PFISTERER Customer Magazine

Issue 1 2020

4 String expertise for 16 With high voltage

the ultimate challenge through the Gulf of Patras

www.pfisterer.com
Legal Notice 4 String expertise for Editorial
Publisher
the ultimate challenge
PFISTERER Holding AG
Rosenstrasse 44
Dear reader,
10 Short News
73650 Winterbach
Germany
Tel: +49 7181 7005 0 Reliability and security are key
Fax: +49 7181 7005 565
requirements for people. This is
[email protected]
www.pfisterer.com 12 Kadaň – From Vision
particularly applicable to energy
Editorial Team to High-Performance infrastructure because we all depend
Production
PFISTERER Kontaktsysteme GmbH
Rosenstrasse 44, 73650 Winterbach
on a reliable energy supply at the end
Thomas Bachmann, Christiane Bär, of the day. Therefore, reliability and
Katrin Brecht, Alejandro Escobin,
Natalie Fischer, Valentino Magnano, 16 With high voltage security have always been the core
through the Gulf of Patras Stephan Götschel Dr. Konstantin Kurfiss
Ivan von Meister, Peter Müller,
Lambros Papadias, Dr. Frank Schmuck, principles behind PFISTERER’s solu-
Frank Straßner, Gregor Vollbach
tions. This is evident in lots of aspects
Text Concept and Text Editor
Karolina Kos
20 Short News of our day-to-day work.
www.xyzeiler.de

Sympra GmbH 22 One solution for all Therefore, the French network operator like to draw our expert interview with
Agency for Public Relations
Stuttgart types of cable damage – RTE has confirmed that we provide Karin Ohlenforst from the Global Wind
long-term security by qualifying our Energy Council (GWEC) to your atten-
Art Direction
the Universal Repair Kit expertise in the integration of mainte- tion. This forecast gives us an exclusive
BERNETBRANDS
BERNET COMMUNICATION GmbH
Stuttgart from PFISTERER nance-free silicone rubber composite insight into the global trends in the
© Copyright by insulators into existing chain designs field of offshore wind energy (Page 26).
PFISTERER Holding AG 24 SEANEX optimises for overhead lines (Page 4). These
66 kV connection sili­cone rubber composite insulators And, should there be any cable damage
technology for offshore are also manufactured in a state-of- despite all the care and attention, we
wind turbines the-art production environment at ensure reliability in an emergency with
PFISTERER
our new plant in Kadaň in the Czech our Universal Repair Kit, which is suit-
Customer Magazine
26 Global trends in offshore Republic. This plant has already been able for all cable sections (Page 22).
Issue 1 2020
qualified by numerous energy compa-
wind power nies too (Page 12). Have a read and be inspired! We hope
you find this information interesting
We also ensure supply reliability in and look forward to being able to pro-
an entirely different way: working as vide you with reliable support in your
a team with Hellenic Cables, we are upcoming projects.
responsible for the realisation of a new
undersea cable connection through the Best regards,
Greek Gulf of Patras with high-volt-
age joints and outdoor terminations
(Page 16). And, with SEANEX, we are
also ensuring reliability in the field
of renewable energy production in the Stephan Götschel Dr. Konstantin Kurfiss

66 kV offshore field (Page 24). We would PFISTERER Holding AG Board of Directors

2 CONNECT 2020 CONNECT 2020 3

String expertise for Some of these strengths are due to the silicone rubber
material that is used. The insulating jackets of composite
105,000 km
is the total length of the transmission

the ultimate challenge

insulators are made from a formulation specially devel-
grid operated by RTE
oped for high-voltage outdoor use. A key property of sili-
cone rubber is that it is hydrophobic: it causes moisture
to bead and run off the insulator surface. This prevents

60
the formation of a continuous film coating, which could
become conductive due to dissolved contaminants and
allow creepage currents to flow. The result is very good cross-border
PFISTERER was successfully qualified by the French transmission system operator arcing resistance in heavily polluted environments like connections
Réseau de Transport d’Électricité (RTE) as a supplier of overhead line insulator railway tunnels. “Silicone rubber also has the ability to
recover and transfer its hydrophobicity. That means it can
string solutions for the 225 kV and 400 kV extra high voltage levels. Qualification restore its hydrophobicity if hydrophobicity is lost or re-
centred on the precise integration of silicone composite insulators including duced, and transfer it to attached contamination layers,”
explains Dr.-Ing. Christiane Bär, head of composite mate-
protective fittings into existing string designs as an alternative to glass cap insu- rials development in the corporate technology department
lators for special applications. It was a challenging process that required at PFISTERER. Therefore the usual maintenance activi-
extensive expertise. This story illustrates why, in addition to material quality and ties on conventional insulators in outdoor applications –
such as cleaning or surface treatments – can be elimi-
modern manufacturing processes, the application-specific design of string nated. Silicone composite insulators are also breakage
components with full consideration of their interactions is crucial to ensure the resistant under shock stresses. Their low weight facili-
tates transportation and installation, and enables sleek
reliable, safe and economical use of insulator strings for decades. mast designs.

Cost-effective durability
»This is where silicone “These properties have led to the widespread acceptance

composite insulators really of silicone composite insulators. PFISTERER has ac-

companied their continuous development with innovative
show their strengths.« solutions and practically relevant groundwork,” says
Dr.-Ing. Frank Schmuck, Director Corporate Technology
Ivan von Meister and head of OHL (overhead lines) Composite product
Project Manager at PFISTERER
portfolio management at PFISTERER. He also authored
the reference book “Silikon-Verbundisolatoren – Werk-
stoffe, Dimensionierung, Anwendungen” (Springer-Verlag).
Technology transfer:
Qualification centred on the Whether used throughout the grid or selectively as at
With nearly 105,000 km of lines, RTE operates the larg- precise integration of RTE, composite insulators support the operational reli-
silicone composite insulators
est transmission grid in Europe. Almost half of its 400 kV ability and economic efficiency of high-voltage overhead
including protective fittings
and 225 kV overhead lines transmit electricity over long into existing string designs for lines and hence also of electrical power transmission
distances and to 60 cross-border connections with the glass cap insulators. systems. “RTE attaches great importance to safety and
United Kingdom, the Benelux countries, Germany, Switzer- economy in its commitment to high electricity availability
land, Italy and Spain. Lines at 150 kV, 90 kV and 63 kV are in line with modern standards – both as a grid operator
used for regional sub-transmission. Mainly glass cap in France and as a partner to energy suppliers worldwide,”
insulators are used in the insulator strings for the over- states Michel Bartissol, president of PFISTERER’s
head lines. RTE uses silicone composite insulators French subsidiary. As the local contact for RTE in Illzach,
where lines traverse industrial zones, coastal areas or he worked closely with PFISTERER’s sites at Malters
mountainous regions. in Switzerland and Kadaň in the Czech Republic for the
project implementation.
Ivan von Meister, a project manager at PFISTERER who
played a leading role in the qualification of the new com- Since January 2019, PFISTERER has supplied silicone
ponents for RTE, describes the background: “In these composite insulators for various suspension and strain
areas, conditions for operating overhead lines are more strings in accordance with RTE standards for voltages
difficult due to increased air pollution or rough, inacces­ and load classes 225 kV / 150 kN, 400 kV / 300 kN and
sible terrain. This is where silicone composite insulators 400 kV / 600 kN including protective fittings. Their design
really show their strengths.” was the outcome of an extensive qualification process.

4 CONNECT 2020 CONNECT 2020 5

 nical industry organisations such as CIGRE and IEC,
for example. And thanks to customers worldwide who
entrust us with challenging tasks.”

Every design is complex, whether for standard applica-

tions or a special solution. The overarching goal is al-
ways to arrive at a functional and economically optimised
Arcing horn,
end product. Christophe D’Hondt, technical support en- earth side
Insulator end fitting
gineer at PFISTERER, outlines the complexity: “Each insu-
Corona
lator string has to fulfil numerous mechanical and elec­ protection ring,
trical requirements. Sometimes they demand conflicting earth side
design characteristics, but nevertheless they all have to Silicone
Insulator
be implemented as a lifelong cohesive and efficient whole.” long-rod insulator
installation
(length not to scale)
The design for RTE is a case in point – with added difficulty. length

The silicone composite insulators had to be integrated

Arcing horn,
with protective fittings into RTE string designs which high-voltage
Double sealing
normally use glass cap insulators. This was the ultimate side
system with
Strong under strain: RTV and HTV
Fitting the 1,200 kN double challenge for PFISTERER’s string experts: the seam-
strain insulator strings less implementation of a technology change within very Insulating
Corona
by PFISTERER with silicone
tight design constraints and with interdependent design protection ring,
jacket
composite insulators and
protective fittings. Each insulator
criteria. Insights into the design of insulators and prote­ high-voltage side

can support mechanical loads ctive fittings for 400 kV double strain insulator strings Fibreglass rod
of up to 600 kN. This is illustrate some of the requirements and the typical differ-
equivalent to a weight of around
61 t on the ground.
ences between glass cap and silicone composite insulators.

Strong under strain. Safe in operation.

For decades of safe and reliable operation: The precise design of the composite insulators and protective fittings by PFISTERER for existing RTE string designs
When transmission lines pass through mountainous ter- was assisted by 3-D-models. Shown on the left is a model of the double suspension string for 400 kV / 600 kN with silicone composite insulators (each 300 kN).
rain, they are sometimes routed across significant The detailed view on the right shows a cutaway of the internal structure of string components.
PFISTERER met these special challenges with knowledge changes in elevation. This can cause increased tensile
drawn from experience: almost 100 years of designing forces on the conductor cables, which also affects insu­
overhead line systems and more than four decades with lator strings and masts. In such applications, RTE uses
silicone composite insulators. “Our expertise develops special heavy-duty double strain insulator strings with requirement that the 400 kV insulators used in the string influences the withstand voltage value. This marks the
with the latest technology and shapes it,” says Thomas composite insulators and a total load capacity of 1,200 kN each have to be able to take a load of up to 600 kN. One limit up to which no flashover may occur on the insulator
Bachmann, head of the OHL Composite division at (see figs. page 7 for an example string structure with of the critical factors here is the design of the insulator’s string despite an overvoltage. If this limit value is
PFISTERER. “Through our extensive involvement in tech­- component labels). It follows from this as a mechanical metal end fittings. They are usually cast for attachment exceeded and a flashover occurs, the arcing protective
to glass cap insulators. With composite long-rod insu­ fittings form a spark gap that acts as a surge arrester.
lators, end fittings are pressed onto the fibreglass rod. Their geome­try causes the arc to extinguish itself at a
In this case, the force required to break the insulator sufficient distance from the insulator jackets and in a
increases with the compression length of the end fitting controlled manner.
and the diameter of the fibreglass rod. The higher the
tensile forces that a silicone composite insulator has to Based on operational experience, for lifelong reliability
transfer, the greater the crimp area (compression area) and the consistently advantageous use of high-voltage
that has to be provided. An important design variable is insulators with silicone rubber insulation, it is necessary
the “damage limit” of the fibreglass rod, below which to integrate corona protection as well. Conventional co-
practically no fibre breaks occur. rona protection is aimed at preventing corona discharges
on metallic string components with associated phenom-
The dimensioning of end fittings, in turn, can influence ena such as audible noise as well as radio and TV interfer-
225 kV / 150 kN how electrical requirements are implemented, for ence. Additional corona protection is usually implemented
400 kV / 300 kN example in the design of protective fittings. Arcing pro-
tective fittings are provided to protect high-voltage insu-
in the form of corona protection rings. These are intended
to prevent corona discharges on the insulator surface in
400 kV / 600 kN lators against the damaging effects of an arc, which damp conditions, known as water droplet corona, and on
can be caused by overvoltages due to a lightning strike metal string components in direct proximity to the insu-
PFISTERER supplies silicone composite insulators for
or switching operation, for example. The critical factor lator surface, thereby preventing damage to string com-
various suspension and strain strings in accordance with
RTE standards for voltages and load classes 225 kV / 150 kN, for this protective function is the distance or clearance ponents and the insulating jacket. Corona protection
400 kV / 300 kN and 400 kV / 600 kN including protective fittings. between the arcing protective fittings. It significantly can be combined with arcing protection and implemented

6 CONNECT 2020 CONNECT 2020 7

in one protective fitting. Or corona and arcing protection To achieve the predefined installation length with silicone
can be provided separately in two protective fittings, as composite insulators while taking the required load
required by RTE for their own insulator strings. classes into account, the string specialists at PFISTERER
developed an alternative design for the end fitting. This
Efficiency through standards. approach would only work if PFISTERER could guarantee
Agility for individual needs. that the insulators were manufactured with smaller
An effective lever for implementing requirements econo­ installation length tolerances than usual. In parallel,
mically is to use standardised resources and procedu­ the existing string designs posed another complex de-
res enterprise-wide. “PFISTERER has many established sign challenge: there was also very little space in which
components and proven designs for integrated insulator to integrate the multi-part arcing protection fittings and
strings. This enables us to directly cover many different corona rings. Within very narrow limits, both protective
standard applications,” says Ivan von Meister. “At the fittings had to be carefully coordinated with each other.
same time, we are used to adapting what we have and
developing individual solutions when specific applica- Christiane Bär explains the coordination process and why
tions or customer specifications require it.” RTE’s existing it is so important: “Protective fittings have to meet cer-
string designs result in fixed installation lengths for tain design criteria to function properly. Corona rings have
the respective insulators, including protective fittings. to be precisely positioned at particular places in the
These limited PFISTERER’s use of standard component insulator string, for example. With arcing protective
Efficient development: PFISTERER uses simulation software that calculates electric field strengths to assist the design of protective fittings and insulators.
designs when implementing RTE’s mechanical and elec- fittings, there has to be an exactly defined clearance be- The images above show electric field strength simulations on the high-voltage side protective fittings (left) and on the high-voltage side silicone rubber surface of
trical requirements described above. But the design is tween their arcing horns. At the same time, these design the insulator (right). The colours indicate that the specified field strength limit values in each case of 18 kV / cm (left) and 4.2 kV / cm (right) are not exceeded.
a success – professional and lean. characteristics must not interfere with each other. The
critical factor here is a sufficient distance between coro-
na rings and arcing horns. Otherwise, instead of burning
safely between the arcing horns, an arc could jump to the for RTE (see figs. top). “In conjunction with values production. These include the material formulation for
corona, destroy it thermally, and possibly damage the from experience, the calculations confirm whether a string manufacturing the insulating jacket for composite insu-
insulator and insulator string.” The correct coordination design is suitable from the point of view of corona pro- lators. High temperature vulcanising (HTV) silicone
is illustrated in figures left. tection, or still needs some adjustments. This speeds up rubber, highly filled with aluminium trihydrate (ATH) is
the design process and provides certainty for the sub­ preferred. It wins out over low-viscosity silicone rubber
PFISTERER used state-of-the-art simulation software sequent dielectric testing of insulator strings,” explains types that are not filled with ATH, such as room tempe­
to calculate the electrical field strengths and assist the Jaka Strumbelj, development engineer and specialist in rature vulcanising (RTV) or liquid silicones (LSR), with
electrical design of the insulators and protective fittings electric field simulations at PFISTERER. “It requires its outstanding erosion and leakage track resistance as
experience in applying numerical computer models and well as very good dynamic hydrophobic characteristics:
interpreting the results.” PFISTERER has summarised rapid hydrophobicity recovery and short transfer times.
its 15 years of involvement in this field in an in-house The youngest plant in the PFISTERER Group, in the
specification for performing the calculations, based Czech city of Kadaň, is now the largest site for silicone-
on global project experience and independent studies. related production (more on page 12). In June 2019, it too
was successfully audited for cooperation with RTE.
Top in tests
Insulators and protective fittings by PFISTERER have
proven their quality and faultless operation as part of
Proven resilience:
a string assembly in numerous mechanical and electrical Example of a silicone
tests. PFISTERER had these tests conducted on behalf composite insulator
of RTE by independent test institutes. The correct coordi­ clamped into a tensile
testing machine to test
nation of the protective fittings was confirmed by dielectric the maximum tensile
testing at EGU, including lightning impulse testing (see strength. PFISTERER
fig. page 8). Extensive arcing tests on the strings were insulators for RTE
were designed for load
carried out at KEMA – in some cases with increased classes 150 kN, 300 kN
requirements according to RTE standards: the 400 kV and 600 kN. All were
strings, for example, withstood a maximum short- successfully tested.

circuit current of 63 kA for 0.25 sec., and thus demon­

strated their excellent short-circuit strength.
Correct coordination: The distance between the corona rings and arcing horns is critical for the functionality of the corona and arcing protection. If the
distance is insufficient, a flashover could jump from the arcing horn to the corona ring (red dashed line) and damage string components. If the distance PFISTERER ensures the consistently high quality of its
is correctly designed, however, a flashover can only occur in a controlled manner between the arcing horns (green line), protecting insulators and other products for RTE and all customers worldwide in com-
string components. This is demonstrated in a lightning impulse test conducted for RTE on a 225 kV single suspension string in the EGU high-voltage lab pliance with international norms and by following con-
(image on the right).
tinuously optimised internal standards for materials and

8 CONNECT 2020 CONNECT 2020 9

News
Cables for wind energy FrontCon – Rethinking the connection principle
One of the longest 110 kV underground cable lines in of 17.30 km each) with integrated fibre optic cables in This enables a very short and compact contact system
Germany will be built in 2020 near Trier. Soon, electricity the cable screen and with two conductor cross sections for all voltage levels and large conductor crosssections
from the wind turbines in the Hunsrück region will flow (1,200 mm² and 1,800 mm²) will begin to be laid in order up to 2,500 mm². The time required is reduced by up to
17.3 kilometres to the Osburg substation. Distribution to achieve the required transmission power. 60 connecting 80%. Installation takes only around 2 hours – not longer
network operator Westnetz considers this measure an elements (in the form of IXOSIL 110 kV crossbonding than for conventional cables with standard connections.
investment into the energy revolution. The existing grid joints and transition joints from 1,200 mm² to 1,800 mm²) At the same time, possible damage when stripping the
is reaching its limits due to increasing quantities of will be used. individual strands is prevented. That significantly reduc-
wind energy. es the risk of installation errors.
In total, Westnetz is investing approximately 19 million
PFISTERER is supplying the complete 110 kV cable system euros in the cable route, which will mainly run along FrontCon is available as a connection technology for
including cable accessories as a turnkey solution. In early public roads. Completion is projected for autumn 2020. CONNEX cable connectors and IXOSIL terminations, as
2020, a total of 52 km of underground cables (in 3 phases well as for cable connections in MSA joints and type­
tested with specific cables. The first cable projects have
now been in operation for several years. The contact
system can be adapted for any fittings, enabling reliable
and cost-effective solutions in cable systems. It can be
Kabelweg
Etgert installed vertically or horizontally.
Breit
Talling
Naurath Immert High-voltage power cables increasingly utilise single-
Neunkirchen strand insulated conductor designs that significantly re-
Bescheid Thalfang duce skin and proximity effects, enabling more power
Thomm Lückenburg transmission with the same cross-section. But this con-
Herl
Lorscheid ductor structure complicates the cable connection pro-
Beuren cess. PFISTERER has developed FrontCon, which uses a
Farschweiler completely new connector principle to significantly sim-
Rascheid plify and shorten installation.
Osburg

Conventional connecting of single-strand insulated cable

conductors is a time-consuming process: separate the
individual strands, strip them one by one, then rearrange
them as far as possible in the original form without
Dr. Konstantin Kurfiss returns damaging any of the strands – A challenge and despite
best efforts, the original conductor structure is usually
to PFISTERER not achieved.

As of 1 January 2020, PFISTERER Holding AG has appointed Dr. Konstantin Faster, better connections for PFISTERER receives the
Kurfiss as a new member of the Executive Board alongside Stephan single-strand insulated cables. Golden Amper Award 2019
Götschel. Dr. Kurfiss has more than 15 years of experience in electrical With FrontCon, PFISTERER is therefore pursuing a new At Amper 2019, the international electrotechnics and elec-
power transmission and distribution technology and assumes overall frontal approach: In contrast to the conventional solution, tronics trade fair in Brno, Czech Republic, PFISTERER
responsibility for sales and technology at PFISTERER. He already worked FrontCon is installed directly on the end of the cable – was awarded the Golden Amper for FrontCon in the elec-
for PFISTERER between 2005 and 2013, where he was most recently re- no work is required on the individual strands. Specially trotechnics category. This innovative approach con-
sponsible for international sales. By mutual agreement between PFISTERER developed contact balls make contact with the front fac­- vinced an expert jury of leading scientists. Exhibits are
Holding AG and its former CEO Martin Billhardt, he retired from the es of the individual strands. Together, these contact balls judged on their global competitiveness, technical and
Management Board at the end of 2019. behave like a liquid. They compensate for slight uneven- technological level, originality of the used solution, safe-
ness at the conductor end, and ensure that the same ty and user comfort, and service and spares availabili­-
contact forces are applied across the whole conductor ty. This is the second time that PFISTERER has won the
cross-section. Golden Amper award.

10 CONNECT 2020 CONNECT 2020 11

Kadaň – From
Vision to High-
Performance
Production
Manufacturing at the highest level, using state-of-the-
art technology and building on the extensive expertise
of our innovation centres in Germany and Switzerland
– this was our vision when we were planning our new
branch in Kadaň, Czech Republic. The new plant brings
together the production knowledge of our experts we
have acquired over many years at the other branches
and combines it with optimum manufacturing condi-
tions for silicone rubber processing.

An ambitious project that we were only able to tackle

with the help of many participants. With their active sup-
In Kadaň, decades of experience from
Germany and Switzerland meet state-of- port, we managed to build one of the most advanced
the-art production technology. and efficient plants in the PFISTERER Group, allowing us
Silicone composite insulators for overhead lines are one of the
to produce highest-quality energy infrastructure prod- products manufactured at Kadaň.
ucts for our customers in an outstanding manufacturing
environment.

Continuous optimisation of
know-how and processes
A key area of silicone rubber processing in Kadaň is the
production of silicone composite insulators for overhead
lines and control units for cable accessories, such as Kadaň
cable terminations, connection parts and cable joints, Karlovy Vary
Prag
(Karlsbad)
which are also manufactured in Kadaň. The insulators
made of silicone rubber are used on high-voltage over-
head lines to prevent voltage arcing between mast and
Brno
power line. Control units use geometrical field control to (Brünn)
reduce the electric field strengths at the settling edges
of the outer conductive layer of the high voltage cables.

12 CONNECT 2020 CONNECT 2020 13

 Under state-of-the-art test conditions, our
This combines decades of experience from Germany and products are tested for our customers in
Switzerland with the latest production technology. With application situations in accordance with all
relevant standards. Test procedures are highly
the goal in mind to continuously optimise quality and effi-
automated and traceable.
ciency, we use internally trained auditors to monitor
the procedures non-stop. This allows us not only to syn-
chronize processes but to permanently test and refine
them as well. A film is worth a
thousand words
A concise plant layout, cleanly defined procedures and If you want to get a better
a multitude of identical machines facilitate fast and flexi- feel of what it actually looks
ble high-volume production. Operating data can be like, we invite you to watch
recorded, analysed and evaluated in real time. Using our branch video:
cutting-edge test conditions, our products are tested
for functionality and resilience in application situations
– highly automated, traceable and compliant with
standards.

Testing institutes and customers put their

trust into the new location
The Kadaň site is frequently inspected by a certification
authority. It meets the ISO 9001, ISO 14001 and OHSAS
18001 international standards for quality management,
environmental management and occupational health
and safety.

Although the location is still relatively new, 90 % of our

customers have already qualified the plant in a short
time, including companies such as Amprion, RTE France,
Enel, E.ON, GE Power Grid Solutions EMEA, Innogy,
Siemens, TenneT TSO and the Saudi Electricity Company.
To meet the high demand, we have created a full-time
position, which is solely responsible for coordinating cus-
tomer audits that take place almost every week in Kadaň.

The use of high-grade transparent silicone makes it possible to

detect even the smallest irregularities in the material.

14 CONNECT 2020 CONNECT 2020 15

A new land-sea cable connection
in the Strait of Rio-Antirrio near
Patras will in future link the Pelo-
ponnese to the 400 kV grid in
central Greece. Together with
Hellenic Cables SA, PFISTERER
is ensuring safe and punctual con-
nection with IXOSIL high-voltage
joints and outdoor terminations.
The two partners have been
working together successfully in
joint MV, HV and EHV projects for
around 15 years, mainly in Euro-
pe, but also internationally.

The spectacular Rio-Antirrio Bridge

has linked mainland Greece to the
Peloponnese peninsula since 2004.

The view over the Strait of Rio-Antirrio is stunning: at this connection of southern Greece to the power plants in the
point, only two and a half kilometres of blue sea sepa- east is now being improved. Planning for the land-sea
rate the Peloponnese in southern Greece from the central cable connection began around five years ago, and a year
mainland. Since 2004, a spectacular bridge has spanned ago Hellenic Cables and PFISTERER were awarded the

With high voltage

the entrance to the Gulf of Patras, providing a permanent contract against competitors. The two companies
road link. But the idyll is deceptive. As in the whole of are linked by a long-standing partnership, as Eduardo
Greece, the area is considered seismically active, espe- San­tana, Director of PFISTERER’s PTS Cable business unit,

through the Gulf of Patras

cially since the 65 metre deep strait lies on a tectonic emphasises: “Hellenic Cables as a manufacturer of power
fault zone. A challenge for all infrastructural facilities, cables and PFISTERER as an independent expert in cable
which must be built to withstand earthquakes. fittings have always shared the same philosophy of im-
plementing the maximum technical for our clients and
Preliminary tests successfully completed in 2016 making a decisive contribution as a team to the overall
The client for the current project to expand the 400 kV success of such projects.” Starting with initial projects
grid further is the energy supplier IPTO, a subsidiary in the MV and HV sectors, the 420 kV fittings from
of PPC, the largest energy supplier in Greece. While the PFISTERER underwent cable-specific system testing
eastern connection of the Peloponnese through the with Hellenic Cables in accordance with IEC 62067 in
Corinth Canal is already well developed, the western 2016. “For quali­fication purposes, the CONNEX and

16 CONNECT 2020 CONNECT 2020 17

 Close cooperation boosts projects
“Hellenic Cables and PFISTERER are a prime example
of a successful partnership,” stresses Lambros Papadias.
“In close exchange, we face the technical challenges in
the projects together and benefit from each other’s many
years of experience.” Following earlier projects in
Greece, Romania and the Balkans, numerous joint con-
tracts have since followed throughout Europe, such as
the connection of TENNET’s Dolwin Alpha offshore con-
verter platform in the North Sea. Another project in­
volving PFISTERER in Greece was the 150 kV connection
to the Cyclades Islands; in March 2019, a further 400 kV
EHV project was completed successfully in western Greece
with Hellenic Cables.

And the next projects are already in the pipeline: in ad­

dition to the current installation of the EHV connection at
Patras, preparations are underway for a new 170 kV
submarine cable connection between the Peloponnese
and the island of Crete. Here, too, Hellenic Cables and
PFISTERER won the joint contract.
Two three-phase EHV submarine cables
are connected to the land cables on both shores
using PFISTERER connection joints.

»Hellenic Cables and PFISTERER are

a prime example of a successful partnership.«
For qualification purposes, PFISTERER’s CONNEX and IXOSIL fittings were
tested with higher requirements. Lambros Papadias,
PFISTERER delegate, Greece

IXOSIL fittings were also tested at 230 kV instead of the by IXOSIL slip-on joints (land / sea cable) from PFISTERER,
usual phase-to-earth voltage of 220 kV in accordance followed by further joints at intervals of 300 to 800 m,
with the higher re­quirements of the Greek network op- depending on the length of the land cable sections. For
erator. The lightning impulse tests were increased from connection between the sea and land cables, the IXOSIL
1,425 kV to 1,550 kV. The PFISTERER systems passed all transition joints and SICON connectors also ensure a
the tests with flying colours – an important prerequi- safe transition between the different cable diameters of
site for the current EHV project,” reports Lambros 1,200 mm2 for the sea cable and 2,500 mm2 for the land
Papadias, PFISTERER Delegate for Greece and neigh- cable. For monitoring purposes, one phase of the sea
bouring Balkan countries. PFISTERER is currently one cable and one phase of the land cable are equipped with
of the few suppliers of fittings worldwide that can show a fibre optic conductor.
it has passed this test successfully. In order to respond
optimally to individual market requirements, PFISTERER While the EHV connection in the Strait of Rio-Antirrio
maintains a strong local presence. At the same time, the uses XLPE cables of the same kind, the PFISTERER
PFISTERER plants in Germany and Switzerland are de- fittings are generally universally applicable and compa­
veloping technical solutions with an international vision. tible with XLPE cables from all suppliers. In addition to
the planning, manufacture and delivery of the IXOSIL
The installation of IXOSIL joints and outdoor
400 kV under the sea joints and outdoor terminations, PFISTERER is also terminations for the new 400 kV land-sea cable link
The new EHV connection on the west coast of the Pelo- re­spon­sible for their installation by its own EHV-trained near Patras is in full swing.
ponnese is based on two three-phase submarine cables. in­s tallers . The joints are placed on land in ducts and
These are connected to the land cables on both shores then buried.

18 CONNECT 2020 CONNECT 2020 19

News
True dedication – customer Peak excitement: TENSOREX C+
service in the eye of the storm at the Junghans Terrassenbau Museum

A technical masterpiece: the creation of energy for small Therefore, it is no coincidence that PFISTERER has been
mechanical clockwork using tightly-wound metal springs. asked by the management of the Terrassenbau Museum
But craftsmanship has mastered that too … all over the to illustrate this sophisticated application by creating an
world and in the Black Forest in particular. You can marvel image of the TENSOREX C+.
at this technical masterpiece in the new Junghans Terra­
ssenbau Museum in Schramberg.

North The principle of spring tension is in no way limited to

Carolina
clockwork. An outstanding example of its application in
South
Carolina industrial technology is provided by our TENSOREX C+
spring retensioning system which is used for overhead
Georgia
lines for electric trains in both local and long-distance
rail transport.

Florida
Bahamas
PFISTERER has been named a
On Friday 6 September, having left a wake of devastation Although the worst Global Market Leader Champion again
in the Bahamas, Hurricane Dorian made landfall in Cape was over, Tim had to
Hatteras, North Carolina, as a Category 1 storm. Tim drive the whole way and services. PFISTERER once again met all the nec-
Hurricane Dorian's path of devastation.
McLaughlin, PFISTERER NAM Sales Director, played through flooded essary criteria and was listed as a Global Market Lead-
a part in the relief effort, providing rapid assistance after streets, dodging debris and toppled trees, to deliver er Champion in the “high voltage cable accessories and
190,000 people in the local area were stuck without power. the connectors as fast as he could. Simple handling and power grids” segment. This award is simultaneously
reliable installation then enabled the customer to restore praise and motivation.
Dorian was the first major hurricane of the 2019 Atlantic service swiftly to the local community by replacing failed
hurricane season, and is regarded as the worst ever natu- cables with pre-made cables connected with SICON 2-hole The basis for the ranking is the Global Market Leader
ral disaster to hit the Bahamas. On 1 September, the Cate- NEMA lugs. This is one more reason why the energy sup- Index for Germany, Switzerland and Austria, which was
gory 5 hurricane slammed into the Abaco Islands with wind plier uses proven SICON screw connectors by PFISTERER developed by the HBM Unternehmerschule (School for
speeds of 295 km / h. The damage was catastrophic. in all conceivable application scenarios. Entrepreneurs) at the University of St. Gallen in cooper-
ation with the Akademie Deutscher Weltmarktführer
Preparing for the worst, the U.S. states of Florida, Georgia, (Academy of German Global Market Leaders) and a
South Carolina, North Carolina and Virginia declared a media partner “WirtschaftsWoche”. It includes German
state of emergency and issued evacuation orders. On companies that have a leading position in their respec-
September 6, Dorian finally reached Cape Hatteras – only tive markets. The Global Market Leader Index uses an
60 miles away from our North America Sales Director objective and transparent selection process where the
Tim McLaughlin – and caused a power outage affecting The magazine “Wirtschaftswoche” (Economic Weekly) selection criteria and the calculations are made public
190,000 people. has dedicated its October 2019 special edition entitled when the complete Index is published.
“Deutschlands Weltmarktführer 2020” [Germany’s
Rapid delivery of SICON screw connectors World Market Leader 2020] to global technology leaders
Two days later, McLaughlin received a call requesting an that are mostly family-owned companies. Following
urgent delivery of SICON screw connectors. These are ide- appearances in 2017 and 2018, PFISTERER has now
ally suited to connecting all kinds of copper or aluminium made the list for the third time in a row. Global compa-
cables, solid or stranded, for voltages up to 245 kV and nies that are especially successful in their market seg-
conductor cross-sections of 16-400 mm² – so they are also ment are given the title of global market leader, which
ideal for quick repairs to storm-damaged power lines. Tim McLaughlin (right) on arrival at Cape Hatteras. demonstrates the outstanding quality of their products

20 CONNECT 2020 CONNECT 2020 21

One solution for all effort and costs for preventive storage are correspond-
ingly high. Faced with this challenge, PFISTERER,
Coherent overall concept – ready-to-use
“The Universal Repair Kit is a cable repair system

types of cable damage –

as a cable-independent manufacturer, looked for a with real added value for our customers, because it
cost-effective, quickly deployable repair solution that offers the highest flexibility with the lowest inventory
minimises both downtimes and storage costs and thus costs. In the overall concept, however, we go one step
the costs for operators. further, because we also want to make the provision of

the Universal Repair Kit

all components as simple as possible when needed,”
Replace – plug in – finished explains Alejandro Escobin. This is why PFISTERER
The solution is based on the universal plug-in principle designed a systematically pre-sorted container box that

from PFISTERER
of the PFISTERER fittings. They can be used to connect contains all the components required and can be trans-
all types, materials and diameters of different cables, ported safely and quickly to the point of use. This box is
because as a cable-independent manufacturer, PFISTERER individually adapted to the cable systems installed in the
offers suitable connector configurations for all cable types. customer’s grid, so that the plugs and joints can be used
A pluggable cast resin joint in turn serves as a universal universally for all conceivable applications. This com-
connecting piece between the different cables. In combi- pletely eliminates the previous extensive storage for
nation with a defined XLPE replacement cable, universal every eventu­ality. “Our fittings are dry systems. They
and reliable repair sets for defective cable sections can are thus oil and gas-free and therefore immediately
be assembled very quickly. At the same time, the modular ready for use – simply ready-to-use. They are also easy
Faulty cable section design of the joints and connectors reduces the range of to store and have a long shelf life,” Escobin adds.
parts that need to be held in stock. Once the defective cable
section has been located and exposed, the affected sec-
tion is simply cut out and the two remaining ends are
2x Box
fitted with connectors. Then a replacement cable, also
1x Box A Replacement
cable
1x Box A
equipped with plugs, is placed between the cable ends Quick Deploy Solutions
and finally all plugs are plugged into the joints – done.
V-Muffe V-Muffe In order to be optimally equipped at all times, preventive
In order to make the installation and storage of the preparation and planning for all possible scenarios in
Universal Repair Kit as easy as possible, PFISTERER an energy grid is necessary. The new Universal Repair
1x Box B 1x Box B 1x Box B 1x Box B
developed a universal cast resin joint from its existing Kit is therefore part of a whole series of quickly deploy-
range for voltage levels up to 170 kV, which is also suit- able solutions – the Quick Deploy Solutions – with which
1x BOX “x” suitable for defective cable 1x BOX “x” suitable for defective cable
able for underground applications. It can connect any PFISTERER provides its customers with preventive sup-
cable conductors such as copper or aluminium, as well port for rapid deployment, necessary repairs, installation
as different diameters and insulation materials. At the work, maintenance or revisions. These include connec-
same time, the new universal joint fulfils all necessary tion solutions for easily transportable emergency trans-
1 2 3 4 3 2 1 shielding requirements up to cross-bonding or fibre formers, as well as construction cable systems and a
optic conductor monitoring and is therefore ideally universal kit based on just a few components for bridging
[1] CONNEX plug connector for existing cable ends, [2] CONNEX connection joint, [3] CONNEX plug connector for replacement cable, [4] replacement cable.
suited for replacing defective joints or cable sections. and bypassing plant components in substations. In ad­
PFISTERER will soon also be offering pluggable termina- dition, PFISTERER provides training for the customer’s
tions for cable damage near a termination. employees and fitters and also ensures continuous
service for the components.
Less stock and less outlay
“The special feature of our solution lies in the univer-
One wrong move with an excavator Trouble-free grid operation is a must for energy suppliers. ­sa­lity of the joints used and the configured replacement
shovel and you have a problem. Continuous supply must be ensured as far as possible, cable. This can correspond, for example to the cable
not only with a view to customer satisfaction, but also with the largest cross-section installed in the operator’s
The cable is cut, and hundreds of regarding high downtime costs. However, with thou- grid – and then acts as a new connection, suitable for all
households and businesses are left sands of civil engineering works every day, cable damage applications. This means that it does not matter what
cannot be avoided completely. On top of this, there are type of XLPE cable or cross-section is affected in the
in the dark. A quick solution is then cable faults caused by weather conditions, ageing and event of damage. Thanks to the connection fittings, the
necessary: with its Universal Repair water ingress. The problem: in view of historically grown pluggable spare part fits all XLPE cable types in the net-
Kit, PFISTERER offers the first uni­ grids and the corresponding large number of different work,” explains Alejandro Escobin, Senior Product Manager
cable types, materials and cable diameters used, preven- HV-CONNEX at PFISTERER. This means that grid opera-
versal cable repair system – suitable tive preparation for possible emergency operations is tors do not have to spend a lot of time and effort on main­
for all XLPE cables, regardless of a logistical challenge for grid operators. In the event of taining all cable types, as far as this is possible at all.
a broken cable or a line fault, there is no time to pro­ At the same time, installation is simplified for the fitters,
type, age or diameter. cure replacement solutions with long delivery chains. The as only one universal system needs to be used.

22 CONNECT 2020 CONNECT 2020 23

SEANEX optimises 66 kV connection
Von 33 kV
auf 66 kV
technology for offshore wind turbines Offshore wind power is coming of age:
at 66,000 volts, wind farms are pushing
into the high-voltage range and taking MV
technology to its limits.

SEANEX by PFISTERER is an offshore

variant of the successful CONNEX HV
connection system that is specially
adapted for 66 kV inter-array cabling.
With SEANEX, too, PFISTERER exploits
the advantages of the robust inner
cone system. At the same time, tower cable, the tower segment construction phases can
be clearly separated. The joints can be preinstalled on-
the fitting is the most compact and shore in the tower segment or base element, resulting in
most lightweight offshore connection shorter offshore installation times. Then, at sea, the tow-
er wiring is connected by simply plugging in. What’s more,
so­lution for 66 kV. in contrast to outer-cone plugs there is no need to build
a transition box.
Offshore wind power will become more and more import-
ant in the energy mix of the future. Numerous projects One connection technology for the
worldwide are in the planning stage – not only in Europe, whole offshore wind farm
which has long been a pioneer, but especially in Asia and Since the beginnings of offshore wind power, PFISTERER
the United States. Countries such as China and Taiwan, has been involved in developing numerous platform pro­
where PFISTERER is also active, are focusing heavily on jects for offshore grid connections. With its CONNEX fit-
offshore wind farms and thinking big. In view of the high tings, PFISTERER is the only manufacturer offering an
total output from such large-scale farms, the inter-array offshore-certified solution that has been tried and tested
cabling, which connects the wind turbines to the offshore for 20 years. “On the platforms, we have always worked
substation, is an important factor. As the nominal power with HV, so it was an obvious and logical step to use
of wind turbines increases, it is a greater challenge to proven HV concepts for the inter-array cabling,” Dr. Peter
Proven high-voltage technology: dry pluggable inner cone solutions for
transport the electricity reliably, safely and as loss-free offshore inter-array cabling as well as transformer and GIS connections – Müller notes. “Now with HV CONNEX fittings and the new
as possible. Cables become thicker, heavier and less flex- GNV GL certified. SEANEX plug, all connections in the whole offshore wind
ible, connection and assembly take more time, and the farm can be uniformly implemented with inner-cone tech-
overall infrastructure installation costs rise. For this rea- nology – from the wind turbines and platform to the on-
son, recent years have seen a step change in the voltage shore substation. PFISTERER is currently providing in-
level for connecting modern offshore wind farms, from as it offers many installation and handling advantages,” ex- fitting. During the development process, HV specialists ter-array cabling equipment for 102 Siemens turbines in
33 kV to 66 kV – i.e. from medium to high voltage. By op- plains Dr. Peter Müller, Head of Renewables at PFISTERER. at PFISTERER always kept the design-to-cost principle in the new East Anglia One (EA1) wind farm. With a total out-
erating at a higher voltage, 66 kV cables can transmit more Compared to an outer cone design, the maintenance-free mind. The new fitting combines all the proven perfor- put of 714 MW, this is the first large-scale wind farm at the
power, with a smaller cross-section and lower current inner cone fittings are much more robust because of mance features – salt water resistance, solid insulation, 66 kV voltage level.
than conventional 33 kV cables. That means reduced costs their separate mechanical and electrical contacts. As a pluggable and touch-safe – yet it is much more com­
together with improved supply reliability and more power. result, they cope better with sudden load changes. In pact, lighter in weight, and lower in cost. The cast resin
addition, the fittings are touch-safe at all times, which joint measures a mere 39 cm long and weighs just 28 kg.
PFISTERER developed the SEANEX offshore solution makes working in tight spaces much safer and simpler. SEANEX plugs also have a rotatable bell flange so that
specifically for these market requirements. As the in­ As for durability, the inner cone system guarantees reliabil- they can be easily plugged in from any position, without
ventor of the inner cone technology that has always formed ity far beyond the projected operational life of a wind farm. having to twist the cable. “Aside from the lower costs, these
part of the proven CONNEX HV connection system, advantages give our customers greater flexibility for
PFISTERER has decades of operational experience on off­- SEANEX – lightweight, robust and easy to install handling and installing the HV fittings,” Dr. Peter Müller
shore platforms. Now SEANEX optimises this tried-and- Specially developed for the requirements of interconnect- points out.
tested system for connecting wind turbines. “The inner ing wind turbines, the SEANEX connector in conjunction The most compact inner cone connection system for 66 kV: SEANEX is
cone system is optimal for offshore wind turbine cabling, with the associated cast resin joint represents a unique Thanks to the pluggable connection between the sea and around 30% smaller than conventional size 4 components.

24 CONNECT 2020 CONNECT 2020 25

 + 39,8 GW
Installed offshore wind power
capacity in 2018 in GW (gigawatts)
Interview
Karin Ohlenforst
Forecast increase by 2023
Director of Market Intelligence UNITED KINGDOM

7,963
The Global Wind Energy Council (GWEC) is an international trade associ- GERMANY
ation for the wind energy industry and comprises manufacturers, devel-
opers, suppliers and trade organisations. The association advises partner 6,380
organisations and governments on local energy market development, with BELGIUM
the aim of promoting the worldwide expansion of wind energy. The annual
Global Wind Report provides detailed insight and analysis for the wind 1,186
industry and is the most widely used data source in this energy sector. USA

0,030
DENMARK

1,329
www.gwec.net SOUTH KOREA

0,073
CHINA

NETHERLANDS
4,588
1,118 OTHERS

0,171 Total values:

(megawatts)
Europe 18.278
Asia 4.832
USA 0,030

Global trends in
offshore wind power
Forecast increase in offshore wind
power 2019-2023 in GW
The Global Wind Energy Council (GWEC)
publishes an annual report analysing global 4,3 3,1 5,3 5,6 4,8

trends in the wind power industry. In this Europe 2,3 1,8 3,0 4,3 4,5

Asia
interview, Karin Ohlenforst, Director of Market 0,8
USA 2019 6,6 2020 4,9 2021 8,3 2022 9,9 2023 10,1
Intelligence, discusses the future of global
offshore wind power.

Karin, where do you see the largest future example in California, so the U.S. as a whole could see a What role do inter-array cabling and transmission For this reason, too, transmission is becoming increas-
growth in the offshore wind market? significantly larger increase. That will depend on the play in such large-scale projects – also with regard ingly important.
According to our research, offshore wind currently has development of floating technology, among other things. to increasingly powerful turbines?
the largest growth potential in the wind power sector. We I think we are not at the limit yet in terms of turbine size Is floating technology coming? Is it the future trend?
expect to see a total volume of 190 gigawatts (GW) by What are the biggest drivers of – capacities of over 15 MW are conceivable in the future. Floating wind turbines will certainly be a bigger phe-
2030 – currently there are 23 GW worldwide. Europe has development potential in offshore wind power? But even with current technology, we are still a long way nomenon in the future. In our outlook to 2030, we have
the largest share at the moment, with 18 GW, but future There are two main factors. First, wind power is easily com- from exploiting wind power’s global potential. With re- included a potential of around 10 GW. Development
growth will happen outside Europe. First in Asia, then in petitive today in terms of electricity generation costs, and gard to costs, however, inter-array cabling plays an is currently still in its early stages, but many offshore
the U.S. too. China’s offshore capacity is likely to reach in many countries it is already cheaper than coal, gas or important role, especially the required cable lengths. So markets cannot be exploited without floating techno-
around 60 GW by 2030, and total capacity in Asia will be nuclear power. Countries that continue to rely on these there will be further advances in cabling / transmission ­logy – South Africa and the U.S. West Coast for example
about 100 GW. Countries like Japan and South Korea will conventional energies can also expect high socio-economic – more so than in tower design, for example. The change- – because of the deep water and steeply shelving
play an important role, but so will Vietnam and Thailand. costs. Second – and this is new – offshore wind power is over from 33 kV to 66 kV is a hugely significant step. We coastlines. Floating technology may help to develop
America’s East Coast has grand ambitions at the mo- now able to replace entire nuclear power plants, based on can also see the growing importance of this area in the these offshore markets, but the necessary cable
ment. Here we are expecting to see growth of 1015 GW in size alone. Japan for example is looking at large-scale off- ever greater weighting given to transmission in tenders lengths drive the price up, and at the end of the day, it
offshore capacity over the next ten years. But there is shore projects as a possibility for replacing nuclear power and auctions. And with floating technology, even larger has to be worthwhile.
generally still a lot of potential in the United States, for generation. And that will mean really big offshore projects. offshore projects in the order of 1-2 GW are conceivable.

26 CONNECT 2020 CONNECT 2020 27

 M2020-003 EN1  01/2020  Art Direction: BERNETBRANDS, Stuttgart  We accept no liability for printing errors / Subject to technical modifications

ALL CABLES LOVE PFISTERER. As an independent cable accessories specialist, we have everything that
cables need. Connection systems, joints and cable terminations from PFISTERER can make any XLPE cable –
regardless of the cable manufacturer or cable diameter – a voltage-proof connection up to 550 kV.