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Centaur Cable Saddles – A Short-Circuit Tested HV Cleating Solution

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The Centaur Cable Saddles are the only solution for cleating large diameter High Voltage power transmission cables, that has been put through, and passed, the most rigorous of short-circuit testing procedures. The cable saddles were designed by Ellis Patents to fill the gap in the market which presented serious safety risks.

The Centaur product range typically handles 275kV to 400kV cables, from 100mm up to 162mm outside diameter, and is generally installed within tunnels and affixed to supporting steel-work.

Why is a short-circuit tested High Voltage cable cleat so important?

At present, neither the British or European standards take into account cleats on cables of this size. As a result, those specifying for such projects are very much left in the hands of the manufacturer, who in most cases, simply provide warranties for their products. The risk lies in the fact that none of the limited number of products available have been short-circuit tested, meaning warranties are based purely on calculations and mechanical tests.

How the Centaur Cable Saddles are tested

Using cables manufactured by ABB in Sweden, the centaur cleats were tested to 162kA peak (63kA RMS) for one second, in both three-phase and phase-to-phase fault installations. A copy of the full test report from KEMA is available upon request.

The saddles have also been successfully tested for corrosion resistance having been subjected to an independent salt spray test, carried out in accordance with BS EN 9227:2006 corrosion tests in artificial atmospheres.

Centaur Saddle Design features

The product consists of an extruded and pressed aluminium saddle and hinged aluminium over-strap retention which incorporates a LSFZeroHalogen (LSZH) nylon liner to cushion and protect the cable in the event of a short-circuit. The saddles are available in lengths of either: 400mm, 600mm and 800mm to allow for different mounting centres. The product range can also be supplemented by intermediate short-circuit straps as well as a roller system for easy pulling of cables.

For more information on the Ellis Centaur saddle range, please contact our Sales Team.

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Galvanic Corrosion Protection and Prevention in Harsh Environments

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When specifying products for use within harsh environments, choosing the correct materials is vital. For example, in offshore oil and gas installations, equipment experiences exposure to high levels of seawater and salt-spray, which are highly corrosive due to the dissolved chlorides within. Offshore installations are not the only projects that experience harsh, corrosive environments, other corrosives that affect a wide range of industries include: chlorine, ammonia and hydrochloric acid.

In May we reviewed the effects of galvanic-corrosion between two dissimilar metals, in that example we explored the use of stainless steel cleats with galvanised steel support structures. Corrosion can take many different forms and choosing the correct materials and finishes is key to minimising its effects. We have outlined common corrosion control methods, explaining how and where they should be implemented.

Choosing materials based on their galvanic characteristics

Different metals have different electrode potentials, therefore when two different metals are electrically connected in the presence of an electrolyte, such as seawater, the more active metal will become anodic leading to loss of electrons and increasing oxidisation in a process known as galvanic-corrosion.

Metals and alloys are ranked in order of noble to active, in what is called the galvanic series. A more noble metal, such as stainless steel, will have much better corrosion-resistance than a more active metal such as cast iron.

Galvanic Series of Metals

Galvanic corrosion can be controlled and minimized by selecting metals in similar positions within the galvanic series. A more active metal can also be used as a sacrificial anode, attracting corrosion in order to protect the more noble metal from corrosive attack. Alternatively, depending on the installation, a cleat separation washer can be installed between the dissimilar metals increasing the distance between each metal and removing the electrical and physical contact points, critical to causing corrosion.

Passivation

During manufacturing, certain metals form a layer of metal oxide on the surface in a process known as passivation. Although the process occurs naturally, it can be enhanced through chemical passivation treatments and anodising. The layer protects against corrosion as it is tightly bound to the surface, preventing further penetration of oxygen and corrosive molecules.

The most common examples include aluminium and stainless steel. Usually, if these metals are damaged the layer reforms quickly, however this process is not without its faults. Pitting corrosion can occur in aluminium when chloride ions interfere with the reforming process and high chromium carbides can affect welded stainless steel.

If the products are properly selected for the intended application, passivated metals can provide high levels of corrosion-resistance. This is why stainless steel cleats are the preferred product within offshore installations.

Protective Finishes and Coatings

Various protective coatings can be applied to metals to help shield metallic surfaces from the surrounding environment, including epoxy power coating, oven-baked enamel, hot-dipped galvanisation and PVC-type coatings. Care must be taken when installing products with these coatings as any damage during installation and fitting, drilling and cutting etc. must be re-protected to ensure the integrity of the rest of the coating.

Hot-dipped galvanised products offer two forms of protection as the zinc coating protects the surface of the steel and becomes a sacrificial anode if damaged.

Non-metallic components

In highly corrosive environments, where metals are not suitable due to high levels of corrosion, non-metallic products are commonly being specified as an alternative. It is important to remember that plastics are not completely impervious to chemicals and often suffer from UV exposure, which should be taken into consideration when specifying project materials.

The possibility of corrosion may not be at the forefront of material specifications and in times of economic hardship, may be over looked. However, with the World Corrosion Organisation estimating the annual cost of corrosion, throughout all industries, at $2.2 trillion, it truly is a global issue. We believe any short-term savings made from overlooking the extensive effects of corrosion will be more costly in the future and the figure from the WCO backs this up.

If you are concerned about potentially corrosive environments affecting products you may be specifying, we are able to offer expert advice on the best product to suit your specific requirement.

Have you had any experience with corrosion and would like to share your experiences then please leave a comment below. Learn more about our offer of electrical lugs.

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Repairing PVC Sheathed SWA and Armoured Cables

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If the sheath or jacket of an armoured cable is damaged it is important to repair the sheath as soon as possible to prevent further problems such as moisture ingress.

Heat Shrink Repair Sleeves

Repairing a cable with a heat shrinkable repair sleeve is suitable for power cables at any voltage. The SWRS sleeve is adhesive lined and features a stainless steel, self-locking channel, providing corrosion protection to the cables armouring and water tight seal around the sheath.

Supplied as standard in 1 metre lengths, the sleeve and channel closure system can be cut as required to fit the application. A soft-flame gas torch is also required to heat the cable repair sleeve.

Self Amalgamating Tapes

Self amalgamating tapes can be used to repair smaller sections of damaged SWA cable. 3M Scotch Silicone rubber or 3M Scotch EPR self amalgamating tapes are available, depending the the cable type being repaired.

Be sure to keep any tools or sheath abrasion brushes or cloths clean, as any oil or grease contamination on the outer cable jacket will prevent proper bonding and cause early sheath repair failure.

Starting at least 30mm from the damage, wrap the tape around at an angle of about 30o and pull the tension on the tape to reduce the width by about 1/3rd as you wrap. The tape should be overlapped 50/50 as you go. Once you’ve covered one way continue 30mm past the damaged sheath area, then wrap the tape back the other way, alternating the angle of the application to oppose the first layer.

3M Scotch Cable Jacket Repair Tape 2234



For more information on SWA cable repair techniques and products, please contact us.Learn more about our offer of power cable lugs.

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Understanding Switchgear and Equipment Bushings

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In recent years there has been a large influx of European switchgear. This has often lead to confusion about the type of switchgear being used and the switchgear bushing to which the cables are to be terminated.

Correct cable terminations

This has led to the discovery of conventional heat shrink terminations being used incorrectly in instances where the bushings were compatible with CENELEC style separable connectors, E.g. Pfisterer CONNEX and Euromold connectors. This can lead to delays on site in sourcing the correct cable termination type, not to mention the practical difficulties and increased costs in re-terminating the cables.

Specify the correct equipment

One of the ways to avoid this issue is to cross check the cable termination specified with a database of equipment manufacturers, ensuring that the termination type sourced is completely suitable for your switchgear bushing. This can be a lengthy process if the relevant information isn’t readily available.

Therefore, ETS Cable Components are able to offer this service using our expansive database of switchgear and bushing equipment and equipment manufacturers to insure the correct equipment is matched at tender stage.

The advantages of this bushing selection service being:

  • Correct costs for termination materials.
  • Compatibility with the cables being used.
  • Accurate installation costs.
  • Reduction in lost time on site.
  • Happier clients!

Switchgear Familiarisation Training

Additionally, we are able to offer familiarisation training for your installation team, on-site support and the technical expertise you would expect from one of the UK’s leading cable accessory distributors.

Please contact Nick Timms for more information on sourcing the correct terminations and connectors.

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Fire Resistant Cleats for Fire Performance Cable

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There are two types of fire performance cables currently on the market, flame retardant and fire resistant. The ‘normal’ type of fire performance cables are considered flame retardant, giving off low smoke emissions when subject to a fire, but only have a limited performance against sustained exposure to flames. The other type of cable is classed as fire resistant and will continue to operate for a period of time while exposed to fire.

In recent years there has been a large increase in the number of projects and developments that have been using Fire Performance cables. These cables are used within vital emergency systems and are designed to continue to work during a fire outbreak, powering smoke extractors, fire-fighting lifts and emergency lighting systems.

The cable fire test, BS8491, ensures that cables are able to hold up against direct flame, mechanical impact and water spray for a designated amount of time. The cables are clasified F30, F60 or F120, representing the length of time, in minutes, of the fire test.

Fire rated cleats to match the cables

In the past, as there has been no agreed test for a cleat to go through in order to rate its performance in a fire. Typically cast iron cleats have been used due to their high melting point, this has been considered enough to provide the necessary safety reassurances.

The downfall to this strategy is that iron is an expensive material and so makes cable cleats extremely costly, along with a slow manufacturing process and a heavy and brittle end product. These factors, added to the growing demand for fire performance cables, has increased the need for buyers and contractors to seek an effective solution.

Phoenix Cable Cleat and Fire Performance Cable Test: BS8491

phoenix stainless steel cleat fire test phoenix cleat fire test phoenix fire resistant cleat

A New Product Opportunity

The fireproof Phoenix Cable Clamps represent a solution to this problem. The cleat meets the required criteria called for by independent testing to BS8491:2008 (F120) where the cleats were subjected to an average temperature of 839 degree Celsius for 120 minutes. The Phoenix fire rated cleat was granted LUL approval for use on the London Underground (LUL Enginerring Standard 1-085 & Approved Products Register 1661) last year.

ETS Cable Components worked with Ellis Patents with the design of the product after seeing an opportunity through the increased use of fire performance cables in major new developments. The phoenix clamp is manufactured from marine grade 316L stainless steel, which was chosen primarily due to its high melting point, but also due to its high strength, abrasion and corrosion resistance.

We stock a full range of LU approved Phoenix Cable Clamps to accommodate all sizes of fire resistant cable from all cable manufacturers. Please contact our Sales Team for more information.

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A History Of Marconite Conductive Concrete

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As stockists of Marconite, we’re able to supply the conductive concrete and pre-mix with short lead times and with no minimum order quantity, to celebrate this, we’ve decided to look at the history of Marconite Conductive Concrete, where it comes from and why it was developed.

Conductive clay such as bentonite has been used for electrical earthing for decades, however as technology and needs have increased, the demand for a more permanent earthing compound arose.

Formulating an earthing material from purposely manufactured synthetic material, that provided lower resistivity, higher strength and lower maintenance than traditional Bentonite clay, was required. The mixtures comes under many guises: conductive concrete, admix and pre-mix, but one of the resounding industry names is Marconite.

For an inside look, we’ve invited Dave Wilson from the James Durrans Group to talk about Marconite’s history and how the Marconi Company developed this effective earthing product.

In the 1960’s the Marconi Company were at the forefront of the worlds’ communication and defence sectors. Designing highly sensitive electronic systems, their engineers increasingly encountered requirements beyond the technology of the time. Marconi realised that to overcome these issues that they would need an entirely new and highly conductive method of electrically earthing installations.

From inception, this new method needed to be permanent, required no maintenance, must be chemically inert, capable of forming strong structures and could be used anywhere, even in difficult ground conditions. In 1973 Marconi’s research, combined with process engineering skills from the James Durrans Group, culminated in the product named Marconite®.

From concept, Marconite® has been solely manufactured from unique raw materials and to a specific process, at their Scunthorpe works. The resulting product is a true semi conducting material that does not need water in order to conduct electricity. When used as an aggregate replacement and mixed with cement it forms a conductive concrete that can be used to encase earthing systems significantly magnifying their effect.

Aside from electrical earthing, resulting from its exceptional electrical properties, Marconite® has been widely used as an antic-static flooring system. If made into solid block, when assembled into buildings they act as a Faraday Cage, protecting the sensitive electronic equipment housed within from EMP radiation. Finally, if used in its dry granular state, it can be placed in trenches or beds to enhance existing ground conditions, a process known as soil enrichment.

Today, over 40 years since its inception, Marconite remains the industry default and standard to which all others are benchmarked. Its’ continued use around the world are testament to the vision of its original development and to the longevity of its abilities.

In the past year within the UK it forms an essential part in the latest high speed broadband networks, is extensively used in the latest power generation plants and provides rail engineers maintenance free earthing solutions. Whilst across the world it has been used in mass transit systems in Malaysia, solar power farms in the Middle East and as an essential component of national defence systems.

Diagram of Marconite installation:

As Marconite stockists and distributors, please contact our Sales Team with your earthing requirements.

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020 8405 6789
E.T.S. (Portsmouth) Limited T/A ETS Cable Components
Unit 44, Barwell Business Park
Leatherhead Road, Chessington
Surrey, KT9 2NY
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