Cable Joints & Terminations HV

OCS Group – Hazardous Area & High Voltage Commissioning, Inspection & Training Services

by Chris Dodds T&D - estimated reading time 5 minutes

Headquartered in the USA, OCS Group is one of the largest independent inspection company’s, developing many proprietary services and products over the last 20 years for all their clients within the oil, gas, energy and hazardous area industries.

OCS Group works in collaboration with the regulators, government agencies and leading industry bodies for electrical safety in the work place to provide the best training available in the USA in respect to hazardous areas and high voltage power systems.

It is acknowledged that OCS Group is the industries leading expert in electrical safety and this has resulted in a growing relationship and ongoing collaboration with UL to provide the best of industry related competency based training. In addition, OCS is the leading training provider to drilling contractors and operators working in hazardous area and on high voltage systems in their region.

With offices in the USA, Singapore, Australia, Indonesia, Malaysia, Saudi Arabia, UAE and India, OCS Group provides a wide range of services to international oil and gas industries and other industrial engineering and energy markets.

OCS GROUP – Life Cycle of Services

OCS Group delivers these services with an unwavering commitment to the highest safety and quality standards, evidenced by IS0 9001:2015 certification.

Project Management & Commissioning

OCS has global experience of over 150 successful hazardous area and high voltage project management, engineering, testing and acceptance projects delivered on time and budget.

All projects are managed through proprietary software developed in house specifically for land assets, jack-ups, platforms, FPSO’s, drill ships and refineries.

Inspections, Audits & Compliance

OCS Group over 20 years has built strong relationships with operators and contractors providing solutions for all types of hazardous area and high voltage inspections, audits and compliance surveys.

• Rig Inspections
• Hazardous Area
• DROPS
• NDT
• MCT
• Valuation
• Rope Access
• Competency Audits

Preservation & Reactivation

OCS Group provides VCI materials, experienced and qualified personnel for application and preservation management for large and small projects. For 20 years OCS Group has been providing rig and asset re-activation services, continuously proving the process by ensuring your asset is ready to operate.

Software Solutions

• Hazard Trac: Hazardous Area Strategy and Management Software
• Drops Trac: Managing Drops on an asset, regional or global scale.
• Project Trac: Managing complex asset builds ensuring project delivery
• Inspection Trac: Tracking routine inspections and corrective action closeouts
• MCT Trac: Managing and Maintaining the required MCT register

Training & Competency

• CompEx Scheme: 01-04
• CompEx Mechanical
• Marine High Voltage (STCW-USCG)
• Hazardous Areas HAET – IADC
• Electrical for Industrial Applications
• Electrical for Renewable Applications
• Customized Training Programs
• Online Training

High Voltage

Houston based OCS Group has been awarded the United States Coast Guard (USCG) Marine High Voltage Safety accreditation as a Marine High Voltage Training Provider.

Hazardous Area Electrical (Ex) Management

OCS Group is a leading hazardous area (Ex) equipment Inspection Company, evidenced by their loyal clientele comprised of renowned, international drilling companies.

OCS Group follows IEC and NEC standards, employing CompEx certified inspectors to work on every Ex hazardous area inspection. Additionally, the technical training of staff ensures the professionalism of the entire inspection crew and operations personnel have the specialised knowledge and skills necessary to comprehensively complete the job with utmost client satisfaction.

The hazardous area management plan includes creating a register of every item within the Ex location. The equipment is inventoried, logged, inspected, tagged and verified for compliance. The end result is a detailed report outlining the remedial tasks required to make the hazardous area zone safe.

The Hazardous Area Electrical Register (HAER) Inspection consists of several Phases to choose from. Client Preparation required is an up to date area drawings and to provide all hazardous area equipment certification and maintenance system records for review.

• Phase One is a detailed inspection of all Ex equipment located in the identified ‘Hazardous Area Locations’ (or Zones)
• Phase Two is a separate scope of work of remedial task management to correct the deficient items identified in Phase One
• Phase Three is optional and can consist of a specific scope of work such as an Emergency Shutdown Devices (ESD), or a competency assessment of the assets’ workforce in a live simulation of an electrical Safe Work Practices
  (SWP) audit

OCS Group – Solutions For Success

THORNE & DERRICK are national distributors of LV, MV & HV Cable Installation, Jointing, Substation & Electrical Equipment – we service UK and global businesses involved in cable installations, cable jointing, substation, overhead line and electrical construction at LV, 11kV, 33kV and EHV.

Since 1985, T&D have established an international reputation based on SERVICE | INTEGRITY | TRUST.

Contact us for 3M Electrical, ABB, Alroc, AN Wallis, CATU Electrical, Cembre, Centriforce, CMP, CSD, Elastimold, Ellis Patents, Emtelle, Euromold, Filoform, Furse, Lucy Electric & Zodion, Nexans, Pfisterer, Polypipe, Prysmian, Roxtec, Sicame, WT Henley.

Invitation

Thorne & Derrick invite you to join LinkedIn’s largest LV-HV Electrical Discussion Group : Low & High Voltage Power, Cabling, Jointing & Electricals. 

Discussion subjects include cable installations, cable jointing, substation, overhead line and electrical construction at LV, 11kV, 33kV and EHV. Network, engage and promote your profile, company or products with over 10,000 influencers.

MV Heat Shrink Cable Terminations Can Fail Despite Passing VLF Tests

IMCORP – Providers of Factory Grade® technology, bringing MV HV power cable and accessory manufacturers’ QC reliability to field installations worldwide.

by Chris Dodds T&D - estimated reading time 5 minutes

OVERVIEW
0.1 Hz VLF test and IMCORP’s Factory Grade® technology are compared side-by-side at utility solar site.

CHALLENGE
VLF test passes cables, but cable terminations were still failing.

RESULTS.
Based on distribution system experience, utility uses IMCORP’s Factory Grade® technology to identify workmanship defects and VLF test induced damage.

A utility client of IMCORP asked them to commission medium voltage cable systems at a new generation facility after experiencing several MV cable termination failures.

The cable installation contractor had already tested the MV cable systems with a very low frequency (VLF) test.

Uninformed contractors often make a claim based on a common myth that ‘proper’ VLF testing would detect serious MV-HV cable defects while not harming healthy cable insulation or aggravating minor defects.

In addition, the misguided claim often states that passing a VLF test means the medium or high voltage cable system will deliver years of trouble free service.

Wrong.

Unfortunately the owner initially believed these commonly held myths, energised the MV power system and subsequently experienced several catastrophic failures that damaged switchgear, costing them significant down time and losses in generation revenue.

Substandard MV HV cable jointing and installation necessitated the replacement of multiple HV heat shrink cable terminations after a succession of in-service cable termination failures.

Pictured opposite the heat shrink anti-track tubing has been removed shown the tracking between the medium voltage heat shrink and XLPE cable insulation.

The IMCORP Factory Grade® technology pinpointed dozens of MV cable terminations that did not meet the accessory manufacturer’s minimum performance standards.

When the cable terminations were dissected the technician not only found cable jointer workmanship issues, including insufficient shrinkage of heat shrink layers, but clear evidence of damage caused by the VLF test that passed the medium voltage cable terminations a short time before.

Ben Lanz (Director, Applications Engineering at IMCORP) comments, “a VLF test passed this heat shrink termination. An offline 1.5Uo 50/60Hz PD partial discharge assessment with 5pC sensitivity identified this MV cable termination which is why we have the picture. The original installation defect and VLF test damage are plainly visible. This case along with many others is the reason IMCORP recommend a factory comparable PD test for critical medium/high voltage power installations and QC spot checks for newly trained cable jointers and installers of MV-HV joints, terminations and connectors. I acknowledge that a VLF test was the best the utility and power industry had 10 years ago but with the evidence we have now, I generally don’t recommend going over the operating voltage with a VLF test since it can not find most MV-HV cable detects found by a factory comparable PD test.”

The 2 most serious cable termination anomalies were small voids on the medium voltage XLPE cable insulation shield interface and “fall-in” cable insulation problem at the conductor shield interface.

Could a failure to remove the semicon screen from the XLPE insulation of MV-HV cables contribute to this type of cable failure?

Here, the semicon screen was removed sufficiently from the MV-HV cable using correct cable jointing tools. Most likely the VLF test burned a track in voids caused by insufficient void filling mastic at the semicon cutback and/or insufficient shrinking of the heat shrink tube with the green zinc oxide (ZnO) stress controlling layer on the inside of the cable termination.

MV Cable Termination Failures

Here, failure of the heat shrink stress control component of the cable termination was poorly placed in relation to the semi-conductor screen cut causing termination failure of the substation cables linked to a generation plant on an onshore windfarm.

Manufacturers Standards

Reducing Cable Termination Failures

Of course site standards and international working procedures vary but the following professional advice has universal methodology:

“There are three main components to reducing the risk of failure during the infant mortality phase of an installation’s life (bathtub curve): 1) Have policies that ensure you only procure high quality equipment 2) Ensure that equipment is installed by qualified, trained and experienced personnel who work to high standards 3) Commission it thoroughly with a view to exposing flaws and weaknesses and then correcting them. As has been proven many times before, thousands saved today may cost you millions tomorrow.”

Thorne & Derrick International

Cable Installation, Jointing, Substation & Electrical Equipment Distributors

Since 1985 T&D have serviced UK and international businesses involved in cable installations, earthing, duct sealing, jointing, substation, overhead line and electrical construction at LV, MV & HV.

Our customers are contractors, specifiers and end-users involved in cable installations, cable jointing, substation, overhead line and electrical construction at LV, MV & HV.

Medium voltage power cables can fail for several reasons – pictured below is a common installation error near the outer semicon screen cutback by the cable jointer on the heat shrink cable termination – the highest electrical stress point in an open air cable termination.

To prevent this IMCORP recommend MV HV Jointer Training coupled with a factory comparable partial discharge test after installation to provide feedback to the cable installer – 50/60Hz offline PD test with better than 5pC sensitivity.

Partial Discharge (PD) at the crossed cores of the HV cable causing failure of the heat shrink cable termination

LV-HV Jointing, Termination, Substation & Electrical Eqpt Distributors 600V to 66kV 

Authorised Stockists & Distributors for Leading HV Cable Accessory Manufacturers

Cutting 11kV Cables Using Cembre Battery Cable Cutting Tools

by Chris Dodds T&D - estimated reading time 5 minutes

Product Category: Cable Cutting Tools

Featured Manufacturer: Cembre

Cable Cutting Tool Model: Cembre B-TC950 Cordless Hydraulic Cutting Tool

Contributed By: Watkins and Jacomb Construction Power & Consultancy

WJCPC are specialist LV HV Cable Jointing contractors with over 20 years experience in the electrical industry covering the utilities, renewable energy, rail, data centre and general industry sectors – with UKPN competency for LV HV Jointing, Confined Spaces, Substation Entry and Fault Finding.

The video below shows WJCPC cutting a section of BS6622 11kV 3 core medium voltage power cable using the battery operated Cembre B-TC950 tool prior to terminating into the MV cable box using heat shrink terminations.

The Cembre B-TC950 battery operated cable cutting tool has a capacity to cut up to 95mm outside diameter power cables including 11kV and 33kV. The Cembre tool features a dual speed cutting action – the two speed operation and automatic switching from a rapid advancing speed of the ram to a slower, more powerful speed for cutting copper and aluminium conductors.

Not suitable for cutting steel wire armour (SWA) or live/energised cables.

Cembre B-TC950 has a cutting power of 880 bar (12,700 psi).

How To Use Cembre Cutting Tools

Cutting Blade Advancement

The user or jointer should press the operating button (5) to activate the motor-pump – the ram will gradually move forward until the lower cable cutting blade (3) touches the cable conductor. To halt the advancement of the tool blade, release the button (5) and the motor will cut out. Ensure the cutting blade is exactly positioned on the desired cutting point of the cable – if not re-open the blade following instructions and reposition it.

Cable Cutting

Firmly hold the Cembre tool and operate the button (5) to gradually move the lower cutting blade (4) to cut through the conductor. When the conductor cut is clean and complete, release the button (5), otherwise the maximum pressure relief valve has activated.

Blade Retraction

By operating the pressure release button (6), the ram will retract and open the lower cutter blade of the tool.

Cembre B-TC950 Cable Cutting Tools – Distributed by T&D

Cembre B-TC950 Battery Operated Hydraulic Cable Cutting Tool

Construction & Spare Parts

Dimensions 518 x 468 x 83 (20.4 x 18.4 x 3.3).

1. Locking Lever
2. Upper Cutting Blade
3. Lower Cutting Blade
4. Tool Handle Grip
5. Operating Button
6. Pressure Release Button
7. Battery
8. Battery Capacity Indicator
9. Battery Checkbutton
10. Battery Release
11. LED Worklight
12. Ring For Shoulder Strap

T&D distribute a complete range of cable cutters including ratchet, hydraulic and battery operated for precise and clean cutting of power, control and instrumentation cables with steel wire armour or braid and lead covered sheathings – ratchet cable cutters are recommended for cropping cable conductors of LV-HV cables where working space and access is confined in high voltage cable end termination boxes.

11kV Cable Preparation

Training & Tools

Failure to effectively and precisely prepare MV-HV cables by the jointer is a common cause of 11kV cable failure – images 1+2 below are clear examples of jointers workmanship deficiencies on a recent project which WJCPC were contracted to correct and complete following the condemning of the 11kV cable installation by the main contractor.

The 11kV 3 core XLPE medium voltage power cables show a reckless finish to the easy peel semiconductor screen with a toxic mixture of jagged edges, scoring marks and deep ringing – this could have been caused by the jointers using fully bonded screen removal tools with incorrect depth setting rather than the correct semicon stripping tool. The use of the correct cable jointing tools for each stage of cable preparation is critical to ensure safe and reliable installation and service of MV joints and terminations.

Compare images 1+2 with the perfect uniformity of MV cable preparation in image 3 achieved by WJCPC.

Critical to the long term stability and field performance of 11kV cable terminations and joints is perfect preparation of cable – care should be taken to ensure appointed MV HV Cable Jointing contractors are suitably trained and equipped with the required jointing, cutting and crimping tooling to perform medium/high voltage cable installations.

THORNE & DERRICK are national distributors of LV, MV & HV Arc Flash Clothing, Cable Installation, Jointing, Substation Duct Seals & Electrical Equipment – we service UK and global businesses involved in cable installations, cable jointing, earthing substations, overhead line and electrical construction at LV, 11kV, 33kV and EHV.

Since 1985, T&D have established an international reputation based on SERVICE | INTEGRITY | TRUST.

Contact us for 3M Electrical, ABB, Alroc, AN Wallis, CATU Electrical, Cembre, Centriforce, CMP, CSD, Elastimold, Ellis Patents, Emtelle, Euromold, Filoform , Furse, Lucy Electric & Zodion, Nexans, Pfisterer, Polypipe, Prysmian, Roxtec, Sicame, WT Henley.

132kV Surge Arresters

Surge Arresters

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

This following Product Update is about 132kV surge arresters – the ABB PEXLIM surge arrester is manufactured and specified to provide overvoltage protection to high voltage 132kV electricity networks and gas insulated substations.

132kV

ABB PEXLIM is a 132kV surge arrester for protecting UK DNO electrical infrastructure including HV substations, transformers, switchgear, capacitor banks, motors, bushings and cables distributing high voltage power – usually the arrester is installed on overhead line to underground transitions on power networks.

The ABB design is safe, secure and effective.

💡 Did you know?

The ABB PEXLIM surge arrester is National Grid compliant and approved for 132kV electricity networks – contact us for technical specification support, competitive quotations and immediate delivery from UK stock for 132kV surge arresters.

• System Voltage 24-170kV
• Rated Voltage 18-144kV
• Nominal Discharge Current 10 kA_peak
• Surge Arrester Classification IEC 60099-4 Ed 3.0 Station; SL
• Surge Arrester Classification IEEE Std. C62.11-2012 Station
• Up To Line Discharge Class 4
• Mechanical Strength (SSL) 1600Nm

T&D can supply an extensive range of Joints, Terminations & Connectors MV HV to support the installation and routine maintenance of 132kV polymeric type (XLPE) insulated cable systems – this includes copper earth tapes manufactured by ABB Furse to provide effective Earthing & Lightning Protection to high voltage substations up to 400kV.

This range of HV sure arresters complements our line of 132kV link boxes with UK DNO and National Grid Approval.

Lightning strikes the ground in Britain about 300,000 times a year – for the utility industry this is a risk factor that must be countered by the MV HV substation designer, EPC or power distribution contractor.

UK DNO’s take the uninterrupted supply of electricity to our homes and business seriously, very seriously.

Use our #powercutmap for regular updates or if you can’t see your #powercut you can report it with just a few clicks https://t.co/vFgjOxBIER pic.twitter.com/HITQfFS97V

— Northern Powergrid (@Northpowergrid) June 15, 2018

Surge Arresters

T&D working with ABB can provide surge arresters for electrical protection of all types of medium/high voltage MV HV assets – view the Buyers Guide or better still call us to discuss your particular requirements. Surge arresters can be supplied with compliance to all UK DNO specification requirements including WPD, Northern Powergrid, UKPN and Scottish & Southern Energy (SSE).

ABB surge arresters protect HV electrical power supply systems against the catastrophic effects of lightning and switching overvoltages.

See also Surge Diverters | Sheath Voltage Limiters

Dowload here.

Causes Of Overvoltages In High Voltage Electricity Networks

To view further information about ➡  Medium Voltage 11kV – 33kV Surge Arresters

Thorne & Derrick Working With ABB

Since 1985 Thorne & Derrick based in the UK have been specialist distributors of LV, MV & HV Cable Installation, Jointing, Substation, Arc Flash Clothing & Electrical Equipment – customers include UK and worldwide contractors, specifiers, traders and end-users involved in cable installations, sealing cable ducts, cable jointing, substation earthing, overhead line and electrical construction at Low, Medium & High Voltages up to 132kV.

Should you require any technical support, specification guidance or would like us to visit you and discuss the range of ABB Surge Arrester products please do not hesitate to contact us – T&D are proud to distribute the ABB ranges of MV HV Electrical Equipment.

Chris Dodds (T&D) with Donald Thompson (ABB MV Surge Arrester Sales Manager) at Thorne & Derrick’s office in County Durham UK earlier today.

Suppliers of MV HV Joints, Terminations & Connectors | 3M | Prysmian | Nexans Euromold | Pfisterer | Elastimold | NKT

PFISTERER Training Courses – Cable Jointer Training For MV HV CONNEX Connectors

MV CONNEX Training With PFISTERER | Thorne & Derrick

Cable Jointer Training

PFISTERER have announced the launch and opening of their Medium Voltage CONNEX & SEANEX Training Courses covering CONNEX Size 1 to 3-S-XL products up to 52kV – the training courses are being conducted from their new purpose built training facility in the UK.

Safety and reliability are essential factors in medium voltage power system applications placing particular demands on assembly and installation skills of the cable jointer.

It is therefore imperative that all medium / high voltage cable jointers who work with CONNEX products are trained and certified by PFISTERER.

You can contact Thorne & Derrick to arrange your PFISTERER training course today.

• Theoretical product and PFISTERER application overview
• Full explanation and demonstration of the installation procedure
• Full CONNEX assembly undertaken by candidates

hv Training Courses

For specific dates about scheduled PFISTERER Training Courses please call us.

PFISTERER are able to offer training on site, please contact us to discuss your requirements and to obtain a quotation.

Plug-In Connectors For Medium & High Voltage Cable Connections

Jointer Certification

If successful certification will be issued by PFISTERER – Jointer Certificate is valid for 3 years.

PPE whilst attending the training course will be required to be provided by participants – boots, glasses, gloves, flame retardant workwear.

If the participants require accommodation whilst at PFISTERER this is borne by the participants.

For training courses held at PFISTERER Orgreave, PFISTERER will provide refreshments and lunch if appropriate.

On Site Jointer Training

Contact us to discuss your specific medium/high voltage jointing training requirements.

Thorne & Derrick recommend the use of Alroc tools for the preparation of medium/high voltage cables to effectively remove the cable sheath, semicon screen and insulation.

PFISTERER Cable Jointer Training Courses & Training Facility

Contact us to book your PFISTERER Training Course and maintain your warranty.

Spaces are available for up and coming courses.

PFISTERER offer a wide range of other training courses that can be tailored to suit your needs please contact T&D for further information.

Meet The Pfisterer Trainer

Jon Reed (HV Cable Jointer & Trainer for PFISTERER Accessories) – here a watchful Jon is supervising the initial 33kV cable preparation prior to installing the CONNEX connectors at PFISTERER’S new Jointer Training Facility dedicated to ensuring excellent workmanship, competency and in-date certification for MV HV Cable Jointers working on gas insulated switchgear and high voltage electrical equipment.

THORNE & DERRICK are national distributors of LV, MV & HV Cable Installation, Jointing, Duct Sealing, Substation & Electrical Equipment – we service UK and global businesses involved in cable installations, cable jointing, substation, overhead line and electrical construction at LV, 11kV, 33kV and EHV.

T&D stock and distribute PFISTERER CONNEX Connectors for medium / high voltage cable connection and termination to electrical systems – we provide competitive prices for PFISTERER CONNEX connectors used to terminate and connect polymeric insulated MV-HV cables into gas insulated switchgear and electrical equipment from extensive UK stocks.

Electrical Safety from Pfisterer

Voltage Detectors | Phase Comparators | Insulating Poles | Portable Earthing