What are the Common Failures in Power Cables?

Jun. 17, 2025

Power cables play a critical role in transmitting electricity safely and efficiently. Among the most commonly used types are Copper/XLPE/SWA/PVC Power Cables and Aluminium/XLPE/SWA/PVC Power Cables. However, during operation, these cables may encounter various issues due to environmental factors, installation errors, or aging components. Below, Zhuhaicable outlines the most common power cable failure modes and their underlying causes.

AL/XLPE/STA/PVC 600/1000V NA2XBY Cable

Common Causes of Power Cable Failures

1. Mechanical Damage
Mechanical damage is one of the most frequent failure causes, especially during installation. Over-bending, pulling, or accidental impact can cause internal or external damage that may not be immediately noticeable but can lead to breakdowns over time.

2. Moisture Penetration
Moisture ingress is often found at cable joints or damaged sections. It compromises insulation and can lead to corrosion or short circuits. Proper sealing and regular inspections at joints are essential to prevent moisture-related failures.

3. Insulation Aging and Deterioration
With time, cable insulation materials may degrade due to continuous overloading, heat buildup, or poor ventilation. This aging process reduces the cable’s ability to withstand voltage stress, increasing the risk of failure.

4. Voltage Overload
Unexpected surges, such as those caused by lightning or grid fluctuations, can exceed the insulation’s dielectric strength, leading to punctures or flashovers. Proper surge protection and grounding systems can mitigate this risk.

5. Design and Manufacturing Defects
Inadequate design, poor-quality materials, or substandard manufacturing processes can result in premature failure. Choosing cables from a trusted and certified manufacturer is key to ensuring long-term performance and safety.