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1. Laurens Pots | TKF
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2. 22 March, 2019
Laurens Pots

3. INTRODUCTION
From a cable manufacturer...
…to a leading technological supplier of connectivity solutions

4. CONTENT
▪ The learning curve of array cabling
– Trends
– Standardisation
– Opportunities, armour losses explained
– Risks: are wet designs future proof?
▪ TKF
– New design of subsea array cable
– Installation advantages

5. DON’TTHINKTHE MARKET IS SETTLED ALREADY
MarketTrends for array cables:
▪ Bigger turbines, operating voltage from 33kV to 66kV
▪ Distance between turbines increased, more turbines per string
▪ Asian wind farms, on shore substations instead of off shore:
- Today the volume of medium voltage array cable is bigger than the volume of export cables
- Need for bigger cables, 3x800 mm2 and up
Increase of problems and failures:
▪ Cable installation performance of lighter cables during trenching,
▪ Cable installation failures,
▪ Termination failures due to installation and application environment,
▪ 90 subsea cable losses in the past 7 years resulting over 350 M€ claims (source 4Coffshore),
– On-going process of new industry standards, IEC standards and Cigre recommendations to catch up

6. INCREASING NUMBER OF STANDARDS
Design and testing:
▪ IEC60840
▪ IEC60502
Current ratings:
▪ IEC 60287
▪ IEC60853
4 years
Design
▪ IEC60840
▪ IEC60502
Testing
▪ IEC63026
Additional testing
▪ TB722- water barrier identification and long term water aging
▪ HD623 – Mechanical testing for submarine cables
▪ TB499 - Recommendations for Testing of Long AC Submarine Cables
Current ratings:
▪ IEC 60287
▪ IEC60853
▪ TB640 - Guide for Rating Calculations of Insulated Cables
▪ Cigre WG B1,56 - Verification of current ratings calculation
Cable losses:
▪ Cigre WG B1,64 - Evaluation of Losses in Armoured Three Core Power Cables

7. ARMOUR LOSSES
▪ Armour wire
- Thickness
- Hardness, permeability
- Saturation
▪ Construction
- Lay length armour
- Lay length cores
- Coverage density

9. Cable metal screen
identification (submarine)
Dry design Wet design
Accerlated water
aging testing
Pre-conditioning
50Hz or 500Hz
aging testing
Residual stress
testing
Cigre TB 722

10. RISK OF WATERTREEING INWET DESIGN ARRAY CABLES
▪ Most experience in MV land cables
▪ Most research on XLPE, limited on EPR
▪ Limited experience of WT in subsea
▪ No clear correlation of test methods
▪ Higher E stress
▪ Salt water (lots of)
▪ High Pressure
▪ Continues high load profile
▪ Mechanical stress
Source : Harmonics in Windpower Energiforsk
2018: 469
Ageing tests are carried out using nice sine wave
Ageing tests are carried out @ 40ºC

11. NEW SUBSEA CABLE FACTORY LOCHEM
▪ HighVoltage XLPE extrusion
▪ AluminiumWelding
▪ Lay-Up
▪ Armouring
▪ Faraday Cage
▪ Test Facilities

12. TKF NEW SUBSEA CABLE DESIGN: ENVIRONMENTAL ADVANTAGES
- No Lead
- No bitumen
- No risk of leaching of chemicals or metals
into the marine environment
- Easy and clean recoveries possible
- Good recyclability after clean recoveries

13. TKF NEW SUBSEA CABLE DESIGN: INSTALLATION ADVANTAGES
- Compression up to 30 kN allowed resulting
in a larger weather window
- Double crush load resistance
- Good bending stiffness (tapes incorporated
provide less friction so layers can move
independent from each other)
- Long manufacturing length resulting in
higher installation flexibility (see next slide).
- Reduction of offshore termination time
- Easy removal of swellable yarns
- Easy to strip outer sheath
- No precautions for dirtyingTP or
cable deck

14. COMPATIBLE ANDTESTED ACCESSORIES
▪ Hang off systems, improvement of air
tightness, 10 x conventional cable.
▪ Terminations, improvement of earthing system
reducing installation failures.
▪ Pulling head, lowering vessel time since only
one end-cap per cable end is needed.

15. TEST FACILITIES
▪ Installer (contractor): Boskalis
▪ End customer: EnBW
▪ Project HoheSee: Cable installation in progress
Cable Type: 3x630 18/30 kV
Total cable length: 52.334 m
▪ Project Albatros: Cable production finished
Cable Type: 3x240 and 3x630 18/30 kV
Total cable length: 27.000 m