Engineering Resilience and Quality into the Next Generation Power Grid

The global electrical infrastructure, foundational to modern society, is facing a confluence of unprecedented challenges: rocketing demand driven by digitalization and electrification, coupled with an aging physical grid built for a bygone era.

Our recent expert panel discussion featuring Ben Lanz, Sr. Director, Industry Affairs at Osmose; Bob Hobson, Associate Technical Consultant for Cable at Burns and McDonnell; and Dr. Yingli Wen, Technical Expert at Consolidated Edison, highlighted that solving this complex equation requires a radical reevaluation of how we design, install, and manage our power cable systems—the oftenunseen workhorses beneath our streets.

The conversation made it clear that utilities must shift away from merely maintaining systems to proactively engineering them for longevity and absolute reliability, acknowledging that power cables, particularly when properly installed, offer reliability levels unmatched by overhead systems.

The Age of Unprecedented Demand

The primary catalyst forcing this industry transformation is the massive surge in electricity consumption. Panelists noted that 30 years ago, the scale of current power demand was unimaginable. Today, power is essential not just for traditional uses like cooking and cooling, but for next-generation applications such as driving electric cars, supporting massive AI functions, and powering sprawling data centers. Dr. Yingli Wen, reflecting on this rapid acceleration, emphasized the breadth of the technological drivers: “The increase in demand is very rapid, taking into consideration not only increased number of electric vehicles, but also the increased use of AI and other computer-related programs such as quantum computing, machine learning.” This increased load places significant stress on the existing infrastructure, especially underground networks. Dr. Wen pointed out a critical physical consequence: the increased power elevates the operating temperature of cables, which simultaneously reduces the cable’s current-carrying capacity and increases the probability of hazards. Addressing this requires a move beyond traditional management models, leading utilities like the one Dr. Wen represents to explore advanced techniques like the Dynamic Load Release program.

From Average Metrics to Total Cost of Ownership

The grid currently operates in many areas, using “our grandfather’s grid,” built for a different time. For decades, utilities relied on average metrics to guide operations, but these averages now “obfuscate the challenges that we’re facing”, says Ben Lanz. Coupled with this aging infrastructure is the increasing risk profile of the population itself, with more people moving into highrisk areas like coastlines, floodplains, and the wildland urban interface.

The combination of aging assets, high risk, and immense demand necessitates a shift in economic thinking toward the total cost of ownership (TCO). Lanz stressed that investments should be made with durability in mind: “We really need to be thinking about the total cost of ownership and how do we extend the life of these assets. We are going to make the investment so that these systems can last 50, 60, 100 years instead of the typical of what people used to claim; 20 to 30 years.”

Furthermore, the public’s tolerance for outages has significantly lowered. Bob Hobson observed that the days when a power failure was simply tolerated are gone; “in the past, the customers “understood that things break. Nowadays, they do not want to hear it.”

The Looming Workforce Crisis and the Imperative of Safety

Compounding the technological and demandside issues is a growing personnel crisis. The highly skilled veterans who built and maintained the existing grid are either rapidly approaching retirement or have already retired. Simultaneously, for years, young engineers gravitated toward computer science and electronics, leading to a personnel shortage in the power sector. This scarcity is especially acute in the high-voltage cable business, interacting critically with the need for high-quality workmanship, especially when handling medium and high-voltage cables.

Safety standards have progressed dramatically from the days when electricians would check a circuit by simply grounding it. Today, safety is paramount. Hobson articulated a strong safety philosophy: “We, as a company, personally believe that we don’t have the right to ask a worker to be exposed to any risk that would jeopardize their health or life.”

This safety emphasis brings a design challenge. OSHA guidelines suggest that Personal Protective Equipment (PPE) should be a last resort, meaning engineers should ideally design systems that eliminate the need for PPE during routine work. Hobson states that he would “like to challenge all the engineers in the power industry, both young and old, to start taking a look if we can design cable systems and the associated equipment to not require PPE.”

The specialized skills needed for cable splicing highlight the training gap. In the era of old paper-insulated lead-covered (PILC) cables, a technician needed five years and 1,500 hours of classroom work to perform a splice. While modern pre-molded accessories simplify the process, they introduce new risks related to insufficient training.

In response to this, some utilities have established rigorous internal training and quality assurance systems. Dr. Wen explained that her utility has an in-house splicing school, mandatory training, and refresher courses. Furthermore, failed splices are subject to forensic analysis: “If the splice fails within a reasonably short time period, we will do forensic analysis. If it is believed to be due to workmanship, then we will talk to the splicer and invite the splicer to the forensic session. Then the splicer would need to be recertified.”

The Defect Epidemic: Workmanship vs. Manufacturing

The most significant finding discussed by the panel concerned the true cause of cable failures. While the industry has historically focused on issues like water ingress in solid dielectric cables, data suggests the overwhelming majority of faults stem from defects introduced either during manufacturing or, more commonly, during installation.

Lanz presented stark findings, noting that “up to 90% of failures in aged cable systems are traceable back to anomalies that existed from the very beginning”. He specified the distribution of problems based on extensive assessments: manufacturing problems account for about 5% of defects (though these are often systemic and repetitive within a batch), while installation problems are the culprit 95% of the time.

The shocking data point is that “about 40% of new installs have at least one substandard component, meaning it did not leave the factory that way. Somebody damaged it, and it is not meeting the minimum performance expectations.”

These faulty installations act as “ticking time bombs” that may take months or years to fail. Crucially, once an aged medium or high-voltage system faults once, it is 10 times more likely to fail again.

Lanz argued to realize long-life cable systems and remove future operating and maintenance cost dictates a change in commissioning strategy: “We need to bring our focus back to the cable system design phase to make sure they are designed correctly, they’re installed correctly, the manufacturing process has sufficient quality control, and include in the design specification a commissioning assessment that actually can scan the line and find the installation defects before you energize.”

On the manufacturing side, cleanliness and precision has become critical, reflecting levels seen in integrated circuit facilities. Dr. Wen confirmed that utilities are working closely with manufacturers, implementing rigorous controls: “We have a periodic audit of the manufacturing facility to make sure they produce the cable to our specification….” While the science of cable creation is well-known, Lanz suggested the remaining manufacturing issues often relate to the “human element rather than the science,” such as checking that factory test equipment is effective. Hobson acknowledged the manufacturers’ drive for continuous improvement, noting that in transmission systems, if a cable passes all factory tests, the probability of failure is very low, “except in the splices where humans touch it.”

The Promise of Monitoring and Next-Gen Designs

If defects can be removed and systems protected from extreme events, the lifespan of existing cables can be dramatically extended. Studies show that even 30 to 40-year-old cable systems, when scanned, often exhibit electrical performance comparable to new cables, aside from specific localized defects. The recipe for quality cable systems, Lanz concluded, is clear: “remove defects, protect against extreme events, and if an event occurs, go back and re-baseline the system.”

For newly installed lines, commissioning scans that fix initial defects can lead to significant cost savings and reliability improvements. Looking forward, the industry is exploring solutions to monitor cable health continuously. Lanz labeled online monitoring as the “Holy Grail of all of the testing approach.” Dr. Wen offered a crucial caveat, suggesting that while promising, the technology is still immature. “Online monitoring is one of the best programs to ensure the reliable operation of the power system. But I want to mention currently, even though a lot of companies provide that solution, in my opinion, a lot of these solutions are still in their infancy,” Dr. Wen cited challenges related to accuracy, ease of installation, longevity, and cybersecurity.

Innovation is also continuing in cable materials and technology, particularly at the high-end, with the resurgence of DC power systems. Due to advancements in switching power supplies, which negate the need for the large transformers required by AC, medium voltage DC cables are being considered for renewable sites.

Despite the multitude of challenges discussed— from aging infrastructure and workforce shortages to the epidemic of installation defects—the overall outlook for cable systems remains positive. Hobson concluded with a reassuring assessment of the systems already deployed: “You have heard us talk about all the problems with cables, but all in all, I think everybody could agree, cable systems worldwide are doing really well.”

“Underground cable systems have historically shown to be ten times more reliable than overhead lines” Lanz concluded.

The reliability data supports this perspective, cementing cable systems as the backbone of a truly resilient grid—provided the industry successfully addresses the human and quality control challenges introduced during its deployment.

The Road Ahead

The future resilience of the power grid hinges on proactive engineering, rigorous quality control, and continuous operational event monitoring of cable systems. While unprecedented demand, aging infrastructure, and workforce shortages pose serious challenges, addressing installation defects, prioritizing safety, and adopting advanced technologies can extend asset lifespans and ensure reliability. By shifting from reactive maintenance to “total-cost-of-ownership thinking” and embracing innovation in design, materials, and monitoring, utilities can build a next-generation grid capable of supporting modern society’s energy needs safely, efficiently, and sustainably.

Watch the full Power Panel discussion HERE.