Case study: Red Eléctrica de España
Aneesh Chandran | 3 minute read | 24 November 2024
Monitoring cable joints and terminations to prevent critical failures
Synaptec’s cable condition monitoring solution (since launched as Greenlight®) was selected as part of Elewit’s Advanced Venture Client Program to instrument a critical and highly challenging underground transmission circuit in Madrid. Synaptec retrofitted its cable monitoring solution to an existing 400 kV cable in order to demonstrate zero-maintenance, zero-power sensing at multiple remote locations to support asset condition monitoring. The Greenlight solution provided permanent and synchronous comparison of electrical and mechanical stresses at cross-bonding points, providing live insight into the electrical and thermal behaviour at the most common failure points of HV cable circuits.
Automate inspection
Pinpoint failure locations enabling targeted maintenance
Early warnings
Find damage indicators with instant alarms alerting operators to vulnerable locations
Reduced maintenance cost
Avoids costly outages, inspections, and repairs associated with a cable failure
Red Eléctrica de España is the Transmission System Operator (TSO) of Spain, which is responsible for transmission grid infrastructure, development, and power system operation. One of these assets is the 12.7 km underground section of a 400 kV overhead circuit near Madrid airport, where Red Eléctrica required an affordable cable monitoring solution to help prevent critical outages.
Elewit is the technology platform for Redeia (owner of Red Eléctrica), who are responsible for driving the energy transition and connectivity towards a sustainable future.
The challenge
Upgrade works of Madrid-Barajas Airport in 2002 resulted in a part of the San Sebastián de los Reyes-Loeches-Morata 400 kV double circuit line, which ran very close to a new runway, being undergrounded.
A total of 12.7 km of the overhead transmission line was converted to an underground cable circuit. As a critical transmission circuit supplying the capital city, reliability is of paramount importance to the network operator.
As with most HV cable circuits, it is comprised of multiple sections jointed at cross-bonding points. Such bonding points are known to account for around 57% of all downtime, since it is at these locations that mechanical and environmental impacts can, over many years, cause damage.
The 12 km tunnel is a significant maintenance and inspection challenge, and Red Eléctrica looking to explore solutions that automate inspection and gather accurate data on joint health that would support their analytical models of the circuit. Conventional monitoring technologies were considered, but ultimately not selected due to their impracticality in such remote and inaccessible locations.
Our solution
Synaptec’s Greenlight solution allows synchronous and accurate instrumentation at multiple locations over long distances, without complex control power, or data networks being installed. Synaptec’s cable condition monitoring solution – since developed into Synaptec’s Greenlight solution – was selected by Red Eléctrica for deployment on the first major section of the circuit.
Three-phase Passive Secondary Converters for voltage (PSC-3-V) were retrofitted inside the substation from the overhead to underground line and connected to the existing substation voltage transformer to monitor voltage-based harmonic content changes. Single-phase Passive Secondary Converters for current (PSC-1-C) were installed along with split-core current transformers, over the phase cable at the substation and over sheath bonding cables at the joint bays. This enabled the system to monitor the phase and sheath currents in real time. Passive Temperature Transducers (PTT) were installed over cable joints to monitor their temperature.
At one cable end, all remote measurements of current, voltage, and temperature are acquired continuously and in real-time, and collated within the Synthesis® server. The Synthesis data service enabled secure recording of all data for offline analysis by Synaptec experts, and Red Eléctrica personnel are also able to use the data to validate and refine ATP models of the asset’s behaviour.

PSC-1-C and industry-standard CT installed.

Distributed Electrical Sensing (DES) Interrogator.
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