Conductor Structure Design of Large-Cross-Section Circular Compressed Submarine Cable Conductors

In order to satisfy the industrialisation requirements for the design of circular single-filament circular compacted submarine cable conductor structures, a design methodology for circular single-filament circular compacted conductors is hereby presented.The following parameters are to be considered: The diameter of the conductor, the diameter of the conductor single filament, the diameter of the conductor stranded, the diameter of the conductor outer diameter post-compaction, the amount of compaction per layer and the number of single filaments per layer. It is demonstrated that, in accordance with the design methodology, the optimisation process for the structural dimensions of 630mm² and 1800mm² conductors is illustrated, in conjunction with final design exemplars. Subsequent to the fabrication of the conductors through custom conductor manufacturing processes, the DC resistance of both 630mm² and 1800mm² conductors was examined through rigorous testing. It is proposed that the subsequent phase of optimisation for circular single-wire compacted structure conductors should be undertaken in accordance with national standard requirements and resistance test data. During the production of circular compacted submarine cable conductors, the conductor structure dimensions were repeatedly optimised and adjusted by modifying parameters such as conductor resistivity, compaction coefficient, compaction levels for each layer, and stranding pitch. The process under discussion integrated economic considerations for submarine cable manufacturing, ultimately yielding a conductor design structure offering optimal cost-effectiveness. Following a period of extensive production validation, the finalised manufacturing specifications for the conductors were established. This process was undertaken in order to confirm the stability of both the conductor structure and its resistive properties.