Electrical Reliability: What Makes Systems Hold Up

Executive Summary

Rapid decarbonization. Massive load requirements of electrical vehicles (EVs) and data centers. A growing demand for renewable energy. Our grid is expected to produce more power at the lowest possible cost. The reliability of our modern electrical infrastructure has never been more critical. But the increasingly heavy loads on existing cables are causing systems to fail.

For project managers and technicians, maintaining the status quo is no longer enough. We now must look toward future-fitting an aging grid to handle today’s needs. 3M is using decades of material science innovation to help reduce installation variability and build long-term grid resilience through trusted components.

Our Stressed Systems and Declining Workforce

The electrical grid is facing a perfect storm. With increasing load requirements due to the data center boom, residential and industrial systems are being pushed close to their thermal limits. Growing regulatory pressures and sustainability goals are driving a major push toward integrating more renewable energy into the grid. At the same time, reliability is becoming more important than ever, as a single minute of downtime can cost businesses thousands of dollars.1

Another major challenge adds a layer of complexity to this perfect storm: The U.S. is currently experiencing an electrician shortage of approximately 80,000.2 Additionally, experienced electricians might not have the necessary training in modern medium voltage systems, and new electricians are being placed in the field more quickly to fill labor shortages. In short, there are too many projects to be done and not enough skilled technicians to do them. As a result, human error is the leading cause of medium voltage cable failure.1

Updating the grid is not as simple as ripping and replacing millions of miles of existing underground cable. We need solutions that streamline installation, make work easy and intuitive for technicians, enhance long-term performance and safety, and reduce downtime.

Top Priority: Reliability

A single component failure can derail schedules, inflate budgets, and create serious safety risks on the jobsite.
 

• The cost of failure: An improperly installed cable accessory, such as a splice or termination, can trigger tens of thousands of dollars in emergency repairs, lost productivity, and delayed schedules.
• In solar and wind farms, failure can mean several days of downtime as a team must find the failure buried underground, dig it up, and replace it.
• Medium voltage cables are made of several layers that have to be stripped back to access the conductor. Today, this is a manual, labor-intensive process that requires advanced skill.
• The need for predictability: Successful updates to the electrical grid must rely on proven products and predictable installation processes that remove guesswork in the field.

“Using predictive analytics to forecast load, renewable output, and pricing could support more dynamic energy management strategies,” said Bekhe Purkis, 3M Electrical Markets Division Leader, Canada. “In addition, adoption of on-site generation and storage, such as battery systems, thermal storage, and distributed generation, can reduce grid dependence during peak stress periods.”

The Solution to Modernizing the Grid

3M has been a trusted industry cornerstone for nearly 100 years and remains committed to engineering electrical innovations for consistency and long‑term performance. Our latest solutions are designed to future‑fit the grid by applying our high‑performance materials to some of the most demanding environments in the industry.
 

• Advanced cable accessories: Data centers are full of expensive, sensitive equipment and sophisticated fire suppression systems. 3M™ Cold Shrink Medium Voltage Cable Accessories require no open flames or special tools, minimizing the risk of accidental fires. Their dynamic “living seal” expands and contracts with variations in temperature and load on the cable during thermal cycling, helping to provide secure, repeatable installation. These products are easier to install in tight spaces and simple to use, providing faster, easier installation; helping improve efficiency and performance; and potentially creating significant cost savings.
• Heavy-duty electrical tapes: 3M insulating, shielding, and specialty tapes are built for durability in demanding environments. With strong, flexible backings and excellent insulating properties, 3M electrical tapes withstand moisture, abrasion, corrosion, alkalis, and acid. Tape elasticity continues to contract after application, allowing for more flexibility during installation and helping seal connections from external contaminants long-term. 3M splicing tapes can handle high-voltage stresses up to 69kV, making these tapes excellent solutions for high-powered data centers that can quickly overheat.
• Protective and connection solutions: 3M™ Sensored Cable Accessories combine industry-standard medium voltage cable accessories with high-accuracy voltage and current sensors. 3M™ Insulating Plug Voltage Sensors can interface with various monitoring and control devices to provide real-time visibility into the complete cable system. Additionally, the existing equipment can be retrofitted using 3M industry-standard retrofit components within the required cable accessory.