XWA 500kV Cable | Ultra High Voltage
Powering the Backbone of National Grids
XWA 500kV cable represents the highest level of extra high voltage (EHV) cable engineering, designed for projects where maximum transmission capacity, extreme electrical stress control, and long-distance efficiency are essential. At this voltage level, XWA leverages advanced EHV production lines and precision-controlled XLPE insulation processes to ensure insulation purity and uniform electric field distribution. Combined with comprehensive type testing and full-process quality control, this enables us to deliver high-reliability 500kV cable systems capable of stable, long-term operation under extreme electrical and thermal conditions.
500kV Cable Specifications & Construction
- Conductor: High-purity aluminium or copper conductors, typically from 1600 mm² up to 2500 mm²+, engineered for ultra-high current transmission.
- Insulation System: Advanced XLPE insulation with precise electric field grading, designed to withstand extreme voltage stress and minimize partial discharge.
- Metallic Sheath Design: Options include lead sheath or welded aluminium sheath, optimized for fault current capacity, moisture barrier performance, and grounding configuration.
- Outer Sheath: Heavy-duty PE sheath providing protection against mechanical impact, environmental exposure, and long-term aging.
- Voltage Rating: Uo/U 290/500 kV, Um 550 kV.
- Operating Capacitance: Ranging from 0.18 µF/km to 0.21 µF/km depending on conductor size.
- Charging Current: Ranging from 16.5 A/km to 18.9 A/km.
XWA 500kV Cable Size Datasheet
| Conductor Type | Cross-Section (mm²) | Outer Diameter (mm) | Net Weight with Pb Sheath (kg/m) |
|---|---|---|---|
| Aluminium | 1600 | 131 | 32.1 |
| Copper | 1600 | 133 | 40.5 |
| Aluminium | 2000 | 142 | 34.1 |
| Copper | 2000 | 142 | 45.2 |
| Aluminium | 2500 | 147 | 36.2 |
| Copper | 2500 | 147 | 51.2 |
Why Partner with XWA for 500kV Ultra-Critical Projects?
500kV transmission projects demand absolute reliability, precise engineering, and a partner capable of delivering at the highest voltage level. XWA power cable manufacturer combines advanced manufacturing capability with real-world project experience to support mission-critical infrastructure.
- Precision Electric Field Control
Our advanced XLPE insulation system is manufactured under strict process control to ensure uniform electric field distribution, reducing partial discharge risk and extending service life. - Engineered for Maximum Power Throughput
Designed to carry ultra-high current loads over long distances, optimizing efficiency while minimizing transmission losses in backbone grid applications. - Proven Manufacturing & Quality Assurance
With 15+ years of high-voltage cable experience, XWA implements full-process quality control—from raw materials to final testing—ensuring consistent, reliable performance at 500kV level. - Capability for Complex EHV Installations
Our cables are engineered for demanding environments, including long-distance underground routes, utility tunnels, and high-load transmission corridors, with full technical support. - Complete System Solution Provider
Beyond the cable itself, we support joints, terminations, bonding systems, and project-level technical guidance, ensuring seamless system integration. - Competitive Factory-Direct Advantage
As a direct manufacturer, XWA offers cost-effective solutions for large-scale EHV projects, helping you stay competitive without compromising on quality or compliance.
Typical Applications of 500kV Cable
500kV EHV electrical cables are deployed in national-level transmission systems where extremely high power demand, long-distance delivery, and grid stability are critical. These projects typically involve complex engineering, strict reliability requirements, and long-term infrastructure planning.
- National Grid Backbone Transmission
500kV underground cables form the core transmission arteries of power systems, carrying bulk electricity across regions with maximum efficiency and minimal losses. - Cross-Regional & Cross-Border Interconnections
Enabling high-capacity energy exchange between regions or countries, 500kV systems support grid balancing, energy trading, and enhanced supply security across interconnected networks. - Integration of Mega Power Generation Facilities
Essential for exporting power from nuclear plants, large hydro stations, and ultra-large thermal power plants, where continuous high output requires stable and high-capacity transmission channels. - Ultra-Long-Distance Underground EHV Links
Applied in projects where overhead lines are restricted, such as metropolitan areas, environmentally protected zones, or river/sea crossings, requiring advanced thermal design and installation techniques. - Large-Scale Renewable Energy Transmission
Supporting the delivery of massive renewable energy from offshore wind farms, desert solar bases, and remote generation sites to major load centers over long distances.
Installation & Support
- Bending Radius: Typically ≥ 3.5m depending on design.
- Thermal Design: Critical for maintaining current capacity over long routes.
- Installation Complexity: Requires specialized engineering and equipment.
- System Integration: Includes EHV joints, terminations, bonding systems, and monitoring.
Our team of technical experts is available to answer your questions, provide custom solutions, and support your project from planning to installation.
FAQs of XWA 500kV EHV Cable
What types of projects typically require 500kV cables?
A: 500kV cables are used in national grid backbone systems, ultra-long-distance transmission corridors, and cross-regional interconnections, where very large amounts of power must be transferred reliably.
What are the key challenges in 500kV cable systems?
A: The main challenges include electric field control, thermal management, installation complexity, and insulation reliability. These require advanced design, strict manufacturing control, and experienced project execution.
What accessories are required for a complete 500kV cable system?
A: A complete system includes EHV joints, outdoor/indoor terminations, cross-bonding systems, sheath voltage limiters (SVL), surge protection devices, and monitoring systems such as DTS (Distributed Temperature Sensing).
How is thermal performance managed in 500kV installations?
A: Thermal performance is controlled through cable spacing design, thermal backfill materials, soil resistivity management, and in some cases forced cooling systems, ensuring stable operation under high load conditions.
What is the typical lead time for 500kV cables?
A: Due to the complexity and customization involved, lead time is typically 8–16 weeks after technical confirmation, depending on project scope and specifications.
Can XWA support complete EHV transmission projects?
A: Yes. XWA provides end-to-end support, including cable supply, accessory matching, technical consultation, and installation guidance for large-scale EHV projects.
Can the 500kV cable be customized for specific project requirements?
A: Absolutely. Conductor size, insulation structure, sheath type, and system configuration can be fully customized based on electrical load, installation method, and environmental conditions.