Jointers Blogs
Euromold Connectors – Termination Of 33kV MV Prysmian Power Cables Using Nexans Elbows
January 23rd, 2018
- Application: Connection & Termination Of 33kV Cable Into MV Siemens GIS
- Cable Connector Type: Nexans Euromold Interface C Bushing Connector
- Cable Connector Part Code: Euromold (M484TB/G-32-95.240UN5+KIT)
- Cable Type & Manufacturer: Prysmian 33kV XLPE Single Core
- Cable Jointer: Daniel Croft
- by Chris Dodds T&D – estimated reading time 5 minutes
Dan is currently IAC Cable Installation Engineer Nordsee Cluster for Nordsee Two GmbH
Euromold Connectors
Today, we welcome Dan Croft onto our Jointers Blog to demonstrate the skill level and competency required to terminate 33kV cables into gas insulated switchgear manufactured by Siemens using Euromold Connectors.
The medium voltage power cable manufactured by Prysmian is expertly prepared by the 33kV Competent Cable Jointer using precision engineered and professional cable jointing tools – the 33kV Prysmian cable was stripped and prepared using the following;
Cable Jointing Tools
- Alroc MF2-60 Outer Cable Sheath Stripping & XLPE Removal Tool
- Alroc CWB18-60 Bonded Semicon Removal Tool
- Alroc AR25 Inner Semicon Removal Tool
- Boddingtons 244240 XLPE Insulation Chamfering Tool
- Kevlar String
Nexans EXPERT MV Cable Jointers Tool Kits
Installing 33kV Connectors
Daniel explains the Euromold connector installation, “the 33kV copper earth screen is bonded to the outer sheath so a window needs to be taken out with Kevlar string, a bit of heat and a tool such as a flat head screwdriver. Used very carefully and precisely in order to remove the window without damaging the screen underneath. Also, all MV cable preparation work such as stripping of bonded screen and XLPE insulation removal must be conducted to the highest possible standard – this includes sanding and polishing of the XLPE insulation layer to ensure there is a “super smooth” and unblemished surface. This is achieved by the cable jointer using precision shaving techniques then sanding (with 240,320 and 400 grit sandpaper sheets). Finally, the 33kV cable insulation is polished with super fine paper and carefully heated creating a surface as smooth as glass. The 33kV cable is then ready to terminate using the Euromold connector type dependent upon the medium or high voltage equipment Bushing Interface type.”
➡ Euromold connectors are available in Interface A-F specifications to terminate MV-HV cables into switchgear, transformers and substations including up to 66kV connections.
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33kV Cable
33kV Cable Specification. The medium/high voltage power cable specification is 33kV single core XLPE insulation with 240sqmm aluminium conductor and copper tape screen – the semicon screen layer is fully bonded to XLPE. Also the cable sheath has an additional fully bonded semicon layer. The cable sheath has a semi-conductive later bonded to it which needs removing for electrical separation between the copper earth tape and outer sheath.
33kV Connectors. 33kV cables are terminated using Nexans Euromold Connectors and connected into the electrical equipment to create a “touch-safe” screened MV cable termination into the gas insulated switchgear.
Flashguard Installed. Arc free and arc flash protection solution for MV Power Distribution Electrical Equipment – the physical barrier stops the MV-HV connectors or terminations becoming free from the switchgear or transformer bushing in the unlikely event of a fault.
Thorne & Derrick International
Should you require any assistance with the selection or specification of Prysmian cable joints please do not hesitate to contact us.
T&D distribute the most extensive range of MV & HV Cable Joints & Terminations, Cable Installation Accessories & Cable Pulling Equipment – we service UK and international clients working on underground cables, overhead lines, substation earthing 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, Earth Tapes, Electrical Safety, Cable Glands, Arc Flash Protection & Fusegear.
- Distributors for: 3M, ABB, Alroc, Band-It, Catu, Cembre, Centriforce, CMP, Elastimold, Ellis Patents, Emtelle, Furse, Lucy Zodion, Nexans Euromold, Pfisterer, Polypipe, Prysmian, Roxtec.
LV – Low Voltage Cable Joints, Glands, Cleats, Lugs & Accessories (1000 Volts)
MV HV – Medium & High Voltage Cable Joints, Terminations & Connectors (11kV 33kV EHV)
Cable Laying – Underground Cable Covers, Ducting, Seals & Cable Pulling Equipment
Medium Voltage Cable Joints Using Fire Proof Prysmian Cable Joints – 15kV EPR Okonite
January 15th, 2018
- Application: 15kV EPR Okonite Medium Voltage Cable – Primary UD Cables
- Cable Joint Type: Prysmian Cable Joints – Medium & High Voltage
- Cable Jointer: Christopher Fusarelli Splicer at The United Illuminating Company
Joints, Splices & Terminations to suit Okonite Cables LV MV HV | 15kV
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by Chris Dodds T&D - estimated reading time 5 minutes
MV Joints & Cable Preparation
1. MV Cable Preparation. The medium voltage cables are expertly prepared by the cable jointer/splicer using basic tools such as cable jointing knife, needle nose pliers and a scale ruler – no specialist cable jointing tools were used to complete this MV cable preparation or joint. To achieve this level of precision and accuracy without damaging the cable and jeopardising the medium voltage cable joint requires an exceptional skill level. The 15kV cable manufactured by Okonite is 750 KCMIL with EPR insulation and ready to be connected using Prysmian cable joints. The white tape overlap section between the copper tape screen and semicon screen is used to secure the medium voltage cable shielding in place.
2. Medium Voltage Cable Joints – Fire Proof. The medium voltage cable joint is over-wrapped to provide fire protection and arc proofing. This MV cable joint was for a new medium voltage circuit with several cable chambers so the 15kV cable is actually open on both ends and not grounded – “the phasing is not completed until every medium voltage cable joint or splice is completed except the first and last, and that’s when we phase it,” comments Christopher.
3. Medium Voltage Straight Joints – no tee (or branch) cable joints were installed, “this particular MV circuit isn’t very long and goes from substation to a dozen or so manholes, then the medium voltage cable terminates at a riser. If our circuit has wyes or tees, we still typically phase at the end,” added Christopher. Branch joints can be used to split main feeder cables into two cables that can be directed to other loads. 
Cable Pulling – the cable gang pulling 15kV 500MCM medium voltage EPR cable. Here the contractor is preparing to piece out a circuit that runs through the middle of the manhole (cable splicing or jointing chamber).
Prysmian Elaspeed Cable Joints
Prysmian Elaspeed cold shrink cable joints and splices are medium voltage cable accessories extensively specified in North American markets – Elaspeed are not molded cable joints. Elaspeed cable joints feature a core constructed from ethylene propylene rubber (EPR) on a vertical triple extruder which maintains concentricity on medium voltage cables. Cable joints are installed cold-applied without the requirement for heat or open flames associated with heat shrink cable joints.
Watertight Cable Joints
The circumferential pressure of the Prysmian Elaspeed cable jacket in conjunction with the cold flow properties of the mastic supplied with the cable joint kit will prevent water ingress. The Elaspeed MV cable joint has successfully passed external water pressure tests of 45 psi. In addition, the tight interface between the cable and cable joint body can withstand pressures up to 30 psi.
Compact Joints
Prysmian Elaspeed joints mimic the behaviour and performance of MV EPR cables in terms of bending radius in tight manhole situations – cable joints or splices can be bent to the same radius as the cable without impacting upon the performance of the joint. The small and smooth profile of the completed joint occupies less installation space where confined space working does not permit oversized joints.
Medium Voltages
Prysmian Elaspeed joints are available in the following voltage categories: 15kV, 25kV, 28kV, 35kV – the cable joints are available to also connect 3 core conductor armoured cables and aluminium inter-locked armoured MV-105 cables, including TECK Cable. Transition joints are also available to splice 3 or single core conductor paper lead (PILC) cables to 3 or single core conductor EPR / polymeric cables.
Prysmian | Cable Joints | Terminations | Cable Cleats | Connectors Distributor
Thorne & Derrick International
Should you require any assistance with the selection or specification of Prysmian cable joints please do not hesitate to contact us.
T&D distribute the most extensive range of MV & HV Cable Joints & Terminations, Cable Installation Accessories & Cable Pulling Equipment – we service UK and international clients working on underground cables, overhead lines, substation earthing 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 Protection & Fusegear.
- Distributors for: 3M, ABB, Alroc, Band-It, Catu, Cembre, Centriforce, CMP, Elastimold, Ellis Patents, Emtelle, Furse, Lucy Zodion, Nexans Euromold, Pfisterer, Polypipe, Prysmian, Roxtec.
LV – Low Voltage Cable Joints, Glands, Cleats, Lugs & Accessories (1000 Volts)
MV HV – Medium & High Voltage Cable Joints, Terminations & Connectors (11kV 33kV EHV)
Cable Laying – Underground Cable Covers, Ducting, Seals & Cable Pulling Equipment
More…
T&D’s Power Blog covers: LV MV HV & EHV Transmission & Distribution, Substations, Switchgear, Cable Jointing & Termination, Cable Fault & Repair, Underground Cables
➡ Visit Power Blog.
33kV Heat Shrink Cable Joints Connecting XLPE Cable In Underground Trench
January 8th, 2018
- Application: Connecting XLPE Insulated High Voltage Cable In Underground Trench
- Cable Joint Type: 33kV Cable Joints (Heat Shrink)
- Cable Jointer: Garry Hardaker Electrician & HV Jointer (Offshore)
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by Chris Dodds T&D - estimated reading time 5 minutes
33kV Heat Shrink Cable Joints
Protecting High Voltage Cables From Water Damage
33kV heat shrink cable joints are high voltage cable jointing kits complete with mechanical connectors or compression crimp connectors for cable jointing of polymeric (XLPE) insulated cables.
Polymeric insulated cables distributing high voltage electricity at 33kV can be used to joint cables with XLPE or EPR type insulation, armoured/unarmoured and with copper wire screen (BS7870) or copper tape screened cables (BS6622).
Heat shrink cable joints feature integrated stress control sleeves and torque controlled mechanical shearbolt connectors can be used to connect conductors (copper or aluminium) without resort to use of crimping tools or associated die sets.
Mechanical cable connectors are ideal for confined space cable jointing where there is restricted working space in manholes, cable vaults and underground trenches, especially on large cross sectional area conductors where hydraulic crimping heads coupled with foot pumps are required for conductor jointing. Bolted cable connections, such as Pfisterer SICON connectors, are installed directly onto the 33kV conductor using standard Allen keys. The bolt shears off smoothly and cleanly when tightened by the cable jointer.
Pfisterer Sicon – cable lugs and connectors with stepless shearbolts for use with cable joints and terminations on high voltage power cable systems
Heat Shrink
Primarily, a heat shrink cable joint provides electrical insulation, mechanical protection and stress control for high voltage power cables – integral also to the cable joint design is the requirement to prevent water ingress into the cables. Although initial risk assessments would include consideration of electrical water damage, such as cable flood damage, the requirement to deliver medium/high voltage power can necessitate cable exposure to potential flooding, condensation and water immersion. A robust cable joint is designed to withstand the deteriorative effects of water in both indoor or outdoor environments.
The cable joint kits include thick-wall heat shrink adhesive lined tubes to provide high performance water sealing, protection and corrosion resistance in above ground exposed or direct buried underground cable trenches – the outer protection heat shrink tubing (colour black) provides a moisture barrier to water ingress through the activation of an inner lining of adhesive which melts and flows upon the application of a heat source provided by the cable jointers gas torch.
Prior to installing the outer shrink tube the jointer should clean, de-grease and abrade the outer cable sheath of the 33kV cable – to achieve an even wall thickness the cable jointer should keep the flame moving and avoid scorch or burn damage to the heat shrink or cable.
The jointer will apply heat evenly to the centre of the cable joint – once the heat shrink tube is fully recovered (“shrunk”) the joint should be smooth, wrinkle-free and the heat activated sealant should be visible at the tube ends in contact with the cable sheath.
The tough and durable heat shrink provides reinstatement of cable sheath or jacket insulation and withstands trench backfill prior to energisation of the HV joint.
The 33kV joints are installed using normal procedures for heat shrink cable joints with clear installation instructions confirming precise cable stripping dimensions and marking measurements for sheath, semicon and insulation removal – joints are installed using the standard cable jointing tools depending upon cable construction.
Although not designed to be permanently submerged in water, 33kV cable joints use heat shrink tubes to prevent water ingress into high voltage cables whether buried underground or located onto cable containment in MV-HV substations.
Should you require any assistance with the selection or specification of MV-HV joints or terminations please do not hesitate to contact us.
Further reading:
- Dangers Of Substandard Heat Shrink Cable Terminations On High Voltage Systems
- HV Cable Terminations – A Report Into 11kV Heat Shrink Termination Failure
Jointing 33kV Cables Using Heat Shrink Joints
The following Training Video shows the installation process for installing heat shrink joints to single core 33kV cable – this Video is for familiarisation purposes and not intended as a substitute for attending recognised industry training courses and achieving manufacturers competency. The Video produced by SPS with narration provides comprehensive guidance from the initial stripping and removal of the 33kV cable sheath to the final completion of the heat shrink joint.
More 33kV Products For High Voltage Cables ♦ 33kV Surge Arresters ♦ 33kV Fuses ♦ 33kV Lugs ♦ 33kV Portable Earthing ♦ 33kV Cable Terminations
Thorne & Derrick Specialist Electrical Distributor
LV ♦ MV ♦ HV
T&D distribute the most extensive range of LV, MV & HV Cable Jointing, Terminating, Installation & Cable Pulling Equipment – we service UK and international clients working on underground cables, overhead lines, substation earthing 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 Protection & Fusegear.
- Distributors for: 3M, ABB, Alroc, Band-It, Catu, Cembre, Centriforce, CMP, Elastimold, Ellis Patents, Emtelle, Furse, Lucy Zodion, Nexans Euromold, Pfisterer, Polypipe, Prysmian, Roxtec.
LV – Low Voltage Cable Joints, Glands, Cleats, Lugs & Accessories (1000 Volts)
MV HV – Medium & High Voltage Cable Joints, Terminations & Connectors (11kV 33kV EHV)
Cable Laying – Underground Cable Covers, Ducting, Seals & Cable Pulling Equipment
More…
T&D’s Power Blog covers: LV MV HV & EHV Transmission & Distribution, Substations, Switchgear, Cable Jointing & Termination, Cable Fault & Repair, Underground Cables
➡ Visit Power Blog.
Insulated Tools & Live Cable Jointing
December 19th, 2017
Ad: Insulated Tools (Live Line & Cable Jointing Tool Sets) – T&D supply a full range of insulated tools kits for electrical engineers, cable jointers and overhead linesmen
Electrical Safety & Live Working Equipment
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uploaded by Chris Dodds - Thorne & Derrick
In the UK the Distribution Network Operators permit appropriately accredited ICP’s to carry out live cable jointing onto service and mains connections on their low voltage electrical distribution systems – those cable jointers must be trained, assessed and authorised as competent to work on live cables with a professional working knowledge (practical and theoretical) of the electrical safety considerations when jointing energised cables.
Furthermore, contractors must use approved and tested insulated tools, jointing tools and electrical safety equipment to prevent workplace risk becoming workplace accident.
Insulated tools will protect workers against contact with live circuits and cables. Without them you could be risking serious injury, liability or even death.
Typical 400v low voltage cables jointed under live conditions are waveform, wavecon, PILC STA and Consac – live working is essential but not encouraged and suitable arc flash clothing should be worn when carrying out maintenance on energised substations, cables and electrical equipment. See the UK HSE HSG85 document for further information about safe working near dead or live electrical equipment.
The following series of site photographs kindly contributed by Billy Ayling, an authorised Live Cable Jointer, shows the stages of cable stripping, preparation, shrouding and branch jointing of wavecon cables. The photo’s were taken by the Jointers mate.
- Application: Live Cable Jointing
- Cable Joint Type: Breech/Branch Joint
- Cable Type: Wavecon Cables – 95sqmm 3 Core Wavecon Breeched
- Cable Jointer: Billy Ayling (Self Employed – DNO (SSE) Trained Live LV / 11kV Jointer
About Billy,
Billy has worked in the utility industry since leaving school in 2001 and has been a cable jointer since 2010. Professionally trained at SSE Thatcham Jointing School and authorised to fault find, repair and cable joint wavecon, consac, PILC SWA and associated services with additional skills including operating and linking on the low voltage electricity network.
Cable Jointing In The Danger Zone
With nerves of steel and the concentration powers of a chess Grandmaster a live cable jointer must maintain a steady hand and focussed mind when working on live cables.
Billy comments, “the main risk during live cable jointing is losing concentration – generally I would not speak to my Jointers mate whilst live working on cables unless something critical to the cable joint installation is required. All adjacent conductive metal work must be shrouded using rubber insulating shrouds UV stabilised suitable for outdoor and underground use in cable trenches. Only one phase should be worked on at a time.”
Typically, when working on Live LV Conductors insulating gloves should be used when working on, or in close proximity to cables – UK DNO’s such as Scottish Power Energy Networks (SPEN) according to their policy guideline Rubber Gloves For Electrical Purposes recommend jointers wear Class 1 insulated gloves (7.5kV) to the British Standard BS EN 60903 (2003).
Hand protection is vital as is the use of dielectric boots where there is a real risk to the cable jointer of electrical shock from either low voltage or high voltages – see insulating boots for further information on suitable PPE for jointers.
An 11kV Jointer
Billy has ascended the voltages and is currently a high voltage cable jointer authorised to work on 11kV polymeric (XLPE) and 11kV paper (PILC PICAS) insulated cables.
1 View From The Trenches – working conditions complicate but do not prevent skilled cable jointers from live working in cramped and confined underground cable trenches. Here, the cable fault has been located and the damaged cable excavated prior to jointing. In the field, jointer training centre conditions are never replicated with an onus on the jointer to maintain high skill levels, concentration and dexterity in the face of bad weather and under pressure to restore power to our homes or businesses with minimum disruption.
2 – Mud, Mud, Glorious Mud – plodging in muddy holes with conditions favoured by hippo’s the cable jointer must maintain complete awareness of the electrical safety precautions and considerations required for safe live working on LV cables. The centre of the wave is accurately located on the cable – this must be done to ensure correct cable stripping and separation of the copper neutral earth wires. Also, the waveform cable is marked up for where to strip the cable prior to jointing.
3 Get Stripped! – the cables are carefully prepared using jointers tools to remove the cable sheath and expose the cable and conductors to allow the cable joint to be installed. Here, the jointer has relied on insulated cable knives to safely remove the waveform cable sheath. Correct cable preparation is essential to avoid malfunction of the cable joint post-energisation.
4 Shocking Risks – the cable jointer uses insulated tools to work on the live cables to avoid potential electrocution when live working. The jointer uses insulated cable wedges to space cores for testing (hence the lamps) and provide space for the ‘w’ breech connectors. Insulated tool kits would usually include insulated pliers, cable cutters, sockets, spanners, wrenches and screwdrivers – contact us for further information.
5 Shrouded For Safety – the jointer uses Boddingtons rubber insulating shrouding to protect against live voltages up to 1000V when underground cable jointing. Insulated clamps hold the protective shrouding in position covering the live cables so the LV cable joint can be positioned and installed.
6 Insulated Tools – the jointer has used an insulated ratchet tool to tighten the shear off bolts on the mechanical shearbolt connectors. Insulated wedges to were used to separate the cable cores and an insulated knife used to strip insulation from the cores. Cable joint is manufactured by TE Connectivity and approved by SSE – this is a completed wavecon to wavecon 95sqmm 3 core mains breech joint.
7 Hometime – the branch joint is completed with the shell encapsulating the jointing resin and ready for trench backfilling. Live cable jointing should only ever be carried out by competent and certified Jointers using the correct jointing, insulated tools and electrical safety equipment.
SSE Scottish & Southern Energy – a live low voltage 185sqmm wavecon straight joint prior to filling the joint shell with cable joint resin.
Cable Joints – The Birdcage. Here, the cable jointer ensures the binders are cut off before cable joint is ‘complete’ making a cage around the crutch rather than just split apart as per the previous photo. Although forming part of the SSE jointers trade test at the Jointing School this is rarely used in the field. The neutral earths are formed as a “bird-cage” type arrangement at the cable crotch using wire binders. Image: Lee Richards (LV 33kV Competent Cable Jointer).
Insulated Tools & IEC 60900
IEC 60900 Symbol
Quality insulated tools should be tested to IEC 60900 – this standard controls hand tools for live working up to 1000 V a.c. and 1500 V d.c.
Look for the official 1000V symbol, this will ensure the tools protect workers against accidental or incidental contact with electricity voltages up to 1000V. Purchase a copy of IEC 60900 from the IEC webstore here.
T&D also distribute the complete range of Class 0, 1, 2, 3 and 4 ranges of insulating matting to provide protection to utility workers, substation workers and cable jointers working on low, medium and high voltage cables and power systems.
Thorne & Derrick
Specialist Electrical Distributor
LV ♦ MV ♦ HV
T&D distribute the most extensive range of LV, MV & HV Cable Joints & Terminations for repairing, jointing and connecting 11kV/33kV cables in underground cable trenches or substations, switchgear and transformers – the extensive range of cold shrink and heat shrink joints and terminations are supported by a complete range of cable jointing tools to enable the removal of sheath, insulation and screen from LV, MV & HV cables.
Customised & Standard Insulated Tool Sets – Tested To IEC 60900: 2012.
Cable Jointing Tools for Low, Medium & High Voltage Jointers – Boddingtons Electrical
132kV Cable Joint By Energi Cable Engineering Limited
December 11th, 2017
132kV Ericsson Transition Joint – 3 Core Cable Joint XLPE To Oil Filled Cable
Uploaded by Chris Dodds T&D
- Contractor: Energi Cable Services
- Contributed By: Dan Chessher
Energi Cable Engineering
Energi Cable Engineering have developed a strong and close relationship with two of the leading manufacturers of high voltage cable systems: NKT of Denmark and LS Cable & Systems of South Korea. Through these partnerships Energi Cable Engineering can design, specify, procure and deliver high voltage cable systems up to 500kV to provide solutions for XLPE, Oil Filled and Gas filled cable systems.
Energi Cable Engineering provides a complete range of cable accessories for XLPE, oil filled and gas filled cable systems. The highly experienced team of cable design engineers ensures that a fully engineered solution is provided to meet customer requirements, including all the ancillary equipment.
More from ECS
- 132kV Cable Sheath Testing With Pfisterer GIS Terminations
- 132kV HV Cable Testing Using Amprobe ISO 5000 Test Equipment
- Oil Cabinet Monitoring Oil Pressure On 132kV Circuit
- 132kV Outdoor Sealing Ends (ODSE) Manufactured By nkt Cables Installed By Energi Cable
- Degasifier Trailer – Oil Preparation For Extra High Voltage Cable Circuits
66kV Ericsson Transition Joint
See more: MV HV EHV Cable Jointing & Installation Photo Blogs.
Thorne & Derrick | Stockists & Distributors for 3M Electrical | Nexans Euromold | Pfisterer Connex | Joints Terminations Connectors up to 66kV from Stock
