Power cables have undergone a remarkable evolution since their inception, reflecting the dynamic intersection of technological advancement and the increasing demand for efficient energy transmission. From humble beginnings as insulated copper conductors to the sophisticated high-voltage cables of today, their development has been shaped by a persistent drive to enhance efficiency, safety, and sustainability in electrical distribution networks. This evolution encompasses innovations in materials science, manufacturing techniques, and engineering standards, all aimed at delivering reliable and resilient power supply solutions across diverse industries and geographical regions.
In today’s world cables and wires are present everywhere making our connected and electrified way of life possible. They have come a long way since history.
Around 250 years ago, people were curiously looking to improve everyday life and this led to the invention of machines, steam engines and factory lines. The first set of electrical wires invented were uninsulated and it soon became apparent that without some sort of insulating material the ability to pass large currents would be problematic.
In the late 1800s and early 1900s, electricity became increasingly important for transmitting electrical power over long distances and supplying power to homes and businesses. Around this time in the 1880’s, insulated wires came into existence and armoured cables were introduced in 1906 with flexible sheathing and rubber insulated conductors. During this period, the use of electricity was better understood and was extended to areas of production, communication, and more.
In the 1950’s latex and rubber insulation was replaced by Polyvinyl Chloride (PVC) and in 1970’s Cross Linked Polyethylene (XLPE) materials enhanced the electrical and mechanical properties of insulation, making wires more resistant to heat, moisture, and other environmental factors.
During the 19th century, advances in technology and manufacturing processes led to the development of modern wires and cables. Till the mid-20th century copper wire was the primary material used for electrical wiring, after which aluminium was more commonly used.
Today, wires play a crucial role in modern life. From armoured wires to fibre optic cables, wiring technology is used in everything from quantum computing, micro processing to telecommunications and beyond.
The construction of cabling and wiring systems has dramatically improved with the use of new materials in the manufacturing processes.
Introduction of Polymer Compounds for Insulation
Significant stride in cable manufacturing came with Germans starting Poly-Vinyl Chloride’s (PVC) testing as insulation material for cables in 1930’s, but was commercially viable only by 1950’s. PVC insulated cables slowly started replacing rubber cables in many areas particularly in domestic wiring. New cable types like Optical Fibre cables, Submarine cables for Internet, Control cables, and many more have been developed as per requirement and feasibility.
The development of optical fiber cables, which function on the principle of complete internal reflection, has been the most fascinating breakthrough of them all. In 1953, Harold Hopkins and Narinder Singh Kapany, an Indian American scientist, both worked at Imperial College of London and succeeded in building image-transmitting bundles with over 10,000 fibers. Afterwards, they were able to send images across a 75 cm bundle made up of thousands of fibers. The technology proved effective only when NASA started utilizing it for television cameras on Moon missions in 1968.
All we can say about Cables is that although they have been developed for supporting various tasks like communication or electricity distribution etc., they have opened avenues for inventors and infra-developers to push boundaries for human development and convenience.
Latest Developments
Havells India to expand cable manufacturing capacity in Alwar
Havells India has planned to expand the cable manufacturing capacity at its Alwar, Rajasthan, unit from an annual 32.9 lakh kilometres to 74.1 lakh kilometres.
The cable business unit, comprising power cables and flexible cables, is its biggest vertical, contributing to 34.1% of its `18,843 crore revenue in FY24.
The expansion will take place in a phased manner and will be fully commissioned by March 2026 at the cost of `375 crore. The company will finance the expansion through its internal accruals. Havells India is expanding to meet the increasing demand for its cable products. The existing plant operates at around 70% capacity.
World’s deepest ever power cable by Prysmian
Prysmian, a clutch of global power cable specialists, has claimed an industry record after an installation 2,150 metres down.
The installation of the non-metallic armoured 500kV HVDC cable was the deepest yet in the power sector. The cable was installed in a testing phase for the Tyrrhenian Link, a €1.7bn ($1.84bn) project to connect Sicily, Sardinia, and the Italian mainland.
The cable in question uses a composite material that can achieve a 50% weight reduction on steel when deployed in water, said Prysmian, which used its Leonardo da Vinci vessel to carry out the installation.
The same cable has previously been installed at 550 and 1,000 metres.
Underground power cables connecting Perumbakkam with Velachery substation
The work on installing the 400-kilo volt (kV) cable network to link Ottiambakkam substation with the Guindy substation via Velachery has begun.
The Tamil Nadu Transmission Corporation (Tantransco) which is executing the work has completed linking the cable on the stretch from Ottiambakkam to Perumbakkam through overhead power lines and has started the work of installing underground cable from Perumabakkam to Velachery, which is progressing at a fast pace.
According to a senior Tantransco official, the 400-kV cable network linking will assist in offering several sources for sustaining power connections continuously. Installing the UG cable via the Station Service Road from Taramani to Velachery railway station is an important project that has begun. The UG cable has to be linked from Perumbakkam to Velachery Main Road as already a 400-kV UG cable network has been installed from Velachery to Guindy substation through the southern arm of the Inner Ring Road.
Conclusion
The evolution of power cables has witnessed remarkable advancements, driven by the growing demands for efficiency, reliability, and sustainability in energy transmission. From early developments to the latest innovations, the journey of power cables exemplifies a continuous quest for improved performance and environmental responsibility.
Furthermore, real-time monitoring, fault detection, and adaptive power management have been made possible by the development of smart grids, which has completely changed the functionality of power cables.
Looking ahead, the evolution of power cables is poised to continue, driven by ongoing research into materials science, digital technologies, and sustainable energy solutions. As global energy demands rise and environmental concerns intensify, the development of next-generation power cables will play a crucial role in shaping a more efficient, reliable, and sustainable energy future.
