Blog

Jointers Tools | 66kV Cable Preparation Tools | Some Recommendations

• uploaded by Chris Dodds- Thorne & Derrick Sales & Marketing Manager

66kV XLPE Cables

Jointer Training & Tools

Thorne & Derrick are Specialist Stockists & Distributors of cable joints and terminations for 66kV power cables – this includes the provision of 66kV Jointer Training using Nexans Power Accessories UK facility. To support the installation of 66kV joints, terminations and connectors we stock and distribute a full range of Jointers Tools to enable the preparation of all critical stages of the cable stripping process – this includes removal of cable sheath, insulation XLPE, lead sheath and bonded semicon screens.

Manufacturers of cable preparation tools provide competing options in the design, functionality and application of their cable tools – it is usually a mixture of cable jointers personal preference and client approval which informs the tool selection process, nevertheless the following information provides guidance and some recommendations for tools to use when stripping 66kV cables.

Can I Use Standard 33kV Tool Sets To Prepare 66kV Cables?

Yes, but…..

Although 66kV is classed as high voltage, due to the construction diameters of 66kV cables often 33kV medium voltage cable preparation tools can be used – for the Nexans Jointers Training Courses the standard MV cable tools are compatible with the training cable up to 300sqmm at 66kV.

However, for future 66kV projects it would be necessary for the jointer to upgrade their tool set to enable the preparation of larger diameter cables above 300sqmm conductors.

Naturally, when using medium voltage category tooling there will be a requirement for the cable jointer to undertake additional glassing of the XLPE insulation to achieve the required chamfer prior to installing the MV HV joint, termination or connector.

Cable Jointing Tools | 66kV IAC Inter-Array Cables

US02 MAX | here the Jointing Tool is shown here in use on the high voltage cable preparation of 66kV/72kV 1200sqmm single cable XLPE insulation with bonded semicon screen – minimal polishing and chamfering required with a clean and precise transition.

Cable Sheath & Lead Sheath Removal

Typically, Alroc cable sheath stripping pliers, PG types, would be used for removal of the outer cable sheath/jacket depending on the outside diameter of the cables to be jointed and terminated – these tools effectively strip the PE (polyethylene) sheath from medium/high voltage power cables. The lead sheath (Pb) is generally removed using jointers knives – the lead sheath should be carefully scored and then peeled from the cable.

Cable Insulation & Bonded Screen Removal

Note for larger diameter 66kV power cables, 300sqmm+, the standard 33kV cable preparation tools will be unsuitable – for removal of XLPE insulation with bonded screens we would recommend Alroc CAMF4/40-90 tool.

The 66kV Training Course utilises single core 300sqmm cables with a 48.1mm diameter over the bonded semicon screen – depending of jointers preference any semicon shaving tool from reputable manufacturers including Alroc, Ripley or Boddingtons could be used.

Similarly, any XLPE cable insulation removal tool suitable for 46.1mm primary insulation diameter cable could be used.

The preferred bonded screen stripping tool is used to leave various lengths of black insulation screen from the outer sheath cut and the measurement varies depending on the type of joint, termination or connector.

Chamfer | Groove | Shave – Alroc CAMF4/40-90-BBCF Multi-function 66kV Cable Tool

Chamfer & Polish

Aluminium Oxide

For the chamfer we would recommend the Alroc GRI tool along with conventional glass to achieve a smooth finish to the XLPE insulation – the cable insulation would then be polished using aluminium oxide abrasive strips, usually 180/240 grit and 400 grit.

The XLPE insulation must be polished smooth with an appropriate aluminium oxide grit paper until the XLPE surface is smooth and wrinkle-free. To finish this process, reverse the paper and “buff-up” with the smooth side.

Alroc GRI Tool

Cable Sanding Machines & Tools for MV HV Cables up to 130mm Diameter

Reducing Repetitive Strain & Improving Cable Preparation Processes

Typically 66kV Cable Specification

➡ The following cable specification is based on 66kV XLPE Insulated Lead Sheath Single Core 300sqmm cable to IEC 60840:

Cable oversheath marking by embossing in two lines as follows:

• CABLEL 0317 2016 09* ELECTRIC CABLE 66000 VOLTS IEC 60840 1×300 CU ‘ref number’**
  *Year and month of manufacture
  ** Insulation Core Lot number (8 digits by embossing and 2 last digits by indenting)
• By ink – meter marking at on metre intervals

66kV Cable Structure

Cable Manufacturer Hellenic Cables S.A.

1. Conductor:
   Annealed bare copper round strand compacted class 2 BS EN / IEC 60228 of nominal cross-section equal to 300sqmm longitudinally waterblocked by waterblocking yarns and/or waterblocking tapes and/or waterblocking powder between conductor inner strands (approx diameter over 20.4mm)
2. Semiconductive tape applied helically with overlap
3. Conductor non-metallic extruded screen:
   Extruded semiconducting compound of 1.0mm nominal thickness (0.60mm minimum at any point thickness)
4. Insulation
   XLPE super-clean according to IEC 60840 of 12.0mm nominal thickness (minimum average thickness of 11.0mm, minimum at point thickness 10.80mm – approx diameter over insulation 46.1mm)
5. Core non-metallic extruded screen:
   Extruded semiconducting compound bonded to insulation of 1.0mm nominal thickness (0.60mm at any point of thickness)
6. Semiconductive waterblocking tape applied helically with overlap
7. Metallic sheath:
   Lead alloy type PK021S or other suitable alloy type according to EN 50307 of 2.0mm nominal thickness
8. Cable sheath
   MDPE type ST& according to IEC 60840 of 2.7mm nominal thickness.
   Sheath colour: Black
9. Extruded semiconducting compound serving as electrode for the DC voltage test of the oversheath

Pfisterer CONNEX | 3M Cold Shrink | Nexans Euromold | Nexans Slip-on | Heat Shrink Cable Terminations – stocked and distributed by Thorne & Derrick

Cable Innovation Tools & Accessories for Low & High Voltage Power Systems

THORNE & DERRICK are Specialist Distributors of LV HV Cable Jointing, Earthing, Substation & Electrical Eqpt up to 66kV – this includes the most extensive range of Ex Stock Innovation Tooling to facilitate safe and reliable preparation, termination and installation of cables.

Feeder Pillars From Lucy Zodion – LV Electrical Power Distribution

• uploaded by Chris Dodds - Thorne & Derrick Sales & Marketing Manager

Thorne & Derrick with Lucy Zodion supply both standard and bespoke feeder pillars in a selection of materials, paint finishes and dimensions to meet all indoor and exterior power distribution, control and lighting requirements up to 1,000 volts with IP65 door seal – this includes LV substation and network pillars with DNO supply cut-outs for utility applications.

Specialist EV Charging Pillars can be produced to customer specification for electrical vehicle charging points and applications.

The wide range of Lucy Zodion pillars from the Fortress range include mini, slimline, single-door and double-door types available in galvanised mild and stainless steel with cast iron option for heritage applications.

➡ Contact us to discuss how T&D and Lucy Zodion can provide innovative custom design solutions and ex stock delivery of standard feeder pillars to your project.

The series of feeder pillar images below shows a behind the scenes look into the manufacturing of bespoke pre-wired pillars.

Pre-Wired Feeder Pillars

Design Process

Lucy Zodion CAD driven design procedure guarantees a well engineered product from enquiry to delivery. The dedicated design team will work with a client not only from the start, but through all the processes to the finished product. Lucy Zodion have designed and produced some very exciting innovative products over the last few years, and T&D offer customers the latest cutting edge technology with highly skilled engineers and designers.

110V, 230V and 400V a.c. variant feeder pillars are available in both above ground and in-ground locations equipped with earth leakage and overload protection devices to ensure high operator safety levels. Compact retractable power pillars with telescopic design to mount flush to the floor surface provide discreet electrical power for typical applications including markets, shopping centres and airports.

1.

2.

Pictures 1 and 2 show the intricate engineering detail that goes into the design of a bespoke pre-wired feeder pillar. Although you can tell that the feeder pillar is only partially complete you can see the attention to detail and pride that Lucy Zodion input into all of their feeder pillars.

After manufacture the feeder pillars are thoroughly tested within the purpose built LV test area at Lucy Zodion to ensure they meet BS7671 and meet the requirements of BSEN 60439. The test procedures and quality assurance inspections driven by the ISO 9001 accreditation ensure all products including pillars perform correctly and safely.

3.

4.

Pictures 3 and 4 show how painting or powder coating the feeder pillars helps them to blend into their environmental surroundings to suit the needs of the client.

5.

6.

Pictures 5 and 6 shows a stainless steel feeder pillar that is ideal for high saline, coastal and marine atmospheres to provide power for temporary events – the pillar is manufactured in non-corrosive 316 grade stainless steel for hostile climatic conditions.

7.

8.

9.

10.

11.

Pictures 7 to 11 show that careful consideration is taken when designing the feeder pillar to ensure that the installer, end user and maintenance team are satisfied with the completed installation. In this case an external override switch which is provided to avoid opening the feeder pillar unnecessarily. Please note the space below the isolator on the right for the Distribution Network Operator (DNO).

12.

Picture 12 shows how feeder pillars can be sympathetically painted to suit their surroundings. Lucy Zodion can paint feeder pillars to any RAL or BS. This specific pillar has been modified to provide temporary supplies for regular events that take place in recreational areas including parks, open spaces, playgrounds, nature reserves, wildlife sites and sports pitches.

Fortress Feeder Pillars From Lucy Zodion : Galvanised & Stainless Steel 20+ Sizes

Feeder Pillars

T&D distribute the complete range of Lucy Zodion pillars for low voltage power distribution to the building services, rail, construction, utilities, oil and gas, retail and leisure, ports, airports and heavy industries – GRP feeder pillars, cast iron, galvanised and stainless steel types customised to your application:

• Pre-Wired Power Distribution Panels (Outdoor IP65 & Underground Retractable)
• Substation Power, Cable Distribution & LV Interconnection Panels (Onshore Wind)
• DNO Single & 3 Phase Network Pillars (25A-800A)
• Network Rail & Electrification – Station & Trackside Pillars (incl. London Underground)
• Low Voltage Connections – New Housing & Commercial Development Pillars (LV)
• Defence Estates MoD – Load Shedding Fuse Pillars
• Lighting Feeder Pillars – Street, Road, Flood, Sports Stadium & Car Parks
• BT Telecommunications & Interface Pillars
• Environment Agency – Rivers, Coastal & Waterways
• Cast Iron Electrical Distribution Pillars – National Heritage & Historic Buildings
• Also: Street Lighting Cut Outs

➡ For further information about how Lucy Zodion provide control and power distribution products for street lighting applications, please review the Lucy Titan (Cut-outs) and Lucy Trojan (Isolators) ranges of products.

Read our Blog with Lucy Zodion: Cut-Outs & Isolators – What’s the Difference?

Thorne & Derrick – Stickists & Suppliers of MV HV Joints, Terminations & Connectors

T&D distribute the most extensive range of LV, MV & HV Cable Jointing, Terminating, Pulling & Installation Equipment – we service UK and international clients working on underground cables, overhead lines, substations and electrical construction at LV, 11kV, 33kV and EHV transmission and distribution voltages.

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

• 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

T&D, CATU Electrical Safety & Arc Flash Protection Specialists for SAP’s, Linesmen, Jointers & Electrical Engineers – Largest UK Stockist

Sonel MPU-1 | Leakage Current Alarm Signaller for LV MV HV Networks

Sonel MPU-1

• uploaded by Chris Dodds - Thorne & Derrick Sales & Marketing Manager

Overhead Line Safety Monitoring

Sonel MPU-1 leakage current alarm signaller is designed to be installed to measure AC leakage current in low LV and medium voltage MV power networks.

Repairs, renovation, reconstruction, and modernisation of medium voltage overhead live lines always involves the potential risk and danger of breakdown, accident, arc flash or electric shock to employees who are doing the work.

These risks can be minimised through the use of appropriate personal protective equipment such as insulating mats, electrical insulating gloves, dielectric boots and non-flammable clothing.However all these safety measures will not detect increasing current flowing through the pole grounding, that if too high of a level can be the first warning of danger

Sonel MPU-1

The Sonel MPU-1 is designed to make measurements which can define the medium voltage power network’s safety condition for leakage current.

The device enables a limit to be set for a maximum safe value of flowing leakage current and for values above this limit visual and sound alarm is activated. The preset minimum current level where the loud audible alarm with a warning light signaling is switched is 1 A, in accordance with the PTPiREE guidelines.

♦  PTPiREE Polish Power Transmission and Distribution Association was established on 29 August 1990. PTPiREE is an association of the Distribution Network Operators (Enea Operator, Energa – Operator, PGE Dystrybucja, Tauron Dystrybucja, innogy Stoen Operator and PKP Energetyka) and the Transmission Network Operator (PSE). It works for the transformation of the Polish power industry, aiming to improve the operational efficiency of the LV MV HV power network, as well as the quality of services and customer service. Its operation includes consulting, training and publishing.

Contact us NOW to request FREE DEMO

Using the leakage current alarm signaller it is also possible to manually set a different minimum alarm in the range from 0.5 to 9.9A (with the possibility of an increased alarm range at the time of manufacture for individual needs).

MPU-1 is dust and water proof to IP-67 in accordance with EN 60529 and can operate in temperatures from -10° to +50° C. The device is supplied in a hard carrying case for easy transport also with additional accessories to the workplace and protects against dirt or accidental damage.

Sonel MPU-1

Sonel MPU-1

Features

• Constant monitoring of current flowing on earthing
• Measurement with the use of single clamp or two clamps simultaneously. In the case of using two clamps, current value is summed up, which allows for checking twin pylons (rotational), with independent clamp for each component pylon
• Work mode LED indicator
• Visual and sound alarm (built in speaker) in the case of a higher value of leakage current than the defined limit (factory default set to 1A)
• No DC current measurement
• Measurement with flexible clamps (Rogowski coil) – Sonel F series
• Measurement in 50 Hz or 60 Hz frequency low and medium voltage networks
• Auto ranging
• Battery level monitoring
• Ergonomic handling
• MPU-1 for operation requires F1, F-2 or F-3 clamp (additional accessories)

The leakage current alarm signaller can be connected to measure a power network or device according to the pictures below:

Pic 1 Device Working with Single Clamp	Pic 2 Device Working with Two Clamps	Pic 3 Work in medium voltage mode – alarm limit value and battery level can be seen on the screen	Pic 4 Work in low voltage mode – value of current measured with the clamp and battery level can be seen on the screen	Pic 5 Inputs in MPU-1 Signal

Leakage current measurement with clamp

Sonel MPU-1 Leakage Current Alarm Signaller

Technical Specification

Standard accessories:

• Carrying case L5- Sonel WAWALL5
• Power supply adaptor Z11- Sonel WAZASZ11
• Cable for charger – Sonel WAPRZLAD230
• Mounting strap – Sonel WAPOZOPAKPL

Additional accessories:

• F-1 clamp (ø 38 cm) – Sonel WACEGF1OKR
• F-2 clamp (ø 25 cm) – Sonel WACEGF2OKR
• F-3 clamp (ø 12 cm) – Sonel WACEGF3OKR
• Lead for battery charging from socket of car lighter (12V) – Sonel WAPRZLAD1212V2

Should you require any further information about Sonel MPU-1, The Leakage Current Alarm Signaller, for LV MV HV Networks, please do not hesitate to contact Thorne & Derrick.

Overhead Line Equipment

Thorne & Derrick hold an up to date library of product approvals across the power transmission and distribution sectors including all UK DNO’s drawing on information from the DNO G81 documents, National Grid Asset Codes and Network Rail PADS approvals – we distribute substation and overhead line power grid infrastructure products for 11kV/33kV/66kV/132kV networks. This complemented by the most extensive range of Joints, Terminations & Connectors for the installation of medium/high voltage cable networks into substation switchgear, transformers and overhead lines.

• Transmission, Substation & Distribution Insulators
• Insulators – Tension | Suspension | Post Types 11kV 33kV 132kV
• Trident Package – Conductor Clamps | Insulators | Accessories
• Conductor & Insulator Fittings – Helical Fittings | Wedge Clamps | Suspension Shoes
• 66kV Cable Accessories | Cable Joints | Cable Terminations
• 132kV Cable Accessories | Cable Joints | Cable Terminations
• Portable Earthing Kits, Leads & Equipment
• Arc Flash Clothing & Protection

UKPN Waveform Cable 3 Core 95sqmm-185sqmm-300sqmm LV

UK DNO: UKPN UK Power Networks

Approved Manufacturer: Nexans Cables

Voltage: Low Voltage Cables 0.6/1kV

Cable Type: Waveform Cable (3 Phase XLPE Insulation – Solid Aluminium Conductor)

Cable Designation: AL/XLPE/CWS/PVC 3 Core

Solid Aluminium Conductors: 95sqmm, 185sqmm, 300sqmm

➡ Download UKPN Waveform Cable 3 Core 95sqmm-185sqmm-300sqmm LV

Waveform Cable Construction

1 Solid Aluminium Conductor

2 XLPE Insulation

3 Binding Yarns or Tape

4 Rubber Bedding

5 Copper Wires

6 PVC Sheath

See complete range of waveform cables.

Waveform Cables

Stock | Supply | Service | Cables | Joints | Terminations | Connectors 33kV

JOINT ♦ TERMINATE ♦ CONNECT ♦ GLAND ♦ CLEAT ♦ CRIMP ♦ DUCT ♦ SEAL ♦ REPAIR ♦ CABLE ♦ TOOLS

UKPN 33kV XLPE Aluminium Wire Screen Single Core 185sqmm-300sqmm IEC 60502-2

UK DNO: UKPN UK Power Networks

Approved Manufacturer: Nexans Cables

Voltage: Medium Voltage Cables

Cable Type: 33kV Power Distribution

Cable Designation: AL(WB) XLPE/AWS/WBT/PE 1 CORE 19/33KV

Solid Aluminium Conductors: 185sqmm, 300sqmm

➡ Download UKPN 33kV XLPE AWS Single Core 185sqmm-300sqmm IEC 60502-2

See our complete range of Cables MV HV.

33kV Cable Construction

1 Aluminium Conductor With Water Blocking Protection

2 Semiconducting Screen

3 XLPE Insulation

4 Semiconducting Screen

5 Semiconducting / Waterblocking Tape

6 Aluminium Wires Screen

7 Waterblocking Tape

8 PE Outer Sheath

9 Extruded Semiconducting Layer

Stock | Supply | Service | Cables | Joints | Terminations | Connectors 33kV

JOINT ♦ TERMINATE ♦ CONNECT ♦ GLAND ♦ CLEAT ♦ CRIMP ♦ DUCT ♦ SEAL ♦ REPAIR ♦ CABLE ♦ TOOLS