Advanced Materials and Manufacture of High Voltage AC and DC Power Cables for Deepwater Offshore Wind Applications

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Innovate UK
Innovate UK
Innovate UK
Innovate UK
Innovate UK

£1,696,205

Dec. 1, 2022

Nov. 30, 2024

Power generation from offshore wind is subject to harsher environments than onshore wind, which can cause greater challenges for the reliability of critical infrastructure. One asset that is fundamental to the economic success of an offshore wind farm is the subsea cable transmission infrastructure. This includes inter-array and export cables, failure of which can lead to significant loss of revenues through a reduction in the availability to export generated power, as well as penalties imposed by regulators.

Since 2013, 8 TWh of electricity generated offshore has been lost due to subsea cable faults resulting in GBP \>1bn of losses for operators. In the offshore wind industry, 80% of the total cost of insurance claims are attributed to cable failures, while subsea cable expenditure only accounts for 8% of the capital cost of a new windfarm.

This becomes more significant with the increasing trend to construct larger offshore windfarm developments at greater distances from the coast line in deeper water depths, This is done to take advantage of higher wind speeds and more stable wind frequencies as the distance from the coastline increases, thereby maximizing electrical generating capacities and revenues. Additionally, the increased use of submarine electricity trading cables between countries also exposes cabling systems to challenging environmental conditions.

High voltage deep-water subsea power cables are complex composite structures required to conduct high voltages and currents in an underwater environment and to have the structural strength and flexibility to be installed in severe metocean conditions. Such demanding conditions expose submarine cabling systems to a greater risk of deterioration and damage, particularly from an increase in water depths, with significant limitations to their installation and operation arising from limitations from materials, design, and manufacture.

Therefore, better cable designs utilising advanced materials and manufacturing processes are required to reduce the risk and consequence of cable failures. A move to more robust cable designs is anticipated to realise a reduction in the likelihood and frequency of cable failures. This will minimise the repair and replacement costs of failed submarine cabling and thereby increase electrical generation and transmission availability.

This project brings together BPP Cable Solutions and LS Cable and Systems to develop advanced cable designs using novel materials and manufacturing processes for high voltage AC and DC power cables. This is anticipated to address the known shortcomings and limitations with existing submarine cable designs.