Document Number: EDS 02-0031

Date: 21/11/2013

ENGINEERING DESIGN STANDARD

EDS 02-0031

INSTALLATION OF POWER CABLES AND JOINTS IN AIR

Network(s):

EPN, LPN, SPN

Summary:

This standard describes the decision making process, methods and materials to be
used when cables and joints are required to be installed in air and need to be
protected from fire.

Originator:

Paul Williams

Date:

21/11/2013

Approved By:

Steve Mockford

Approved Date:

28/11/2013

Review Date:

28/11/2016

This document forms part of the Companys Integrated Business System and its requirements are mandatory throughout UK
Power Networks. Departure from these requirements may only be taken with the written approval of UK Power Networks
Director of Asset Management. If you have any queries about this document please contact the originator of the current issue.

Document History
(The document history notes below are intended as a guide only and may not cover all of the changes. If you wish to make use
of this document it should be read in full.)

Version

Date

Details

Originator

4.0

21/11/2013

Document scope changed to cover all voltages

Paul Williams

3.0

12/06/2012

Document reviewed and updated

Paul Williams

2.2

22/08/2011

Document reclassified from EI to EDS

Don Fossett

2.1

14/02/2011

Document rebranded

Don Fossett

2.0

23/06/2009

Document reviewed and updated

Paul Williams

1.0

13/01/2006

Original Issue

Paul Williams

THIS IS AN UNCONTROLLED DOCUMENT, THE READER MUST CONFIRM ITS VALIDITY BEFORE USE

Version: 4.0

Installation of Power Cables and Joints in Air

Document Number: EDS 02-0031

Version: 4.0
Date: 21/11/2013

Contents
1

Introduction ............................................................................................................. 3

Scope ....................................................................................................................... 3

Design Guidelines Flow Chart for Installing Cable and Joints in Air ................... 4

Cable Installation ..................................................................................................... 5

4.1

New Cable Installations in Air .................................................................................... 5

4.1.1

Cable Types .............................................................................................................. 5

4.1.2

Cable Spacings ......................................................................................................... 5

4.2

Existing Cable Installations ........................................................................................ 5

Cable Joint Installation ........................................................................................... 6

5.1

Transition Joints between Existing Solid PILC and new XLPE Cables ....................... 6

5.1.1

Heatshrink Joints ....................................................................................................... 6

5.1.2

Resin Filled Joints ..................................................................................................... 6

5.1.3

Other Types of Resin Filled Joint ............................................................................... 7

5.2

XLPE to XLPE Joints ................................................................................................. 7

5.2.1

Heatshrink Joints ....................................................................................................... 7

5.2.2

Resin Filled Joints ..................................................................................................... 7

5.2.3

Other Types of Resin Filled Joint ............................................................................... 7

5.3

Transition Joints between Existing Fluid Filled and new XLPE Cables ...................... 8

5.4

Joint Spacings ........................................................................................................... 8

5.5

Existing Joint Installations.......................................................................................... 8

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Installation of Power Cables and Joints in Air

Document Number: EDS 02-0031

Version: 4.0
Date: 21/11/2013

Introduction

The purpose of this engineering design standard is to provide additional detailed guidelines
for the actions to be taken when considering, installing and commissioning the installation of
underground cables and cable joints in an in-air situation (i.e. cable tunnels, substations,
cable basements, underground pits, etc.)

Scope

Underground cables and cable joints are designed to be buried direct in the ground.
Installation in air should be avoided to limit the possible effects of a fire, caused by a failure
and its subsequent spread, unless no other engineering solution is possible.
However, it is accepted that operational constraints mean that cables and joints do
occasionally need to be installed in air.
This standard details the design guidelines, additional measures to be taken and materials to
be used, when cables and joints have to be installed in an in-air situation.
The flow chart in Section 3 illustrates the decision process that shall be undertaken when
deciding on the appropriate course of action to be employed when a project needs to
consider the requirements for cable and joints to be installed in air.

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Installation of Power Cables and Joints in Air

Document Number: EDS 02-0031

Version: 4.0
Date: 21/11/2013

Design Guidelines Flow Chart for Installing Cable and Joints in Air
START

Does the project require

only cables to be installed
in air

Yes

Do the new cables have a

flame retardant sheath

No
Does the project
require cable & joints to be
permanently installed
in air

No

Install cables as
required

No
Paint all exposed
cables with
intumescant paint

Yes

Can the joint be located

in an area away from regular
personnel access

No

Are the joints going

to be in service for less
than two years

Yes

No

Do not install joint

seek alternative
location

Yes
Yes

Can the joint be installed

with at least the minimum
spacing's in Section 4

Do not install joint

replace cable from
end to end

No

Yes

Is the Joint a
Heatshrink
Joint

Yes

No

Is the Joint a resin

filled Joints

Paint exposed joint

and adjacent cables
with intumescant
paint

No

Yes

Is an approved
flame retardent joint
shell available

Yes
Use flame retardent
joint shell and fill
with approved resin

No

No
Is the Joint a fluid filled
Cable or fluid filled to XLPE
transition joint

Yes

Can the joint

be located in a
suitatbly sized
bunded area

Yes
Paint exposed joint
and adjacent cables
with intumescant
paint

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Installation of Power Cables and Joints in Air

Document Number: EDS 02-0031

Version: 4.0
Date: 21/11/2013

Cable Installation

4.1

New Cable Installations in Air

4.1.1

Cable Types

All new install underground cables should have a flame retardant sheath, if they are to be
installed in an in-air situation (i.e. in a cable tunnel, substation, cable basement or a cable
pit), except where the exposed length is less than 3 metres when standard cables with either
PVC or polyethylene sheaths can be used.
If a cable type without a flame retardant sheath needs to be installed, because the
installation of a flame retardant cable is not practical or possible (i.e. there is no suitable
position for a joint between the two cables types). Any exposed length of cable in excess of
3 metres shall be protected by a suitable intumescant paint, applied in accordance with the
manufacturers instructions.
Tests have shown that three coats of Dulux Pyroshield Emulsion are sufficient to provide the
required level of flame resistance for all types of cable.
4.1.2

Cable Spacings

Based on the information contained within the BEWAG* report Special report on Fire
Resistant Cable Installation in Tunnels, all new cross linked polyethylene ( XLPE) low
smoke zero halogen (LSOH) cables shall be installed in trefoil formation.
*BEWAG Berlin Power Utility, now part of the Vattenfall Europe Group.

In order to limit damage should a cable failure occur and to provide clear access, the
minimum separation distances in Table 1 shall be observed:
Type of Spacing

Minimum Separation Distance

Vertical separation between circuits

200mm

Horizontal clearance for personnel access

Minimum 600mm

Cable and nearest adjacent floor or wall

200mm
Table 1 Minimum Cable Spacings

In addition, consideration should be given to providing additional separation between

adjacent critical circuits.
The provision of blast shielding between phases or circuits is not recommended as it is
considered that it may increase the overall effects of a cable failure by not allowing the
blast pressure to dissipate and create a pressure cell and increasing the likelihood of the
blast being reflected back onto the fault area compounding the damage.
4.2

Existing Cable Installations

In these cases, where cables without a flame retardant sheath have already been installed in
an in-air situation, the normal risk assessment process shall be carried out. If it is decided
that additional precautions are required, the circuit(s) in question shall be switched out and
the methods detailed in Section 4.1 of document shall be employed.

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Installation of Power Cables and Joints in Air

Document Number: EDS 02-0031

Version: 4.0
Date: 21/11/2013

Cable Joint Installation

In general, the installation of permanent cable joints in an in-air situation should be avoided
unless no other economic engineering solution is possible, especially as experience shows
that cable joints are more prone to in service failure.
Joints to be in service for a period of less than two years can be installed but are subject to
the same installation requirements.
There are three main types of cable joints and each should be considered based upon the
known reliability of each type:
5.1

Transition Joints between Existing Solid PILC and new XLPE Cables

Experience has shown that this particular type of joint is more prone to an electrical failure
than other types due to a mix of old and new technology and particularly the condition of the
existing PILC cables. Therefore, the use of such joints in an in-air situation should be
avoided unless no other economic engineering solution is achievable.
5.1.1

Heatshrink Joints

When a standard commonly used heatshrink joint is to be used in an in-air environment. The
surface of the each complete joint shall be painted with three coats of intumescant paint,
applied in accordance with the manufacturers instructions.
Tests have shown that three coats of Dulux Pyroshield Emulsion are sufficient to provide the
required level of flame resistance for all types of joint.
5.1.2

Resin Filled Joints

When a standard commonly used resin-filled joint is to be used in an in-air environment, the
black plastic joint shell, supplied in the kit shall be replaced with a new clear plastic flameretardant shell. Table 2 details the current available range of 11kV flame retardant joints
shells available from UK Power Networks Logistics or the manufacturer TE Connectivity,
currently these are only shells available at all voltages between LV and 132kV.

11kV Joint
kit Stores
Code

Flame
Retardant
Joint Shell
Stores
Code

04120S

04118M

13.0 Litres

240 to 300mm Transition Straight Joint (Triplex to PILC)

04121C
04119W
Table 2 Flame Retardant Joint Shells for 11kV Transition joints

13.0 Litres

Joint Description

95 to 185mm Transition Straight Joint (Triplex to PILC)

Resin
Volume

Each flame retardant joint shell is installed in the same manner as the existing shells
supplied in each of the above kits, using the components in the kits and filled with the same
volume of jointing resin.

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Installation of Power Cables and Joints in Air

Document Number: EDS 02-0031

Version: 4.0
Date: 21/11/2013

5.1.3

Other Types of Resin Filled Joint

For all other types of joint the surface of each complete joint shall be painted with three coats
of intumescant paint, applied in accordance with the manufacturers instructions.
Tests have shown that three coats of Dulux Pyroshield Emulsion are sufficient to provide the
required level of flame resistance for all types of joint.
5.2

XLPE to XLPE Joints

Experience has shown that this particular type of joint is less prone to an electrical failure
than other types. Therefore, the use of such joints in an in-air situation is acceptable as long
as the following engineering solutions are applied.
5.2.1

Heatshrink Joints

When a standard commonly used heatshrink joint is to be used in an in-air environment. The
surface of the each complete joint shall be painted with three coats of intumescant paint,
applied in accordance with the manufacturers instructions.
Tests have shown that three coats of Dulux Pyroshield Emulsion are sufficient to provide the
required level of flame resistance for all types of joint.
5.2.2

Resin Filled Joints

When a standard commonly used resin-filled joint is to be used in an in-air environment, the
black plastic joint shell, supplied in the kit shall be replaced with a new clear plastic flameretardant shell. Table 3 details the current available range of 11kV flame retardant joints
shells available from UK Power Networks Logistics or the manufacturer TE Connectivity,
currently these are only shells available at all voltages between LV and 132kV.

11kV Joint
kit Stores
Code

Flame
Retardant
Joint Shell
Stores
Code

04102U

04099J

6.0 Litres

150 to 300mm Triplex Straight Joint

04103E
04099J
Table 3 Flame retardant joint shells for 11kV Transition joints

6.0 Litres

Joint Description

35 to 95mm Triplex Straight Joint

Resin
Volume

Each flame retardant joint shell is installed in the same manner as the existing shells
supplied in each of the above kits, using the components in the kits and filled with the same
volume of jointing resin.
5.2.3

Other Types of Resin Filled Joint

For all other types of new joint the surface of each complete joint shall be painted with three
coats of intumescant paint, applied in accordance with the manufacturers instructions.
Tests have shown that three coats of Dulux Pyroshield Emulsion are sufficient to provide the
required level of flame resistance for all types of joint.

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Installation of Power Cables and Joints in Air

Document Number: EDS 02-0031

Version: 4.0
Date: 21/11/2013

5.3

Transition Joints between Existing Fluid Filled and new XLPE Cables

Experience has shown that this particular type of joint is less prone to an electrical failure
than other types and as the pressure within the joint is continuously monitored the chance of
failure is lower. Therefore, the use of such joints in an in-air situation is acceptable as long
as the following engineering solutions are applied.
All joints of this type contain large volumes of potentially flammable cable fluid; therefore any
joints of this type shall be installed in a suitably sized bunded area, large enough to capture
the volume of oil contained in the joint and the fluid filled cable connected to it.
To prevent the spread of fire the surface of the each complete joint shall be painted with
three coats of intumescant paint, applied in accordance with the manufacturers instructions.
Tests have shown that three coats of Dulux Pyroshield Emulsion are sufficient to provide the
required level of flame resistance for all types of joint.
5.4

Joint Spacings

In order to limit damage should a joint failure occur and to provide clear access, the
minimum separation distances in Table 4 shall be observed:
Type of Spacing

Minimum Separation Distance

Vertical separation between adjacent joints

200mm

Horizontal clearance between adjacent joints

Minimum 600mm

Horizontal clearance for personnel access

Minimum 600mm

Joint and nearest adjacent floor or wall

200mm
Table 4 Minimum Cable Spacings

The provision of blast shielding between phases or circuits is not recommended as it is

considered that it will increase the overall effects of a joint failure by not allowing the blast
pressure to dissipate and create a pressure cell and increasing the likelihood of the blast
being reflected back onto the fault area compounding the damage.
5.5

Existing Joint Installations

In these cases, where joints have already been installed in an in-air situation, the normal risk
assessment process shall be carried out. If it is decided that additional precautions are
required, the circuit(s) in question shall be switched out and the methods detailed in Sections
4.1 and 4.2 of this document shall be employed.

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