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Green Hydrogen A Renewable Energy Technology

This article has been republished with the kind permission of Jules Daly | Marketing & Communications Manager at Powersystems Ltd (High Voltage Electrical Engineering).

About Powersystems

Powersystems was established in 1977 to provide industrial customers with the expertise that only the local electricity board previously offered. 40 years on Powersystems are still supporting some of their first customers a testament to the service provided. Continued support of these industrial customers and increased activity in the grid connections and renewable energy markets has been the core of Powersystems success.

Powersystems reviews Green Hydrogen as a renewable energy technology and some of the challenges the sector faces as we wait for the Hydrogen Strategy publication from the UK Government this year.

Hydrogen is the lightest element of the periodic table and the most common substance in the world.  It can be used as feedstock, fuel or energy carrier and does not emit CO2 when burnt, that is why you often hear about its high potential for decarbonising the economy.

Now, as nations come forward with net-zero strategies to align with their international climate targets, hydrogen has once again risen up the agenda for the UK and Australia through to Germany and Japan.

Potentially hydrogen could soon power trucks, planes and ships. It could heat homes, balance electricity grids and help heavy industry to make everything from steel to cement.

But doing all these things with hydrogen would require staggering quantities of the fuel, which is only as clean as the methods used to produce it. Moreover, for every potentially transformative application of hydrogen, there are unique challenges that must be overcome.

In order to meet the 2050 decarbonisation policies and targets, the UK requires deployment of new technologies in traditional roles. One of these is the innovative technology around the uses of Green Hydrogen.

• Powersystems update on The Climate Change Committee (CCC) has launched what it describes as the world’s first ever detailed route map for a fully decarbonised nation
• The Sixth Carbon Budget(2033-2037) charts the decisive move to zero carbon for the UK

What is Hydrogen?

Hydrogen is an explosive and clean-burning gas. Since the weight of hydrogen is less than air, it rises in the atmosphere and is therefore rarely found in its pure form, (H₂).

In a flame of pure hydrogen gas, burning in air, the hydrogen (H₂) reacts with oxygen (O₂) to form water (H₂O) and releases energy.

The energy released enables hydrogen to act as a fuel. This energy can be used with relatively high efficiency.

Hydrogen can be made by splitting water with electricity (electrolysis) or by splitting fossil fuels or biomass with heat or steam, using “reforming” or “pyrolysis”. Any CO2 can be captured and stored.

Hydrogen can be stored, liquified and transported via pipelines, trucks or ships. And it can be used to make fertiliser, fuel vehicles, heat homes, generate electricity or drive heavy industry.

Hydrogen is usually considered an energy carrier, like electricity, as it must be produced from a primary energy source.

In a hydrogen economy, hydrogen would be used in place of fossil fuels, which currently provide four-fifths of the world’s energy supply and emit the bulk of global greenhouse gas emissions. This could aid climate goals because hydrogen only emits water when burned and can be made without releasing CO2.

What is Blue Hydrogen?

Blue hydrogen is when natural gas is split into hydrogen and CO2 either by Steam Methane Reforming (SMR) or Auto Thermal Reforming (ATR), but the CO2 is captured and then stored. As the greenhouse gasses are captured, this mitigates the environmental impacts on the planet. Simply put, hydrogen is considered blue when the emissions generated from the steam process are captured and stored underground via industrial carbon capture and storage (CSS).

What is brown/black hydrogen?

Brown hydrogen is produced from fossil fuels and currently accounts for around 95 per cent of global production. The oldest way of producing hydrogen is by transforming coal into gas. This gasification process converts fossil-based materials into carbon dioxide, carbon monoxide, and hydrogen. Gasification is achieved at incredible high temperatures without combustion, with a controlled amount of oxygen and/or steam. The carbon monoxide then reacts with water to form carbon dioxide and more hydrogen via a water-gas shift reaction.

Generated via coal gasification syngas and hydrogen can be separated from the other elements using absorbers. It is the result of a highly polluting process since both CO2 and carbon monoxide cannot be reused and are released in the atmosphere.

What is Pink hydrogen?

Hydrogen obtained from electrolysis through nuclear energy is coloured pink.

Hydrogen from Biomass

Hydrogen can also be produced from Biomass via gasification. Depending on the type of biomass but also on the use of carbon capture and storage technologies net carbon emissions can be lower using these technologies

What is green hydrogen?

Green hydrogen is produced using electricity generated from renewables such as solar energy, biomass, electricity (e.g., in the form of solar PV or via wind turbines), instead of fossil fuels. And currently accounts for 1% of overall hydrogen production.

Green hydrogen has the potential to provide clean power for manufacturing, transportation, and more — and its only by-product is water. With green hydrogen, zero carbon emissions are produced. It is in essence the gold standard of hydrogen in the clean energy sector.

Why is Green Hydrogen a Big Deal?

Green hydrogen is one of several potential low-carbon fuels that could take the place of today’s fossil hydrocarbons. Admittedly, hydrogen is far from ideal as a fuel. Its low density makes it hard to store and move around. And its flammability can be a problem.

However, the case for hydrogen is clear; the UK requires a zero-emission fuel that is well understood, has extensive regulations and standards in place, is readily scalable and which can be used across multiple energy vectors. Hydrogen is that fuel. In the next decade alone, research by the Fuel Cells and Hydrogen Joint Undertaking  (FCH JU) indicates that hydrogen could reduce CO2 emissions by 1.7 million to 6.3 million tonnes by 2030, supporting the further deployment of 1,800 MW to 9 GW of wind and 830 MW to 4 GW of solar.

There are major technical and economic hurdles to meeting the UK’s Net Zero goals without hydrogen, particularly for heating and transport applications

The country’s gas grid supplies 3x more energy than the electricity grid today, and the transport sector accounted for over 1/3rd of final energy consumption in 2019. While there is significant renewable power generation potential in the UK, notably from offshore wind, electrifying all heating and transport is likely to be an unsurmountable challenge by 2050. Mass electrification would require and overhaul of the current energy system, and massive scale up of batteries, improved transmission systems and smart metering. Alternatively, hydrogen can be integrated into current energy distribution and end-use systems, and utilize high renewables potential in the UK by converting green electrons into green molecules, that can be widely transported and stored seasonally. Mechanisms to store significant volumes of energy are important for coping with extreme environmental events.

Hydrogen is already widely used by industry, so technical problems to storage and transport are not insurmountable. The opportunity for green hydrogen to be applied across a wide range of sectors means there is a large number of companies looking at harnessing and benefiting from a hydrogen fuel economy. The most significant of these are the oil and gas firms (who are increasingly facing the calls to cut back on fossil fuel production). Big oil’s interest in green hydrogen could be critical in getting the fuel through to commercial viability. Cutting the cost of green hydrogen production will require massive investment and massive scale, something the oil majors are uniquely positioned to provide.

Green Hydrogen Projects & Pathways 

Hydrogen offers a pathway to revitalise manufacturing capabilities in the UK and improve the skill base for workers. The UK was a leader in discovering hydrogen and creating fuel cells, and today has several world leading manufacturers and supply chain businesses that with the right support could become global leaders and engines of economic growth for the UK economy. Using hydrogen, the UK could also become a global Centre of Excellence for hydrogen mobility and transport across land, maritime and aviation sectors.

• A recent report published by Powersystems highlights that hydrogen produced with renewable electricity could compete on costs with fossil fuel alternatives by 2030
• UK regions are taking steps to capture the scale of the hydrogen opportunity. Scotland has pro-actively driven hydrogen investment and support for regional initiatives, including the BIG HIT project in the Orkneys, this multi-partner plan involves the Port of Cromarty Firth together with SHFCA members ScottishPower (ScottishPower has created a new business division dedicated to delivering green hydrogen) and Pale Blue Dot, as well as other partners including Scotch whisky producers Glenmorangie, Whyte and Mackay and Diageo. This new green hydrogen hub in the Highlands will see Scotland leading the way for the integration and deployment of hydrogen technology and decarbonisation of local industry.
• Britain’s largest “green” hydrogen production facility is to be built on the outskirts of Glasgow under plans unveiled by ScottishPower. The energy group has submitted a planning application for a 20 megawatt electrolyser next to the UK’s largest onshore wind farm at Whitelee. The electrolyser will use surplus renewable electricity from the wind farm as well as power from a proposed new 40 megawatt solar farm and a 50 megawatt battery storage project to split water into hydrogen and oxygen.
• ScottishPower, through its recently launched Green Hydrogen Business, has signed an agreement with Global Energy Group at their Port of Nigg site to work together to identify processes and plant that could be powered by green hydrogen.
• The H100 Fife project is designed to be a real life test of the use of hydrogen for heating homes. The idea is to build a facility in Levenmouth, Fife, that will use offshore wind power to generate hydrogen from electrolysers.
• In Wales, the government has recently launched a consultation on developing the hydrogen energy sector in Wales
• Across the country, local businesses in East Anglia are partnering with LEPs and local councils to assess opportunities to leverage the region’s rich offshore wind experience to accelerate the hydrogen transition.
• Announced in February and March 2021, The National Grid currently has two UK Projects underway; FutureGrid, which is trialling hydrogen mixes in off-grid pipelines and Project Union, which is exploring the development of a UK hydrogen ‘backbone’ joining together industrial clusters around the country.
• Equinor and SSE Thermal have unveiled plans to develop a 100% hydrogen-fuelled power station in the UK’s Humber region – and it’s believed to be a world first.
• Powersystems recently reported on the global race to produce hydrogen offshore. Wind generation reached its highest ever level, at 17.2GW on 18 December 2020, while wind power achieved its biggest share of UK electricity production, at 60% on 26 August 2020. Yet occasionally the huge offshore wind farms pump out far more electricity than the UK needs. What if you could use wind energy to make hydrogen?

Is the UK late to the Green Hydrogen party?

Given that on the 8 July 2020, the road map was unveiled by the European Union to promote green hydrogen “as a key priority to achieve the European Green deal and Europe’s clean energy transition.” It is seen as a technology which can bridge the gap between electricity production from renewable energy and the goal of decarbonising a large share of the EU’s energy.

Similar policy developments are underway in the likes of Australia, Canada, Japan, Netherlands, Germany, France, Portugal and the US – the pressure is on ministers to ensure that the UK makes early preparations to become a competitive exporter in the sector.

Presently we can only look at promises made as part of the Ten Point plan for a green industrial revolution announced in November 2020. The UK Government expects that driving the growth of low carbonhydrogen could deliver over GBP 4 billion of private investment in the period up to 2030. The UK Hydrogen strategy was due in March 2021

• The Nuclear Industry Council (NIC) and Nuclear Industry Association (NIA) published a roadmap outlining how the UK could co-locate electrolysis at 12-13GW of nuclear reactors. This commitment could enable the production of 75 TWh of green hydrogen by 2050, the bodies claim
• The UK Hydrogen and Fuel Cell Association, has also published a roadmap this month, detailing a potential trajectory for the sector through to 2050. The roadmap has been backed by business giants including Rolls Royce and ITM Power and explores how the UK could target 80GW of green hydrogen capacity by 2050.
• Powersystems recently shared on what we need to know about hydrogen on climate change and decarbonisation in the UK ahead of COP26 In November 2021

What about hydrogen vehicles?

Alongside oil and gas firms, renewable developers see green hydrogen as an emerging market, with offshore wind leader Ørsted last month trumpeting the first major project to exclusively target the transport sector in Denmark. The eye-catching Toyota Mirai helped fuel early hopes that hydrogen fuel-cell vehicles might vie with electric cars to take over from the internal combustion engine. But as the EV market has boomed, the prospect of hydrogen being a serious contender has faded from view, at least in the passenger vehicle segment. There are roughly 18,000 hydrogen fuel-cell cars in the world today and 31,000 forklifts, compared to more than 373,600 plug-in electrics up to December 2020.That said, pundits still expect hydrogen to play a role in decarbonizing some vehicle segments, with forklifts and heavy-duty trucks among the most likely to benefit.

Powersystems looks at the most ambitious shake-up in the bus sector in a generation. The 5-year new funding investment aims to deliver 4,000 new British-built electric/hydrogen buses to provide clean, quiet, zero-emission travel.

The NHS outlined plans to trial hydrogen-powered ambulances in London later this year. The organisation is sourcing retrofitted hydrogen combustion technology from ULEMCo and pairing it with battery technology from Promech Technologies.

Jaguar Land Rover (JLR) updated its business strategy to fully electrify Jaguar models by 2025, with another ambition to begin testing hydrogen fuel cell electric prototypes in the UK this year.

Toyota, Daimler and BMW are leading a group of 13 companies across the world, investing $10 billion over the next decade in developing hydrogen technology and infrastructure. Government investment also has a role to play.

Bath Area Trams Association (BATA) has announced that it is in detailed discussions with American transportation system manufacturer TIG/m and consultants TenBroeke Engineering for a wire-free hydrogen tram project.

Powersystems reports on Hydrogen or electric vehicles? Why the answer is probably both – The distinct virtues of the two main emerging types of greener transport mean both are likely to flourish, depending on the requirements of different types of user.

In Northern Ireland, the first three hydrogen fuel cell double decker busses entered service on Northern Ireland a further 142 buses to come.

In the North East – Teesside, which produces most of the UK’s current hydrogen, a hydrogen transport Centre of Excellence is being set up and funded by the government, with local leaders having even wider hydrogen economy aspirations.

The Government has announced £30m of investment in EV and hydrogen technology to help launch studies into the creation of a UK lithium supply chain, improvements in battery safety and the re-use of car batteries. The Department for Business, Energy and Industrial Strategy (BEIS) revealed the plans, which include a project to extract lithium from hard rock in Cornwall as well as studies into hydrogen storage and the development of solid-state batteries.

What is Green Hydrogen? In order to combat climate change we need to adopt electrification as a clean and sustainable energy solution.

Video by Scottish Power | Iberdrola

Leading sector for UK job creation

Green hydrogen has the potential to become a leading sector in the UK for job creation and exports.

The UK is currently a global leader in the manufacture and design of hydrogen electrolysis systems, with decades of expertise in hydrogen storage, transportation, and combustion technologies. These include the world’s first PEM electrolysis Gigafactory built by ITM Power, membrane free electrolysers developed by CPH2, and high resiliency electrolysers built for the UK & French nuclear fleets by TP Group.

Other emerging technologies Include Solid Oxide Electrolysers currently under development by CERES Power and HiiROC’s plasma process technology.

 ➡ 74,000 jobs could be created from a commitment to hydrogen by the government and supported by appropriate measures

Supporting these highly specialised businesses and other innovative technology companies require highly skilled workers creating thousands of well-paid manufacturing jobs across the UK will provide a competitive advantage towards an emerging global market demand.

Longer-term private sector vision

These new projects may seem small in comparison to the UK’s broader transport, industrial and heat sectors. But it is clear that there is strong private sector support for longer-term, overarching initiatives that deliver an ongoing transition beyond initial pilots.

• The Green Hydrogen Catapult, for example, has convened seven big businesses under a shared mission to increase the world’s green hydrogen production fifty-fold by 2026 – in a move they claim will halve costs
• Business members of the Catapult include Iberdrola, Ørsted, ACWA Power, CWP Renewables, Envision, Yara, and Snam
• Away from the private sector, non-profit the Rocky Mountain Institute will provide support alongside the UN’s pre-COP26 ‘Race to Zero’

£320 billion could be generated by the Hydrogen industry for the UK economy

• Similarly, trade bodies including WindEurope and SolarPowerEurope received backing from Bill-Gates-backed Breakthrough Energy last year to form the Renewable Hydrogen Coalition
• And, while the Catapult is global and the Coalition covers all of Europe, the UK does play host to its own Hydrogen Taskforce, which includes the likes of Shell and BP

The Hydrogen Taskforce is a coalition of the hydrogen industry’s largest organisations that operate in and innovate across this sector. Its aim is to secure the role of hydrogen in the future energy mix.

The Hydrogen Taskforce is committed to working with Government to secure tangible support to aid the creation of infrastructure and delivery frameworks, helping the government to deliver on its promises to level up the regions and its Net Zero by 2050 commitments.

The Hydrogen Taskforce aims to enable the UK to become a world leader in the international application and service of hydrogen, to deliver excellence throughout the supply chain and create a globally attractive export.

All in all, it would seem that all of the ingredients are ready for the UK to begin dramatically decarbonising and scaling up its hydrogen sector. Over the coming weeks, all eyes will be on BEIS, pushing it to bring the Hydrogen Strategy to the table and understand the actions we now need to take as part of the Rollout plan for a UK hydrogen economy.

News: Powersystems have been awarded the electrical balance of plant works contract for South Kyle Wind Farm.

LV MV HV Electrical Safety Equipment & Arc Flash Protection Clothing | Renewables (Solar & Wind Onshore Offshore) | Battery Storage | Data Centres | Oil & Gas | Manufacturing | Substations Switchgear Transformers | Rail | Hazardous Areas

THORNE & DERRICK

SPECIALIST ELECTRICAL DISTRIBUTOR

Thorne & Derrick distribute the most extensive range of Cable Installation & Electrical Distribution Equipment to the Power Transmission & Distribution industry in the onshore and offshore wind, solar, rail, oil/gas, data centre, battery storage and utility sectors.

We service UK and international clients working on underground cables, overhead lines, substations and electrical construction at 11kV and up to and EHV transmission and distribution voltages.

• Key Products: MV-HV Cable Joints & Terminations, Cable Cleats, Duct Seals, Cable Transits, Underground Cable Protection, Copper Earth Tapes, Cable Jointing Tools, Feeder Pillars, Cable Ducting, Earthing & Lightning Protection, Electrical Safety, Cable Glands, Arc Flash Protection & Fusegear.

• Distributors for: 3M Cold Shrink, 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)

Nexans Product Announcement | Nexans Euromold 480TB Elbow Connectors

Nexans Euromold 480TB

Plug-In Separable Tee Connector MV HV

Dead Break Elbow Connector

During the last three years, Nexans have seen a gradual change from the EUROMOLD® 430 series of connectors to the EUROMOLD® 480-series due to the technical benefits offered by the 480 connectors and the brand new CA0 cable adapter.

The complexity imposed on our manufacturing and kitting facilities of producing both connector types affects their ability to respond to orders in a timely fashion and ultimately affects our “On Time, In Full” metrics.

To improve this situation, Nexans have decided to “End Of Life” the 430 family of Euromold connectors – this change will accelerate the natural evolution of the EUROMOLD® Interface C product mix and will begin with immediate effect.

Nexans Euromold 480TB – Interface C – Tee Connector

Nexans anticipate ceasing production of the Euromold 430 connectors on September 1st 2020, which are now officially replaced by the already available Euromold 480 series. This 480 series also benefits from enhanced delivery time, helping to improve inventory management.

Thorne & Derrick

Nexans Main UK Stockist & Distributor

Contact us for Competitive Prices & Fast Delivery from Stocks for Heat Shrink, Cold Shrink & EPDM Rubber Connectors, Joints & Terminations up to 66kV.

Go to our Price List and contact us with your enquiries.

Heat Shrink Cable Accessories for 11kV Triplex Cables

Thorne & Derrick International are specialist distributors of LV, MV & HV Cable Accessories, Jointing, Substation & Electrical Equipment – servicing UK and global businesses involved in cable installations, jointing, substation, overhead line and electrical construction at LV, 11kV, 33kV, 66kV and EHV.

Stocking & Supplying | Duct Seals | Cable Cleats | Cable Glands | Electrical Safety | Arc Flash Protection | Jointing Tools | Cable Pulling Eqpt | Earthing & Lightning Protection | Feeder Pillars | Cable Joints LV | Joints & Terminations MV HV

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Cable Laying & Pulling – Installing LV-HV Cables Into Trench

Thorne & Derrick | Cable Laying & Pulling Equipment Distributors | LV MV HV

• Uploaded By Chris Dodds – Thorne & Derrick Sales & Marketing Manager

Thorne & Derrick | Specialist Distributors of Cable Pulling Equipment | LV MV HV up to 400kV

Today, in Part 2 of a 2 part series covering Cable Pulling & Laying Equipment, Thorne & Derrick look at the equipment requirements and preparation for cable pulling when installing cables into cable trench. In Part 1, we discussed the procedures and equipment requirements for cable pulling and laying into ducts.

Cable Pulling Equipment & Preparation

Trench

In Part 2 of our series of articles about Cable Laying & Pulling Equipment, we look at the equipment and process requirements for pulling and laying cables in an open trench.

Open trench cable laying is often used as opposed to laying cables directly into cable ducts. This method of laying cables into the ground tends to be used where the cables in use are of a higher voltage (MV HV Cables) and therefore have a greater outside cable diameter.

Press Release | Thorne & Derrick Appointed Approved Stockist for UK Leading Cable Pulling Equipment Manufacturer

The Preparation Of The Cable Trench

Prior to the cable being laid, the cable trench must be dug and prepared properly.

This means that the trench must be of adequate size to allow for the cables and ducting required.

Different cables will require different sized cable trenches – the higher the cable voltage, the bigger the cable and therefore the bigger the cable trench required.

The trench width and depth also depends on the where the cable trench is being dug. For instance, a cable being laid underneath a public footway will not be laid as deep as one under arable land that is to be ploughed.

When a trench is to be dug, it should be sufficient to allow the installer to install the cables and ducting at the correct depth for the cable being used.

It should also allow the cables to be installed within the bending radii specified.

The cable should be installed within the specified pulling dimensions and without damaging the cable sheaths.

When laying a cable into an open trench, there are 8 key components within the typical equipment layout used excluding the trench and the cable.

• Cable Winch – the cable winch is situated at the end of cable trench and is designed to be simple and robust. The winch provides smooth and controlled pulling of the cables through the trench. It is the cable pulling winch that provides the actual pulling of the cable. There is a number of different cable winches available dependant on the type of cable being pulled. Winches vary between telecommunications, power cables and lightweight cabling.

• Winch Wire Rope – the winch wire rope is attached to the cable in order for it to be pulled through.  The wire rope gives extra strength and allows for heavier cables to be pulled through. In addition, the use of the winch wire prevents any potential damage being caused to the cable sheath.

• Swivel Link – the swivel link provides the connection between the cable and the winch wire rope. Each swivel link is designed and used to allow the wire to rotate when being pulled and avoid kinking or twisting. The extra layer of protection provided by the swivel link means damage to the cable sheath is reduced even further.

• Cable Socks – cable socks or stockings are available in either stainless steel or Kevlar but are traditionally constructed of high tensile, galvanised steel wire. Often called cable socks or grips, these are another level of protection between the cable and the cable winch. Fitted to the end of the cable, they are attached to the swivel link and avoid direct contact with the cable. All pilot and telephone, LV, 11kV, 20kV, 33kV, 66kV and 132kV cables should be normally pulled in using a correctly sized cable sock which is securely fixed to the LV-HV cable. More complex cable pulls may require the use of a cable pulling eye attached directly to the cable conductors.

• Straight Cable Rollers – the straight line rollers are, as the name suggests, for use in the straight part of the trench. Varying in size and weight, the straight rollers are selected by the size of the trench they are to be used in. The rollers enable to the cable to be pulled through without making contact with the base of the trench which would damage the cable outer sheath. Full range of cable trench rollers are available – cable pullers should check that cable rollers are in serviceable condition moving easily on their spindle and with rolling surfaces free from damage. Leading cable rollers are usually placed at the cable trench side at the cable pulling end with slide rollers on bends and “hoop” type rollers along straight cable section runs. Contractors can use inverted skid plates shall be used to prevent the cable or pulling wire rising into obstructions. At cable duct entries a bell mouth should be attached at end end with cable rollers positioned to give central access into the bell mouth.

• Corner Rollers – Angled corner rollers are to be used within the trench where there is a bend in the trench. Typically these incorporate a vertical and horizontal roller to allow for the pulling of the cable. Providing the same level or protection as the straight rollers they are both used alongside each other.

• Draw Off Roller – the draw off roller is the first piece of equipment the cable will come into contact with. When the cable is pulled through the open trench, the draw off roller leads the cable straight from the drum into the trench. The cable is then pulled through the trench with the draw roller acting as an initial guide for the cable.

• Cable Drum Trailer – the cable drum trailer is used to transport the cable drum. In addition the trailer is also used to stabilise the cable drum whilst the cable is being pulled through the trench.

Duct rods provide a strong, lightweight, labour saving solution for installing cables into ducts or pipes with or without draw ropes.

Cable Protection

Installation Of Cable Trench Covers & Cable Protection Tiles

All cables and ducts laid into cable trrench should be over-protected by a cable protection cover or tape depending upon the highest voltage cable to be protected within the cable duct – typically in the UK the following cable protection tapes and covers are used for LV, MV and HV cables.

Marker tile tapes or Stokbord covers are installed over the cable in the appropriate trench drawings – usually there is no requirement to install either above approved cable ducts installed using trenchless techniques (i.e. directional drill) but either may be installed if it is deemed that additional MV-HV cable protection is required. When Tile Tape is used it should be cut cleanly and installed so that the medium/high voltage cable is fully covered along the whole length of the installed cable duct.

• LV Service Cable 40m x 200mm x 2.5mm Tile Tape
• LV Mains Cable 40m x 200mm x 2.5mm Tile Tape
• 11kV MV Cables 40m x 200mm x 2.5mm Tile Tape
• 22kV MV Cables 40m x 200mm x 2.5mm Tile Tape
• 33kV MV Cables 1000mm x 244mm x 9mm Stokbord
• 66kV MV Cables 1000mm x 244mm x 9mm Stokbord
• 132kV MV Cables 1000mm x 244mm x 9mm Stokbord

More info  ➡ Tile Tape | Stokbord

Underground Cable Protection

Duct Seals

Where electricity, pilot and telephone cables are installed into electricity cable ducts the utility engineering standard would normally recommend all cable ducts entering substations and buildings to be duct sealed to prevent the ingress of water and gas – this also applies to 33kV, 66kV and 132kV high voltage substation cables where cable transits are required.

Thorne & Derrick distribute an extensive range of Duct Sealing & Cable Transit Systems to protect utility assets and provide flood protection to substations from water entry via unsealed cable ducts and building penetrations.

Cable Pulling & Cable Laying Equipment Suppliers & Distributors

Thorne & Derrick International distribute the most extensive range of Cable Pulling & Cable Laying Equipment to enable the installation of low, medium and high voltage power cables into underground trench or duct – products also supplied for fibre optic blowing, subsea trenching, offshore umbilical installations and pulling armoured cables onto cable tray.

Cable Blowers | Cable Lubricant | Duct Rods | Cable Socks | Cable Jacks | Cable Rollers | Cable Protection Covers MV HV | Cable Joints MV HV | Duct Sealing

Cable Laying & Pulling – Installing LV-HV Cables Into Duct

Thorne & Derrick | Cable Laying & Pulling Equipment Distributors | LV MV HV

• Uploaded By Chris Dodds – Thorne & Derrick Sales & Marketing Manager

Today, in Part 1 of a 2 part series covering Cable Pulling & Laying Equipment, Thorne & Derrick look at the equipment requirements and preparation for cable pulling when installing cables into ducts. In Part 2, we discuss the requirements for cable pulling and laying into cable trench.

Cable Pulling Equipment

& Preparation Duct

Cables installed into cable ducts are typically used on projects where the cable duct is buried deep into the ground, sometimes up to 1200mm depth – this includes LV Low Voltage, MV Medium Voltage or HV High Voltage ducted power cables.

Guidelines for the minimum depths for the installation of underground cables are stipulated by the DNO depending on whether cables are laid direct into cable trench or installed in suitable cable ducts depending on ground location types:

• Footways, Grass Verges Or Private Property
• Carriageways (including Road Crossings)
• Normal Agricultural Land

Arrangement of the cable trench will depend upon the cable voltages typically LV, 11kV, 20kV, 33kV, 66kV and 132kV.

LV cables could include Service Cables (Single Phase Concentric | 3 Phase Concentric | Split Concentric) and Mains Cables (3 Phase Waveform).

Auxiliary multi-core and multi-pair cables are usually laid at similar depths to the power cable with which they are associated. Pilot and telephone cables installed alongside 11kV and 33kV cable circuits shall normally be installed at LV cable minimum depths of cover.

So for instance, the installation of 33kV power cables into class 1 cable duct is usually covered in the local DNO’s Approved Equipment Register, Guidelines or Excavation and Cable Installation Manual. Additionally, engineering construction standards provided by UK DNO’s will cover the installation of new LV, 11kV, 20kV, 33kV, 66kV and 132kV cables, plus associated pilot and telephone cables.

For the protection of LV MV HV cables Thorne & Derrick distribute a complete range of underground protective cable ducting

Prior To Cable Pulling

Due to the nature of the cables that are often installed in these applications, there are a number of checks that must be carried out prior to beginning the cable pull:

• The cable duct lines must be checked for any obstructions and anything that is found must be removed. This is often done with the use of duct brushes or ‘foam pigs’ which are pulled through the duct.
• It is essential to ensure that the cable duct is of adequate size to accommodate the cable due to be pulled. This is done by pulling through a 3 metre length of cable through the duct which is subsequently checked for damage prior to the full cable being installed.
• If, during these checks, the 3 metre length of cable has any damage greater than half the depth of the outer sheath the duct route must be repaired before the full length cable is pulled through. This protects the integrity of the final cable.

Press Release | Thorne & Derrick Appointed Approved Stockist for UK Leading Cable Pulling Equipment Manufacturer

There are a number of items of cable pulling equipment to be used when installing cables into duct lines. Cables can vary in size and voltage, however the same process and equipment is used. When installing cables, there is typically up to 9 different pieces of equipment used.

• Cable Winch – the cable winch is used for physically pulling the cable through the duct, reducing the need for manpower and increasing productivity. Electrically powered, the cable winch is much safer and reliable than manually pulling cables through.

• Rope Guide Roller – the rope guide roller is exactly as the name suggests – a roller to guide the draw ropes or cabling ropes that are coming out of the jointboxes or manhole. This is to reduce the damage and strain put on the ropes therefore prolonging the lifespan of the equipment used. The rope guide roller is made from an aluminium roller mounted onto a frame that has been plated with zinc.

• Cable Bellmouth – the duct bellmouth is used as a means of providing additional protection to the cable when it is being pulled through the duct. The rollers on the bellmouth ensure that the cable can be pulled in any required direction without any damage being caused. The bellmouth is located at the exit of the cable duct through which the cable is being pulled.

• Cable Drum Trailer Or Cable Jacks – the cable drum trailers and cable jacks are used as a means of storing and transporting cable drums. Cable drums are large wooden wheels which are used to hold cable. Cable drum trailers make the transportation of extremely heavy cable drums easier, safer and more reliable. Often equipped with braking and road lighting, the cable drum trailers are attached to the back of an appropriate vehicle such as a tractor to assist in the transportation of cables. Cable jacks are used as a means of supporting and stabilising the cable drums. Cable drums are located at the edge of the manhole cover or opening when installing cable into underground ducts for the cable to be easily rolled off.

• Swivel Link – the swivel link is zinc plated, solid steel link that is attached to the winch rope. This link can, as the name suggests, swivel a full 360° allowing the rope to be pulled through without any twists occurring.

• Conduit Rod – the conduit rod is fed through the manhole cover opening and is used to install draw or winch ropes. The rod is manually fed through the underground duct and is extremely easy to handle. The conduit rod comes with a range of accessories available such as flexible guide tips, end connectors and rod repair kits.

• Cable Socks – cable socks or stockings can also be called cable socks or grips. These cable socks are used to support the pulling of cables through a duct. Attached to the end of a cable prior to pulling, the cable stocking is an efficient method of support when pulling the cable

• Manhole Roller – the manhole roller is specifically designed to be placed at the entrance of the manhole to assist in the guiding of the cable. Not only does the roller make the cable installation easier, it also protects the cable from being scraped on the edge of the manhole. The manhole roller is constructed of a steel frame and aluminium rollers. Complete range of cable rollers are available also for cable trench applications.

• Cable Lubricant – cable lubricant is applied to the outside of the cables when being pulled through the duct. The lubricant assists in the pulling process by removing friction between the cable and the rollers. This not only speeds up the process but also prevents snagging and therefore damage to the cable.

Pictured: Cable Laying & Pulling Equipment – Ducts

Duct rods provide a strong, lightweight, labour saving solution for installing cables into ducts or pipes with or without draw ropes.

Cable Protection

All cables and ducts should be over-protected by a cable protection cover or tape depending upon the highest voltage cable to be protected within the cable duct – typically in the UK the following cable protection tapes and covers are used for LV, MV and HV cables:

• LV Service Cable 40m x 200mm x 2.5mm Tile Tape
• LV Mains Cable 40m x 200mm x 2.5mm Tile Tape
• 11kV MV Cables 40m x 200mm x 2.5mm Tile Tape
• 22kV MV Cables 40m x 200mm x 2.5mm Tile Tape
• 33kV MV Cables 1000mm x 244mm x 9mm Stokbord
• 66kV MV Cables 1000mm x 244mm x 9mm Stokbord
• 132kV MV Cables 1000mm x 244mm x 9mm Stokbord

More info  ➡ Tile Tape | Stokbord

Underground Cable Protection

Duct Seals

Where electricity, pilot and telephone cables are installed into electricity cable ducts the utility engineering standard would normally recommend all cable ducts entering substations and buildings to be duct sealed to prevent the ingress of water and gas – this also applies to 33kV, 66kV and 132kV high voltage substation cables where cable transits are required.

Thorne & Derrick distribute an extensive range of Duct Sealing & Cable Transit Systems to protect utility assets and provide flood protection to substations from water entry via unsealed cable ducts and building penetrations.

Cable Pulling & Cable Laying Equipment Suppliers & Distributors

Thorne & Derrick International distribute the most extensive range of Cable Pulling & Cable Laying Equipment to enable the installation of low, medium and high voltage power cables into underground trench or duct – products also supplied for fibre optic blowing, subsea trenching, offshore umbilical installations and pulling armoured cables onto cable tray.

Cable Blowers | Cable Lubricant | Duct Rods | Cable Socks | Cable Jacks | Cable Rollers | Cable Protection Covers MV HV | Cable Joints MV HV | Duct Sealing

11kV Sweated Ferrule With Crepe Paper Insulation & Lead Sleeve

Image Courtesy of: Dean Wilson (Owner Director at D.C. Jointing Ltd).

D.C. Jointing Ltd are Specialist Electrical Cable Jointers – a team of 15 skilled staff in all aspects of offshore and onshore cable jointing up to 132kV.

D.C. Jointing Ltd secured a prestigious 3 year Medium & High Voltage Cabling 11kV-66kV contract with WPD, a UK DNO, for the installation of 3M Cold Shrink Joints and Terminations – the awarded contract exemplifies the impressive reputation for quality workmanship provided by DCJ to UK DNO’s, IDNO’s and private networks.

The HV cable jointing success for D.C. Jointing demonstrates their versatile competency at jointing modern technology polymeric cables while also retaining “old-school” 11kV jointing expertise as evidenced in the featured photograph.

Location : Wimbledon, London UK

Date : 2003

11kV Sweated Ferrule With Crepe Paper Insulation & Lead Sleeve

Further Reading

• Pfisterer Connex Size 4 Terminations Connecting 66kV Gas Cable
• Transition Joint EHV – Oil To XLPE NKT Cable Joint
• Pfisterer Inner Cone Plugs Size 5s Connecting & Terminating 132kV EHV Cable

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