intercompatible CAble REpair (iCARE) 2

Started

Other Power and Storage Technologies(Electricity transmission and distribution)

Applied Research and Development

ENGINEERING AND TECHNOLOGY (Electrical and Electronic Engineering)

Not Cross-cutting

Project Contact
National Grid Electricity Transmission

Network Innovation Allowance

Ofgem

01 January 2025

31 January 2027

ENA months

£1,750,000

Power

London

Network Innovation Allowance

Project Contact, National Grid Electricity Transmission

An ERTS solution that can promptly re-establish service in the event of a cable fault and would greatly improve resilience of a fast-changing electricity infrastructure. Cable repair times will be reduced from weeks to days if this project is successful. The existing ERTS product of Pfisterer covers up to 170 kV. Design limitations on weight and size, handling issues for installation and behaviour of epoxy curing process restrict the ability to scale up to either 275kV or 400kV systems currently this project will explore feasibility and prototype testing to remove these challenges and limitations. A modular lego approach where onsite jointers will prepare both cable ends with male connectors. A factory pre-tested back to back female joint will be shipped to site for assembly and energisation. The key goals of this project is to develop this solution for 400kV and to (1) identify technically viable next generation of hybrid filler materials for non-linear stress grading applications and robust methods to connect two female components with inert materials, (2) ensuring optimised design with respect to weight and size of the joint while effectively manage the field stress in critical regions and (3) roadmap these novel materials for future prototype demonstration in T3. A subsequent T3 project is being planned that will see this solution fully tested at both 400kV and 275kV and market ready within T3 if this initial project proves successful. New material development for non-linear graded materials using hybrid fillers. This will facilitate the development of new stress grading applications for higher voltage cable connector applications.Develop and fabricate new novel materials for non-linear stress gradingCharacterise and optimize the functional performance of these materialsDesign analysis of 275/400kV rated connectorMaterial deployment roadmap for next generation HV cable connector productsProject management, recommendation and dissemination 1) Significantly reduce cable repair time leading to lower capital expenditures utilising these new materials (reduced weight/increased capacity).(2) Reduce management and associated costs of spare parts and perishable items.(3) Improve availability[GS1

Although substantial studies have been performed on overhead line and cable, there is far fewer studies on the potential risk posed to interfaces within cable joints for high voltage (HV) cable systems.There are significant cost and time associated with any cable repair, with the situation likely to worsen with an increasing number of cable installations and an ageing fleet of cable assets. The availability of aUniversal Joint would enable a package to be made available for a speedy cable repair solution that can promptly re-establish service in the event of a cable fault, this emergency return to service solution would greatly improve resilience of a fast-changing electricity infrastructure.

02/04/25