Blog

Cable Lugs | How To Choose The Right One?

Thorne & Derrick | Distributed from Stock | Approved Supplier | UK & Export Sales

Klauke Cable lugs

The choice of cable lugs available for all kinds of applications in the electrical sector is huge.

Making the right choice can be harder than you might think. However, choosing the right lug is essential to ensuring a clean and secure crimping result.

This overview provides a more detailed insight into the most common lugs for copper conductors, helping explain to you what you need to look out for when making your choice so that your connection will indeed be secure and long-lasting.

Cable lugs for copper conductors, connected to the conductor by way of so-called cold forming, are some of the most common connectors in electrical engineering.

They can be roughly divided into three groups:

• Compression cable lugs according to DIN 46235 
• Tubular cable lugs as commercially available standard types
• Solderless terminals according to DIN 46234

Cable & cable lug: the perfect pair

Choosing the right cable lug also depends on the conductor class to be processed. As an example, the following cable lug types are available for cables according to DIN EN 60228:

• Class 1, 2, 5 and 6 conductors: compression cable lugs according to DIN 46235
• Class 2 conductors: standard type tubular cable lugs
• Class 2, 5 and 6 conductors: solderless terminals according to DIN 46234

To ensure safe crimping of conductors using DIN compression cable lugs, crimping tools with coded dies according to DIN 48083-4 are recommended in the standard. The requirements of the respective manufacturer must be observed for tubular cable lugs.

Solderless terminals according to DIN 46234 are processing using indent crimping.

Quality and resistance: on the test bench

Standards also apply to the electrical and mechanical properties of cable lugs. The international standard IEC 61238-1 part 1 applies in this particular instance. It specifies the tests that an electrical connection needs to fulfil in order to ensure long-term safe operation for its intended use.

The electrical connections must undergo different tests for this purpose. This involves an electrical durability test alongside a mechanical tension test. A test cycle simulates a practical application in this test.

Electricity is used to heat up the connection 1000 times to approx. 120 °C in order to bring about artificial ageing. The contact resistance is reviewed at regular intervals in between the tests.

Six high current tests are also carried out where the conductor is heated up to approx. 250°C in one second thanks to a short circuit. This high current test is required if the connector is due to be tested to check it is short-circuit protected.

The Klauke connecting material has also passed this test. The crimping connection passes the test if the contact resistance remained constant throughout.

Manufacturers are responsible for being able to guarantee the safety of their connections. With these additional tests that are carried out, you can rest assured that our connecting material satisfies the highest demands.

In addition, a significant amount of our materials are UL-tested and certified. This is particularly useful when control cabinets are to be supplied to North America, for example.

Electrical and mechanical properties of cable lugs

However, we also place additional requirements on the quality of our products that go beyond these standard requirements. Cable lugs made by Klauke are annealed as part of an additional manufacturing stage. This means we can reduce any hardening and tension in the material, as well as reduce the risk of breaking during crimping.

The quality of our cable lugs is already evident from their visual characteristics. Burr-free production and a consistently flat palm are signs of a high-quality product – likewise clean final machining of the tube section.

Contact our Sales Team for prices, technical support or to place an order for cable lugs or installation tooling for cutting and crimping cables manufactured by market-leader Klauke.

Klauke cable lugs and crimping tools are used by Jointers, Linemen, Panel Builders and Electrical Engineers to install underground cables and overhead line conductors on power, transmission and distribution networks including LV MV & HV systems, 11kV-33kV.

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 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

Should you require technical assistance to select the correct cable crimping or cable cutting tools please contact us.

Thorne & Derrick are Specialist Distributors of cable tools to enable the preparation of all LV MV HV cables prior to the installation of Joints, Terminations & Connectors – this includes Klauke, Cembre, Alroc and Boddingtons cable jointing tools for removal of cable sheath, screen and insulation on 11/33kV (MV) and 66kV/132kV (HV) power cables.

View the complete range of Cable Crimping & Cable Cutting Tools

Telecoms Cable Winch Supplied to Full Fibre, Gigabit-capable Network Infrastructure

• uploaded by Chris Dodds | Sales & Marketing Manager at Thorne & Derrick 

Customised Cable Winch

Working with client NGE, Thorne & Derrick have supplied a custom engineered Telecoms Cable Winch for the pulling and installation of fibre optic cables to the Liverpool Backhaul project – the cable winch will support the high-speed fiber infrastructure project which will connect all 6 local authority areas in the Liverpool Region, by delivering Gigabit internet connectivity to a diversity of key economic activities.

Thorne & Derrick have supplied the AW1000 is an extremely robust piece of engineered plant, designed specifically to cope with Fibre Optic and light cable pulls, which are becoming a mainstay in today’s economic environment, especially as Fibre Optic is being laid to cope with the increasing demand for broadband internet. The Winch is designed and manufactured by SEB International in the UK, to be simplistic in operation, and consequently the client installation team will find the winch is also straightforward to maintain and service.

The result is a product, which is cost effective, and will provide many years of service. The AW1000 will be an excellent investment and addition to the plant fleet of construction companies responsible for the installation and maintenance of fibre optical cabling systems.

Custom Cable Winch for Offshore Cable Pulling Project

Pictured : More information Customised & Refurbished 5 Tonne Cable Pulling Winch

This refurbished and customised 5 tonne cable winch was customised to enable the pull and installation of medium/high voltage power cables – the winch was delivered within 2 weeks from receipt of client order. The cable winch enabled the installation of cable runs up to 120 metres from the variable frequency drive (VFD) to the compressor junction box which goes from underground cable trench to above ground and onto the cable containment ladder racking system.

The cable winch modification was based on the standard SEB TW5000 version with additional cable tension dynamometer – the dynamometer continuously checks the cable pulling tension to ensure the forces do not exceed the recommended guidelines.

Cable Pulling Equipment

Thorne & Derrick distribute an extensive range of Cable Pulling & Laying Equipment to enable the safe installation of fibre and copper cables within the telecommunications industry. Safely installed cables reduces operational and maintenance requirements to the network and reduced service interruption to telecom cables, wires, ducts, cabinets and exchanges – products include cable spiking tools, conduit rods, cable lubricant, cable socks and rollers.

Cable Rollers | Cable Socks | Duct Rods | Cable Lubricant | Drum Jacks | Duct Seals

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

Thorne & Derrick Appointed UK Stockists & Distributor for the Hand Safety Tool Company

Press Release | Uploaded by Chris Dodds 14.2.2023

Thorne & Derrick are delighted to announce we have been appointed the UK Distributor for the Hand Safety Tool Company range of No Touch Hands Free Tools.

This range of market-leading tools reduce serious hand injuries in the workplace when manoeuvring suspended loads during push-pull operations. To support the introduction of the product range we can provide on-site or online Demonstrations to end-users. There are a diverse range of all-purpose designs that keep hands off and away from potential injury areas and keep workers out of the risk zone. Over recent months our Sales and Marketing Teams have benefited from Product Training with Jim Walts (Director – The Hand Safety Tool Company) and we now have in place stock of their ShoveIt range of tools.

Reducing Risk & Worker Injury

Thorne & Derrick are available and interested to discuss potential applications to improve safe operations in the utility, rail, renewable, oil/gas, port authority, manufacturing and construction industry sectors. The tools mitigate high-risk pushing and pulling operations and associated hand or finger injury – users can guide loads, move and position objects, as well as grab slings and taglines without physically placing hands on the item.

The range of Safety Tools keep your hands off loads enabling “hands-free” lifting – this mitigates the risk of load handling and improves Health & Safety in the workplace.

Insulating Matting | Bespoke Cut to Size Switchboard Mats

Matting

Thorne & Derrick are able to arrange manufacture of insulating and switchboard matting from our wide range of premium, low odour, rubber matting to your exact sizes and design and in accordance to IEC61111. Our REACH/PAH/CE approved compliant rubber compounds provide no off gassing which can cause nasty smells within internal environments. Rubber which has a pungent odour usually has been heavily recycled and been manufactured with the use of prohibited chemicals which are banned by REACH/EU. REACH regulations are tightening, and many online reviews of current non regulated matting products found on the market have regular end user complaints of a ‘toxic odour’ and ‘smell’ that does not disappear’. The advice given by the supplier is to ‘clean with soap and water’ or ‘leave outside for a prolonged period’.

The truth is really these products are most probably non-compliant and should not be placed into the European market. Contact us for odour free matting options.

Stockists & Suppliers of the CATU Electrical Safety range of Insulating Matting | LV MV HV

LV MV HV Electrical Safety

Oil Filled Transformers | Driving Uptime Through Asset Winterisation

Oil Filled Transformers

in the Wind Power Industry

Are Low Oil Level Trips Causing Asset Downtime?

This Case Study covers the problems caused by low oil level trips on aging transformers, the impact it has on downtime, availability and power generation. It goes on to discuss how Thorne & Derrick assisted Ventient Energy in custom designing and supplying a fit for purpose electrical heating solution to overcome the problem and effectively Winterise assets preventing downtime.

Who should read this? – Asset Managers in the onshore wind industry with responsibility for managing and maintaining oil filled transformers.

Causeymire – Ventient Energy

Thorne & Derrick have recently worked in partnership with Ventient Energy to provide a bespoke electrical heating solution for an onshore wind application. After a number of site meetings and application surveys with the client to understand the problem, T&D proposed a bespoke heating jacket solution to prevent downtime due to low temperatures.

Jon Priddy of Ventient Energy describes the problem

“For those of you managing assets with ageing oil filled transformers you may find this useful. If you do you’ll know that the tank expands and contracts with heat and cold. As they age the tank loses that capacity to contract and so now you have a bigger volume but the same amount of oil and usually a very finely tuned oil level sensor which as we know is a primary safety and protection feature.

Come the winter and those high pressure low wind speed days and bang, we have a trip. I have spent many a late night with the site team topping up, getting the contacts to close and getting everything back on. The result is downtime, a hit on availability and a hit on generation.

What’s the answer? A hugely costly campaign to change out all the transformers, a nearly as expensive retrofit of conservators (if you have the room and a good design), heating the transformer compartment in a large drafty steel tower fighting the physics of heat loss.

Obviously it doesn’t affect every site but typically anything over 15 years where the tank has lost that capacity to contract back to normal shape after the summer or high generation is a candidate.”

The nature of the problem included a number a variables and it was agreed that T&D would provide 5 trail heating jackets which would be put into use throughout the winter of 2022/23. The jackets were installed to the “top 5 offenders” during previous winters.  The trials have proven successful and the client experienced no outages as a result of low oil trips during one of the harshest UK winters on recent record.

Pictured – fabricated model of the bottom of the transformer was made using the measurements taken from site survey. This meant the electrical heating jackets could be manufactured and test fitted prior to delivery.

The Solution for Oil Filled Transformers

Ventient approached Thorne and Derrick with a request for feasibility on applying a thermostatically controlled electric heating blanket to the base of the transformer with a view to stopping the oil from contracting to the point of a trip. This typically applies on high pressure (clear skies) low wind speed days and nights when there’s little in the way of current going through the transformer and temperatures drop to or minus zero.

Consideration had to be given to:-

Jacket Design – the client needed a solution which was simple and could be easily fitted, ideally as a single piece. The jacket also had to provide a very good fit as any additional heat losses may have negatively affected the overall performance. Representatives from T&D made the journey to Causeymire wind farm to carry out a site survey.

Power Supply  – the power available was restricted due to only a single socket outlet being available.

Energy Efficiency – the design needed to be fit for purpose but using excessive power to solve the problem wasn’t an option.

Heat Loss – T&D have many years trace heating design experience and have carried out thousands of heat loss calculations for pipes, tanks and vessels. This was particularly challenging as we didn’t know the optimum oil temperature that would prevent it contracting enough to cause a trip. A safety factor had to be built into the design without using unnecessary power/energy.

Maintenance – any solution needed to be low/zero maintenance due to the remote location. The solution offered a fit and forget heating jacket. Once commissioned the jackets will operate using built in digital control thermostat. Any maintenance/inspections can be carried out alongside other routine maintenance.

Before & After Jacket Was Fitted to the Oil Filled Transformers

Heating Blanket For Oil Filled Transformer

Custom Heating Solution

Bespoke Heating Jacket

Client feedback

“The blankets were installed last year and wired up in November. A winter with some spectacularly low temperatures and some nights with low wind speeds has followed. And until 2 weeks ago, no low oil trips. This is the first winter in the last 6 where we haven’t had the problem.

Almost by way of verification the low oil trip 2 weeks ago occurred on one of the transformers without the blankets. The blankets are currently set to come on at 5°C ambient air temperature.

As usual with these things team work makes for the dream work. A huge shout out to Terry McDonald of Thorne & Derrick for crunching the numbers, doing the physics and coming up with a design, that was easy to fit and forget.

The great support and encouragement from the Ventient team, Alexa Belsham, Rui Meneses, who were willing to spend the cash and give it a try. For the support as ever from Tony Crombie who helped make the case and for Colin McIver of DWT for coming up with a power supply solution. A true “can do” team and collaboration.

So in short, it looks like we have a fix for this expensive (in every sense) issue with ageing oil filled transformers in colder climes.”

T&D have over 30 years process heating experience and are your pro-active problem solvers. If you are reading this and experiencing similar issues, please reach out to T&D and we will be happy to arrange an initial meeting to discuss your requirements.

Who are Ventient Energy?

Ventient Energy is a dynamic, pan-European renewable energy business and is one of the leading generators of renewable energy in Europe. They are Europe’s leading independent onshore wind group, with over 140 generating sites.

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

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. Thorne & Derrick 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.