Jointers Blogs
11kV Triplex Cables Terminated Onto Switchgear Bushings Using Heat Shrink Cable Terminations
December 8th, 2017
- Application: 11kV Triplex Cables Terminated Onto Switchgear Bushings
- Cable Type: 11kV Triplex Cables BS7870-4.10 – 3 Core Cable High Voltage (HV) Power
- Cable Jointer: Watkins and Jacomb Construction Power & Consultancy
- Featured Product: Heat Shrink Cable Terminations 11kV
Heat Shrink Terminations
In order to safely and professionally prepare medium/high voltage cables a complete set of cable jointing tools are required to enable the stripping and removal of the 11kV triplex cable sheath, insulation and screen – this includes Alroc tools used by jointers for MV/HV cable preparation and Cembre tools to cleanly cut and crimp cables.
The jointers have used cable cleaning wipes to carefully remove debris, dust or contaminants from the Triplex cables to ensure the overall reliability of the 11kV heat shrink cable terminations.
Lucy Switchgear
11kV cables are shown terminated using heat shrink terminations into Lucy VRN2a SF6 Ring Main Unit with a 200A Circuit Breaker to UKPN specification – the Sabre range of RMU’s manufactured by Lucy Switchgear are non extensible ring main units for outdoor high voltage substations. Along with low voltage distribution cabinets, these RMU’s can be easily coupled to the distribution transformer forming a compact outdoor package substation.
The 11kV heat shrink terminations are crimped using mechanical shearbolt cable lugs and bolted to the interface bushings of the air insulated cable box.
Terminating Triplex Using Cold Shrink
Here, the 11kV Triplex cables are shown terminated into a high voltage cable termination box using 3M Cold Shrink terminations – the concertina style bushing boot is cold-applied and suitable for both straight or right-angled 11kV switchgear connections, part code 3M 92EE717-1.
The bushing boots insulate the cable lug connection onto the bushing interface located on the electrical equipment. The Triplex copper wire screens are shown bonded to earth using brass mechanical shearbolt cable lugs.
The unarmoured Triplex cables are provided with mechanical cable retention and moisture ingress protection using heat shrink cable glands – the glands provide a watertight and fume-tight cable seal where the Triplex cables enter high voltage connection boxes, switchgear, bulkheads, or other enclosures.
The HV cables are cable ducted within the hot zone and a stand-off insulator is mounted in each HV cable box. The cable sheath is shown terminated to an earth bar mounted onto the stand-off insulator.
Image: NPG Northern Powergrid
Triplex Cable Sheath Earthing Arrangement 11kV
Should you require any assistance with the selection or specification of 11kV triplex cables or 11kV cable lugs please do not hesitate to contact us.
♦ Also 11kV : Nexans Connectors | Pfisterer Plugs | 3M Joints & Terminations | Ellis Cable Cleats | Duct Seals
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, substations and electrical construction at LV, 11kV, 33kV and EHV transmission and distribution voltages.
- Key Products: MV-HV Cable Joints & Terminations, Cable Cleats, Sealing Cable Ducts, 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.
11kV Cable Terminations – HV Switchgear Substation Installation & Commission
December 7th, 2017
- Project Scope: 11kV Cable Terminations, Switchgear, Transformers – LV HV Cables
- Featured Contractor: ISS Industrial Switchgear Services Ltd
- Cable Specification: 11kV 3 Core XLPE Cable BS6622 IEC60502-2
- Switchgear Type: Air Insulated 11kV High Voltage Switchgear Siemens NXAIR
- Credit: Peter McKenna (Operations Manager) & John Bower (Manager & 33kV SAP)
- All Images Courtesy: ISS Industrial Switchgear Services Ltd
11kV Terminations
ISS were contracted to carry out the Design, Build & Installation of 10 new low voltage switchboards and a 24 panel 11kV high voltage switchboard, cabling and terminations installation.
The high voltage cables were connected using 11kV cable terminations into Siemens NX air insulated switchgear – the armoured 3 core 11kV cables with polymeric insulation (XLPE) were glanded using top-hat type cable glands and terminated into the switchgear using 11kV indoor heat shrink cable terminations.
Careful selection of the correct cable lugs are required – 11kV lugs tested to relevant international standards should be used with extended barrels for excellent connection and circuit conductivity.
The 11kV cable containment design and erection shown in the image below was carried out by ISS – 11kV cable spacings and cable cleat ratings were calculated and correctly specified by ISS to protect and restrain the high voltage cable circuits in the event of a short circuit.
ISS design engineers created and installed a bespoke A frame arrangement located on the ground floor to support the bottom cable entry of 11kV cables into the switchgear units located on the first floor.
A total of 22 new 11kV/415V high voltage transformers manufactured by Wilson Power Solutions were installed by ISS and all associated new low voltage (LV) power supply cables.
The LV cables were BS5467 type single core XLPE insulated power cables with aluminium wire armour and stranded copper conductors, 300-500sqmm.
High Voltage Cable Chamber – showing 11kV high voltage switchgear, terminations, cable cleats and containment
HV Switchgear – Siemens NXAIR Air Insulated Switchgear
Siemens NXAIR circuit-breaker switchgear is used in medium/high voltage transformer and switching substations up to 24kV for primary electricity distribution.
All HV switchgear from the Siemens NXAIR air-insulated range are approved with internal arc classification IAC A FLR, loss of service continuity category LSC 2B and partition class PM.
Some features of the high voltage switchgear include:
1 As an electrical insulating medium – air is always available
2 Type-tested HV switchgear according to IEC 62271-200 or VDE 0671-200
3 Use of standardised block-type current transformers
4 450,000+ air-insulated switchgear panels of Siemens in operation worldwide
5 Uses maintenance-free high voltage vacuum circuit-breakers or contactors
6 Testing of the vacuum circuit-breaker and make-proof earthing switch in switchgear panel
7 Pressure-resistant partitions
8 Flexibility regarding the low-voltage equipment (removable compartment, plug-in wires)
9 Quality assurance in accordance with DIN EN ISO 9001
11kV 24kV Air Insulated High Voltage Switchgear – Siemens NXAIR
Industrial Switchgear Services
ISS Ltd are a HV/LV Power Engineering company operating nationwide, undertaking Turnkey Electrical Distribution Projects and Site Service activities including installation, commissioning, pre-commissioning, final commissioning, HV/LV switching, maintenance, repairs, refurbishment of HV/LV AC & DC Switchgear, power transformers, SCADA systems, control panels, HV/LV cabling, cable terminations and associated ancillary equipment.
ISS Ltd manufacture low and high voltage switchgear, protection cubicles, LV generator changeover panels, marshalling cabinets and bespoke protection and control equipment.
- HV Switchgear & Cable Terminations 11kV 33kV
- LV Switchgear & Cable Gland Terminations
- Transformer & Rectifiers
- Substation Construction 11kV 33kV
- Protection & Control
22kV Rail Cable Installation
“ISS have completed further 22kV high voltage protection upgrades, upgrading 5 circuits at this particular site, all communicating back to a new 22kV switchboard installed a few miles away on the cable network. ISS removed the existing MBCI Translay, MCRI Overcurrent, MRTP Pilot Wire Supervision, KCEG Directional Overcurrent/Earth Fault MVTW Destabilising Relays. These have been replaced with a new Line Differential ABB RED615 Relay and Modem and Agile P14D Back Up Protection Relays.”
“New multicore cables have been installed from the switchboard back to the Marshalling cubicle, with ISS successfully proving the SCADA signals back to the RTU and control room. ISS commissioned the circuit into service, carrying out On Load Line Diff stability checks. A great team effort, from the design and manufacture of the protection fascia’s from our Manchester HQ, to the installation and commissioning of the circuits for a London based rail network. Great collaborative interfacing and planning between everyone involved to upgrade 22kV cable circuits on an operational railway” – Peter McKenna (ISS Operations Manager).
22kV Rail Cable Installation
More ISS project information:
Commissioning 25kV AIS Switchgear On Containerised Rail Traction HV High Voltage Substations
Flood Defence & Replacement Of Low & High Voltage
11kV Switchgear & Cables
The disaster recovery project involved the replacement of water damaged high voltage electrical equipment and cables – this included replacement of primary high voltage switchgear, cable terminations, associated power transformers and distribution cables.
Watch, listen and learn more about the project:
Should you require any further information about 11kV Cable Termination, Switchgear, Substation & High Voltage services provided by ISS please call 0161 344 1117.
3M Scotchcast Cable Joint – Resin & Taped Manhole Cable Splice 600/1000V
December 4th, 2017
- Application: Resin & Taped Manhole Cable Joint / Splice 600/1000V
- Cable Joint: 3M Scotchcast Cable Joints
- Cable Jointer: Andy O’Malley (IBEW 258 EHV Cable Jointer / Cable Splicer)
- Featured Manufacturer: 3M Electrical
Cable Jointing In Confined Spaces
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by Chris Dodds - Sales & Marketing Manager Thorne & Derrick
Prior to jointing cables in confined spaces control measures and risk assessment must be undertaken. This picture was taken from outside the manhole once the cable joint was complete – the looped cables were spliced using 3M Scotchcast cable joints to effect a repair to damaged cables in a confined space.
Initially the cable jointers bump test their gas detectors then gas sample the manhole with the lid on for the presence of harmful, flammable or toxic gas.
If all is safe to proceed the jointers remove the lid. Next the working space is vented with forced air while the jointers constantly monitor the confined space with their gas detectors. Access to the manhole is via a wooden ladder with the cable jointers wearing a rescue harness – a tripod and winch are positioned and a gate guard around the manhole is erected to prevent trips, falls or accidents.
The cable is jointed within the manhole to prevent overbending strains on the low voltage cable when fed back into the manhole if jointed at ground level – cable duct seals can be used to prevent the migration of flammable gas or flood waters into the manhole.
The 500kcmil 100 volt rated DC cable circuit is operating at 600 volt – the cable joint/splice utilises 3M Scotch Electrical Tapes with no heat shrink or cold shrink tubing.
3M Scotchcast Cable Joint – Resin & Taped Manhole Cable Splice 600/1000V
3M Scotchcast Cable Joint
3M cable joints use Scotchcast resins for the low voltage jointing of cables with XLPE, EPR, PVC or PILC insulation up to 3.3kV. Resin cable joints specially modified with high performance hydrocarbon resistant, low smoke zero halogen, fire resistant and flame retardant resins are available to withstand harsh operating and environmental conditions in industrial and hazardous area locations. The 3M cable joints are specified throughout ther oil, petrochemical, gas, mines, telecoms, rail and industrial cables are available – suitable for direct burial (underground) or exposed onto cable containment.
3M SCOTCHCAST LV RESIN CABLE JOINTS – Benefits
Resin Cable Joints – Features & Benefits Of 3M Scotchcast Cable Jointing Systems
Contact Thorne & Derrick to discuss your application for jointing LV cables – we can provide expert technical support, training and specification advice to ensure the correct supply of electrical LV cable joints to suit industrial and hazardous area location cables.
T&D – Main Distributors For 3M Electrical
Should you require any assistance with the selection or specification of cable joints or terminations using 3M Cold Shrink on MV-HV cables please do not hesitate to contact us.
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, 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, Earth Tapes, Electrical Safety, Cable Glands, Arc Flash Protection & Fusegear.
- Distributors for: 3M, ABB, Alroc, Band-It, Catu Electrical, 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
11kV Switchgear Cable Terminations, Jointing & Spiking In High Voltage Substations
December 4th, 2017Jointing, Terminating & Installation of 11kV Substation Cables
Guest Post from Mick Beeby - Technical & Operations Manager at UK Power Solutions Ltd
Uploaded by Chris Dodds - Thorne & Derrick Sales & Marketing Manager
“I spent a couple of days on site this week with one of our team of Operations Engineers, connecting 4 new ESP adopted 11kV high voltage substations on Phase 2B of the Ballymore Royal Wharf Development in London.
UKPS have provided the electrical infrastructure for Phase 1, 2A and now 2B to date.
This includes 1 x UKPN 11kV boundary substation with 2 RMUs, 1 x SSE 11kV boundary substation with 2 RMUs, 11 x ESP 11kV permanent distribution substations and 1 x ESP 11kV TBS installed and disconnected again, 1 x UKPN 11kV metered TBS to private high voltage transformer.
There are more ESP 11kV distribution substations to install in Q1 2018. This now takes us to 10 of a final 12 total on this ESP 11kV ring.
An IEC was received from SSE for the DNO/iDNO boundary end of the ESP 11kV circuit, which was made Dead, Isolated and Earthed before the 11kV cables were identified and cables spiked under a Sanction-for-Test. A Permit-to-Work was then issued for the 11kV cable jointing, followed by pressure testing under another Sanction-for-Test and final energisation and 11kV phase checks to bring 4 new 11kV high voltagew substations onto the system.”
1 of 4 new ESP 11kV high voltage substations connected on this visit, taking the total on this ESP 11kV ring to 4 substations, and 11 on the Ballymore Royal Wharf development so far.
2 x 3c 11kV polymeric SSE specification straight cable joints of TE Connectivity MXSU series, to loop 4 high voltage substations into the existing ring of 4, making 8 total.
5 Way Transformer Mounted Cabinet post energisation testing. 5 outgoing LV circuits to the multi-occupancy buildings on Phase 2b of the Royal Wharf development.
1 of the 4 new ESP adopted substation internally, comprising Schneider RN2C SF6 Ring Main Unit, Schneider 11000V/400V transformer and Schneider 5 Way Transformer Mounted Fuse Cabinet with incoming high voltage 3c 11kV XLPE polymeric cables.
About Mick Beeby
With over 25 years of experience in the UK Electricity Distribution sector, coming from an apprentice electrician, through Electrical Fitter, Project Manager and Senior Authorised Person roles. Familiar with many types of low voltage, medium voltage and high voltage switchgear, transformers and cables. In depth familiarity of Schneider Genie Evo 11kV switchgear, switchgear cable terminations including complete stripping, re-build and testing.
In depth theoretical and practical knowledge of MV-HV testing and commissioning, cable fault location and cable repair, including test equipment application and limitation.
Experience of all aspects of medium voltage distribution substation testing and commissioning; cable sheath testing, cable/switchgear IR testing, over voltage testing (DC/AC/VLF), primary and secondary injection testing, transformer testing, CT mag curves, CT polarity, soil resistivity and earth electrode systems testing.
Unlike the Distribution Network Operator, we can design & install your private High Voltage network downstream of your HV metering point, providing a more complete package of works to save you time & money. pic.twitter.com/7GtXGzSefH
— UKPS (@ukpowersolution) November 29, 2017
Schneider
Schneider Genie Evo Air Insulated
MV HV Switchgear 3.3kV 13.8kV
The Schneider GenieEvo concept is an evolution from the extremely successful Genie philosophy which offers increased levels of flexibility and greater choice for the distribution of medium/high voltage power – this is achieved by allowing separate selection of the MV-HV switchgear and protection and control modules. GenieEvo extends the concept of Genie by offering a gas free circuit breaker to the MV-HV product portfolio.
- Schneider GenieEvo comprises
Cast resin encapsulated MV medium voltage system
Demountable vacuum circuit breaker
Controlled air, resin encapsulated series disconnector
Flexible pre-engineered protection and control modules
1. Vacuum circuit breaker 2. Controlled air disconnector 3. Top entry pilot box 4. Internal arc protection 5. CT chamber 6. Cast resin insulated busbar system with optional earth shielding 7. Multi functional protection and control unit 8. Unit fascia with active operating mimic display 9. Front access cable and vacuum test facility 10. Rear entry MV medium voltage cable box 11. Internal arc vented via dedicated cable trunking for operator safety 12. Mechanical operations counter 13. Circuit potential indicator as standard 14. VT chamber
Medium & High Voltage Switchgear
Thorne & Derrick International
T&D distribute the most extensive range of MV & HV Jointing & Terminating, Installation & Cable Pulling 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, Sealing Cable Ducts, Cable Transits, Underground Cable Protection, Cable Jointing Tools, Feeder Pillars, Cable Ducting, Copper Earthing, 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.
Switchgear Cable Terminations
T&D distribute MV-HV Switchgear Cable Terminations to suit 11kV/33kV connections into air, oil and gas insulated switchgear or transformers including heat shrink, cold shrink and separable connectors for both inner cone and outer cone bushings from leading manufacturers including Nexans Euromold, 3M and Pfisterer.
♦ See more: Heat Shrink Cable Terminations 11kV 33kV | Cold Shrink Cable Terminations 11kV 33KV
MV HV – Medium & High Voltage Cable Joints, Terminations & Connectors (11kV 33kV EHV)
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.
Drum Heating & Cable Straightening Jackets For 132kV Extra High Voltage Cable Terminations
November 30th, 2017
- Application: Drum Heating & Cable Heating HV EHV
- Drum Heater Type: Heating Jacket For Silicone Oil Drums
- Contractor: Matthew Taffs (CRS Ltd) – EHV Cable Jointer & Director
- Featured Manufacturer: Prysmian 132kV Click Fit Cable Terminations XLPE
- Featured Product: Thorne & Derrick Drum Heater HF5-D
- Extra High Voltage Cable Type: 132kV Prysmian Single Core XLPE 800sqmm
Terminating 132kV Cables
Cable Oil & Drum Heating
Drum Heaters
Cable heating jackets are initially used to heat the EHV cable to enable relaxing and straightening of the high voltage power cable prior to cable preparation and stripping using cable jointing tools – typically the cable heaters provide a stable temperature of 85 degrees Celsius (185F) for at least 12 hours to the XLPE cable to improve cable manipulation for the HV jointer.
Straightening tubes are then applied to the heated cable and allowed to cool.
The following day cable jointing commences.
The drum heating jacket is applied around the oil drum (silicone oil) and heated to a temperature between 105 – 115 degrees Celsius.
This is done firstly and most importantly to ensure there is no moisture in the oil and secondly to make the oil thinner so it can be pumped into the high voltage cable termination. Once the oil has reached a temperature exceeding 105 degrees Celsius the cable jointer can check with a flash light the condition of the oil.
The heated oil should remain clear with no signs of bubbles, white clouds or foaming.
The oil is then pumped from the drum into the cable terminations insulator to a measurement given on the drawing/ cable jointing instruction. Once the insulator is full to the required measurements, the top is then bolted on and then the cable jointer must press crimp the connector using hexagonal process (HEX) at the correct positions.
T&D supply an extensive range of High Voltage Jointing & Electrical Equipment to enable cable lubrication, cable pulling and installation of 66kV/132kV power cable systems – this includes 132kV surge arresters for electrical protection against overvoltages caused by lightning strike and switching operations.
♦ View complete range of 132kV Terminations, Joints & Sealing Ends
Pictured: T&D drum heater providing consistent and stable electric surface heating to oil drums for EHV cable termination installations.
In order to achieve the required drum heating temperature of 100+ degrees Celsius the heater jacket was used in conjunction with a base drum heater to accelerate the high temperature heating requirement of the oil – you can see the plate of the base drum heater in the photo below.
Cable Repair Services Ltd
CRS are predominately a reactive cable faults and services team specialising in repairing high voltage fluid filled cables.
CRS have a wealth of experience maintaining, repairing, jointing, terminating and fault-finding on all types of HV fluid filled cable systems ranging from 33kV to 400kV.
All CRS operatives have been trained to the highest standards by companies such as BICC, Prysmian and Balfour Beatty and are able to undertake jobs safely and efficiently while remaining cost effective. Their highly skilled Cable Jointing and Oil Technicians have the capability to joint both polymeric (XLPE) and fluid filled cables up to and including 400kV.
Additional cable services include PILC cable jointing (11kV-66kV), HP gas jointing (66kV-132kV), pilot cable jointing, joint bay refurbishment, cable sheath repairs, serving faults, cable fluid leak locating, gauge calibration and circuit fluid pressurisation.
CRS Cable Repair Services Ltd (CRS Ltd) – trained staff have completed course training to comply with UK Power Network (UKPN) types A,B & C confined spaces.
Prysmian | Cable Joints | Terminations | Cleats | Connectors Distributor
- Thorne & Derrick Distributors for: 3M, ABB, Alroc, Band-It, Catu, Cembre, Centriforce, CMP, Elastimold, Ellis Patents, Emtelle, Furse, Lucy Zodion, Nexans Euromold, Pfisterer, Polypipe, Prysmian, Roxtec.
MV HV – Medium & High Voltage Cable Joints, Terminations & Connectors (11kV 33kV)
More…
T&D’s Power Blog covers: LV MV HV & EHV Transmission & Distribution, Cable Duct Sealing, Substations, Switchgear, Cable Jointing & Termination, Cable Fault & Repair.
➡ Visit Power Blog.
