KEC International Limited (under the brand name Asian Cables), a leading manufacturing and exporter of power cables in India, has been selected to supply cable materials for the EHV power supply to the data centre in Mumbai to upgrade its cloud services.
BACKGROUND
Mumbai is among the world’s rapidly expanding megacities, with a population exceeding 20 million. The city stands as a major centre for finance, commerce, entertainment, and technology. The city is home to some of India’s largest data centres and industrial facilities.
These sectors demand significant energy resources, and Mumbai’s electricity requirements are expected to rise by 50% by 2030. To meet future energy needs, investments in power transmission infrastructure are necessary.
A leading IT service provider is developing the largest data centre in Mumbai to upgrade its cloud services. Such facilities require substantial demand for electricity to power the servers and cooling systems. To meet this demand, an extra-high voltage (EHV) 220kV underground power cable must connect the data centre to the Maharashtra State Electricity Transmission Company Limited (MSETCL) network. This upgrade necessitates increasing the power capacity in the area.
Given the scale of the project, it was necessary to select a cable producer with proven expertise in extra high voltage projects. Without a solid track record, risks like technical errors, safety issues, and performance failures could compromise the project’s success and power supply reliability.
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CHALLENGES
The Maharashtra State Electricity Transmission (MSETCL) Board needed to upgrade the 220kV EHV cable specifications from 2000 sq.mm copper to 2500 sq.mm copper (1600A load capacity) to meet high continuous current ratings of more than 1500 amps for the data centre and industrial complex in Thane.
KEC International Limited, under the brand name Asian Cables, is a leading manufacturing and exporter of power cables in India. They were selected to supply cable materials for the EHV power supply to the data centre.
Some key challenges included:
- Manage the tension in the CCV production line for cable weight of 52kg per metre while maintaining excellent centricity of the insulation and semicon around the conductor
- Installing a larger diameter cable which requires higher pulling forces and larger equipment on-site.
SOLUTION
To address these challenges, KEC International chose Borouge Borlink™ LS4201S and DYM-542HVS supersmooth semiconductors along with Jacket: Borstar® HE6062. These materials were specifically selected because of the high production output, electrical performance and optimal adhesion between the semiconductive layers and cross-linked polyethylene (XLPE) insulation, meeting the unique demands of cable manufacturing and installation.
Borouge’s Superclean XLPE materials are manufactured using an advanced closed-loop process that ensures the highest level of cleanliness to withstand high electrical stresses. The insulation material’s performance is enhanced when paired with supersmooth semiconducting layers.
These materials were selected to meet the unique demands during cable manufacturing and installation to ensure the reliability of uninterrupted power flow with a long service life.
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“This is our first prestigious data centre project in India with highest conductor size, type and voltage grade and having a large overall cable weight (approximately 52kg/m) which is difficult to handle on site. It was also a great and impressive challenge to manage the line tension in CCV line of insulated core with such a huge weight”, said Mr. Anjan Banerjee, Vice President Technical Service & New Products of KEC International Ltd.
The successful execution of this project has reinforced Borouge’s reputation as a reliable partner for major EHV undertakings. By leveraging Borouge’s innovative solutions and close collaboration with KEC International, this project will enable the growth of Mumbai’s industrial and digital undertakings with reliable, uninterrupted power supply.
Additionally, Borouge’s participation demonstrated the potential of EHV projects in the Indian Subcontinent, showcasing their ability to navigate challenges and deliver outstanding outcomes.
