Malta’s second electricity interconnector – a 122-kilometre AC cable linking Magħtab to Ragusa – has reached key stages in its manufacturing process, as representatives from Interconnect Malta (ICM) recently travelled to the United States to observe production and testing firsthand.

Shaun Micallef Vassallo (representing the commercial team) and Ing. Christian Spiteri (representing the technical team) visited the Nexans High Voltage USA facility in Charleston, South Carolina and spoke to WhosWho.mt about their visit and the project. 

The visit formed part of ongoing oversight for Interconnector 2, a project designed to double Malta’s connection to the European electricity network and reinforce the country’s energy resilience. It is co-financed by the European Regional Development Fund.

Who was behind this visit?

Ing. Christian Spiteri is a mechanical engineer with several years of experience working on major national infrastructure projects. His portfolio includes the hydrogen-ready gas pipeline between Malta and Sicily, the second interconnector project linking the two countries, and Malta’s first offshore floating wind farm.

Shaun Micallef Vassallo is an energy and environmental economist with experience in consultancy for large public institutions, drafting energy policy, negotiating EU energy legislation, and supporting the implementation of large-scale energy projects.

‘A deeper appreciation for the complexity’

Reflecting on the visit, Ing. Spiteri said what struck him most was witnessing the sheer scale and precision involved.

“What stood out most during our visit to the Nexans facility was gaining a deeper appreciation for the complexity, precision, and engineering involved in producing these types of cables,” he explained. Observing each step in person gave him “a truly [clear] understanding of how many specialised steps, quality checks, and technical considerations are required to ensure that the final product performs as expected.”

Accompanied by a consulting engineer, the team also validated that manufacturing and testing were being carried out in line with the tender’s requirements and established industry practice. Ing. Spiteri added that “visits like this highlight how much expertise and commitment sit behind something that, from the outside, may not be properly appreciated.”

Advanced manufacturing now underway

Production of the interconnector is progressing across several stages, with multiple components being assembled. According to Ing. Spiteri, the project has now reached the “lay-up” phase, in which individual cable elements are combined.

He noted that the interconnector is far more sophisticated than a single electrical conductor. “It additionally incorporates two fibre-optic cables within its structure and protective layers,” he said. More than 100km of these fibre-optic components have already been produced in Norway and shipped to Charleston for integration.

Quality and durability testing is ongoing throughout the production cycle. “The cable undergoes continuous online and offline testing – including being tested at levels significantly above its standard operating conditions to ensure that it can withstand even the most extreme, worst-case scenarios,” Ing. Spiteri noted, adding that the team witnessed several of these tests during their visit.

‘A critical project for Malta’s future energy system’

From an economic and policy perspective, Shaun Micallef Vassallo emphasised the strategic importance of Interconnector 2 for Malta’s long-term energy needs.

The new subsea and onshore AC link will have a continuous rating capacity of 225MW and operate at 220kV, running in parallel with the existing interconnector but at a safe distance. Once operational, it will reinforce the stability of Malta’s grid, support future demand growth, and reduce dependency on local generation.

“Once implemented, the Project will strengthen the security of supply of the Maltese distribution system, cater for the projected increase in the electricity demand, facilitate renewable energy integration and growth, and reduce local emissions,” he said.

He added that Interconnector 2 will play an essential role in enabling Malta to tap into its renewable potential, especially offshore wind. “Given the intermittent nature of renewable electricity, Interconnector 2 will provide the stability that the Maltese electricity system needs to into our significant offshore renewable potential.”

As Interconnector 2 progresses, both technical and commercial teams at ICM continue to monitor developments closely to ensure the project remains on schedule and in line with international standards. With production advancing and testing ongoing, Malta is one step closer to securing greater energy stability and supporting its transition toward cleaner, more resilient power systems.