Cable Joints & Terminations HV

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 

QTII v QTIII | 3M Cold Shrink Terminations – Features & Differences

Power Cable Terminations for MV HV Electrical Systems Utilising 3M Cold Shrink

Cold Shrink Terminations – 3M QTII v QTIII

Stocked & Supplied by Thorne & Derrick | Technical Support | Competitive Prices

UK & International Projects

Thorne & Derrick distribute 3M Cold Shrink Cable Terminations for medium and high voltage (11kV 33kV 66kV) cables and electrical power systems – we provide competitive prices for cold shrink cable terminations from extensive stocks to UK and international destinations.

3M Cold Shrink terminations are available in a Standard QTII range (3M Quick Term II – Partially Integrated) and a Premium QTIII range (3M Quick Term III – Fully Integrated).

QTII & QTIII type cable terminations are suitable for terminating and connecting MV HV cables. Below highlights the features of using cold shrink technology for both types of cable terminations as well as exploring the differences.

3M QTIII COLD SHRINK CABLE TERMINATIONS

Premium Cable Terminations | 3M Quick Term III – Fully Integrated

3M QTIII Premium cable termination offers the greatest simplicity and flexibility in the full range as it covers a wide range of cable types and sizes. One of the main features that differentiates the QTIII from the rest is a shorter adjustable tail to enable it to fit into the wide range of boxes meaning fewer installation steps so there is less room for jointer error.

➡ WATCH & LEARN Video Demonstration of QTIII Cold Shrink Terminations:

3M QTII COLD SHRINK CABLE TERMINATIONS

Standard Cable Terminations | 3M Quick Term II – Partially Integrated

3M QTII requires additional installation steps to the Premium range explained in the video below.  However the Standard QTII range still offers additional benefits over heat shrink cable terminations which have many more parts to install and require heat and further tools.

➡ WATCH & LEARN Video Demonstration of QTII Cold Shrink Terminations:

QTII & QTIII Features

• Fabricated one-piece cold shrink termination body which allows fast and easy installation on a wide range of cable types and sizes
• Installation temperature ranging from -20°C to +50°C
• The high-K stress control material distributes the electrical field evenly across the insulator and minimises the electrical stress on the termination
• Permanent radial contact pressure
• Quick and easy to install by puling out the spiral core
• No heat/flame or tools are required for installation
• Meets and exceeds the requirements for European Standard CENELEC HD 629.1 and IEC 60502-4.v

COLD SHRINK TERMINATIONS

3M QTII V. 3M QTIII

The following tables and videos demonstrate the specification differences and features of both the 3M QTII and 3M QTIII versions of Cold Shrink cable termination.

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• 66kV Terminations | NEW Stock Introduction for 3M Cold Shrink Cable Terminations
• Stress Control | MV Cable Terminations by 3M Electrical
• Q/ Can 3M Electrical Offer MV Cable Joints For Hazardous Areas?
• MV Cable Jointing & Some Jointers Tips Using 3M Scotch Tapes

Supplying Cable Termination, Jointing, Pull-in & Electrical Equipment up to 66kV

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, Pfisterer CONNEX 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 MV HV.

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

Nexans Power Cable Accessories & The Innovative JTS Joint for Medium Voltage Cable

MV Cable Joint – JTS

Improved Reliability & Safety at Reduced Cost

Nexans Power Cable Accessories is the UK’s leading cable and accessories company that has recently announced the launch of a new innovative product range that will ensure safer, easier and time efficient installations.

With their UK base in Castleford Nexans Power Cable Accessories has launched the new JTS Heat Shrinkable MV Joints range which boasts unique design features developed to reduce installation time, minimize risk of failure and simplify installation.

Launched at ENERGYX2021 event in Chester, the new JTS Heat Shrinkable Joints Range feature a range of design innovations that will deliver cleaner, quicker and simpler jointing installations.  These features include:

• Innovative triple wall technology where three inner tubes have been extruded as one, and as such, requiring only one heat shrinking activity instead of three
• The use of this triple wall tube meaning the chance of misalignment is reduced by a factor of 3 to 1 and;
• The inclusion of a revolutionary integrated faraday cage section within the connectors mastic patch minimizes misalignment in critical areas.

MV | Robust Outer Sealing & Protection & Advanced Electrical Stress Control

latest innovation to MV cable joint range

Speaking about the new product range Joe Roberts, UK & Ireland Sales Manager at Nexans Power Cable Accessories UK said: “We are delighted to be launching this product range to market and with what we consider to be some of the most innovative technology available to date”.

“As a business we pride ourselves on pioneering new ways of working and new technologies that ultimately make cable installations slicker, quicker and easier whilst consistently delivering products that meet the very highest standards of health and safety.  We are immensely proud of our new JTS Heat Shrinkable Joints range and are very much looking forward to launching it, not only at ENERGYX, but over the coming months as we introduce these products to the marketplace.”

Alongside the range of unique design innovations, the new MV Cable Joint JTS Heat Shrinkable Joints Range also offers a host of additional installation benefits designed to speed up, simplify and improve safety across the install process.  These include:

• A compact, slim design with sizes ranging from 95mm² to 1000mm²
• Market leading insulating properties for safer installations
• Advanced screen connection and armour continuity for maximum control of fault currents
• Thick walled outer tubing for high mechanical strength and impact resistance
• Resistance to water penetration & chemical aggression
• Stabilized UV protection for external longevity
• Halogen free material content with outer LSOH jacket for safer use in enclosed spaces
• Fitting single core and three core MV cables up to 42kV
• Quick and Easy to install – saving labour time, with no additional retraining required
• Excellent Insulating Properties – for safer installations
• Plus Premium Technical Support from our UK based technical staff

MV Heat Shrink Cable Joint Development

After engaging with Europe’s major MV installation companies to find out their thoughts on how to improve standard MV heat shrink cable joints. The main features were found to be – reduce the installation time, minimise the failure risks and simplify the installation.

Reduce Installation Time

This was achieved by the innovative design featuring “triple wall” technology, where the three inner tubes for semi conductive conductor screen, insulation, and semi conductive insulation screen have been extruded into one simple triple wall tube. This requires only one heat shrinking activity instead of the usual three, and the new design of roll on mastic pad to go over the connector eliminates the requirement for additional mastic tapes as in previous designs which can tend to stick to each and become very messy. The new design results in a much quicker and cleaner installation.

Minimise The Failure Risks

By the application of the triple wall extruded tube, this has effectively reduced the problem of misaligning the over tubes by a factor of 3 to 1 and maximizes coverage of the screen cut area – this, together with a new design of roll on mastic patch over the conductor area featuring a revolutionary “Faraday Cage” built in inner semi conductive layer also minimizes potential for misalignment in these critical areas.

Simplify the installation

By the application of these new and innovative design features, together with improved jointing instructions featuring high resolution images and easy to read step by step text, the whole process of installation has been simplified and no additional jointer training will be required to install the JTS.

TRIPLE WALL HEAT SHRINK CABLE JOINTS

Single Tube with Triple Function

The below video shows the Triple Wall design of the JTS Joint reducing installation times with corresponding labour savings.

Traditionally, heat shrink joints required several separate stages for the installation of the complete cable joint with multiple layers of heat shrink tubes needed to provide stress control, insulation and conductive functions – the labour intensive jointing procedure introduced increased risks of jointer error including tube misalignment and flamework deficiencies (scorching of tubes by overheating).

Nexans

Nexans is a global player in energy transition.  The Group designs solutions and services in these main business areas: Building and Territories, High Voltage Projects, Rail and Mass Transit, Renewables, Data Centres and Industry Solutions.

In the UK, Nexans Power Cable Accessories provides complete solutions including cables, accessories and training services for energy transmission and distribution networks. As the leading European specialised innovator, manufacturer and distributor of low- medium- and high-voltage accessories, as well as connection technology, Nexans Power Cable Accessories has been a leader in pre-assembled cable accessories for over 60 years.

Nexans manufactured Cable Accessories are in extensive service throughout the UK DNO power grid – the Euromold brand of separable connectors are approved and are approved by several DNO/IDNO operators dependent on the product, voltage and network.

The joints and terminations are increasingly preferred and adopted by NERS Accredited Independent Connection Providers (ICPs) working on 11kV private networks.

Thorne & Derrick International, based in the UK, are the Specialist Distributor for the Nexans Power Cable Accessory range of Screened Separable Connectors (Euromold), Cold-Applied (AIN AFN) & Heat Shrink Joints (JTS) & Cable Terminations (MONO) for Medium Voltage Power Systems up to 66kV; we hold extensive stocks and provide the most competitive commercial and technical levels of customer service in the UK.

Record Business Growth for Thorne & Derrick & Nexans Power Accessories (UK) Ltd

By Chris Dodds | Sales & Marketing Manager at Thorne & Derrick International

In 2018, Thorne & Derrick signed a UK Distribution Agreement with Nexans Power Accessories – this united the leading UK based Specialist Electrical Distributor with a 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% year-on-year leap in sales.

This success is due to our shared commitment to increasing stock holding, customer service levels, technical training and product innovation. Despite acknowledged supply chain and logistical challenges, due to politics and pandemics, we have worked hard together to overcome and mitigate impacts on the customer.

Our dynamic agreement supports existing customers and develops new market-share for the Nexans range of cable joints, terminations and connectors for use with medium voltage power systems up to 66kV.

No Time for Downtime | Resilient & Reliable Power Systems

Thorne & Derrick have been at the forefront of many critical national infrastructure projects supplying customers with world-class cable accessory products to build new medium voltage electrical systems; powering the renewable energy revolution and the digitalization of the world economy.

A combination of multiple major project wins by Thorne & Derrick during 2021 within the wind and data-centre sectors coupled with buoyant substation projects across other sectors has fuelled our impressive sales results.

“We look forward to our shared future together with Nexans and thank our customers for their business – 2021 was a record sales year for us in 36 years of trading. Our project experience and approved vendor status with key clients has enabled us to build a solid reputation for the reliable supply of Nexans products – we have a multi-million pound stock capacity at our Bristol location where orders can be supplied on next day delivery. This includes a complete offering for both the JTS & MONO heat shrink ranges of 11/33kV joints and terminations and the market-leading brand of Euromold connectors,” comments Chris Dodds (Sales & Marketing Manager at Thorne & Derrick).

“Congratulations to all our distribution network for a successful 2021 even in the face of adversity. Let’s hope we can further strengthen our relationships in 2022 and continue these record breaking years!” enthuses Joe Roberts (UK & Ireland Sales Manager at Nexans Power Accessories).

Innovation | New product launches including the JTS MV Joint have enabled Thorne & Derrick to increase market-share with power contractors. JTS provides unique design features developed to reduce installation time, minimise risk of failure and simplify installation by the cable jointer.

THORNE & DERRICK

SPECIALIST ELECTRICAL DISTRIBUTOR

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

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

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

Blog | Thorne & Derrick Connecting High Voltages & Energising Data Centres

Cold Shrink Joints From 3M Electrical – MV HV Ranges

Cold Shrink Cable Joints By 3M

MV HV Cold Shrink Joints

Stocked & Supplied by Thorne & Derrick | Technical Support | Competitive Prices | UK & International Projects

Thorne & Derrick distribute 3M Cold Shrink Cable Joints suitable for jointing, connecting and splicing medium and high voltage (MV-HV) cables including 11kV, 33kV, 66kV and 132kV – we provide competitive prices for cold shrink cable joints from extensive stocks to UK and international destinations.

3M Cold Shrink Cable Joints include built in components to ensure sound insulation, stress control and adequate earth potential over the screens of medium voltage cables. The 3M Cold Shrink Technology ensures constant radial pressure is exerted over the cable for the duration of the cable joint’s life.

The Simple Application Of A 3M Cold Shrink Cable Joint

1. Place the 3M Cold Shrink splice body onto the prepared cable, connect the cores and clean cables thoroughly.	2. Thoroughly grease the connected cable in preparation for the cable splice body.	3. Once in position, begin to remove the inner coil from the cable joint body.	4. For extra peace of mind, take advantage of the fact that cable splice body position is easily checked.
5. Place the earth stocking over the splice body. Ground and secure with 3M Constant Force Springs.	6. Insulate the constant force springs with Scotch 23 Rubber Splicing Tape and then overlay with Scotch Rubber Mastic Tape 2228.	7. Position the pre-parked 3M Cold Shrink Outer Protection Tube over the stocking and beginning to remove the inner supporting core.	8. Continue to remove the inner core until the outer tube is fully shrink, completing the cable joint.

3M Cold Shrink cable joints are available in a Standard cost-effective range or Premium options for medium/high voltage (MV HV) power systems.

The Standard range covers many of the most common cable configurations and size ranges unique to the UK market but requires the electrode to be built up by the cable jointer using Scotch 13 electrical semi-conductive tape.

3M Standard Cold Shrink Cable Joints

The Standard 3M Cold Shrink Cable Joints are available for both single core and 3 core cable connections for medium/high voltage cables including 11kV 33kV 66kV and 132kV.

3M premium Cold Shrink Cable Joints

The Premium 3M Cold Shrink Cable Joints are available for both single and 3 core cable connection for medium/high voltage cables including 11kV 33kV 66kV and 132kV.

3M Super Premium Cold Shrink Cable Joints

The Super Premium 3M Cold Shrink Cable Joints are available for both single and 3 core cable connections or medium/high voltage cables including 11kV 33kV 66kV and 132kV.

Cold Shrink Joints Features

• Prefabricated one-piece Cold Shrink splice body with integrated semi‑conductive electrode forms a faraday cage over the connector and eliminates the use of tapes or additional moulded or metallic electrodes
• Fast and easy installation at temperatures ranging from -20°C to +50°C
• Suitable for a broad range of cable type and sizes
• Permanent radial contact pressure
• Simple assembly by pulling out the spiral core
• Meets exceeds the requirements of European Standard CENELEC HD 629.1 and IEC 60502-4

More from 3M Electrical

• Continuous Shearhead Bolt vs. Crimp Compression Technologies By 3M Electrical
• 3M Electrical Tapes Guide | The Tape For Every Task
• 3M Terminations | Surface Tracking on Medium Voltage Cable Terminations by 3M
• 66kV Terminations | NEW Stock Introduction for 3M Cold Shrink Cable Terminations
• Stress Control | MV Cable Terminations by 3M Electrical
• Q/ Can 3M Electrical Offer MV Cable Joints For Hazardous Areas?
• MV Cable Jointing & Some Jointers Tips Using 3M Scotch Tapes

Supplying Cable Termination, Jointing, Pull-in & Electrical Equipment up to 66kV

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, Pfisterer CONNEX 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 MV HV.

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