Blog

Thorne & Derrick | Product Training With PFISTERER

9th March 2022 by Natalie Lundie Supply Chain: Marketing Lead | Thorne & Derrick

Thorne & Derrick welcomed Karl McFadden (Commercial Sales Manager at PFISTERER) and Drew Houghton (Commercial Sales at PFISTERER) to our offices for product training including an overview of their market-leading and new generation of SICON shearbolt connectors.

Additional manufacturer updates included an impressive presentation on their major project award at Seagreen with SSE Renewables for the SEANEX range of cable connectors for 66kV inter-array cable termination.

Seagreen Offshore Wind Farm project is located 27km off the coast of Angus in the North Sea and is a joint venture between TotalEnergies (51%) and SSE Renewables (49%). Seagreen will be Scotland’s largest and the world’s deepest offshore wind farm when complete.

The Sales and Marketing Team at Thorne & Derrick benefitted from the slick content, engaging animations and well presented slides that successfully simplified the complex.

We shall now look forward to further strengthening our business relationship in 2022 with ongoing product training, technical support and joint sales-marketing strategies.

Pictured SEANEX is a dry pluggable inner cone connection and termination system designed for renewable energy offshore applications up to 66/72.5kV – based on the PFISTERER CONNEX system the SEANEX components have been further developed for the service and operational requirements in the offshore renewable industry.

SEANEX is certified by DNV GL and compliant with the new offshore standard IEC 63026.

Read Article | SEANEX | PFISTERER Connectors Selected For 66kV Wind Turbine Terminations At Seagreen Project

Connex Stocks

“I genuinely enjoyed today’s presentation – Karl and Drew demonstrated such technical authority, purpose and passion in both representing and presenting the PFISTERER brand and its credentials, that’s infectious. This week we have significantly increased stock holding levels of the CONNEX range of connectors to satisfy customer demand within substation projects for the termination of 33kV cables – our ability to specify CONNEX correctly and deliver from stock overnight has driven sales forward for Thorne & Derrick,” comments Chris Dodds (Sales & Marketing Manager at Thorne & Derrick.

The PFISTERER CONNEX range of high voltage electrical equipment includes: plug-and-sockets, multiple sockets, busbar couplings, surge arresters and voltage testing systems.

INNOVATION AS A BUSINESS DRIVER

PFISTERER meets future challenges with the knowledge that comes from one hundred years of experience. This expertise has developed continuously with advances in technology – and technology has advanced thanks to PFISTERER’s expertise.

Numerous innovations and patents continuously drive our growth with further investment in R&D planned for 2022 and beyond.

The PFISTERER corporate group has been dealing with the interfaces in the flow of electricity ever since it was founded back in 1921. Their success has turned PFISTERER into a globally active company – with a distribution network in 70 countries and 21 locations in Europe, North and South America, Asia and the Middle East.

SEANEX by PFISTERER | High Voltage Connections For Inter Array Cables 66kV

PFISTERER – DISTRIBUTORS, STOCKISTS & SUPPLIERS

Thorne & Derrick provide competitive prices and fast delivery from stock for the complete range of PFISTERER CONNEX MV HV inner cone cable plugs and connection terminations.

Thorne & Derrick supply from stock MV HV cable plugs and terminations manufactured by PFISTERER MV-CONNEX that are suitable for medium voltage levels and applications up to 33kV where MV cables must be reliably connected, terminated and distributed within the electricity supply industry.

March 2022 VOLTS!

THORNE & DERRICK LV HV Jointing, Earthing, Substation & Electrical Eqpt

Welcome to our industry bulletin – VOLTS.

So what is VOLTS?

VOLTS is our monthly round-up of industry news, projects, videos, technical tips, training information, promotions, webinars and career opportunities from Thorne & Derrick. Take a moment to Follow Us on LinkedIn to receive future VOLTS.

Press Release

In 2018, Thorne & Derrick signed a UK Distribution Agreement with Nexans Power Accessories – this united a leading UK based Specialist Electrical Distributor with the global driver of the world’s transition to a more connected and sustainable energy future.

Since inception our contracted agreement has delivered consecutive annual business growth, last year including a 65% record year-on-year leap in sales.

Press Release | Record Business Growth for Thorne & Derrick and Nexans Power Accessories (UK) Ltd

pROJECTS & NEWS

PADS Approved

Following extensive and successful field trial testing the Nexans Euromold range of Connectors & Bushings have now received Full Acceptance by Network Rail with Official PADS Approval – specifically this includes Nexans Tee Connector model QM909TB Interface F and associated equipment bushing QM909AR. The product authorisation by Network Technical Head Power Distribution HV/LV on behalf of the Network Rail Acceptance Panel (NRAP) permits the installation of the Tee Connectors and Bushings to ground mounted oil filled transformers up to 52kV.

Read Press Release | Network Rail Full Acceptance for Nexans Tee Connectors & Bushings for 25kV Power Transformers

Thorne & Derrick supply an extensive range of 400V-33kV Rail Cable Accessories & Power Distribution Systems to contractors undertaking LV Power Distribution, HV Electrification & Substations, DC Traction & Networks, OLE and Track Feeder Cable Renewals.

25kV Switchgear Terminations | Nexans AFN36-6 42kV single core cable terminations are Network Rail PADS Approved for indoor 25kV air insulated switchgear applications. The cold-applied Slip-on rail cable termination is approved for use with Siemens ASG25 – 25kV air insulated switchgear for AC traction power supply systems.

Thorne & Derrick | Approved PFISTERER Stockist | CONNEX |  SEANEX | SICON

Let’s Meet

Throughout March, Thorne & Derrick continued to invite their supply chain to our offices and we also conducted online meetings to ensure staff are up-to-date with product developments, discuss sales-marketing campaigns and strategy plan for the year ahead.

Thorne & Derrick welcomed Karl McFadden (Commercial Sales Manager at PFISTERER) and Drew Houghton (Commercial Sales at PFISTERER) to our offices for product training including an overview of the market-leading and new generation Sicon brand of stepless shearbolt connectors. Additional manufacturer updates included an impressive presentation on the project award at Seagreen with the SEANEX range of dry pluggable high voltage cable connectors for 66kV inter-cable termination.

Thorne & Derrick hold extensive stocks of the MV-CONNEX separable connector range of inner-cone plug type cable connections for use with 33kV electrical equipment – this is supported by the provision of Jointer Competency Training to ensure the reliability of electrical connections.

Blog | Thorne & Derrick | Product Training With PFISTERER

Read Article | SEANEX | PFISTERER Connectors Selected For 66kV Wind Turbine Terminations At Seagreen Project

Sealing Inter-Array Cables

Working with Orsted, Van Oord and the Inter Array Project Manager from LS Cable & System, Thorne & Derrick have specified a cable sealing system to prevent water ingress into the power and fibre optic cores of de-energised high voltage inter-array cables (IAC).

Manufactured by 3M Electrical their range of EC type Cold Shrink cable end caps will provide protection from exposure to moisture, contamination, corrosion, ozone, UV radiation and other environmental hazards.

The proposed product solution was adopted based upon safe working procedure, field service history and product testing according to ASTM D 412-75: – the Cold Shrink technology cable caps are a flame-free and tool-less installation.

The 3M EC-4 type cap will be applied to protect and seal the exposed power core cable ends following the cable pull-in in general accordance with the installation process outlined in the video below – these will be mounted by the Cable Installation Contractor on the wind turbine foundation and offshore substation (OSS) after removal of excess pull-in lengths.

The fibre-optic cables will be sealed with 3M EC-1 type cap – Scotch 2228 type mastic tape is used to wrap and build-up the diameter of the fibre optic cable where the outer diameter of the FO cables are smaller than 11.6mm. Scotch 2228 is a conformable, self-fusing electrical rubber mastic tape with a strong, temperature stable adhesion for maximum continuous operation up to 90° Celsius.

The Changhua 1 and 2a offshore wind farms will comprise a total of 111 Siemens Gamesa 8 MW turbines. The offshore construction will be carried out during 2021 and 2022, with the project expected to be fully up and running in 2022.

Powering Data Centres

Thorne & Derrick have established an impressive project portfolio across UK, European and US built data centres; supporting the ever-changing industry and modern infrastructure changes with LV-HV Energisation & Electrical Equipment.

This month we supplied cable cleats and management products NTT’s Hemel Hempstead 2 (HH2) Global Data Centre. The HH2 facility provides 6MW of high quality data centre space across 6 data halls – each data hall has its own dedicated plant to a 2N configuration. With 30,000 square feet of net technical capacity, Hemel Hampstead 2 offers excellent connectivity options providing access to multiple carriers and cloud providers. 20kW is possible with high-power rack densities.

Read more about the Data Centre here.

Image Credit: https://www.ntt.com/en/services/data-center/nexcenter/virtual-tours/uk-hemel-hempstead-2-3.html

Working with Ellis Patents, Thorne & Derrick specified and supplied the following cleats for high voltage cable restraint to the client:

• Ellis Vulcan Trefoil Cleats VRT+08 for 630sqmm HV Cables
• Ellis Vulcan Trefoil Cleats VRT+06 for 240sqmm HV Cables
• M10 x 30mm Bolts & M10 Short Spring Channel Nuts

Cable Cleats For Short Circuit Protection

A cable cleat is a device designed to provide securing of cables when installed at intervals along the length of the cables, and is a vital component to ensuring worker safety. Holding Power is Ellis Patents guarantee that their Cable Cleats will contain dangerous short circuit forces – protecting your people, power and plant. It is important that when selecting cable cleats for high voltage cables that the cable cleats can handle the anticipated fault currents especially at working voltages of 11kV/33kV. 

All cable cleats stocked and supplied by Thorne & Derrick are short-circuit tested to the current updated version IEC61914:2015. Read the blog for further information on conforming to the current IEC standard ➡ Withdrawn IEC 61914:2009 | Cable Cleats for Electrical Installations

Ellis Cleats | Emperor | Vulcan | Atlas | Phoenix | Single Trefoil Quad Bundled Cables

Technical Tips Playlist 

Thorne & Derrick are the Specialist Distributor & Stockist for Nexans in the UK for their ranges of Cable Accessories up to 66kV. Nexans have created a 4 Part Video Playlist focusing on FAQ’s about their Euromold range of separable connectors.

Featured Jointers

Read | Energi Cable Services Ltd | 132kV 3 Core Oil To 1 Core XLPE Transition Joint

Containing Cables for Network Rail

Pictured: GRP Cable Containment Rail Solution | 300 metres of 110mm depth solid cable tray manufactured from GRP for a Network Rail project using PY1 type resin – several pallets are pictured at MITA prepared for despatch to the Reading Independent Feeder project which was originally part of CP6 enhancement scheme and constructed to minimise the impact of power and distribution failures on the operations of the GWML.

Thorne & Derrick can provide competitive prices and delivery for the complete range of MITA Cable Management & Containment Systems – contact us with your enquiries.

GRP Tray

Sector Spotlight | Offshore Wind

Thorne & Derrick International are Specialist Suppliers to the UK and international Offshore Wind Industry of products to provide safe and reliable Cable Termination, Jointing, Installation & Power Systems up to 66kV. Based in North-East England, we supply projects from the North Sea to the Nordics – our Exports Division support international offshore wind power projects from USA to China.

1 Block Island Offshore Wind Farm USA | Thorne & Derrick, as Approved Vendors to GE Renewable Energy supplied Earthing, Static Discharging & Electrical Safety Equipment to the substations plus a 33kV Cable Accessories package to power, joint and connect the medium voltage switchgear and transformers.

2 Operational Offshore Wind Farms (12 Locations) | Thorne & Derrick, as Approved Vendors to Orsted, supplied both standard and customised heat shrink joints manufactured by Nexans to enable planned maintenance and repair of the ABB, NKT, TFK & Prysmian High Voltage Cables – included land and subsea cable systems operating at 33kV.

3 Multiple Offshore Wind Farm Assets | Thorne & Derrick, as Approved Vendors to JDR Cable Systems, developed MV Jointers Tool Kits to provide offshore wind technicians with the specialist tools needed to prepare inter array cables up to 33kV prior to the installation of joints, terminations or connectors to the highest standard – included tools to enable the removal of the cable outersheath, insulation (XLPE) and semicon screens.

The Jointers Tool Kits are designed to provide their jointers with the specialist cable tools needed to prepare inter array cables up to 33kV prior to the installation of joints, terminations or connectors to the highest standard.

4 Bespoke & Standard Cable Clamps, Saddles & Cleats | Developed client customised cable support and cleat systems for high voltage cables in the nacelle/tower of WTG’s for a world leading manufacturer of wind turbines currently under NDA.

We are also approved vendors to SSE Renewables, Swire Energy Services (ALL NRG), Vestas Wind Systems A/S, Correll Group, Van Oord, Vattenfall, Boskalis and other leading renewable energy companies throughout the world.

5 Cable Pull-in Equipment | Working with Balfour Beatty plc on the Viking Link project Thorne & Derrick supplied a range of cable drum handling, socks, rollers and lubrication products to enable the safe pulling and trenching of high voltage power cables.

Image Courtesy | Max States Site Engineer at Balfour Beatty plc (Viking Link) – here the EHV 526kV cable is pictured being pulled from a 62 tonne cable drum (1240m circuit) into the cable trench via rollers in July 2021. Viking Link is a 1,400 MW HVDC submarine power cable under construction between the United Kingdom and Denmark.

Industry event

THORNE & DERRICK | EVENT SPONSORS

Thorne & Derrick are proud to be sponsoring the Earthing Conference UK this May in Birmingham.

The aim of this Earthing Conference UK is to demystify the subject of earthing and present the subject in a clear, straightforward manner. Earthing as a subject has been under-represented over the years and this event will attempt to remedy the gaps in technical knowledge and improve practices in the industry.

Read More About The Event | Earthing Conference 2022

www.events.idc-online.com

Phone: +44 (020) 8335 4014

Email: [email protected]

SPONSORSHIP OPPORTUNITIES

Representing your business at the Earthing UK Conference in 2022 will provide you the opportunity to reach key decision makers from a multitude of industries.

For more information on sponsorship and exhibition opportunities please contact: Emma Cameron at: [email protected]

The conference is currently seeking speakers who can talk about their experiences in the field, provide overviews of the applicable industry regulations/legislation and offer case studies and examples from industry. All presenters receive complimentary registration to attend the conference.

Top of The Posts

Thank you to Ellis Patents for supporting us on our most viewed social post this month.

Chris Dodds, Sales & Marketing Manager, worked on a LinkedIn social-push featuring the Ellis No Bolt Cable Cleats. The aim was to educate peers on the safety benefits of the cable cleats, specifically the achieved PADS Approvals and IEC 61914 Compliance. The interaction received was statistically outstanding with exciting project leads to develop for our business. ➡ See the full LinkedIn post.

Jobs

Meet Mane

Mane Contract Services are committed to working with their client partners to help create a greener and cleaner future. For over 20 years, they have provided project staffing solutions to the complete project lifecycle across all Energy sources. Mane have an extensive project and client portfolio across both cable manufacturing & installation, working across UK, EMEA, APAC and USA.

Stephen Stuart and his team at Mane and they are looking to expand their network within the Wind Energy Industry;

– HV Engineering & Installation – 33kV, 132kV, 155kV, 220kV, 400kV
– Commissioning Engineering / Commissioning Management
– Installation Management & Package Management
– Grid Connection and Cable Installation
– Project Management / Construction Management
– Client Representation
– Site Management & Support
– Document Control & Management
– Project Planning / Scheduling– Project Controls Management
– Health & Safety Management

If you are recruiting for yourself or looking for a new career move within the Renewables sector then please get in touch +44 (0) 1923 470 724 or email: [email protected]

For more information – visit their jobs page; https://www.mane.co.uk/energy/

With a network of international offices around the world and a large dedicated team of specialist Account Managers and Head Hunters, Mane are well placed to support your career development or recruitment requirements around the globe.

VOLTS! By,

Thorne & Derrick distribute the most extensive range of Low & High Voltage 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 – this includes Joints, Terminations & Connectors to enable the installation of low, medium and high voltage power cables into underground trench or duct.

Key Product Categories: Connectors, Joints & Terminations MV HV | Cable Preparation & Jointing Tools | Duct Seals | Cable Transits | Cable Cleats | Cable Glands | Electrical Safety | Arc Flash Clothing & Protection | Cable Pulling | Earthing & Lightning Protection | Feeder Pillars

Main UK Stockists for:  3M Electrical, PFISTERER Connex, Nexans Power Cable Accessories (Euromold), Alroc, Ellis Patents, ABB, Roxtec, Cembre & CATU Electrical.

Volts! Archive

Volts! #1 January 2022

Volts! #2 February 2022

Network Rail Full Acceptance for Nexans Tee Connectors & Bushings for 25kV Power Transformers

PR by Chris Dodds Sales & Marketing Manager at Thorne & Derrick | 08.03.2022

Following extensive and successful field trial testing the Nexans Euromold range of Connectors & Bushings have now received Full Acceptance by Network Rail with Official PADS Approval – specifically this includes Nexans Tee Connector model QM909TB Interface F and associated equipment bushing QM909AR.

The product authorisation by Network Technical Head Power Distribution HV/LV on behalf of the Network Rail Acceptance Panel (NRAP) permits the installation of the Tee Connectors and Bushings to ground mounted oil filled transformers up to 52kV – this covers:

Nexans Euromold Tee Connector Model QM909TB | Interface F Nexans Part Number 7009193 | PADS Catalogue No 0086/099432

Nexans Euromold 52kV 1250A Bushing | Interface F including 6 hole KBCDS-400 Clamping Kit & Sealing Gasket | PADS Catalogue No 0086/099430

➡ See Certificate of Acceptance PA05/05422 | Network Rail Certification

Thorne & Derrick are currently supplying this range of transformer terminations to several UK rail projects – we are Approved Vendors to Network Rail, CP6 Framework Delivery Partners and several HS2 Joint Ventures working on rail transport projects.

➡ For further information on Interface F Cable Accessories including Tee Connectors, Slip-on Terminations, Joints & Bushings refer to the download.

Further Reading

• 25kV Live Line Voltage Indicators | Network Rail Approved
• Rail Cable Labels with Network Rail & London Underground (LUL) Approval
• Network Rail Approved Cable Trough Delivered to South Rail Systems Alliance
• 3M LO42 Cold Shrink Tube | Track Feeder Cable Joints | Network Rail Approved

25kV Switchgear Terminations

Nexans AFN36-6 42kV single core cable terminations are Network Rail PADS Approved for indoor 25kV air insulated switchgear applications.

The cold-applied Slip-on rail cable termination is approved for use with Siemens ASG25 – 25kV air insulated switchgear for AC traction power supply systems.

Nexans 42kV Order Code AFN36-6

Network Rail 054/214930

Network Rail Certificate of Acceptance PADS PA05/06215

AFN36 cable terminations are used to connect medium voltage feeder cables to supply three-phase AC electrical power to traction substations on electrified lines.

Contact Thorne & Derrick for further information, competitive quotations or assistance with the selection and specification of Medium Voltage Rail Cable Accessories.

Rail Cable Accessories, Electrification

& Installation Equipment

Thorne & Derrick supply an extensive range of 400V-33kV Rail Cable Accessories & Power Distribution Sytems including feeder pillars to contractors undertaking Low Voltage Power Distribution, HV Electrification & Substations, DC Traction & Networks, OLE and Track Feeder Cable Renewals – a complete range of Network Rail PADS approved track terminations, cable joints, cable repair and connection products up to 25kV AC.

Full range of Cable Pulling Equipment & Products to ensure safe and efficient of rail cables in to cable ducts and containment infrastructure including cable troughs.

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 | Live Line Testers

Euromold MV HV | Cable Terminations, Connectors, Elbows & Joints

Nexans Supply Electrical Conductors To The Largest Onshore Wind Farm In America

Madeco by Nexans will supply 840 km of cables that it will produce at the Nexans plants in Chile and Peru.

Nexans

Electrical Conductors

Madeco by Nexans continues to promote the development of renewable energies, by concluding a significant agreement with Sigdo Koppers Ingeniería y Construcción SA to provide cabling solutions to the Horizonte wind farm.

There will be 840 kilometres of electrical conductors, mainly aluminium medium voltage, which will be produced in collaboration with Nexans Indeco (Peru), one of the Nexans Group plants in the Andean region. Conductor design was optimized based on the requirements of the project, located in the municipality of Taltal, Antofagasta Region. The first deliveries are planned for May 2022.

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

Colbún’s Horizonte wind farm will have an installed capacity of 778 MW, equivalent to the consumption of more than 700 thousand homes per year. The project is the largest onshore wind farm under construction in Latin America and one of the world’s highest installed capacities.

“ We have worked with Sigdo Koppers and Colbún to find the best solutions, in terms of the of conductors, section and reel design, and thus generate relevant efficiencies that contribute to the success of the project. ” Miguel Fernandez, Commercial Manager Of Nexans In Chile.

“ We are very proud to be part of the largest wind farm under construction in Latin America, and one of the most significant worldwide. Participating and working with the various actors involved in the project reaffirms our commitment to developing renewable energies, both in Chile and in the region, as well as our commitment to supporting the carbon-neutral transition by 2030, thereby ensuring a safer, more sustainable, renewable energy future and, above all, accessible to all. ” Luis Ernesto Silva, Vice President Of Nexans For The Andean Region.

This newly awarded project is part of the Nexans’ strategy to promote energy transition, electrifying the future through innovative solutions, and fostering the development of renewable energy initiatives around the world.

Joints, Terminations & Connectors up to 66kV from UK Stock | Contact Thorne & Derrick

Horizonte Project

Horizonte is a wind farm that will have an installed capacity of 778 MW generating 2,400 GWh per year, equivalent to the consumption of more than 700 thousand homes in the country. It includes the installation of 140 wind turbines on 8 hectares, thereby reducing CO2 emissions by 1.2 million tons annually. Finally, the energy generated is to be released onto the National Electric System as of the fourth quarter of 2023.

For over a century, Nexans has played a crucial role in the electrification of the planet and is committed to electrify the future. With around 25,000 people in 42 countries, the Group is leading the charge to the new world of electrification: safe, sustainable, renewable, decarbonized and accessible to everyone.

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

MV HV High Voltage Cable Joints | Cable Terminations | Cable Connectors | Distributed from Stock | UK & Export Sales

Transformers | Is It Time To Upgrade?

Transformer Replacement Projects Were A Great Success For Smith Brothers In 2021

• Special thanks to Ben Whitaker Business Development & Sales Manager at Smith Brothers 
  for the kind permission to republish

Transformers

Alongside some of the large connections we talk about often, our services and infrastructure division are always working away in the background – to ensure our customers remain online 24-7-365.

And, as technology progresses, transformers have become more efficient in performing their duty of increasing or decreasing voltage for electrical distribution. With that in mind, our Business Development & Sales Manager, Ben Whitaker, takes a look at why replacing your transformer with a modern alternative could result in a ‘greener’ site whilst reducing energy bills.

Transformer replacement projects were a resounding success for Smith Brothers in 2021, and saw us complete 19 in total as organisations continued to strive to reduce carbon emissions and operate their sites more efficiently.

Yet, rather than simply ‘fixing a problem’, investment in new technology which can help to counter rising energy tariffs across the UK has been a firm topic of conversation for our team. It’s nothing new, though. In fact, a study in 2018 suggested that lost energy in transformers contribute to 25% of the UK’s wasted energy.

What’s more, the European Union estimates that 2.9% of all electricity generated across the continent gets wasted in lost energy in transformers, this combined figure equates to 93.4TWh – enough to power Denmark for three years.

Over the past 12 months, Smith Brothers has contributed to the energy sector in the UK significantly through the construction and delivery of renewable energy projects – but also by replacing aged and inefficient transformers.

Transformer Regulation No. 548/2014

During their operation, transformers will lose heat, but legislation imposes in the EU the maximum level of losses for transformers placed on the market or put into service after 1st July 2015. And, while most pre-2014 transformers are manufactured to an undetermined efficiency level, we refer to these as ‘standard loss transformers’.

As of 2014, the minimum requirement for installed transformer assets adhered to Tier 1 level of efficiency. Further regulations were imposed in June 2021, introducing Tier 2, which determines an improved efficiency for newly manufactured transformers.

Tier 2 transformers have been readily available via manufacturers for some time – and have been included in any Smith Brothers tender proposals as a matter of default since 2018. Further energy savings can be achieved through the provision of a Wilson e3 amorphous core transformers, which is also something which we’re proud to be able to supply and install.

No Load Losses

No Load Losses arise within the magnetic core of a transformer and happen as a result of the energy consumed in hysteresis and eddy currents within the material as it is taken through its alternating cycles of magnetisation, in the UK 50 times per second i.e. 50Hz.

There are two ways of reducing no load losses in a transformer:

1) Reduce flux density by increasing the cross-sectional area of the magnetic core. 2) By using higher grades of core steel to reduce the watts/kg for a particular flux density.

The ‘no load losses’ of a transformer is a constant loss of energy and does not vary with increase/ decrease of load.

Load Losses

Load losses arise primarily because of the resistance of the transformer windings, that is the losses produced by the flow of current within the windings. Increasing the copper or aluminium cross-sectional area within a transformer winding has the effect of reducing the current density of the winding – this has the effect of reducing the losses. The load loss of a transformer varies to the square of the load.

Generally speaking – the larger kVA rating and the higher % load of this kVA rating, the more savings can be made by minimalising load/ no load losses.

Detailed below, is a comparison of the no load losses and full load losses of a 1000kVA ‘Standard Loss’ transformer, manufactured in 2013, prior to Tier 1’s introduction and a modern, 1000kVA Tier 2 transformer. We have also included the data for a Wilson e3 amorphous core transformer for comparative purposes. The monetary savings shown are subject to the transformer being run at 80% load 24 hours a day, 365 days a year at an energy tariff average of 12p per KWH.

How do I work out how much energy is being lost from my transformers?

Due to fluctuating loads pulled from individual transformers on operational sites, it’s important to find the right partner to carry out load monitoring and power quality surveyance in order to accurately determine the specific lost energy of sites’ existing transformers.

A good supplier should consider these specific elements:

• 7-day detailed power and power quality logging at nominated LV incomers. Current, voltage, kW, kVA, power factor, harmonics (I& V), flicker, frequency, harmonic loss factor and unbalance
• Load analysis and dentification of voltage dependent equipment
• Determination of PFC requirement and specification
• Detailed analysis of all logging data including harmonic analysis against ENA G5/4-1 at each LV supply (400V)
• Determine true loading of transformers using harmonic derating
• Calculation of existing transformer losses and energy savings associated with selected replacement/s
• Compilation of the technical report including savings & outline recommendations, where applicable

Smith Brothers Ltd is a large, turnkey electrical contractor with over 20 years’ experience. Since their inception in 1999, they have worked on a vast portfolio of projects throughout the UK and overseas, both as an ICP and EPC contractor on schemes up to 132kV.

Offering a range of services and can cater for everything from the delivery of a turnkey project – including design, the supply and commissioning of equipment and cabling installations from LV up to 132,000 volts (220,000V in ROI).

With over 10 years’ experience in the power industry — Ben has specialised in many power distribution projects, as well as maintenance and HV/EHV connections throughout his career. He is responsible for new sales and quotation conversion.

For further information, or an initial discussion regarding replacement transformer options, contact business development and sales manager, Ben Whitaker on: 07387 108 377 or email [email protected].

Stockists | 11kV 33kV 66kV Joints Terminations Connectors – 3M Pfisterer Nexans

THORNE & DERRICK

Thorne & Derrick are national distributors of LV, MV & HV Cable Installation, Jointing, Substation & Electrical Equipment – servicing businesses involved in cabling, jointing, substation, earthing, overhead line and electrical construction at LV, 11kV, 33kV, 66kV and EHV. Supplying a complete range of power cable accessories to support the installation and maintenance of low/medium and high voltage power systems:

• Slip-on Cable Terminations
• Cold-shrink Cable Terminations
• Heat-shrink Cable Terminations
• Cable Joints – Heat & Cold-shrink
• Separable Connectors (Euromold)
• Surge Arresters & Switchgear/Transformer Bushings

Key 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