High-voltage power cable connectors are essential components used to join power cables together, ensuring reliable electrical continuity and mechanical integrity. These connectors include various types such as standard joints, insulated joints, plug-in joints for oil-filled and steel pipe cables, among others. Each type is designed to meet specific operational requirements and environmental conditions.
1. Standard Connector
The standard connector is primarily used to connect two adjacent sections of power cables. In high-voltage systems, a straight-through connector is employed to link the conductor cores of the cables, maintaining an uninterrupted electrical path. For self-capacitive oil-filled cables, the connector must ensure that the internal oil flow remains unobstructed. However, due to the manual installation process on-site, which often involves less-than-ideal working conditions, special attention is given to the crimping of the conductor cores. To prevent electric field concentration at the connection point, the insulation thickness is increased, reducing the electric field strength and enhancing the safety and reliability of the joint. Typically, the insulation is wrapped around the core, with the extended insulation forming a stress cone to manage voltage distribution. A shielding layer is also applied over the insulation, and both ends of the cable are insulated and shielded. An outer copper tube is then used to protect the insulation from atmospheric exposure, allowing the oil-filled cable to maintain its internal pressure and operate safely.
2. Insulated Joint
Insulated joints share a similar structure and dimensions with standard connectors but serve a different purpose. They are commonly used in long-length oil-filled power cable lines, especially for 110–220kV systems. These joints electrically isolate the metal sheath or semi-conductive layer at both ends of the cable, preventing current from flowing between them. This isolation helps reduce sheath (or shield) wear and improves the overall performance and longevity of the cable system.
3. Plug Connector
The plug-in connector is one of the most complex and critical components in oil-filled power cable systems. It is typically used in applications where the vertical drop between two cable segments exceeds the specified limit. By cutting off the oil flow, it prevents the upper cable from drying out and the lower cable from experiencing excessive oil pressure. For example, a 110kV single-chamber plug intermediate joint uses an epoxy housing to separate the oil flows of the two cables. On the other hand, a 220kV double-chamber plug joint employs two inner chambers for each cable, with an outer cavity that allows for sealed oil flow management, ensuring stable operation under varying conditions.
4. Steel Pipe Oil-Filled Cable Connector
Steel pipe oil-filled cable connectors come in two main types: standard connection connectors and semi-plug connectors. The standard connector is used for connecting power cables of standard manufacturing lengths, with an internal insulation structure similar to that of self-capacitive oil-filled connectors. The outer casing is usually a copper pipe slightly larger than the cable itself. For longer steel pipe cable lines, a semi-plug connector is preferred. This type of joint is designed to minimize the loss of cable sleeves in case of an oil leak, by separating the oil supply section. It allows the oil flow to pass through the cable insulation or bypass pipes, ensuring continuous and safe operation. At the junction between the steel pipe and the cable, a sealing structure is used to isolate the oil path, maintaining the integrity of the system.
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