Numerical Investigation to Evaluate the Extrusion Process of Power Cable Designed by CFD Software

It is imperative that durable power cables be developed. Power cables should last more than 20 years in service. It was demonstrated, nevertheless, that such cables include water-tree flaws which eventually spread to conductors and corrode copper, potentially causing premature failure. One crucial factor to consider throughout the procedure is power cable's temperature distribution. The presented work provides a way of cooling the cable utilizing a cooling pipe with circulating water for increasing the effectiveness of heat dissipation throughout High-Voltage Direct Current (HVDC) cable thermal cycling testing. Because of the extensive maintenance needed, a breakdown could have severe financial repercussions. The insulator in the present work is modeled as cubic unit cells with ellipsoid-shaped water voids inside of them. For a 500 kV HVDC power cable, a 3D mode depending on thermal-fluid coupled model has been constructed with the use of Fluent as well as COMSOL multiphasic, finite element simulation tools. In the case when relative distance between the two ellipsoids is short or applied electric field is high, Von Mises stress and effective plastic strain at ellipsoid tips become significant. Two cooling mode, which are, bipolar single pipe and bipolar double pipe were used for analyzing and comparing the distribution of the temperature field as well as carrying the capacity of HVDC power cables. The findings show that while both cooling approaches could increase the carrying ampacity of the cable current, bipolar double tube cooling mode cools the power cable more effectively. A little water circulating velocity could also dramatically lower the temperature of power cable. As a result, throughout the thermal cycling test, the appropriate cooling modes as well as water velocity have been found to both accelerate the heat dissipation of the power cable. The technologies and materials now employed in the manufacture of power cables with aluminum, copper, or lead sheaths render them inappropriate, if not outmoded, for contemporary applications like floating wind farms. The study addresses various power cable types, their operational factors, construction, and working conditions, with a focus on the radial water barrier's role. Designs that are dry or semi-dry are the focus. Additionally, the paper discusses potential future constructions, materials, and ideas for further development. Using thermo-plastic block copolymers for the layer that has high moisture absorption in multilayer coatings is currently being studied, and the results are reported.