155 mm
Indicative cable weight 25 kg/m
PRYSMIAN GROUP | 525 kV HVDC
CONDUCTOR
Bare aluminum wires filled with
water swellable tapes, with nominal
cross-section area up to 4000 mm².
Copper is also available.
INTEGRATED FO CABLE
Up to 4 integrated fiber optic
elements for monitoring purposes,
able to accommodate both
multi-mode and single-mode fibers.
INSULATION
P-Laser, based on HPTE insulation
material which is fully recyclable
and compatible with existing
cable accessories.
METALLIC SHEATH
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.
Electrical data for 3500 mm2 aluminum
Ohmic resistance 0.0081 Ω/km
Coaxial inductance 0.13 mH/km
Capacitance 0.25 µF/km
P-LASER DATASHEET | Submarine
CONDUCTOR
Bare aluminium wires filled with
sea-grade water blocking
compound, with nominal
cross-section area up to 3500 mm².
Copper is also available.

INNER SEMI-CONDUCTIVE LAYER

Water-swellable tapes and extruded semi-
conducting screen layer, to have a smooth INSULATION
electrical interface with insulation. P-Laser, based on HPTE insulation
material which is fully recyclable
and compatible with existing
cable accessories.

METALLIC SHEATH
OUTER SEMI-CONDUCTIVE LAYER The insulated core has a
Water-swellable tapes and lead alloy sheath applied
extruded semi-conducting screen over the longitudinal
layer, to have a smooth electrical water barrier.
interface with insulation.
ARMOUR
Single or double layer of galvanized
ANTI-CORROSION SHEATH steel round wires, flushed with
An extruded layer of insulating bitumen as further anti-corrosion
polyethylene compound; to avoid protection. Double steel layer or
any electrical breakdown by Composite armour designs for high
induced over-voltages, the metallic depth applications are also available.
sheath is short-circuited with the
armour wires at intermediate
distances. Semiconductive
polyethylene is also available.

SERVING
INTEGRATED FO CABLE
Two layers of polypropylene strings,
Up to 4 integrated fiber optic
to protect against abrasion and
elements for monitoring purposes,
reduce cable friction.
able to accommodate both
multi-mode and single-mode fibers.

Dimensional data for 2500 mm2 aluminum Electrical data for 2500 mm2 aluminum

Indicative diameter 160 mm Ohmic resistance 0.0119 Ω/km

Indicative cable weight 50 kg/m Coaxial inductance 0.15 mH/km

Capacitance 0.22 µF/km

Note: Technology under development 11

 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.
MAIN MIND TECHNOLOGY
ADVANTAGES: PERFORMANCES:
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
PRYSMIAN GROUP | 525 kV HVDC
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.
Operating temperature
up to 60°C
High electrical strength, capable
to withstand polarity reversals
and transient overvoltages
Laboratory and Field proven
capability for high water depths
MIND DATASHEET | Submarine

CONDUCTOR
Aluminum keystone conductors,
with nominal cross-section area up to
2500 mm². Copper is also available.
INNER SEMI-CONDUCTIVE LAYER
INSULATION
Carbon black paper layers
High density wood pulp paper tapes,
impregnated with fully degasified
special viscous compound.

OUTER SEMI-CONDUCTIVE LAYER

Carbon black and metallized
paper layers.
METALLIC SHEATH
The insulated core has a lead
alloy sheath applied over
ANTI-CORROSION SHEATH the longitudinal water barrier.
An extruded layer of semiconductive
polyethylene compound, to avoid
any electrical breakdown by
REINFORCEMENT
induced over-voltages. Insulating
One layer of steel tapes, to allow
polyethylene is also available for
for proper thermal expansion and
metallic armours.
contraction of the MIND insulation.

ARMOUR
Double layer of composite wires,
SERVING specially designed for high depth
Two layers of polypropylene strings, applications, combining light weight
to protect against abrasion and features with high tensile strength
reduce cable friction. performances. Steel wires or single
layers designs are also available.

Dimensional data for 1200 mm2 aluminum Electrical data for 1200 mm2 aluminum

Indicative diameter 135 mm Ohmic resistance 0.0247 Ω/km

Indicative cable weight 30 kg/m Coaxial inductance 0.16 mH/km

Capacitance 0.33 µF/km

13
 Milestone
projects
HVDC UNDERGROUND
INTERCONNECTIONS

1. SuedOstLink
Insulation: Power transmitted:
P-LASER 2,000 MW
(the first project to use
270 KM extruded cables at this
Prysmian cable route highest voltage level)

550 KM 4.
of Prysmian HVDC underground cables

5.

2. SuedLink
Insulation: Power transmitted: 1.
3.
XLPE 2,000 MW
2.
580 KM 1,200 KM
Prysmian cable route of Prysmian HVDC
underground cables

3. A-Nord
6.
Insulation: Power transmitted:
P-LASER 2,000 MW

300 KM 640 KM
Prysmian cable route of Prysmian HVDC
underground cables

PRYSMIAN GROUP | 525 kV HVDC

HVDC SUBMARINE
INTERCONNECTIONS

4. North Sea Link

CONNECTING UK AND NORWAY
Insulation: Power transmitted:
MIND 1,400 MW

950 KM 1,500 KM
of Prysmian submarine cables of Prysmian land cables

5. Viking Link
CONNECTING UK AND DENMARK
Insulation: Power transmitted:
MIND 1,400 MW

1,250 KM 135 KM
of Prysmian submarine cable of Prysmian land cables

6. Tyrrhenian Link
CONNECTING SARDINIA, SICILY AND CAMPANIA
Insulation: Power transmitted:
MIND 1,000 MW

1,500 KM 2,200 M
of Prysmian submarine cables max water depth

15
PRYSMIAN GROUP
Via Chiese, 6 – 20126
Milano / Italy
T +39 02 64491
info@prysmiangroup.com

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