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HVDC Cable Accessories for High Voltage DC Cable Systems

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Our HVDC cable accessories are designed for high voltage direct current cable systems used in power transmission and grid interconnection projects. The product range can include terminations, straight joints, connectors, and related accessory solutions for extruded-insulation cable systems, helping support reliable electrical performance, installation integrity, and long-term operation in demanding land power applications.

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Product Overview

Our high-voltage cable accessories are engineered for HVDC and HVAC transmission systems exceeding ±500 kV, offering a complete range of components including:

  • Terminations (indoor and outdoor)

  • Straight joints

  • Elbow joints

  • Plug-in cable connectors

These accessories are specifically designed to maintain industry-leading power loss rates below 0.02% per kilometer, ensuring maximum energy transmission efficiency over long distances.

Constructed using a proprietary blend of corrosion-resistant epoxy composites and advanced XLPE-based insulation, they deliver exceptional performance in extreme environments — from sub-zero polar regions to high-humidity coastal areas and high-altitude desert zones.

Whether deployed in:

  • Offshore wind farm interconnections

  • Transnational grid synchronization projects

  • Large-scale industrial power distribution networks

These accessories ensure uninterrupted power flow with a mean time between failures (MTBF) exceeding 15,000 operational hours, significantly reducing maintenance costs and unplanned downtime.


Features

1. High Voltage Resistance

  • Rigorously tested to withstand ±800 kV transient voltages and continuous operation at ±660 kV.

  • Incorporate multi-layer insulation structures that prevent partial discharge (PD) even under thermal cycling conditions.

  • Suitable for ±500 kV, ±600 kV, and ±800 kV HVDC links as well as 220 kV, 400 kV, and 500 kV HVAC systems.

  • Compliant with IEC 62067 and IEEE 48 standards.

2. Conductive Shielding

  • Equipped with a 0.1mm thick electrolytic copper tape shield, helically wrapped with uniform tension.

  • Effectively reduces electromagnetic interference (EMI) by up to 90%, ensuring signal integrity in adjacent communication cables, fiber optics, and control lines.

  • Provides continuous grounding path and protects against external electrical noise.

3. Insulation Fluid Technology

  • Utilizes high-purity silicone-based insulating fluid with a dielectric constant of 3.8.

  • Maintains stable electrical performance across a temperature range of –40°C to +90°C.

  • Resists oxidation, moisture ingress, and dielectric breakdown for over 20 years of service life.

  • Self-healing properties reduce the risk of partial discharge and electrical treeing.

4. Modular Design

  • Features tool-free connection mechanisms and adjustable clamping systems.

  • Accommodates cable conductor diameters from 25 mm² to 500 mm² (larger sizes available upon request).

  • Facilitates on-site installation in as little as 4 hours per joint, significantly minimizing maintenance-related downtime.

  • Reduces installation errors and improves field assembly consistency.

5. Environmental and Mechanical Durability

  • 316L stainless steel housing provides superior mechanical protection.

  • Marine-grade fluoropolymer coatings offer excellent resistance to saltwater, UV radiation, and chemical exposure.

  • Suitable for underground, submarine, tunnel, and direct burial installations.

  • Withstands vibration, seismic activity, and thermal expansion without performance degradation.


Applications

Renewable Energy Integration

These high-voltage cable accessories serve as critical links in connecting offshore wind farms to onshore grids. Their low-loss feature ensures maximum energy transmission from remote wind turbine arrays to mainland distribution networks.

  • Notable installation: UK’s Dogger Bank Wind Farm interconnection system (world’s largest offshore wind farm).

  • Also deployed in solar farms, pumped storage hydro plants, and tidal energy projects.

  • Supports long-distance transmission from generation sites to load centers.

Industrial Power Grids

Provide reliable power distribution in harsh industrial environments such as:

  • Mining operations (underground and open-pit)

  • Oil refineries and petrochemical plants

  • Chemical processing facilities

  • Steel mills and heavy manufacturing plants

Their resistance to chemical corrosion, mechanical stress, and temperature extremes ensures long-term operational stability and reduced maintenance frequency.

Cross-Border Transmission

Enable efficient HVDC links between nations, facilitating international electricity exchange with minimal transmission losses.

  • Example project: EuroAfrica Interconnector (between Europe and Africa)

  • Also used in NordLink (Germany–Norway) and Basslink (Australia–Tasmania)

  • Supports grid synchronization between regions with different frequencies or grid standards.

Additional Applications

  • Urban underground cable networks (subway, tunnel, and duct installations)

  • Data centers requiring high-reliability power supply

  • Airports, seaports, and railway electrification projects

  • Nuclear and thermal power plants


FAQ

Q: Are these accessories compatible with XLPE-insulated cables?

A: Yes, they are specifically engineered for seamless integration with XLPE and EPR-insulated cables, featuring matching insulation parameters and mechanical compatibility to ensure joint integrity. They also support PILC (paper-insulated) to XLPE transition joints.

Q: What certifications do they hold?

A: They fully comply with:

  • IEC 62067 – HVDC power transmission cables and accessories for rated voltages above 52 kV

  • IEEE 48 – Standard for terminations for AC cables

  • IEC 60840 – Testing of power cables with extruded insulation for rated voltages above 30 kV

  • ISO 9001 – Quality management systems

All products undergo rigorous third-party testing to validate performance, safety, and long-term reliability.

Q: Can they operate in saltwater environments?

A: Absolutely. The 316L stainless steel housing combined with marine-grade fluoropolymer coatings creates a robust barrier against saltwater corrosion, making them ideal for:

  • Offshore wind farms

  • Submarine cable connections

  • Coastal substations

  • Tidal and wave energy projects

These accessories offer a projected service life of over 30 years in saltwater environments.

Q: What is the maximum operating temperature?

A: The accessories are rated for continuous operation from –40°C to +90°C, with short-term emergency overload capability up to 105°C.

Q: Do you provide installation training?

A: Yes, we offer on-site installation training, technical documentation, and remote support to ensure proper installation and long-term performance.


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