Power cables are a critical component of offshore wind farms, and their design and rating are often based on conservative assumptions regarding installation methods, environmental conditions, and cable losses. This conservative approach coupled with a lack of trusted risk mitigation tools frequently leads to oversized and costlier cables, leaving substantial optimization potential untapped.

This paper introduces the Unitech Cable Load Prediction System (CLPS)—an advanced tool developed to enhance the design and operational efficiency of power cables. CLPS integrates a Finite Element Method (FEM)-based digital twin with calibration capabilities using Distributed Temperature Sensing (DTS) data. Currently deployed on a 300 km High Voltage Direct Current (HVDC) trading link, the system is already demonstrating improvements in operational efficiency and revenue generation.

In the context of offshore wind farms, CLPS offers significant value in risk management and cost reduction, particularly through the potential downsizing of conductor cross-sections. The paper presents validation results from the operational HVDC system and simulation studies on a model wind farm. These simulations illustrate how CLPS can effectively manage thermal risks, reduce investment costs, and minimize curtailment losses.

Furthermore, the paper outlines the iterative design process of cable systems for offshore wind farms, showcasing how CLPS supports informed decision-making. By simulating the operation of a representative wind farm, the study highlights the system’s impact on cable sizing, cost savings, curtailment losses, and the management of uncertainties related to thermal resistivity and ambient conditions.