Installation of high voltage cable

accessories

Advantages and benefits of Brugg solutions

Eng. S. Abu Muhammad

Brugg Cables

High Voltage Accessories
Installation Quality circle

Best practices Planning of

& lessons learned installation premises

Installation
Mounting Environment
procedures

Tool selection
and calibration
Installer certification

Brugg Cables Academy

2
 Efficiency improvements in joint
installations
Improved installation procedures & cable preparation

 Easier to remember
and reproduce

 Reduction of installation
time
Short

 Reduction of installation Longer side for parking Joint body

failures
Same for all cable types

Brugg Cables Academy

3
Efficiency improvements in joint
installations

Remove lead (Pb) sheaths with help of fork.

 For all cable sizes Carefully mark & cut Pb Sheath. 

(Attention not cut insulation!)
 Avoid damage of cable
core underneath Pb

 Avoidance of cable
insulation damages
during cable
preparation Fork

Brugg Cables Academy

Efficiency improvements in joint
installations
Cable Heating & Insulation push back
INSULATION PUSH BACK DEVICE

 Straighten the cables

 Relaxation of insulation
mechanical stress

 Reduction of failures
due to displacement of
joint body!

Brugg Cables Academy

 Cable straightening process
Brugg Best practices

• SET HEATING TIME according to conductor size

(Table guide included in all mounting instructions)

• PERFORME THE PUSH BACK OF INSULATION (use

Brugg push on devices) and fit the cables with the
straight Angle.

• WHEN CABLES COOLS DOWN remove the angles and

lay the cables on wooden supports

Brugg Cables Academy

 Efficiency improvements in joint
installations
Precision of cutting &
peeling

Precise cut 
distances

 Reduction of failures
due to bad cable Pull off insulation with 
preparation device to expose 
conductor
Brugg Cables Academy
 Efficiency improvements in joint
installations
piece of glass  Cable peeling & Insulation grinding.
can also be 
used for 
peeling of SC 
SC PEELING & STRIPPING TOOL
Provides precise peeling 

Polishing of 
XLPE by corund 
cloth.

Motorized  GRINDING MACHINE reduces
Time and effort
Brugg Cables Academy
 Brugg best practices for peeling and
grinding

• Use peeling tools to remove the cable outer semi

conductive layer – Correct imperfections with piece of
glass

• POLISHING OF XLPE (XLPE diameter reduction not more

than 0.5 – 0.7 mm)

• Use proper sequence and grain size of corundum cloth

• To obtain optimum SMOOTHNESS OF INSULATION slightly

heat the cable insulation after grinding.

Brugg Cables Academy

 Efficiency improvements in joint
installations
Cut edge of outer semi conductive layer without use
of semi conductive varnish!
 Achieve lower contact
resistance between
No groove no   deflector and SC
sharp edge

Max. concentration of electric 
fields at the edge where SC ends

Brugg Cables Academy

Efficiency improvements in joint
installations
Deflector  Joint bodies

Stress cones

High contact resistance between  Middle Electrode
cable SC layer and deflector avoids
optimal field control particularly in 
high transient overvoltage! 
Deflector Deflectors
Brugg Cables Academy
11
Brugg best practices – Clean insulations

• Avoid
contamination
while preparing
other cables

• Wrap plastic foils

provided with the
installation kits

• Cable preparation
completed.

Brugg Cables Academy

 Efficiency improvements in joint
installations
Sliding of Joint body with
help of gas cushion system

 Avoids adhesion of SC
particles into joint body

 Reduces mechanical
stress of joint body

 Reduction of failures

 Reduction of installation costs

Brugg Cables Academy

.Efficiency improvements in joint
installations
Press (Crimping)
connectors
•Additional equipment
(press dies; pressure
devices) are needed.

Bolted connectors
• Well established
method
• Easy to install, no
special equipment
• Reduced
installation time

Brugg Cables Academy

14
 Efficiency improvements in joint
installations
For large conductor size, the connector  
of two piece avoid additional cable 
BOLTED CONNECTOR length for installation – joint pit 
optimization!
(Clamp with 
concealed 
bolts)

Head of each bolt will break away 
after a specific applied torque. Fill all 
gaps with compound to avoid sharp
edges
Brugg Cables Academy
 Efficiency improvements in joint
installations
Screen connection without plumbing and soldering
Connection of Coaxial cable 
(bonding cable) soldered
 Soldering requires special
skills – Danger of cable core
overheating Bonding  Outer 
cable conductors
 Cooling times required Power 
Cable

Soldered 

Brugg Cables Academy

 Efficiency improvements in joint
installations
Improve screen connection without plumbing

 Reduced installation time

 Reduction of failures due to cable overheating
 Reduction of costs for training and installer qualifications

Brugg Cables Academy

17
 Efficiency improvements in termination
installations
Improved universal gland system for all terminations

Press ring
Gland Adapter  Intermediate 
ring ring

 Reduced installation time

 Reduction of failures due to bad installation
 Reduction of costs for training and installer qualification

Brugg Cables Academy

 Efficiency improvements in termination
installations
Cable screen connection without plumbing or soldering
Cu wires fixed with 
bandits 

Cu braids fixed with 
bandits 

 No cooling time required

 No special skill required

Brugg Cables Academy

19
 Efficiency improvements in termination
installations t _

Cold pouring silicone oil

ca.3200
 No heating required
 Flexible installation
(pump from top or bottom)

4795

2351
1200
200

Brugg Cables Academy

20
Efficiency improvements in termination
installations

Vacuum pump –
to pump gases 
and vapors out of 
insulator.

Pump for filling 
Filling of Silicon oil inside the insulator of silicon oil 
inside insulator
Brugg Cables Academy
Efficiency improvements in termination
installations
GIS Insulators acc. IEC
62271-209

 Easy installation to any

GIS without adapter rings
or intermediate plates

 Reduction of installation
time and costs

 Reduction of stock of
special parts Fasten termination with GIS cable box

Brugg Cables Academy

 THANK YOU VERY MUCH FOR YOUR
ATTENTION.

Eng. S. Abu Muhammad
Brugg Cables.

Brugg Cables Academy