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Heiner Dokters
+49 2575 9710 141
Michael Große Hokamp
+49 2575 9710 180

Environmentally compatible connection to the extra-high-voltage grid

Off the island of Baltrum, TenneT began connecting three offshore wind farms to the extra-high-voltage grid in summer 2024. The new 525 kV DC links of the 2 GW offshore grid connection projects BalWin3+4 and LanWin1 will strengthen the German power grid and increase the share of green electricity. egeplast Power Protect PE-RT in 450 x 61.5 mm was used as a protective conduit – to protect the natural environment by means of horizontal drilling.

The three offshore grid connection projects BalWin3+4 and LanWin1 off the island of Baltrum, with a total route length of 795 km, including 530 km at sea, marked another milestone in summer 2024 on the path to supplying green electricity. Connecting the three offshore wind farms to the extra-high-voltage grid strengthens the German power grid and is another step towards the energy transition.

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So-called grid connection systems are required to connect offshore wind farms to the extra-high-voltage grid. For the 2 GW offshore grid connection projects BalWin3+4 and LanWin1, horizontal drilling was carried out by the transmission system operator TenneT in summer 2024 from the land side of the dike to a work pontoon in the Wadden Sea. The grid connection points of these projects will be located in Unterweser and Wilhelmshaven. The 525 kV DC links will strengthen the German power grid in the future. TenneT is building these DC grid connections with egeplast protective conduits for high- and extra-high-voltage cables up to 525 kV.

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"The new connections will strengthen the German power grid and increase the share of green electricity."
Heiner Dokters

Horizontal Drilling Protects Natural Area

In the course of the realization of the grid connection systems via the Baltrum corridor, the flood protection systems, dunes and particularly sensitive areas (for example, seagrass meadows) in the area of the mainland near Dornumergrode and in the following years the island of Baltrum must be crossed at its eastern end.

In deviation from previous offshore projects, the projects of the 2 GW program (= transmission capacity) are being realized with a higher voltage of 525 kV. In these lines, a so-called “metallic return conductor” is also laid. Overall, one route consisting of three boreholes (positive, negative pole and metallic return conductor) is required per grid connection system for each crossing section.

As part of the offshore grid connection projects BalWin3+4 and LanWin1, routes are being laid across the island of Baltrum to the mainland. To protect the sensitive Wadden Sea natural environment and ensure dike safety, TenneT opted for horizontal drilling to cross beneath the island and the dike structures. For these horizontal drillings, the high-temperature-resistant egeplast Power Protect PE-RT in 450 x 61.5 mm is used. It is a protective conduit for high- and extra-high-voltage cables up to 525 kV, featuring increased thermal stability to withstand the high thermal loads. The combination of high flexibility and strength of the PE pipe used offers optimum properties for carrying out these horizontal drillings.

The total route length of BalWin3 is 245 km, including 200 km at sea and 45 km on land. The route length of BalWin4 is 275 km, including 165 km at sea and 110 km on land. The route length of LanWin1 is also 275 km, including 165 km at sea and 110 km on land.

For construction execution, TenneT commissioned a joint venture (JV) consisting of MATTHÄI Bauunternehmen GmbH & Co KG, MATTHÄI Wasserbau GmbH & Co KG, Bohlen & Doyen Bau GmbH and Beermann Bohrtechnik GmbH. The pipeline construction work is being carried out on behalf of the JV by MATTHÄI and Bohlen & Doyen.

© TenneT

High requirements met by egeFit®

Due to the limited working areas near the flood protection dikes, the dike foreland and the island of Baltrum, the required total lengths of the pipe strings were halved and the two partial strings were connected before drilling using egeplast connection technology egeFit® – “Golden Seam” connector. The long drilling routes did not allow any reduction in tensile forces, meaning that the “Golden Seam” was modified, thus preventing a reduction in tensile force. The modified “Golden Seam” was integrated directly into the pipe string.

egeplast
Power Protect PE-RT

Protective pipes for high and extra-high voltage cables with a low-friction inner layer and individual marking.

UV-resistant signal color layer

Solid wall or co-extruded, optionally with stripes

Inspection-friendly inner layer: optionally highly slidable or abrasion-resistant

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egeplast
egeFit®

Connection Technology “Golden Seam”

Seamless!

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The modification of the egeFit® “Golden Seam” connection technology prevents a reduction in tensile strength. The “Golden Seam” is created through a specially developed integrated recess that automatically accommodates the inner bead. Subsequent removal of the weld bead is eliminated. This type of connection is particularly well suited for limited space conditions on the construction site, enabling the connection of longer pipe strings. The “Golden Seam” is available as a fully integrated solution for Power Protect pipe strings. As an adapter, the connector can be flexibly welded to any pipe end.

Project data

Project Description

525 kV DC cable / LanWin1; BalWin3 and BalWin4 connection of the offshore wind farms with the grid connection point in Unterweser and Wilhelmshaven respectively

Challenges

Construction of a cable protection conduit system for 525 kV extra-high-voltage DC transmission (HVDC) by connecting pipe strings > 600 m

Solution

Use of the egeplast Power Protect PE-RT cable protection conduit system made of PE with increased thermal stability for high- and extra-high-voltage cables up to 525 kV in combination with the egeFit® – “Golden Seam” connector with and without weakening factor

Construction phase

2023 – 2030

Installation

Trenchless construction (HDD)

Pipe System

10,632 m egeplast Power Protect PE-RT 450 x 61.5 mm
1,380 m egeplast Power Protect PE 280 x 38.3 mm
16x egeFit® – “Golden Seam” connector
450 x 61.5 mm; 2x egeFit® – connector
280×38.3 mm electrofusion couplers, loose flanges, other accessories

Project Participants

Client TenneT Offshore GmbH
Construction execution Matthäi Bauunternehmen GmbH & Co. KG, Matthäi Wasserbau GmbH & Co. KG, Bohlen & Doyen Bau GmbH, Beermann Bohrtechnik GmbH

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