Step-by-Step Guide for a 33kV T-Boot Termination

Published 08 Aug 2025

In this guide, Harvey Ross (HV Harv) demonstrates the key stages of a 33kV T-boot termination on a Nexans GT1 incomer. This process requires accuracy to ensure a watertight seal, maintain insulation integrity, and meet manufacturer specifications. Using specialist tools – including the Ripley Tools, US15 Pro Max, US02 & US10, as well as the ALROC LH2 – Harvey shows how each stage can be completed efficiently and to a high standard. All tools featured are available from Thorne & Derrick, jointing tool stockists, suppliers & distributors, trusted by HV professionals worldwide. The video below shows the full process, with our step-by-step breakdown following.

jointing Tools Used in This T-Boot Termination

Ripley US15 Pro MAX

High-precision insulation removal tool designed for fast, consistent results on medium and high-voltage cables.

View Ripley US15 Pro MAX →

Ripley US02

Reliable semi-con screen removal tool ensuring smooth, damage-free stripping for high-voltage cable preparation.

View Ripley US02 →

Ripley US10

Lightweight tool engineered for quick and precise chamfering of conductor ends to improve termination quality.

View Ripley US10 →

Alroc LH2

Heavy-duty cable cutter with a flexible cutting head for easy access to cables in confined spaces.

View Alroc LH2 →

PF CLeaning Wipes

Industrial-grade wipes for effective cleaning and surface preparation during cable jointing and termination work.

View PF Cleaning Wipes →

All of these tools are available from Thorne & Derrick (Power and Cables) – trusted by LV, MV & HV professionals for safety, precision, and performance.

Cable Preparation & Initial Measurements

1. Measure the Bushing

   • Begin by measuring the bushing depth.

   • Measure back 285mm from the bushing end.

   • Sand 65mm of insulation to ensure a watertight seal.

2. Clean the Surface

   • Wipe the prepared surface thoroughly with a PF cleaning wipe.

XLPE Insulation Removal with Ripley US15 Pro Max

3. Remove Outer Insulation

   • Use the Ripley US15 Pro Max to make a circumferential cut, then transition to a spiral cut.

   • This tool excels in tight spaces and removes thick insulation with ease.

4. Finish the Cut

   • Use a hooked cable knife (a “hold-to-fall knife”) to flick out the final insulation section.

5. Remove Water Barrier & Copper Tape

   • Strip off the water blocking layer.

   • Remove the copper binding tape.

   • Clean the outer sheath again with a PF wipe.

Install Mastic & Prepare the Screen

6. Apply Water Mastic

   • Apply mastic around the cable as per kit instructions.

7. Bend Back Copper Screen Wires

   • Fold the screen wires back neatly in preparation for earth bonding.

Stress Control & Semi-Con Removal

8. Measure for Stress Control Tube

   • Mark 65mm from the screen cut to guide the positioning of the stress control tube.

9. Remove Semicon Layer

   • Use the Ripley US02 to remove the semi-conductive layer down to 30mm.

   • Tie off and sand as necessary for a smooth surface.

Cable Stripping & Chamfering

10. Strip Primary Insulation

    • Using the ALROC LH2, set the blade to the depth of the lug barrel.

    • Strip the insulation cleanly.

11. Chamfer the Conductor

    • Use the Ripley US10 to add a smooth chamfer to the end of the insulation.

    • This compact tool creates a clean finish, reducing stress points.

12. Prep Conductor

    • Tape the conductor end to prevent strand splay.

    • Clean the insulation and apply the termination grease (usually supplied with the kit).

Connector Assembly & Final Termination

13. Install Stress Control Tube

    • Slide it down to the 65mm marker created earlier.

14. Install Lug

    • Prep the conductor.

    • Slide on the lug and shear it off according to manufacturer torque ratings.

    • Clean and reapply grease.

15. Fit the T-Boot

    • Apply termination grease to:

      • The lug

      • Stress control tube

      • Inside of the T-body boot

    • Slide the boot on facing the correct direction.

Final Steps: Earth Bonding and Securing

16. Mount the Termination

    • Push the booted termination onto the bushing.

    • Fit the cleat to secure the assembly.

17. Dress Earth Wires

    • Straighten and align the copper screen wires.

    • Use one wire to wrap and secure the bundle for a clean finish.

Complete 33kV T-Boot Termination

What you now have is a fully installed Nexans 33kV T-boot termination, completed with precision using high-quality Ripley cable preparation tools.

Want to place an order for the tools used in this termination? Contact our team of experts – offering 40+ years of industry experience, we distribute the most extensive range of 11kV 33kV 66kV MV HV Medium & High Voltage Cable Joints, Terminations & Connectors from manufacturers including Südkabel, 3M, Prysmian, Nexans Euromold, Elastimold, Pfisterer CONNEX & SEANEX and Shrink Polymer Systems.

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