F E A T U R E A R T
An Assessment of Material Selection
for High Voltage DC Extruded Polymer
Cables
Key words: high voltage DC, extruded cable, cable materials
Introduction
This contribution to the Electrical Insulation Special Issue
provides an assessment of the present major insulation candi-
dates, under development or ready for commercialization, for
high voltage DC (HVDC) extruded polymer cables in Europe,
Japan, and China. It is a contribution on behalf of the Dielec-
trics and Electrical Insulation Society (DEIS) Working Group
on HVDC Cable Systems [1]. It is noted that interest in extruded
polymer HVDC cables by IEEE Electrical Insulation Magazine
dates back to the Nov/Dec 1997 issue of volume 13, when cross-
linked polyethylene (XLPE) was well established and compet-
ing with ethylene propylene rubber for this technology.
The 2015 review by Chen and colleagues [2] provides a com-
prehensive picture of the significant activity and development
worldwide of the commercial installations and plans for the next
decade for HVDC cables, and of the different alternative insula-
tion technologies involved, including the use of extruded poly-
mers for the major installation, with its many advantages that the
materials and application methods afford related to accessories
such as splices and terminations.
As noted in the Chen article, an important factor in the selec-
tion of a suitable insulation system for use in such extruded poly-
mer cables for HVDC is the presence and development/growth
of space charge through the radial thickness of the insulation, in
particular at the interface with the inner and outer semiconduc-
tors (semicons), and the consequent localized enhancement of
the internal electric field, potentially impacting electro-thermal
cable aging and unanticipated electrical breakdown.
The current understanding of space charge development
and aging in present HVDC cable insulation materials and ac-
celerated life testing of such materials is clearly summarized in
CIGRE Technical Brochure 636, prepared by CIGRE Working
Group D1.23, issued in November 2015 [3]. For basic treatment
of the chemistry and physics of space charge development in
polymers, including compounded materials as used in extruded
cables, three IEEE Electrical Insulation Magazine articles [4]–
22 0883-7554/17/©2017/IEEE
I C L E
C. W. Reed
Consultant, Scotia, NY 12302, USA
This article provides an assessment
of the present major insulation can-
didates, under development or ready
for commercialization, for high volt-
age DC extruded polymer cables in
Europe, Japan, and China.
[6] are also noteworthy. Indeed, DEIS, in both IEEE Transac-
tions on Dielectrics and Electrical Insulation and IEEE Elec-
trical Insulation Magazine articles, has covered the creation of
space charge in many issues. Historically, it is noted that in the
1959 book Progress in Dielectrics, John Mason [7] reported on
the significant reduction in DC breakdown of polyethylene by
prestressing with either negative or positive DC voltages.
Recommendations of procedures for the qualification of pro-
spective HVDC insulation systems prior to their acceptance by
the cable manufacturer are documented in CIGRE Brochure
496, from CIGRE Working Group B1.32, for voltages up to 500
kV [8]. HVDC cable manufacturers also make use of CIGRE
Technical Brochure 219, for voltages up to 300 kV, the prede-
cessor document to CIGRE Technical Brochure 496, or of IEC
60840 (edition 4) and IEC 62067 (edition 2) modifications of
these CIGRE documents.
The scope of space charge measurements that may be in-
cluded in qualification for HVDC cable use is given in Section
2 “Development Tests” of CIGRE Technical Brochure 496. It is
written that “the manufacturer should complete all analyses and
IEEE Electrical Insulation Magazine
development testing prior to commencing the prequalification
test. The precise nature and extent of development work, and
analyses should be left to the discretion of the manufacturer but
may include the following:
• An evaluation of the materials and processes involved. Such
evaluations would normally include electrical resistivity
measurements, breakdown tests, and space charge mea-
surements.
• An analysis of the electric field distribution within the ca-
ble system insulation for a range of typical installation and
loading conditions.
• An assessment of the long-term stability, possibly involving
factory experiments to assess the ageing effects of various
parameters, e.g., electrical stress, temperature, environmen-
tal conditions, etc.
• An assessment of the sensitivity of the electric stress distri-
bution to the expected variations in cable dimensions, ma-
terial composition and process conditions (extrusion, post
extrusion treatments, and finishing).”
As described above, CIGRE Technical Brochure 636 provides
a useful examination of thermo-electrical aging mechanisms in-
volved with space charge effects in polyethylene and XLPE dur-
ing Technical Brochure 496 Development and Pre-qualification
Testing.
For application as transmission class (up to 600 kV or higher)
extruded polymer submarine cable designs, consideration herein
is given to both traditional chemically cross-linked polyethylene
(XLPE), which has demonstrated excellent capability for me-
dium voltage AC and high voltage AC (HVAC) extruded cables,
and to newer (polycrystalline) thermoplastic polymer primary
insulation designs, with special consideration to space charge
formation under continuous DC voltage service or polarity re-
versal. We report that both classes of polymer are considered
by leading cable manufacturers worldwide to be qualified and
available for commercial installation.
Chemically Cross-Linked Polyethylene
(XLPE)
The use of dicumyl peroxide for the chemical cross-linking
of polyethylene was invented by Albert Gilbert and Frank Pre-
copio in 1963 [9], leading to the development of XLPE extruded
cables for AC and DC applications up to the present. Progres-
sively, the technology was enhanced by the implementation of
coextruded inner and outer carbon black-filled semiconducting
polymer (semicon) and the removal (in a highly monitored de-
gassing procedure) of chemical bi-products from the chemical
cross-linking by dicumyl peroxide such as methane gas, aceto-
phenone, and cumyl alcohol [10], in order to improve XLPE
against treeing breakdown and other problems. And, in the past
20 years or so, high pressure nitrogen gas rather than steam has
been used to heat the polymer and initiate cross-linking by the
peroxide. Additionally, there have been steady improvements in
polymer purity and manufacturing (the switch to vertical extru-
sion equipment, clean room practices, and extrusion precom-
July/August — Vol. 33, No. 4 23
pounding of the components where filtration of adventitious
impurities and gel particles is performed); plus, on-line QC
measurements (transmission infrared and other properties) are
performed on the molten extrudate, in advance of the crucial
insulation extrusion with “pure” polymer constituents.
This has led to commercial HVAC XLPE cables in the range
of 500 kV and above, and, at the same time, to the steady ex-
amination of space charge behavior with laboratory and lower
voltage cables in considering XLPE for HVDC. In Japan, work
has identified the potential detrimental role of some antioxidants
used for improving XLPE thermal performance, and of some
voltage stabilizers, used for enhancing breakdown and aging
performance, but sometimes these results are at elevated stress
levels above the normal HVDC cable operational level used with
nonextruded polymer designs. Thus, the author believes the cor-
rect acceptability of these normal AC additives, which serve
beneficial roles, is uncertain for DC application. Never the less,
a goal of suppressing space charge behavior and of depressing
anode and cathode charge injection is viewed as essential.
Other work from Japanese industry has been successful in
identifying beneficial roles for space charge suppression from
the use of nano-particles of MgO [11], or select carbon blacks,
or SiO2; or from the inclusion of unspecified molecular level
polar groups [12]. Generally, the mechanism by which these
nano-particles or polar groups are considered to be effective is
their ability to act as traps for electrons or holes (which some
authors assume originate from the inner and outer semicon inter-
faces) or as traps for other intentionally added polar molecules.
We have not found much information on the bonding of these
nanoparticles to the base XLPE structure, but likely solid cova-
lent bonding via a select coupling agent will enhance long-term
performance.
In Japan, two major cable companies have claimed the de-
velopment of 500-kV HVDC XLPE cable systems [12], [13], in
compliance with CIGRE qualification recommendations, claim-
ing the absence of space charge problems up to 90°C.
Three major HV cable companies in Europe have made ma-
jor progress since the early 1990s in developing, producing, and
commissioning transmission level cables using XLPE extruded
polymer cable technology, to progressively higher voltages, first
for AC application but also for DC application, for both under-
ground and subsea applications.
In 2014 A. Gustafsson and colleagues [14] introduced a new
525-kV extruded HVDC cable system and summarized their ex-
perience with DC cable installations worldwide, of progressive-
ly increased voltage level and cable lengths across and between
continents. A “new” XLPE DC insulation is cited for the 525-kV
design, but no further detail was provided on any differences
in the chemistry involved or of space charge assessments made
during the design, construction, and qualification testing.
The second major cable manufacturing company [15] leading
the way with advanced HVDC technology is also a company of-
fering a wide range of electrical equipment and experience with
advanced insulating materials to support such equipment. The
company’s focus for both HVAC and HVDC cable technology is
also based on XLPE technology, extending to as high as 800 kV
(albeit for a short length of transmission cable located in China)
and for the first submarine HVDC cable with a 600-kV rating
connecting Scotland and England.
The third major cable company [16] of note in developing
and commercializing HVDC extruded polymer cable technolo-
gy is highly focused as a HVAC and HVDC cable manufacturing
company, with notable in-house material development expertise.
Furthermore, in 2016 the company successfully completed the
development and commercial introduction of both “new” XLPE
HVDC technology and thermoplastic polymer high performance
thermoplastic elastomer HVDC technology, as noted below.
Mitigation/Suppression of Potential Space Charge
Problems with XLPE
As noted above, cable companies in both Japan and Europe,
using different suppression approaches, have qualified HVDC
extruded cable technology for operation in the 500- to 600-kV
range, according to recommended industry procedures.
Thermoplastic Polymers
In parallel with work in laboratories and by manufacturers to
upgrade and qualify XLPE-based extruded formulations, over
the past decade, the option of using a thermoplastic polymer ma-
jor insulation as an alternative to XLPE has been under steadily
increasing pioneering investigation at research organizations
and major cable manufacturing companies in Europe, Japan,
and China. Thermoplastic polymer major insulation is used to
avoid the cross-linking chemistry in using dicumyl peroxide and
the subsequent need for degassing to remove the residual chemi-
cal species (methane, acetophenone, cumyl alcohol, etc.), ad-
ditionally aiming to extend the operating temperature above the
generally assumed limit for XLPE of 90°C and provide better
accommodation for occasional current overloads.
The material of choice to achieve this is the thermoplastic
polypropylene, which like polyethylene, is a simple polyolefin
synthesized following the cracking of petroleum. Whereas poly-
ethylene has chains of adjacent -CH- groups, in either (mainly)
linear or branched configuration, alternate carbon atoms in poly-
propylene chains have methyl (-CH3) side groups. It is the in-
termolecular van der Waals forces due to these methyl groups
that increase the thermal qualities (crystalline melting point and
glass transition temperature) of polypropylene over those of
polyethylene, offering thermal capabilities in excess of 100°C,
possibly as high as 140°C for limited periods of time. However,
polypropylene does have certain weak properties such as low
temperature brittleness, requiring innovation via blends or co-
polymers with polyethylene or other polymers to correct such
weaknesses.
Yoshifuji and colleagues [17] pursued a non-polypropylene
approach using high density polyethylene modified by grafting
a polar group to enhance thermal performance, improve break-
down, and provide space charge trapping. With poling voltages
of 30 kV/mm, space charge decreased with increasing stress,
while DC breakdown was superior to that of XLPE.
In laboratory studies, Yao Zhou and colleagues [18] pursued
polypropylene/polyolefin elastomer blends, showing several en-
hanced properties relative to polypropylene and XLPE, includ-
ing improved thermal performance, better flexibility, high vol-
24 IEEE Electrical Insulation Magazine
ume resistivity, and high breakdown strength. However, hetero
space charge accumulation was still considered an issue.
In 2015 Green and coauthors [19], in the culmination of sev-
eral years’ work, recognizing the thermal benefit of using poly-
propylene and also its inherent stiffness limitation, performed a
comprehensive compositional optimization of a self-assembling
blend of propylene homopolymer with propylene-ethylene co-
polymer. Laboratory experiments were followed by mini-cable
trials on the optimized blend, from which the authors conclude
the following advantages of a thermoplastic solution relative to
XLPE: good low temperature flexibility, good high temperature
integrity up to about 140°C, and increased breakdown strength.
The authors also conclude that the optimized blend will have
increased ease of manufacture and reduced whole-life environ-
mental impact.
Bin Dang [20] demonstrated an alternative option for poly-
crystalline polypropylene thermoplastic using syndiotactic poly-
propylene, versus the isotactic polypropylene favored by Green
and colleagues. Aware of the slower crystallization rates with
the syndiotactic form, it was found that compounding with SiO2
nanoparticles, using a vinyl silane coupling agent, corrected the
slower rates, as the nanoparticle provided the role of nucleating
agent. (A similar effect has also been found with other nanopar-
ticles in the crystallization of polycrystalline thermoplastics.) A
significant reduction in space charge formation plus a significant
increase in DC resistivity were found, leading to the authors’
consideration of syndiotactic polypropylene/SiO2 for extruded
HCDC cable application.
In 2015 Marco Albertini and coauthors [21] announced the
development of a “P-Laser” polypropylene thermoplastic insu-
lation system with enhanced thermo-mechanical properties for
320-kV DC cable application. Tests on model cables were fol-
lowed by production of a prototype for 320-kV insulation class,
electrical assessment of the prototype, and subsequent prequali-
fication tests performed at 90°C on a complete system, in com-
pliance with CIGRE TB 496.
In September 2016 in further work by the same cable manu-
facturer, the successful development and testing of a new (up-
graded) P-Laser cable system, identified also as high perfor-
mance thermoplastic elastomer), was announced for 600-kV
ultrahigh voltage DC cable application [22]. The newer high
performance thermoplastic elastomer system is highlighted as
a single continuous process, not requiring dicumyl peroxide
chemistry, allowing more efficient cable production and with
better environmental sustainability.
Mitigation/Suppression of Potential Space Charge
Problems with Thermoplastic Insulation Designs
The susceptibility of the new thermoplastic candidates iden-
tified above to space charge development under sustained in-
service DC voltages or to accelerated (higher or much higher)
DC laboratory test voltages has yet to be openly and thoroughly
assessed. However, the writer anticipates that cable manufac-
turers pursuing such technology will have implemented suitable
corrective measures, as dictated in TB 496, Section 2. The same
or similar options for the prevention of charge injection/suppres-
sion via modified semicon materials or fluorocarbon additives/
coatings, or by trapping using nanofillers such as MgO or SiO2,
as suggested for HVDC XLPE, may likely be valid. So far, we
have not been able to confirm corrective measures, if used.
Conclusions
• Both traditional XLPE and newer thermoplastic polymer
technologies have been qualified in compliance with rec-
ommended CIGRE or other industry testing recommenda-
tions for use in transmission-level HVDC extruded polymer
cables up to the 500 to 600-kV range. Commercial designs
are now offered by major cable manufacturers in Europe
and Japan.
• While qualification procedures recommended by CIGRE
and other organizations are claimed for these thermoset and
thermoplastic classes by major cable manufacturers, we
have no details to share to date.
• The writer was also unable to find published information
on space charge behavior or mitigation on production-size
transmission-class HVDC extruded cables; presumably,
this inability, which may only be temporary, is due to the
proprietary nature of such information.
• From laboratory studies and tests on lower voltage cables
and limited tests on higher voltage cables, on some of both
XLPE and thermoplastic candidate polymer formulations, a
significant beneficial effect in suppressing space charge has
been achieved by the addition of relatively low concentra-
tions of spherical nano-particles. Further work to confirm
this finding is underway by different organizations.
• Given the importance of the planned development of trans-
mission-class HVDC extruded polymer cables worldwide,
the completion of the IEEE Standard P1732 “A Recom-
mended Practice for Space Charge Measurements in High
Voltage Direct Current Extruded Cables for Rated Voltages
up to 550 kV” is particularly timely.
References
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Clive W. Reed received his first class BSc
and PhD degrees in physical chemistry at
the University of Bristol, England, fol-
lowed by a postdoctoral fellowship in low
temperature physics at the National Re-
search Council of Canada, Ottawa, Ontar-
io. He worked at the GE Corporate Re-
search and Development Center, in
Schenectady, New York, from 1963 until
retirement in 2002. There he worked on a wide range of insula-
tion design and accelerated life performance and dielectric phe-
nomena R&D for GE’s generator, motor, transformer, aircraft
engine, medical, aerospace, industrial, plastics, defense, nuclear,
and other businesses, both as an individual contributor and as a
group and project manager. He also worked on projects for the
US Department of Energy; the US Navy, Army, and Air Force;
the Electric Power Research Institute; Consolidated Edison
Company; and other electric utilities. Professionally, he has
been active in the IEEE (member of the Administrative Commit-
tee and as chair of the Awards Committee of the Dielectrics and
Electrical Insulation Society), CIGRE (as international chair of
Study Committee D1 for six years), the US National Academy
of Sciences–National Research Council (as member of the Com-
mittee on Dielectrics and chair of the Conference on Electrical
Insulation and Dielectric Phenomena, and editor of two major
industry reports), and the American Chemical Society. He is the
recipient of many awards from these organizations. Since 2002
he has consulted in the defense and electrical equipment field.

26 IEEE Electrical Insulation Magazine