Solar Farms
Guest Article By Paul Hopton Deputy Managing Director at Electrical Safety UK Limited
Thorne & Derrick distribute electrical safety equipment to substation engineers, cable jointers, overhead linesmen and utility workers – this includes insulating gloves, voltage detectors, insulating matting and portable earthing to ensure worker safety when carrying out maintenance on LV-HV switchgear, substations, cables and electrical equipment in the solar industry.
Electrical Safety Products for LV MV HV Cables, Conductors, Substations & Overhead Lines
Electrical Safety UK have helped many companies in different industries in a number of locations around the World to improve their electrical safety management systems.
In this Article we are going to focus on Solar Farms and discuss whether there any hazards that may be specific to that industry.
We recently carried out an electrical safety audit in the Middle East at one of the largest solar farms in the world. The brief was to carry out an audit of their current operations and safety management system to identify if any improvements could be made.
We started by interviewing Electrical Managers, Supervisors and Tradesmen to ascertain where they had good practice and where improvements could be made. The scope of these interviews covered but was not limited to:
We also carried out site surveys and asked personnel who were working on site about electrical safety and the management of electrical risks.
Results
We identified several areas where there were opportunities to improve. These were presented to the site management team in a feedback presentation and more formally in a report. The findings showed significant opportunities in Arc Flash Risk Management, Isolations and Electrical Shock Risk Management.
The main issue specific to Solar Farms that we identified was with the Solar Panels themselves as they generate electricity. The good news is that Solar Farms are modular and so it is easier to produce isolation and safe working procedures, than for more typical industrial or commercial electrical distribution systems.
“Test before touch” or “Test for dead” processes are very important. You should ensure that the correct type of test equipment is used. Voltage indicators should be tested immediately before and after use with a proprietary proving unit.
There are also a lot of power inverters and other enclosures out in the field that should be shrouded to IP2X to minimise electric shock risk during fault finding activities. As the Solar Farm gets older, it is important to make sure that the IP2X protection is maintained by auditing and inspection especially during and after maintenance activities.
I think it is fair to say that Solar Farms have not been around as long as many industrial and commercial electrical networks and can be operated by organisations that do not have a long history of electrical safety management experience. This lack of experience can lead to gaps in their Electrical Safety Management Systems.
Unfortunately, failures of an Electrical Safety Management System can result in serious injury or fatality. Fortunately, these events are rare but because of the complacency that can result from their scarcity, when the holes in the Swiss cheese line up, the worst can happen.
Far better to have someone independent to the Organisation to audit your Electrical Safety Management System to prevent the accident before it happens.
Solar Farms can sometimes be operated and maintained by the Company that designed and installed them rather than the owner. Dependent upon the Company supplying the Solar Farm, they may or may not have a great deal of operational and electrical safety management experience. If they do lack experience, they might be more likely to have an electrical accident.
The Company owning the asset (Electrical Duty Holder) might not take kindly to the exposure to public/regulatory scrutiny that this would bring.
READ Blog | Ten Most Common Errors in Arc Flash Studies
Calculating the arc flash hazard for each of piece of equipment on a Solar Farm should cost significantly less that carrying out an arc flash study on a typical industrial or commercial electrical distribution system.
The reason for this is that Solar Farms tend to be very modular in their construction. Therefore detailed modelling of one of the modules can be quickly and cheaply replicated many times for the rest of the network.
This obviously reduces the overall cost of the arc flash study for a Solar Farm versus other types of electrical networks.
Electrical Safety Management is our core business. We provide expert consultancy and advice services for blue chip organisations across Europe concerned with the safe management of risk associated with all electrical work activities.
Electrical Safety UK provide a multi-faceted holistic approach including a full electrical safety management programme, project management and policy documentation all bespoke to the client’s requirements including fully accredited and bespoke training courses and personnel assessment programmes.
2 Genesis Business Park
Sheffield Road
Rotherham
S60 1DX
Tel: 0800 652 1124
Tel: 01709 961 666
Email: [email protected]
Thorne & Derrick are Specialist Distributors to Solar EPC’s & High Voltage Jointing Contractors working on the design, construction and maintenance of UK, European and international projects supplying an extensive range of LV HV Solar Cables, Jointing, Substation & Electrical Eqpt. Based in the UK, we are highly customer responsive and absolutely committed to providing a world-class service.
We stock LV HV Solar Cables, Accessories & Electrical Equipment to enable the construction, maintenance and operation of utility-scale PV installations – our products connect 600V/1500V solar cables into combiner boxes, inverters, transformers and energise switchgear up to 33kV/132kV for high voltage grid connections.
Since 1985, we have provided expert technical support and express delivery from extensive UK stocks to world-wide destinations.
LV – Low Voltage Cable Joints, Glands, Cleats, Lugs & Accessories (1000 Volts)
MV HV – Medium & High Voltage Cable Joints, Terminations & Connectors (11kV 33kV EHV)
According to Statista, the total amount of data created, copied and consumed in the world was estimated to reach 59 zettabytes in 2020 – this exponential growth projection to support the cloud computing and digitization drive has been accelerated by this year’s pandemic. Our internet connection has been an umbilical, our online life-line, to the outside world connecting friends, families and business – with the Internet under strain European data centre demand is forecasted to rise by a third in 2021.
No Time for Downtime | Resilient & Reliable HV Power Systems
Thorne & Derrick International, based in the UK, are the leading Specialist Distributors of Cable Connection, Earthing, Substation & Electrical Equipment to support the construction and maintenance of High Voltage Power Distribution Systems – we can specify and supply from stock market-leading brands of Joints, Terminations & Connectors in Cold Shrink, heat-shrink, silicone and EPDM rubber technology up to 33kV.
Recently, Thorne & Derrick have supplied products in conformance with the Electrical Work Scope Specifications of owners and operators of hyper-scale digital infrastructure assets including Virtus, K2, Microsoft, CyrusOne, Interxion and Google.
11kV & 33kV Electrical Services & Substation Connections
Separable Connectors | Inner & Outer Cone Style for Gas Insulated Switchgear & Transformer Connections
Cable Terminations & Joints | Heat Shrink, Cold Shrink & Silicone Push-on for Air Insulated Switchgear, Transformers & Circuit Breaker Cubicles
Stockists of 3M ColdShrink, Pfisterer CONNEX, Elastimold and Nexans Euromold (AIN Slip-on & MONO Heat Shrink) cable accessories up to 33kV. Contact us with your Enquiry.
We supply an extensive range of LV Cable Accessories & Installation Equipment to support cable and electrical infrastructure located in server rooms and data halls.
Temporary Cable Supporting Hooks
The CableSafe Extreme hooks, available from T&D stock on overnight delivery, provide orderly support and suspension for temporary cables; creating a cable management system to ensure the safe and reliable delivery of electricity during construction, maintenance or Shutdown/TAR. S-shaped hooks are UV stabilized, Flame Retardant (Class: 94V-0, Flame Class Rating 3) and Cold Weather rated.
Thorne & Derrick supply LV HV Cable Accessories, Installation & Electrical Equipment to service providers working on hyper-scale data centres including Equinix, Virtus, K2, Microsoft, CyrusOne and Interxion. We have recently supplied Warsaw RDCC (Rapid Deployment Data Centres) with sealing systems for the protection of cable ducts against water ingress/gas migration and cable termination products for the connection of 33kV power cables into gas-insulated switchgear and transformers – the project is part of a $1 billion digital transformation plan for Poland announced by Microsoft.
We can assist with the Competitive Supply & Technical Specification of joints, terminations, connectors and preparation tools for the energisation of all types of air or gas insulated electrical equipment from stock up to 66kV.
MV HV – Medium & High Voltage Cable Joints, Terminations & Connectors (11kV 33kV EHV)
EV Charge Points
With a key driver for the electrification of vehicles being the environmental benefits they promote, electric vehicles (EV) are becoming pivotal parts of urban regeneration.
Reducing emissions and improving the carbon footprint of both individuals and communities, EVs and their supporting infrastructure, such as EV Pillars, are now vital assets for cities and towns throughout the world.
From DNO accredited cut-outs and isolators for on-street chargers, through to larger ‘heavy duty’ EV feeder pillars for fast, rapid and super chargers, Lucy Zodion’s products and design team can solve your connection requirements.
Lucy Zodion manufacture a wide range of products suitable to provide Low Voltage Electrical Power Distribution for EV charge points – from distribution network operator (DNO) accredited cut-outs and isolators for on-street chargers, to feeder pillars for electrical vehicle charging.
A UK Government Policy Paper on accelerating our EV infrastructure states that “the UK must have an electric vehicle (EV) chargepoint network that works for everybody, everywhere”.
Yet, it’s still commonplace news to hear of driver frustrations as they compete for a limited number of public charging points.
For Local Authorities and CPOs looking to improve their EV infrastructure, here are our top 5 recommendations:
1. Plan Properly – Anticipate that the process will take longer than expected and, given the increasing demand for new connections, timescales will only get longer
2. Follow The Process – Check with your DNO when ordering a new connection that you are using the right process. Many have fallen foul by not checking first, resulting in an installation that will not get approved
3. Install Quality Products – Installing high-quality products will reduce potential issues that may arise in the future. Ensure all your products comply to the appropriate regulations and are tested regularly
4. Consider Oversizing – Consider oversizing your supply and include some spare capacity in your EV connection and supply pillar. By making your system scalable, you can add to the number of charge points or upgrade the rating of your charge points in the future, when technology supersedes current equipment
5. Maintain Regularly – In order to keep your equipment in good working order test and inspect it regularly. It is pointless having stranded assets that aren’t serving customers and/or earning revenues
Due to the growing demand for Electric Vehicles (EV) around the world and the resulting strain that the charging infrastructure has on our electrical network, a wide range of safe and compliant electrical power and connection solutions are needed.
➡ Blog Feeder Pillars – Electric Vehicle (EV) Power Supply Pillars
Lucy Zodion | Fortress Feeder Pillars | Pre-Wired Feeder Pillars | Street Lighting Cut-Outs | DNO Cut-Outs | Electrical Power Distribution Enclosures
T&D distribute the most extensive range of LV, MV & HV Cable Jointing, Terminating, Pulling & Installation Equipment – we service UK and international clients working on underground cables, overhead lines, substations and electrical construction at LV, 11kV, 33kV and EHV transmission and distribution voltages.
Key Products: MV-HV Cable Joints & Terminations, Cable Cleats, Duct Seals, Cable Transits, Underground Cable Protection, Cable Jointing Tools, Feeder Pillars, Cable Ducting, Earthing & Lightning Protection, Electrical Safety, Cable Glands, Arc Flash Clothing & Fusegear.
Tools to Remove Kinks from Overhead Line & Catenary
The Hydraulic Kink Remover is used to straighten out areas on the contact wire that have developed ‘kinks’ on the UK rail electrification networks. This ensures that the overhead wire is continuously in contact with the pantograph. The catenary wire straighteners are specifically designed for maintenance use on overhead rail cables.
Battery Tool
BDL041
The delivery of electricity to railways is usually through a system of overhead lines. This is called a catenary. Meanwhile, transmission to the trains is through a Pantograph. This a framework which collects power and passes it through to the motors. One of the key maintenance issues is that there is a lot of movement in the cables. This is hardly a surprise given the high speeds of modern trains. As a result, the Pantograph adjusts its position to remain in contact with the overhead line.
Maintaining the Catenary involves regular inspection and repair. In particular, this involves the removal of any ‘kinks’ that develop in the line.
Hydraulic Head
XDH41
Much of the work on overhead lines involves high-level maintenance trains. Above all, they provide a stable platform to work from. Moreover, they provide the hydraulic power needed for the XDH41. For remote or emergency works, where a maintenance train is not available, there is the Stanley Dubuis BDL41. This battery tool shares the same in-line ergonomic handle as the Stanley Dubuis cable cutting and crimping tools.
Likewise, it uses the 18 volt 5.0Ah DeWalt/Stanley batteries, common to the whole range.
| XDH41 | BDL041 | |
| Force | 40 kN | 40 kN |
| Weight | 3.800 kg | 4.950 kg |
| Dimensions (mm) | 205 x 80 x 205 | 375 x 80 x 210 |
| Power Supply | 700 bar hyd. source | 18 V Li-ion battery |
| Rail Networks | 700 V / 1 500 V 3 000 V / 15 000 V 25 000 V |
700 V / 1 500 V 3 000 V / 15 000 V 25 000 V |
| Cases | ||
| Weight | 0.900 kg | 1.320 kg |
| Dimensions (mm) | 310 x 280 x 110 | 550 x 336 x 158 |
| Part No. | Supplied with the tool | Supplied with the tool |
| Capacity | XDH41 tool | BDL041 tool + 2 batteries + 1 charger +1 handle |
Thorne & Derrick supply an extensive range of 400V-66kV Rail Cable Accessories & Power Distribution Systems including feeder pillars to contractors undertaking Low Voltage Power Distribution, HV Electrification & Substations, DC Traction & Networks, OLE and Track Feeder Cable Renewals – a complete range of Network Rail PADS approved track terminations, cable joints, cable repair and connection products up to 25kV, including 3M Cold Shrink, Pfisterer CONNEX and Nexans Euromold products.
Full range of Cable Pulling Equipment & Products to ensure safe and efficient of rail cables in to cable ducts and containment infrastructure including cable troughs.
Reliable & Compliant Cable Accessories for Substation, Trackside & OHL Power Supply
CableSafe Confined Space Safety products significantly reduce accidents in confined spaces
Cable Safety Equipment | Workplace Safety | UK & Export Sales
Manholes, crawl spaces, tunnels, sewers, tanks, pipelines and trenches, all have one thing in common, they are enclosed or partially enclosed and are refer to as confined spaces.
These confined spaces are not intended for continuous occupancy, why? If people work in a confined space, they could face life-threatening hazards such as toxic substances, electrocutions, explosions and asphyxiation, there could result in serious injury or death.
A confined space can be more hazardous than regular workspaces for many reasons, many workers are injured and killed each year while working in confined spaces. To effectively control the risks of accidents with unauthorized confined space entries, the entrance and exit should be restricted.
➡ Thorne & Derrick supply the complete range of Safety Tools & Equipment to enable safe working in sectors such as the construction, renewables, data centres, rail, manufacturing and oil, gas, petrochemical industries. We also offer a range of Push Pull Tools for the reduction in Hand Injuries in the workplace designed to improve safety at work.
CableSafe®’s confined space entry protection barrier or manhole protection barrier is the ideal tool for employees and contractors to secure these dangerous openings. The barrier warns co-workers and public of dangers and prevents unauthorized (or accidental) entry.
“In the construction industry, entering confined spaces is often necessary, but fatalities don’t have to happen,” said Secretary of Labor Thomas E. Perez.
The law requires employers to provide their employees with safe and healthful workplaces. With CablesSafe® range of safety products you can avoid penalties that come with non-compliance to safety standards and legislations.
The CableSafe® Manhole Quick Barrier is very flexible and suitable for signing and restricting access to a broad range of out-of-bounds and hazardous areas via apertures, gaps, doorways, windows, openings, vents, and works corridors.
The easy to install barrier is necessary if you want to work safe, quick and efficient. Manhole quick confined space barrier restricts access of manhole. Made of robust materials and easy to install. Custom size possible.
Made of robust materials and easy to install. CableSafe®’s Manhole entry barriers do not only restrict entry into a confined space, it has been designed with visual cue to alert workers and public to hazard.
Designed as a physical barrier with a sign that hooks easily on the rungs so the warning cannot be missed. This prevents unauthorized entry to manholes, vessels, tanks and vaults.
The barrier is durable, has a diameter of 990 mm (40 inch) and a 4 mm thickness and can withstand impacts, scratches, and other industrial conditions.
For easy installation the barriers are equipped with bolts & nuts. Based on specific needs, magnets (95 Newton; 9.5 KG force) and locks can be provided on request for easy handling and/or locking of the confined space protection barrier.
Confined Space Entry Protection by CableSafe®
Specially designed with a bright yellow colour. CableSafe®’s manhole cover prevents a fall-in for workers while performing activities around an open manhole.
It is strong, can support 140 kilograms and the frame is furnished with anchor bolt holes.
CableSafe® Safety solutions are critical cable essentials and are well proven construction safety products. The CableSafe® range of cable hooks can be used during maintenance, turnaround, outages, shutdowns, construction work to suspend cables and hoses and other work gear and equipment from the working space.
For further information see:
Confined Space Entry Equipment | Safety Products
Confined Space Safety Heavy Duty Barrier
Cable Safety Equipment | Cable Stand | Cable Bridge | Cable Rail | Cable Guard | Dropped Object Prevention Mats
Thorne & Derrick stock and distribute a range of Safety Tools including Push Pull Tools from Hand Safety Tool Company designed to minimise hand injuries by keeping hands out of the line of fire.
Published 02 Sep 2026
Celebrating Charlie & Ella’s Level 4 Sales Executive Apprenticeships At Thorne & Derrick International, we are proud to champion talent development and recognise the dedication required to achieve professional growth. We are therefore delighted to congratulate Charlie Baines and...
Published 11 Aug 2026
Thorne & Derrick will be Exhibiting at Solar & Storage Live UK 2026 at the NEC Birmingham from 22nd–24th September, showcasing our support for HV Cable Accessories, Joints, Terminations, Separable Connectors, Cable Tooling and Grid Connection Products used across...
