Installing 230kV cables is a demanding, specialized task that requires meticulous planning and execution. The primary challenges are far more significant than those for lower-voltage cables and include:

• Extreme Cable Weight and Diameter: 230kV cables are massive. Their weight and large diameter make manual handling impossible and require purpose-built hydraulic drum stands and trailers for safe transport and unspooling.

• Thermal Management: These EHV cables generate a significant amount of heat. The trench must be designed to include specialized thermally stable backfill materials to ensure heat dissipates efficiently. Overheating can lead to rapid insulation degradation and catastrophic failure.

• Mechanical Stress Tolerance: The insulation of 230kV cables is extremely sensitive. Any mechanical stress from improper pulling tension or tight bends can cause non-recoverable damage to the insulation, leading to premature breakdown. This is why tools with real-time feedback are non-negotiable.

• Flawless Splicing: Joints and terminations on a 230kV cable are the most critical points in the entire system. Any imperfection—even an air void—can cause a partial discharge under high electrical stress, leading to a system failure. The process requires a clean environment, highly trained technicians, and precision tools.