High-voltage power cable connectors are essential components used to join power cables together. These connectors include various types such as standard joints, insulated joints, plug-in joints for oil-filled and steel pipe cables, and more. Each type serves a specific purpose in ensuring the safe and efficient operation of high-voltage power systems.
1. Standard Connector
A standard connector is typically used to link two adjacent power cables. In high-voltage cable systems, a straight-through connector ensures a continuous electrical connection between the core conductors of the cables. For self-capacitive oil-filled cables, it's crucial that the internal oil flow remains unobstructed. However, since these connectors are often installed manually on-site, the working conditions can be challenging. To address this, the conductor connections are usually crimped to ensure a secure and stable connection. Additionally, measures are taken to reduce electric field concentration at the joint by increasing the insulation thickness, which helps lower the operating electric field strength and enhances the reliability of the connection.
The insulation around the joint is carefully wrapped, with the ends forming a tapered stress cone to manage electrical stress. An insulation shield is also applied to provide additional protection. The outer casing is typically made of a bright steel pipe that isolates the internal insulation from atmospheric conditions, allowing the oil-filled cable to withstand the required oil pressure and maintain its performance over time.
2. Insulated Joint
An insulated joint is structurally similar to a standard connector but is specifically designed for use in long-distance high-voltage cable lines, such as those operating at 110–220 kV. Its main function is to electrically isolate the metal sheath or semi-conductive layer of the cables at both ends, preventing current from flowing through the sheath and reducing wear and tear. This type of joint is particularly useful in cross-bonding applications, where the sheath currents are minimized to improve system efficiency and safety.
3. Plug-in Connector
Plug-in connectors are considered one of the most complex and vulnerable parts of an oil-filled power cable system. They are primarily used in situations where the vertical drop between two sections of the cable exceeds a specified limit. By cutting off the oil flow, they prevent the upper cable from drying out and the lower cable from experiencing excessive oil pressure. This makes them ideal for use in paper-insulated cables with significant elevation differences.
For example, a 110 kV single-chamber plug intermediate joint typically uses an epoxy housing to separate the oil flow between the two cables. On the other hand, a 220 kV double-chamber plug joint features two separate oil compartments within the connector, each containing a section of the power cable. These inner chambers are connected via an external cavity, creating a sealed system that allows controlled oil flow and maintains proper pressure throughout the line.
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 commonly used for connecting power cables of a fixed manufacturing length. Its internal structure is similar to that of a self-capacitive oil-filled cable connector, with an outer casing made of a copper tube slightly larger in diameter than the cable itself.
Semi-plug connectors, on the other hand, are used for longer steel-pipe filled cable lines. They are designed to prevent a large number of cable sleeves from being lost in the event of an oil leak. These connectors help divide the oil supply into separate sections, allowing the oil to flow through the cable insulation or bypass pipes. At the junction between the steel pipe and the cable, a sealing mechanism is employed to isolate the oil path and ensure reliable operation under high-pressure conditions.
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