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Medium Voltage Cable Field Testing Program | UL Solutions

Medium Voltage Cable Field Testing Program

UL Solutions | Advance Power Grid Safety

UL Solutions, a global leader in applied safety science, announced its Medium Voltage Cable Field Testing Program today to help wire and cable manufacturers meet global market requirements and advance cable system safety.

The new service from UL Solutions helps empower cable manufacturers and utility providers to avoid costly cable system failures. The Medium Voltage Cable Field Testing Program helps cable manufacturers and owners proactively address potential issues by evaluating the performance of cable systems and identifying installation or service aging defects.

The program includes condition assessments and commissioning tests, such as withstand and monitored withstand tests, partial discharge diagnosis, dielectric loss measurement and neutral corrosion evaluation.

Medium voltage cable system failures can significantly impact utility providers and the businesses they serve, from loss of revenue and production during an unplanned outage to additional damage caused by the failure. A variety of factors — including cables, connectors, joints and terminations — can compromise the quality of the cable system, potentially shortening the anticipated life and degrading reliability.

Nexans JTS | HV Joints | 11kV 33kV | Heat Shrink Cable Joints for High Voltage Power Cables – the single one-piece cable joint features Triple Layer Tube (Stress Control | Insulation | Conductive)

“UL Solutions’ capabilities and expertise in the energy and utilities sector help customers develop cables and cable accessories with a focus on safety, quality and performance,” said Paul Ngai, vice president and general manager of the Engineered Materials group at UL Solutions. “Our new testing program for medium voltage cables empowers customers to develop innovative cable systems and enhance power grids that are essential in our daily lives.”

The program is the latest offering in UL Solutions’ more than 30 years of experience in medium voltage cable systems, including cable and cable accessory design and manufacturing, new material research and development, cable system aging and failure mechanisms, and testing and diagnostic technologies.

UL Solutions energy and utilities experts participate in developing testing standards while serving as leaders on international technical committees dedicated to medium voltage cable systems.

About UL Solutions

A global leader in applied safety science, UL Solutions transforms safety, security and sustainability challenges into opportunities for customers in more than 100 countries. UL Solutions delivers testing, inspection and certification services, together with software products and advisory offerings, that support our customers’ product innovation and business growth.

The UL Certification Marks serve as a recognized symbol of trust in our customers’ products and reflect an unwavering commitment to advancing our safety mission. We help our customers innovate, launch new products and services, navigate global markets and complex supply chains, and grow sustainably and responsibly into the future. Our science is your advantage.

Hexagonal Crimping For Aluminium & Copper Cable Conductors

For aluminium and copper: hexagonal crimping according to DIN 48083 Part 4

Thorne & Derrick are leading suppliers of cable lugs and associated crimping tools from Klauke for Low, Medium & High Voltage Cables – this includes battery operated crimping tools with hexagonal crimping dies.

Hexagonal crimping is one of the more traditional crimping profiles. It is most frequently used in practice, as it is suitable for both copper and aluminium conductors. With this crimping profile, the single strands are deformed over a large horizontal area.

Hexagonal crimping is typically used for copper compression cable lugs according to DIN 46235 and aluminium compression cable lugs according to DIN 46329. This crimping profile can also be used to crimp solid cables with full tension.

Hexagonal crimps can be found in panel building industries as a manufacturer specific crimp and also as a DIN standard lug crimp for example in utilities (aluminium and copper conductors including 11kV and 33kV power cables).

The major benefit of hexagonal crimping relates to the central application of force, which is applied in equal measure from all sides and has an effect over a large contact surface. The individual stranded wires of the conductors are deformed as a whole in equal measure without being damaged.

The result is good mechanical stability and a secure connection.

Due to the consistent crimping involved, hexagonal cable crimping is also suitable for the medium and high-voltage range.

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manufacturer-dependent hexagonal crimping

In addition to standardised hexagonal crimping, manufacturer-dependent hexagonal crimping is also allowed in the copper sector for conductor classes according to DIN 60228, Class 2. This crimping has been specifically developed for tubular cable lugs. As a result, it is essential you always revert to a manufacturer-specific system.

Distributed from Stock | Approved Supplier | UK & Export Sales

Freedom of Choice: Wide or Narrow Cable Crimping

Wide and narrow crimping is available depending on the tool selected. This will primarily depend on the cross-section and power of the tool in question. It is possible, for example, to use narrow crimping to crimp a 300 mm² tubular cable lug with a six-tonne battery-powered hydraulic tool. However, this will require several crimpings, something that will of course involve additional time. Therefore, you must take care that you make the right selection when purchasing a tool and ensure it is matched to the range of applications.

Compression cable lugs according to DIN, Cu

• For round conductors, e.g. according to DIN EN 60228 Cl. 1, 2, 5 and 6
• For non-tension copper cables, e.g. according to DIN 48201-1
• For pre-rounded multi-stranded sector shaped conductors
• With code number for clear tool assignment
• Cable lugs to DIN 46235

Klauke Compression cable lugs according to DIN, Copper

Compression cable lugs according to DIN, Al

• For non-tension connections of aluminium conductors to DIN EN 60228 and aluminium cables to DIN EN 50182
• For pre-rounded sector shaped conductors
• Cable lugs to DIN 46329
• Filled with contact grease for optimum transfer resistance

Klauke Compression cable lugs according to DIN, Aluminium

CRIMPING CABLES, LUGS & TOOLS

Thorne & Derrick distribute Cable Lugs & Cable Connectors to terminate, splice and joint LV MV HV cables – this includes copper, aluminium and bi-metallic connectors and a complete range of crimping tools for specific use on all Low, Medium & High Voltage cable types.

➡ Associated Brands & Products | Klauke | Cembre | Pfisterer Sicon | Cable Crimping & Cable Cutting Tools

Cable Jointer Training Courses By Avonside Safety Management

Jointer Training Course

Cable Jointer Training Courses

LV Jointer Training Courses

Avonside Safety Management are industry leaders in the delivery of electrical safety training including LV cable jointer training courses. Offering a range of accredited cable jointing training commonly used with LV cables for jointers with all different levels of experience.

Avonside can provide training both face to face as well as some e-learning to suit the individuals requirements. Learners will attain skills that can be taken and applied to the workplace as they will be prepared to operate in potentially hazardous environments through safely simulating these environments.

JM1 – Cable Jointers Mate

• Jointer Training Course | JM1 – Cable Jointers Mate
• Jointer Training Course | LV1 – LV Live Jointing Course, Single and 3 Phase Services
• Jointer Training Course | LV2 – LV Live Mains Cable Jointing Course
• Jointer Training Course | LV3 – LV Transition Polymeric (Wavecon) to PILCSTA Cable

EUSR

Andrea Tompkins Training Manager at Avonside Safety Management

“Our courses have been endorsed by Energy & Utility Skills meeting the quality standards required by the utility industry.

The Energy & Utility Skills Register is a register of individuals’ training and skills.

Individuals that undertake training and/or assessment on a scheme or programme have this training recorded against their EUSR registration.

Individuals are issued with a unique EUSR ID number as well as a photo ID card upon successful completion – this card also displays the training or skills recorded on EUSR against the individual which can be verified online. EUSR registration is valid for a fixed period of time, usually three years and individuals are required to renew their registrations by undertaking the relevant training once their registration has expired.”

ASM – Avonside Safety Management

Cable Jointing Training – Industry Leading Courses

Avonside Safety Management are industry leaders in the delivery of electrical safety training.

ASM have industry-leading expertise in cable jointing training. They can train a wide range of joint assembly on all commonly used HV and LV cables, catering from inexperienced operatives through to experienced jointers.

Their trainers have a wealth of industry experience and can offer tailored courses to suit your needs including tooling, cable types, joint types and procedures.

ASM have a dedicated training facility located in Redditch offering a market leading learning environment in both practical and classroom environments.

Tel 01527 864 136 | or visit https://avonside-sm.com/

LV, MV & HV Jointing, Earthing, Substation & Electrical Eqpt

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

THORNE & DERRICK Product Categories: Duct Seals | Cable Cleats | Cable Glands | Electrical Safety | Arc Flash Protection | Cable Jointing Tools | Cable Pulling | Earthing | Feeder Pillars | Cable Joints LV | Joints & Terminations MV HV 

Medium Voltage Cable Connections & Accessories

Thorne & Derrick distribute the most extensive range of MV HV Medium & High Voltage Cable Joints, Terminations & Connectors from manufacturers including 3M, Prysmian, Nexans Euromold, Elastimold and Pfisterer CONNEX & SEANEX.

Heat shrink, cold shrink, push-on and slip-over cable accessories enable the jointing, terminating and connection of 11kV-33kV-66kVcables to oil, air or gas insulated switchgear, transformers, motors and overhead lines distributing electricity at medium/high voltages.

T&D hold large stocks of 11kV 33kV 66kV Joints & Terminations suitable for XLPE, PILC and EPR cables, in both heat shrink and Cold Shrink technologies, to service the medium/high voltage power cable accessory requirements of UK and international customers.

Overcoming Cable Corrosion On Steel Wire Armoured & Braided Cables

Cable Corrosion Solutions & Products

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

Solutions To Cable Corrosion

3M Electrical Products provide an extensive range of cable repair solutions to prevent and overcome cable corrosion for the utilities, renewable energy, solar, construction, rail, mining, offshore, oil, gas and petrochemical industries – cable corrosion tapes and protection products are available to suit both direct burial (underground) and cables located onto containment in both indoor and outdoor installations.

Cable repair solutions are available for low and medium voltage cables suffering advanced cable damage caused by atmospheric steel corrosion – both onshore and offshore galvanised steel wire armoured and wire braided cables are especially vulnerable.

The Problem 

Formation of Rust

The overall chemical equation for the formation of rust is:

Iron + Water + Oxygen → Rust

Advanced Cable Corrosion & Degradation

The pictured low voltage cables evidently have serious damage caused by long-term cable corrosion effects. The cable sheathing has been aggressively damaged and stripped back down to the galvanised steel wire armours. Steel typically corrodes or rusts rapidly in moist or humid conditions and the rate of corrosion accelerates with exposure to salt water, for instance in the marine and offshore industry.

The cable sheath should provide both waterproof and corrosion protection to the steel wire armours and copper conductors – in this case there is an urgent demand to prevent further cable corrosion damage to both the accessible and inaccessible cables strapped and cable cleated to the cable tray.

The complexity of the cable repair is compounded two-fold : the area is a “no-heat” zone designated a hazardous area location Zone 2 according to the ATEX Directive therefore traditional heat shrink cable repair kits are precluded from consideration due to the presence of a potentially explosive atmosphere. Furthermore due to the brittleness of the cables, resultant from significant corrosion damage, it was not an option to man-handle and subject the cables to further physical movement and mechanical strain.

Chemical Corrosion of Cables In Industrial

& Hazardous Area Locations

Hydrocarbons in the onshore and offshore oil/gas exploration and production sector seriously impact upon the integrity and ability of cables and cable accessories to provide uninterrupted service – standard polyurethane cable repair and jointing products would overtime degrade to destruction in the presence of aggressive chemicals.

Consequently, 3M Electrical have developed a chemical resistant cable joint utilising their 1402FR resin for harsh and hazardous cable installation environments where hydrocarbon exposure is expected under normal conditions – the Scotchcast resin cable joints have been adopted as specification standard by international oil and gas companies including Exxon Mobil, Chevron, Total and Royal Dutch Shell.

 ➡ Read our Blog for further information about the selection and specification of cable joints according to the ATEX Directive.

Cable Corrosion – 3M Solution

2 solutions to suppress future cable corrosion using 3M Electrical cable repair products :

• Accessible Cables – 3M Scotchrap 50 Tape provides advanced corrosion protection to cables exhibiting excellent resistance to abrasion, moisture, corrosive salt water, soil acids, alkalis and salts.

3M Scotchrap tapes are UV resistant and also resist impact punctures and tears with a very high weather and corrosion proofing performance for use on underground cables.

3M Scotchfil Electrical Putty can also be used to build-up irregular surfaces to provide a smooth, waterproof taping surface around cables where there is localised pitting type corrosion.

Scotchfil putty provides a versatile corrosion resistance solution to general cable and electrical equipment applications, the Scotchfil putty can be wrapped, stretched or moulded to conform to both standard and irregular surfaces.

3M Scotchfil Electrical Putty when over wrapped with either Super 33+ or Super 88 Vinyl Electrical Tape. Scotchfil™ electrical putty can also be used to build up cable joints and fill out major irregularities and voids.

• Inaccessible Cables – where cable access is limited 3M 1603 Insulation Spray can be used to protect cables and surfaces (including galvanised steel cable tray) against weather, moisture, corrosion, oil, alkalies and acids. 3M 1603 sprays provide easy access to hard-to-reach spots. eabling versatile on-site cable repairs without specialist tooling or requirement to disconnect or isolate cable circuits. 3M insulating spray sealers to spray over insulation on wire and cable splices, as a general-purpose sealer, or for touch-up insulation on motor windings and frames. Precautionary and first aid information for this product may be found in its Material Safety Data Sheet and on the product container.

Another type of cable failure is evidenced by visual indication of burning or arcing on the surface of the semiconductive layer of medium voltage cables. If the burning or arcing becomes extensive, the MV cable can fail from the outside in (pictured below).  

The MV cable failure cause was determined to be a damaged cable sheath or jacket, which created a flowpath for corrosive ground water to penetrate the cable and cause severe corrosion to the metallic shield.

Scotch 70 silicone rubber electrical tape is a high temperature arc-and track-resistant tape composed of self-fusing, inorganic silicone rubber and easy-tear and easy-strip liner – the Scotch 70 tape is used as an over-wrap for protection of high voltage terminations and cables against arcing and tracking.

Some Further Reading : Corrosion Types Encountered With Power Cables : Underground Cables and Anodic Corrosion (Stray DC Currents), Cathodic Corrosion, Galvanic Corrosion, Chemical Corrosion, AC Corrosion, Local Cell Corrosion. By Edvard Csanyi (Electrical Engineering Portal EEP).

Whatever the cable condition or type of installation, 3M can provide innovative cable corrosion protection solutions based on Scotch electrical tapes, Scotchcast resin, heat shrink, cold shrink or spray based technology.

LV Cable Joints (Low Voltage Cables)

Thorne & Derrick stock and distribute LV Joints in Cold Shrink, Heat Shrink or Resin Cast technologies – multicore and multi-pair cable joints are available for immediate backfill and energisation of Low Voltage power, control and instrumentation cables 600V/1000V 3.3kV.

Complete range of LV Cable Accessories  ➡

Cable Breakouts | Cable Caps | Cable Lugs | Cable Cleats | Cable Trough | Cable Duct | Feeder Pillars | for 11kV/33kV/66kV networks see MV HV Joints & Terminations

Pfisterer | Nexans Euromold | Prysmian | Cable Joints & Terminations MV HV

Cold Shrink by 3M | Joints | Abandonment | Terminations | Low Voltage LV Cables

Solar Farms | Insulate, Connect & Protect LV HV Electrical Cables & Equipment

Photovoltaic Solar Farms

Reliable 3M Electrical Solutions That Help Keep Your Power On

Since 1985, Thorne & Derrick have been Authorised Distributors for the 3M Electrical range of Low & Medium Voltage Cable Accessories for the insulation, connection, repair and provision of reliable electrical power up to 33kV utilising Cold Shrink, heat shrink, Scotch Tape and Scotchcast Resin technologies.

For more than 30 years, 3M Electrical has been a trusted supplier of advanced materials for the solar industry. From engineered films to modular assembly solutions, 3M products are engineered to enhance performance, help improve reliability, and help drive down the critical cost per watt.

As one of the world’s leading suppliers of advanced films, tapes, coatings and adhesives, 3M have the ability to supply products and provide technical support around the world.

11kV | 33kV | 66kV Connections & Energisation

Thorne & Derrick distribute the most extensive range of MV HV Medium & High Voltage Cable Joints, Terminations & Connectors – this includes heat shrink, cold shrink, push-on and slip-over cable accessories enable the jointing, terminating and connection of 11kV-33kV and 66kV-132kV cables to oil, air or gas insulated switchgear, transformers, motors and overhead lines distributing electricity at medium/high voltages.

3M Electrical Products — the right protection for less downtime, fewer interruptions

Insulate, Connect, Protect & Energise

Each letter below represents an electrical construction or maintenance application.

Match all letters that apply to the facility illustration to see all the places where 3M Electrical Products help you deliver efficient, reliable, and sustainable energy solutions.

Cable Applications

A	Insulate Wires and Cables • Repair and re-insulate LV cables and busbar • Repair or replace busbar insulation • Insulate and seal in harsh conditions
Connect Wires and Cables • Conductor to conductor (pigtail and inline) • Conductor to flat pad or pin-connection	B
C	Splice Cables • Splice underground buried and submerged • Splice in cable tray or ductwork • Shearbolt and compression connectors
Rejacket and Protect Medium Voltage Cables • Rejacket buried and submerged cable • Provide mechanical and abrasion protection	D
E	Terminate Cables • Terminate in switchgear • Terminate live-front busbar connections • Terminate with dead-front separable equipment connection • Terminate in outdoor pole top and substation connection
Motor and Equipment Maintenance • Insulate motor lead connections • Repair busbar insulation • Repair metal housing for motors and pumps	F
G	Be Safe on the Job • Equipment outlet line insulation • Personal protection
Protect Cables from Fire, Water or Corrosion • Resist water, oil and chemicals • Resist abrasion, puncture and cut-through • Resist pipe corrosion	H
I	Fire Protection • Protective wraps • Caulks, putties, foams and large opening solutions • Sprays, sealants and tapes
Locate & Mark • Map path and depth of underground assets	J
K	Maintain & More • Cable identification and cable management • Metal lubrication and rust resistance

Photovoltaic Solar Farms

Voltage Rating of 3M Product Applications

Indicates high voltage application (69KV-145KV)
Indicates medium voltage application (5KV- 46KV)
⚫ Indicates low voltage application (<1000V)

3M Electrical Product Application Guide

NOTE: Products vary within each category. Not all products will be suitable for all the application requirements listed.

*Speciality Tapes coding: S=silicone, C=corrosion protection, G=glass cloth, V=varnished cambric

Thorne & Derrick are Specialist Distributors to Solar EPC’s & High Voltage Jointing Contractors working on the design, construction and maintenance of UK, European and international projects supplying an extensive range of LV HV Solar Cables, Jointing, Substation & Electrical Eqpt. 

Based in the UK, we are highly customer responsive and absolutely committed to providing a world-class service.

We stock LV HV Solar Cables, Accessories & Electrical Equipment to enable the construction, maintenance and operation of utility-scale PV installations – our products connect 600V/1500V solar cables into combiner boxes, inverters, transformers and energise switchgear up to 33kV/132kV for high voltage grid connections.

Since 1985, we have provided expert technical support and express delivery from extensive UK stocks to world-wide destinations.

Further Reading

• Jointing, Grounding & Terminating DC Solar Cables
• Solar Farms Replace Nylon Cable Ties With Metal Cable Ties
• Video : Solution to Terminating & Connecting Photovoltaic Solar Aluminium Cables
• Seaward Solar Utility Pro | Solar Cable & PV Installation Tester
• Bi-Metallic Cable Lugs | Compression Crimp Terminations for Aluminium Cables
• Nexans Euromold Connectors : EPDM Rubber Screened Separable Connectors For Medium Voltage Cables