33kV Jointing Manual Section 4 - Thorne and …...UK POWER NETWORKS 33kV CABLE JOINTING MANUAL I 2012 Section 4 I Page 1 4 INSTALLING HEATSHRINK MATERIALS AND COMPONENTS 4.1 Installing

Section 4 I Page 1UK POWER NETWORKS 33kV CABLE JOINTING MANUAL I 2012

4 INSTALLING HEATSHRINK MATERIALS AND COMPONENTS

4.1 Installing Stress Control and Insulation Materials4.1.1 Single-Core Paper Insulated Cables in Transition Joints • Preparethecableasdescribedinsection3.2.Useachinagraphpenciltomark20mm

ontotheleadsheathand10mmontotheinsulationpapers.

• Removethereleasepaperfromthemediumlengthofyellowstresscontroltape.Stretchthetapetoabouthalfitsoriginalwidthandwrapitaroundtheleadsheathfor20mm.Removethetwinebinderfromthescreenedgeandcontinuewiththetapeoverthescreenpapersandontotheinsulationfor10mm.

• Useachinagraphpenciltomarktheleadsheath20mmbeyondtheyellowstresscontroltape.Positiontheclearbarriertubingoverthecoreendandovertheyellowstresscontroltape,overlappingontotheleadsheathby20mm.UNCONTROLL

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UK POWER NETWORKS 33kV CABLE JOINTING MANUAL I 2012Section 4 I Page 2

• Shrinkthetubingdown,startingontheleadsheathandcontinuingtowardsthecoreend.Oncecompletedthetubingshouldbefullyshrunkandhaveasmoothfinishwithoutwrinklesorcreases.

• Positiontheshortblackconductivesleeve220mmfromthecoreendandshrinkthetubingdownstartingattheopencableendbeforeworkingtowardstheleadsheath.

4.1.2 Single-Core Polymeric Pot Ends • Preparethecablesasdescribedinsection3.1uptoandincludingthescreenremoval

point.Thedimensionforthescreenis80mm.

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• Removetheinsulationfor30mmfromtheendofthecable.

• Cleananddegreasetheinsulationwithanapprovedsolventwipetoremovealltracesofconductingmaterial.Alwayswipefromtheopencutendtowardsthescreenwirestoavoidcontaminatingtheinsulationwithcarbonfromthescreenlayer.

• Wraptheconductivetapesuppliedinthejointingkitaroundthe30mmofexposedconductorstretchingittoabouthalfitsoriginalwidth.

• Increasetheconductordiametersufficientlysothattheinsulatingrodisasnugfitovertheconductor.Pushtheinsulatingrodontotheconductorensuringthatitbuttsagainstthecableinsulation.

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• Useashortstripofyellowstresscontrolmasticandremovethereleasepapersfromashortstripofyellowstresscontrolmastictape.Wrapitaroundtheedgeoftheinsulationscreenstarting20mmfromthescreenedge,beforecontinuingfor10mmontothecoreinsulation.Stretchthetapetoapproximatelyhalfitsoriginalwidthtoobtainafineedgeontotheinsulation.

• Usingalongstripofyellowstresscontrolmasticandremovethereleasepapers.Wrapitaroundthecoreinsulationstarting10mmfromtheinsulationedge,beforecontinuingontotheinsulatingrodcoveringthe'paintedarea'and10mmbeyondontotherodinsulation.

• Useonlyasmuchoftheyellowstresscontrolmastisasnecessarytofillinthestepbetweentheinsulationandtherod.

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• Wraponelayerofredmasticaroundtheinsulatingrod60mmfromitsendandwithawidthof10mm.

• Positiontheblackstresscontroltubingovertheinsulatingrodandbuttitupagainstthecableoversheathcut.Shrinkthetubingdownstartingattheoversheathendbeforeworkingtowardstheinsulatingrodend.

• Useonelayerofredmasticaroundeachendoftheinstalledstresscontrolledtube60mminfromeachendandwithawidtehof10mm.

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UK POWER NETWORKS 33kV CABLE JOINTING MANUAL I 2012Section4IPage6

• Slidetheredinsulatingtubingoverthestresscontroltubebuttingitagainstthecableover-sheathandcoincidingwiththestresscontroltubingedge.

• Shrinkthetubingdownstartingattheover-sheathendandworkingtowardstheinsulatingrodend.

• Placetheblackandredscreenedinsulatingtubingovertheassemblyandpositionittocoincidewiththepreviouslyinstalledtubes.

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• Shrinktheblackandredtubedownstartinginthecentre.Whenthissectionisfullyshrunkitshouldbesmoothwithoutridgesandshouldnotmovewhentwistingthetubeend.

• Continuetheshrinkingprocess,workingtowardsoneendandstopping50mmfromtheend.Thenshrinktowardstheoppositeendstopping50mmfromtheend.Finallyshrinkdownthefirstremaining50mmoftubingfollowedbythesecond50mmoftubing.Thisprocessensuresthatnoairistrappedinsidethetube.

4.1.3 Resin Filled Three-Core Transition Straight Joints (Three-Core Paper to 3 x Single-Core Polymeric Cables)

• Preparethecablesuptothepointasdescribedinsection3.3.

• ProtecttheCopperWovenTape(CWT)withnylontape,startingfrom20mmontotheleadsheathextending30mmontothecores.Thenylontapeshouldbeappliedwithtension.

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• Atthescreenterminationpositionwraponelayerofvoidfillingyellowstresscontrolmasticaroundeachcore,overlappingthescreenpapersby20mmandtheinsulationby10mm.Removethemetalbinderfromthescreenedgeduringthetapingprocess.

• Slidetheclearbarriertubingovereachcoreandposition30mmfromtheendofthemetalsheath.Shrinkdownthetubingstartingatthecrutchpositionworkingtowardstheopencoreends.Checkthetubingisshrunkdownevenlyandfreefromcreasesorwrinkles.

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• Slidetheblackconductingtubingoverthecoreendsandpositionthem50mmfromtheendofthemetalsheath.Shrinkthetubesdownatthispositionstartingatthecrutchbeforeworkingtowardsthecoreends.

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• Slidethesmallyellowmasticwedgeintothecrutchusingtheinstallationtoolprovided.Takethelargerwedgeandinsertitintothecrutchbehindthesmallerwedgeusingthesametool.Removethenylontapeafterinsertionofbothwedges.

• Degreasethecoresusingapprovedsolventwipes.Makeachinagraphpencilmarkontheconductivetubes70mmfromtheleadsheathcutandfor20mmontotheleadsheath.

• Wrapstripsofyellowmasticaroundthecrutchbetweenthetwochinagraphpencilmarks.Applysufficienttensiontostretchthetapetohalfitsoriginalwidthuntila'cone'shapeisformed.

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• Passtheconductivebreakoutoverthecoresandpushitwelldownintothecrutch,usingtheyellowwedgeinstallationtool.Holdthebreakoutinplaceandshrinkitdownstartingatthecentre,beforefirstlyworkingtowardstheleadsheathandthentowardsthebreakoutfingers.

4.1.4 Heatshrink Three-Core Transition Straight Joint (Three-Core Paper to 3 x Single-Core Polymeric Cables)

• Preparethecablesuptothepointasdescribedinsection3.3.

• ProtecttheCWTwithnylontape,starting20mmontotheleadsheathextending30mmontothecores.Thenylontapeshouldbeappliedwithtension.

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• Atthescreenterminationpositionwraponelayerofvoidfillingyellowstresscontrolmasticaroundeachcoreoverlappingthescreenpapersby20mmandtheinsulationby10mm.Removethemetalbinderfromthescreenedgeduringthetapingprocess.

• Slidetheclearbarriertubingovereachcoreandposition30mmfromtheendofthemetalsheath.Shrinkdownthetubingstartingatthecrutchpositionbeforeworkingtowardstheopencoreends.Checkthetubingisshrunkdownevenlyandisfreefromcreasesorwrinkles.

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• Slidetheblackconductingtubingoverthecoreendsandpositionthem50mmfromtheendofthemetalsheath.Shrinkthetubesdownatthispositionstartingatthecrutchworkingtowardsthecoreends.

• Slidethesmallersuppliedyellowmasticwedgeintothecrutchusingtheinstallationtoolprovided.Takethelargerwedgeandinsertitintothecrutchbehindthesmallerwedgeusingthesametool.Removethenylontapeafterinsertionofbothwedges.

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• Degreasethecoresusingapprovedsolventwipes.Makeachinagraphpencilmarkontheconductivetubes70mmfromtheleadsheathcutandfor20mmontotheleadsheath.

• Wrapthestripsofyellowstresscontrolmasticaroundthecrutchbetweenthetwochinagraphpencilmarks.Applysufficienttensiontostretchthetapetohalfitsoriginalwidthuntilaconeshapeisformed.

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• Passtheconductivebreakoutoverthecoresandpushitwelldownintothecrutch,usingtheyellowwedgeinstallationtool.Holdthebreakoutinplaceandshrinkitdown,startingatthecentrebeforeworkingtowardstheleadsheathandthentowardsthebreakoutfingers.

• Positiontheshortlengthofwrap-aroundheatshrinktubeoverthepapercablesothatitcoverstheleadsheathandthethreefingerbreakout.Leaveagapofatleast100mmbetweentheendofthewraparoundandthearmoursealingsleeve.

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• Shrinkthewrap-aroundinplacestartinginthemiddle,untilthesurfacepaintonthetubeturnsfromgreentoblack.Thengraduallymovetoeachendusingthesameprocess.Extraheatshouldbeappliedtothemetalchanneluntilthewhitemarkerlinecanbeclearlyseenunderit.

• Positiontheshortsealingheatshrinktubesovertheturretsoftheheatshrinkbreakout,ensuringtheyarepushedrightintothecrutchandshrinkinplace.

4.1.5 HSL Breakout Module • Preparethecablesuptothepointasdescribedinsection3.4.1to3.4.3.

• Useachinagraphpenciltomarkeachleadsheath100mmfromthearmourcutedge.Foldashortlengthoftinnedcoppermeshinhalflengthways.

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• Wrapthetinnedcoppermesharoundtheleadsheathscenteredonthe100mmmark.

• Positiononeofthelengthsofbraidoverthemeshsothatthelooseendpointsawayfromthecrutchofthecable.

• Securealengthofearthbraidtoeachleadoftheleadsheathsusingoneturnoftherollspringsdirectlyontothecoppermeshwrap.

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• Bendthebraidsbackovertherollspringandthensecureinplacewiththeremainingturns.

• CovereachoftherollspringswithtwolayersofPVCtape.

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• Securethebraidendstothearmoursandthesupportringwitharolloftinnedcoppermeshsandwichingthebraidsbetweenthemeshwraps.

• Finally,securethemeshandbraidstothesupportringandarmoursusingthewormdriveclipsprovided,withoneclipeithersideofthesupportring’scentralridge.

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• CoverthewormdriveclipswithPVCtapetotidyuptheirlooseends.

• Slideasealingsleeveovereachleadsheathandrollspringconnectionuptowheretheearthbraidmeetsthesupportring.Shrinkthemdownstartingontheleadsheathsandcontinuingtowardsthearmourwiresarea.

• Wrapastripofblackmasticbehindthesupportringoverthearmourwires,fillingthespacebetweentheringandtheoutersheath.

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• Passthebreakoutovertheleadsealingsleevesandpulldownintothecrutch.Shrinkthebreakoutdownstartinginthecentrebeforemovingtowardstheover-sheathandthenshrinkthebreakoutfingers.

• Positionthecrutchsealingsleevewithoneendlevelwiththeendofthefingersonthebreakoutandshrinkintoplace.

4.1.6 HSL Cable Core Preparation • Preparethecablesasdetailedinsection4.1.5andremovetheleadsheathsasdescribed insection3.4.4.

• Useachinagraphpenciltomark20mmontotheleadsheath,and10mmontothe insulationpapers.

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• Removethereleasepaperfromoneofthemediumlengthsyellowstresscontroltape.Stretchthetapetoabouthalfitsoriginalwidthandwrapitaroundtheleadsheathfor20mm.Removethetwinebinderfromthescreenedgeandcontinuewiththetapeoverthescreenpapersandontotheinsulationfor10mm.

• Makeamarkontheleadsheathusingachinagraphpencil20mmbeyondtheyellowstresscontroltape.Positiontheclearbarriertubingoverthecoreendandtheyellowstresscontroltapeoverlappingontotheleadsheathby20mm.

• Shrinkthetubingdown,startingontheleadsheathandcontinuingtowardsthecoreend.Oncecompletedthetubingshouldbefullyshrunkandhaveasmoothfinishwithoutwrinklesorcreases.

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• Positiontheshortblackconductivesleeve220mmfromthecoreendandshrinkthetubingdown,startingattheopencableendbeforeworkingtowardstheleadsheath.

4.1.7 Paper Insulation 'Shim Kit' for Cable Cross Sections 70mm² & 95mm² • Forcablesbelowtheminimumsizerangespecifiedonthekitlabela'shimkit'mustbeused.

• Thecableswillbeatthestageofpreparationdescribedinsections4.1.1,4.1.3,4.1.4or 4.1.6.

• Applyapieceoftheyellowstresscontroltape20mmovertheendoftheconductivetubeandontothecleartubingby10mm.Usesomeoftheyellowtapeprovidedinthemainjointkit.

• Positionashortlengthofthesmallerdiameterstresscontroltubing(42/16)overthecoreend,overlappingtheconductivetubesandtheyellowstresscontrolmasticby40mm.

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• Shrinkthestresscontroltubingdown,startingfromtheyellowmastictapeandworkingtowardstheopencoreend.

• Wraponeoftheredmasticstripsprovidedaroundtheendofthestresscontroltube30mmontothetubingand10mmontothecore.

• Positionashortlengthofthelargerdiameterstresscontroltubing(54/24)directlyoverthepreviouslyappliedstresscontroltubeandshrinkdownfollowingthesameprocedureasbefore.

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• Applyoneoftheredmasticstripsprovidedaroundtheendofthestresscontroltube30mmontothetubingand10mmontothepreviouslyappliedredmastic.

4.1.8 Paper Insulation 'Shim Kit' for Cable Cross Sections 120mm² & 150mm² • Forcablesbelowtheminimumsizerangespecifiedonthekitlabel,a'shimkit'mustbe

used.

• Thecableswillbeatthestageofpreparationdescribedinsections4.1.1,4.1.3,4.1.4or 4.1.6.

• Applyashortlengthoftheyellowstresscontroltape20mmovertheendoftheconductivetubeandontothecleartubingby10mm.Usesomeoftheyellowtapesuppliedinthemainjointkit.

• Positionashortlengthofthestresscontroltubing(54/24)overthecoreend,overlappingtheconductivetubesandtheyellowstresscontrolmasticby40mm.UNCONTROLL

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• Shrinkthestresscontroltubingdown,startingfromtheyellowmastictapeandworkingtowardstheopencoreend.

• Wraponeoftheredmasticstripsprovidedaroundeachendofthestresscontroltube30mmontothetubingand10mmontothecore.

4.1.9 Single-Core Polymeric Terminations (Indoor and Outdoor) • Followthecablepreparationproceduresforpolymericcablesasdescribedinsection3.1.

• Useachinagraphpenciltomarktheoutersheath60mmbelowthesheathcutposition.

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• Wraponelayerofredsealanttapeoverthecablesheathdowntothechinagraphpencilmark.

• Bendbackthecopperscreenwirescarefullyandlaythemontothemastictapetakingcarenottocrossoveranyofthewires.Securethewireswithawirebinderatthe60mmmark.

• Makeachinagraphpencilmarkontothecorescreen40mmfromthesheathcut.

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• Removethecorescreendowntothe40mmmarkusingtheapprovedscreenstrippingtool.

• Makeamarkwithachinagraphpencil20mmontothecorescreenand10mmontotheinsulation.

• Removethereleasepaperandwraptheyellowstresscontrolmasticaroundthescreencutbetweenthetwopencilmarks.Stretchthetapetohalfitsoriginalwidthtoachieveafinethinedgeontotheinsulation.

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• Positiontheblackstresscontroltubingoverthecoresothatitislevelwiththeoutersheathcut.Shrinkthetubingdown,startingatthesheathcutendandworkingupwards.Whenfullyshrunkthetubingshouldbesmoothandwrinklefree.

• Removetheinsulationfromthecoreendaccordingtotheinnerdimensionofthecablelugbarrel.

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• Fitthecablelugensuringthatthelugbuttsagainsttheinsulationedgeandhandtightenthesecuringbolts.

• Shearofftheboltheadsusingtheapprovedtoolsandfillintheindentswiththegreyclayprovided.

• Wraptheredsealanttapearoundthelugbarrel,overlappingontotheinsulation.Buildupthediameterdifferencewiththeredtapesothatasmoothandevenprofileisachieved.

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• Removethereleasepaperfromtheredtubing.Placethetubingoverthecableend(withthesealantcoatedenddownwards),levelwiththewirebinder.

• Shrinkthetubingdownstartingattheoutersheathend,beforeworkingtowardsthecable lug.

• Cutthetubingbackontothecablelug,levelwiththetopofthemainbody,ifnecessary.

• Post-heatthepalmofthecableluguntilabeadofthesealantappearsaroundthetopof thetubing.

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• Useachinagraphpenciltomarkthepositionfortheshedsonthetubingatthedimensiongivenintheterminationinstruction.

• Placetwoskirtsoverthecableendandpositiononthepreviouslymademarks.Shrinkeachshedinplace.

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• Foroutdoorterminationstherearefourskirtstobefittedtoeachtermination.Theseshouldbeplacedandshrunkintopositionatthemeasurementsindicatedintherelevantjointinginstruction.

4.2 Installing Mechanical Connectors and Lugs4.2.1 Single-Core Polymeric Straight Joints • Thecableswillhavebeenprepareduptothepointasdescribedinsection3.1.

• Positionthecombinedstresscontrol,screenedinsulatingtubingandoutersealingsleeveoveroneofthecableends.

• Removetheinsulationasdescribedinsection3.1.3.

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• Theconnectorcomeswithmetalinsertstofitsmallconductors.Iftheconductorwillnotfittheconnector,discardtheinsertandusetheconnectorwithoutit.

• Fittheconductorsintotheconnector.Theinsulationshouldbuttagainsttheendoftheconnector.

• Usingtheapprovedinsulatedtooltoholdtheconnector,takeupthetensiononalltheboltsequallywithoutshearingthemoff.

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• Continuetotightenandsheeroffalltheboltsstartingwiththeboltsateachendfollowedbythecentralbolts.

• Filltheboltholesintheconnectorwiththegreyclaysuppliedinthejointkit.

4.2.2 Single-Core Transitional Straight Joints • Thecableswillhavebeenprepareduptothepointasdescribedinsections3.1and3.2.

• Slidethefivepiecetubingsetoverthepolymericcableside.Nestingthetubesetontheplasticbagwrappingwillkeeptheinsideofthetubesclean.Thetubesetshouldbeplacedintheordershown.

Note :Itisimportantthatthefourthtube(thesecondlargest)isplacedwithinthetubeset sothattheuncoatedinneredgepointstowardsthejointcentre.

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• Removetheinsulationfrombothcablesusingthemethodsdescribedinsections3.1.3and3.2.5.

• Theconnectorisa'TwoPiece'designwiththetwohalvessecuredtogetherwithacentralshearbolt.Eachconnectorhalfhastwoconductorsecuringboltswhicharealsooftheshearofftype.

• Fittheconductorsintotheconnector.Theinsulationshouldbuttagainsteachendoftheconnector.

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• Usingtheapprovedinsulatedtooltoholdtheconnector,takeupthetensiononalltheboltsequallywithoutshearingthemoff.

• Continuetotightenandsheeroffalltheboltsstartingwiththoseateachendfollowedbythecentralbolt.

• Filltheboltholesintheconnectorwiththegreyclaysuppliedinthejointkit.

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4.2.3 Resin Filled Three-Core Trifurcating Joints (Three-Core Paper to 3 x Single-Core Polymeric Cables)

• Thecableswillhavebeenprepareduptothepointasdescribedinsection3.1and4.1.3.

• Slidetheplastictrifurcatingendoftheplasticjointboxoverthesingle-corecablesandpositionitawayfromthejointingarea.

• Slidethethreepiecetubingsetsoverthepolymericcableside.Nestingthetubesetsontheplasticbagwrappingtokeeptheinsideofthetubesclean.Thetubesetsshouldbeplacedintheordershown.

• Setthecoresintheirfinaljointingposition.Checkthattheconductorshavebeencuttoallowforanyconnectorcentralmoistureblock.Removetheinsulationfrombothconductors,sections3.1.3and3.3.7,totheconnectorinsertiondepth.

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• Inserteachendofthecoreintoitsrespective'connectorhalf'andfinger-tightenthebolts.

• Alignandpositionthetwoconnectorhalvessothatthecentralfixingboltcanbeinsertedintothecentralfixinghole.Theuseofforceforthisoperationshouldnotbenecessary.

• Holdtheconnectorwiththeapprovedholdingtoolandtightenthetwoboltsononesideuntiltheysheeroff.

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• Repeattheoperationontheothersideoftheconnector.Checkthatthecombinedtubesetislocatedoverthesingle-corecablesandsheeroffthecentralfixingbolt.

• Cleananddegreasetheconnector.Filltheboltholeswiththesuppliedgreyclaytoobtainasmoothfinish.

4.2.4 Heatshrink Three-Core Transition Straight Joint (Three-Core Paper to 3 x Single-Core Polymeric Cables)

• Thecableswillhavebeenprepareduptothepointasdescribedinsections3.1and4.1.4.

• Slidetheouterjointheatshrinksealingbreakoutoverthesingle-corecablesandpositionitawayfromthejointingarea.

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• Slidethefourpiecetubingsetoverthepolymericcableside.Nestingthetubesetontheplasticbagwrappingwillkeeptheinsideofthetubesclean.Thetubesetshouldbeplacedintheordershown.

• Removetheinsulationfrombothcablesusingthemethodsdescribedinsections3.1.3and3.3.7.

• Slidethemechanicalconnectorontotheconductoronthepapersideofthejoint.Theconnectorisfittedwithaninserttoaccommodatesmallersectioncables;ifthecableconductorfitsintotheconnectorwiththeinsertinplace,useit-ifnot,removetheinsertanduseitwithout.

• Checkthattheconnectorbuttsupagainsttheinsulationandfinger-tightenthebolts.

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• Insertthesingle-corepolymericcablesintotheconnectorensuringthattheconnector buttsupagainsttheinsulationandfinger-tightenthebolts.

• Holdtheconnectorwiththeapprovedholdingtoolandtighteneachbolthalfaturnatatimewithasocketuntilitshearsoff.Startwiththeboltnearesttheinsulationateachendbeforemovingontotheothertwobolts,workingtowardsthemiddle.

• Smoothoffanysharpedgesfromtheboltsandthencleananddegreasetheconnector.Filltheboltholeswiththesuppliedgreyclaytoobtainasmoothfinish.

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4.2.5 HSL Trifurcating Joints (Three-Core HSL to 3 x Single-Core Polymeric Cables) • ThecableswillhavebeenprepareduptothepointasdescribedinSection3.1and4.1.6.

• Slidetheplastictrifurcatingendoftheplasticjointboxoverthesingle-corecablesandpositionitawayfromthejointingarea.

• Positionacombinedtubeset(stresscontrol,insulatingtubeandscreenedinsulating)overeachofthesingle-corepolymericcables.

• Setthecoresintheirfinaljointingposition.Checkthattheconductorshavebeencuttoallowforanyconnectorcentralmoistureblock.Removetheinsulationfrombothconductors(3.1.3and3.3.7)totheconnectorinsertiondepth.

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• Inserteachendofthecoreintoitsrespective'connectorhalf'andfinger-tightenthebolts.

• Alignandpositionthetwoconnectorhalvessothatthecentralfixingboltcanbeinsertedintothecentralfixinghole.Theuseofforceforthisoperationshouldnotbenecessary.

• Holdtheconnectorwiththeapprovedholdingtoolandtightenthetwoboltsononesideuntiltheysheeroff.

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• Repeattheoperationontheothersideoftheconnector.Checkthatthecombinedtubesetislocatedoverthesingle-corecablesandsheeroffthecentralfixingbolt.

• Cleananddegreasetheconnector.Filltheboltholeswiththesuppliedgreyclaytoobtainasmoothfinish.

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4.2.6 Mechanical Lugs for Indoor and Outdoor Terminations • Followthecablepreparationproceduresforpolymericcablesinsections3.1.1to3.1.3

beforeinstallinganymechanicallugs.

• Eachkitcomeswiththecorrectsizeandtypeoflugforeachtermination.Removetheconductorinsulationtotheinsertiondepthofthelug.

• Placethelugovertheconductorsothatthebottomofthebarrelbuttsupagainstthecoreinsulation.

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• Tightentheboltsbyhandandcheckthatthepalmholeslineupwiththeirrespectiveconnectionpoint.

• Tightentheboltsuntiltheboltheadsshearoff.

4.3 Installing Connector Stress Control and Heatshrink Insulation4.3.1 Single-Core Polymeric Straight Joints • Fittheconnectoruptothepointasdescribedinsection4.2.1.

• Useachinagraphpenciltomarktheblackinsulationscreenofbothcables20mmfromthescreencut.

• Makeasecondchinagraphpencilmarkontheinsulation10mmfromthescreencut.

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• Stretchoneoftheshortyellowstresscontrolmasticsuppliedinthekittohalfitsoriginalwidth.Wrapitaroundthecorescreenandinsulationbetweenthetwochinagraphpencilmarks.Repeatfortheothercableside.

• Usethelongstripofyellowstresscontrolmastictowrapthemasticaroundtheconnectorwitha50%overlap,stretchingthemastictoabouthalfitsoriginalwidth.Coveralltheconnectorareaandoverlaptotheinsulationoneachsideoftheconnectorby5mm.Makesurethereisasmoothtransitionfromtheconnectorontotheinsulation.

• Positiontheblackstresscontroltubecentrallyovertheconnectorarea.Eachendofthetubeshouldextendbeyondthescreenterminationpointsofeachcable.Shrinkthestresscontroltubingdown,startinginthecentreandworkingtowardseachendinturn.

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• Positionthescreenedinsulatingredandblacktubecentrallyoverthestresscontroltubeandstartshrinkingthesleeveatthecentrepositionusingequalheatoverthewholesurface.

• Whenthetubingisproperlyshrunk,theridgesontheouterblacklayerofthetubeshouldnolongerbevisible.

• Continuetoshrinkthetubefromthecentretowithin50mmofoneend.

• Removetheheatfromthatendandstartshrinkingfromthemiddleagaintowardstheotherendofthetubing.Stopagain50mmfromtheend.Thisensuresthatairinsidethetubeisexpelledasthetubeshrinks.

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• Returntoeachtubeendinturntocompletetheshrinkingprocesscompletely.

4.3.2 Single-Core Transition Straight Joints • Fittheconnectoruptothepointasdescribedinsection4.2.2.

• Wrapashortpieceoftheyellowstresscontrolmasticaroundthepapercablecoreattheedgeoftheshortblackconductingsleeve.Start20mmontheconductingtube,continuingfor10mmontotheclearbarriertube.

• Wrapashorterpieceoftheyellowstresscontrolmasticaroundthepolymericscreen,starting20mmfromthescreenedgeandcontinuingfor10mmontotheinsulation.Stretchthetapetohalfitsoriginalwidthduringthetapingprocess.

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• Usethelongstripsofyellowstresscontrolmastictowrapthemasticaroundtheconnectorwitha50%overlap,stretchingittoabouthalfitsoriginalwidth.Covertheconnectorareaandoverlapontotheinsulationeachsideoftheconnectorby5mm.Makesureaminimumcoverageof2mmisachievedovertheconnectorarea.

• Pulltheblackstresscontroltubingfrominsidethenestedtubesetandpositionitcentrallyovertheconnectorarea,leavinga20mmgapbetweentheoversheathandthetubingend.

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• Shrinkthestresscontroltubingdownstartinginthecentre,beforeworkingtowardseachendinturn.Whenfinishedthetubingshouldbefullyshrunkandwrinklefree.

• Wrapapieceofredsealantmasticaroundeachendofthestresscontroltubing.Startfrom10mmonthestresscontroltubingandextendfor10mmontothecorescreenatbothends.

• Pulltheredinsulatingtubingfrominsidethenestedtubesetandpositionitcentrallyoverthestresscontroltube.Startshrinkinginthecentrebeforeworkingtowardseachendinturn.

Note:Continueontothenextstepwhiletheredinsulatingtubingisstillhot.

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• Pulltheblackandredscreenedinsulatingtubingcentrallyovertheredinsulatingtubeandstartshrinkingthesleeveatthecentrepositionusingequalheatoverthewholesurface.Whenthetubingisproperlyshrunk,theridgesontheouterblacklayerofthetubeshouldnolongerbevisibleandthetubecannolongerbemoved.


• Removetheheatfromthatendandstartshrinkingfromthemiddleagaintowardstheotherendofthetubing.Stopagain50mmfromtheend.Thisensuresairinsidethetubeisexpelledasthetubeshrinks.


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• Pulltheblackcompressionsealingsleeveacrossthejointtothepapercablesideandplaceitsothatatleast50mmofleadsheathisstillvisible.

• Shrinkthetubingdown,startingonthetubesetendandworkingtowardstheleadsheath.Oncecompletedthereshouldbeapproximately50mmofleadsheathstillexposed.

4.3.3 Resin Filled Three-Core Transition Straight Joints (Three-Core Paper to Single-Core Polymeric Cables)

• Fittheconnectoruptothepointasdescribedinsection4.2.3.

• Removethereleasepaperfromoneoftheshortyellowstresscontrolmasticstripsandwrapitaroundthepolymericcorescreen,starting20mmfromthescreenedgeandcontinueontotheinsulationfor10mm.Stretchthetapetohalfitsoriginalwidthtoachieveafinethinedgeontheinsulation.

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• Repeattheexerciseonthepapercablecore,wrappingtheyellowstresscontrolmasticaroundtheedgeoftheconductivetubing.Cover20mmoftheconductivetubingandcontinueontothecleartubingfor10mm.

• Ensurethattheboltholesarefilledwiththesuppliedgreyclaytoleaveasmoothprofile.Usealongpieceoftheyellowstresscontrolmastictofilltheendsoftheconnectorandtheinsulationcutbackcontinuing10mmontotheinsulation,and20mmontotheconnector.Ifthereisastepbetweenthebodyoftheconnectorandthecableinsulationapplyyellowstresscontrolmastictoformasmooththeprofile.

• Removethereleasepaperfromtheyellowstresscontrolmasticpatchandwrapitcentrallyaroundtheconnector,takingcaretoexcludeanytrappedairasitisapplied.Whenfinishedthepatchshouldbesmoothandwrinklefree.

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• Slidethestresscontroltubingfrominsidethenestedtubesetandpositionitcentrallyovertheconnectorarea.Makesurethattheoverlapovereachtapedscreenedgeisequal.Shrinkthetubingstartinginthecentreandworkingtowardseachendinturn.

• Removethereleasepaperfromonelengthoftheredsealanttapeandwrapitaroundtheendofthestresscontroltube.Overlapthetapeontothetubeby20mmandby10mmontothecore.

• Pulltheredinsulatingtubesfromthetubesetsandcentrallypositionthemoverthestresscontroltubes.Shrinkthetubingstartinginthecentrebeforeworkingtowardseachendinturn.Whencompletethetubeshouldbesmoothandwrinklefree.

Note:Continuewiththenextstepwhiletheredinsulatingtubingisstillhot.

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• Positionthescreenedredandblackinsulatingtubescentrallyovertheredinsulatingtubes.Startshrinkingthesleevesatthecentrepositionusingequalheatoverthewholesurface.Whenthetubingisproperlyshrunk,theridgesontheouterblacklayerofeachtubeshouldnolongerbevisibleandthetubescannolongerbemoved.


• Removetheheatfromthatendandstartshrinkingfromthemiddleagaintowardstheotherendofthetubing.Stopagain50mmfromtheend.Thisensuresairinsidethetubeisexpelledasthetubeshrinks.

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4.3.4 Heatshrink Three-Core Transition Straight Joints (Three-Core PILC to Single-Core Polymeric)

• Fittheconnectoruptothepointasdescribedinsection4.2.4.


• Repeattheexerciseonthepapercablecore,wrappingtheyellowmasticaroundtheedgeoftheconductivetubing.Cover20mmoftheconductivetubingandcontinueontothecleartubingfor10mm.

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• Checkthattheboltholesarefilledwiththesuppliedclaytoleaveasmoothprofile.Using alongpieceoftheyellowstresscontrolmastic,filltheendsoftheconnectorsandthe insulationcutbacks,continuing10mmontotheinsulationand20mmontotheconnector. Ifthereisastepbetweenthebodyoftheconnectorandthecableinsulationapply yellowstresscontrolmastictoformaprofile.

• Removethereleasepaperfromoneoftheyellowstresscontrolmasticpatchandwrapitcentrallyaroundtheconnector,takingcaretoexcludetheairasitiswrapped.Whenfinishedthepatchshouldbesmoothandwrinklefree.Repeattheprocesswithallthreeconnectors.

• Slidethestresscontroltubesfrominsidethenestedtubesetsandpositionthemcentrallyovereachconnectorensuringthattheoverlapovereachtapedscreenedgeisequal.Shrinkthetubingstartinginthecentrebeforeworkingtowardseachendinturn.

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• Removethereleasepaperfromonelengthoftheredsealantmastictapeandwrapitaroundtheendofthestresscontroltube.Overlapthetapeontothetubeby20mmandby10mmontothecore.

• Pulltheredinsulatingtubesfromthetubesetsandcentrallypositionthemoverthestresscontroltubes.Shrinkthetubingstartinginthecentrebeforeworkingtowardseachendinturn.Whencompletethetubeshouldbesmoothandwrinklefree.

Note:Continuewiththenextstepwhiletheredinsulatingtubesarestillhot.

• Pullthescreenedredandblackinsulatingtubescentrallyovertheredinsulatingtubesandstartshrinkingthesleevesatthecentrepositionusingequalheatoverthewholesurface.Whenthetubesareproperlyshrunk,theridgesontheouterblacklayerofthetubesshouldnolongerbevisibleandthetubescannolongerbemoved.

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Section4IPage61UK POWER NETWORKS 33kV CABLE JOINTING MANUAL I 2012

• Continuetoshrinkthetubesfromthecentretowithin50mmofoneend.

• Removetheheatfromthatendandstartshrinkingfromthemiddletowardstheotherendofthetubes.Stop50mmfromtheend.Thisensuresairinsidethetubeisexpelledasthetubeshrinks.


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• Positionthethreecompressionsleevesoverthepaperendofthejoint,sothattheyequallyoverlaptheredandblackinsulationtubesandthecoretubes.Theuncoatedendofthecompressionsleeveshouldbepositionedtowardsthecentreofthejoint.Shrinkinplacestartingfromthecentreofthetubestowardsthecentreofthejointbeforefinallyshrinkingfromthecentretowardsthecrutch.

4.3.5 HSL Trifurcating Joints (Three-Core HSL to 3 x Single-Core Polymeric Cables) • Fittheconnectoruptothepointasdescribedin4.2.5.


• Repeatthisonthepapercablecore,wrappingtheyellowmasticaroundtheedgeoftheconductivetubing.Cover20mmoftheconductivetubingandcontinueontothecleartubingfor10mm.UNCONTROLL

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• Checkthattheboltholesarefilledwiththesuppliedgreyclaytoleaveasmoothprofile. Usealongpieceoftheyellowstresscontrolmastictocoverbothendsoftheconnector, 20mmontheconnectorand10mmontotheinsulation.

• Removethereleasepaperfromtheyellowstresscontrolmasticpatchandwrapitcentrallyaroundtheconnector,takingcaretoexcludeanytrappedairasitisapplied.Whenfinishedthepatchshouldbesmoothandwrinklefree.

• Slidethestresscontroltubesfrominsidethenestedtubesetsandpositionthemcentrallyovertheconnectorsensuringthattheoverlapovereachtapedscreenedgeisequal.Shrinkthetubesstartinginthecentrebeforeworkingtowardseachendinturn.

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• Removethereleasepaperfromonelengthoftheredsealantmastictapeandwrapitaroundbothendsofthestresscontroltube.Overlapthetapeontothetubeby20mmandby10mmontothecore.

• Pulltheredinsulatingtubesfromthetubesetsandcentrallypositionthemoverthestresscontroltubes.Shrinkthetubesstartinginthecentrebeforeworkingtowardseachendinturn.Whencompletethetubesshouldbesmoothandwrinklefree.

Note:Continuewiththenextstepwhiletheredinsulatingtubesarestillhot. • Pullthescreenedblackandredinsulatingtubescentrallyovertheredinsulatingtubes

andstartshrinkingatthecentrepositionusingequalheatoverthewholesurface.Whenthetubesareproperlyshrunk,theridgesontheouterblacklayerofthetubesshouldnolongerbevisibleandthetubescannolongerbemoved.

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• Continuetoshrinkthetubesfromthecentretowithin50mmofoneend.

• Removetheheatfromthatendandstartshrinkingfromthemiddleagaintowardstheotherendofthetubes.Stopagain50mmfromtheend.Thisensuresairinsidethetubeisexpelledasthetubeshrinks.


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4.4 Installing Mechanical Earth Bonds and Associated Components4.4.1 Single-Core Polymeric Straight Joints • Completetheproceduresforinsulatingtheconnectorasdescribedin4.3.1.

• Wrapthejointwithonelayerofthetinnedcoppermeshensuringthereisa50mmoverlapontotheoversheathofthecablesidewiththeshortshieldwires.

• Continueacrossthewholejointwiththetinnedcoppermeshata50%overlapandsecureontotheoppositejointside.

• Onthecablesidewiththelongscreenwires,bendthescreenwiresbackacrossthejointandformthemintotwoseparateconductors.Onthecablesidewiththeshortscreenwires,repeatthesameexerciseandfoldthegatheredwiresbacktowardsthejointcentre.

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• Gatherthewirestogetherandcutthemcentrallyabovethetinnedcoppermeshoverlappingthecablesheath.Installthecopperscreenwireconductorsintotheirrespectiveconnectorandtightentheboltsuntiltheheadsshearoff.

• Wrapasecondlayerofthecoppermesharoundthejoint,asbefore,sothatthewholeareaiscompletelycoveredincludingthemechanicalscreenconnectors.

• Cleananddegreasetheoutersheathsofbothcablesfor150mmfromthesheathcut.Slidethelargeoutersealingsleevecentrallyoverthejointarea.

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• Startshrinkingthetubeatthecentrebeforeworkingtowardseachendinturn.Allowtocoolbeforemovingorbackfillingthejoint.

4.4.2 Single-Core Transition Joints • Completetheproceduresforinsulatingtheconnectorasdescribedin4.3.2.

• Wraptwolayersoftinnedcoppermeshat50%overlapoverthejointfromtheleadsheathonthepapercabletotheover-sheathcutonthepolymericcable.

• Foldbackthecopperscreenwiresoverthejointandformthemintoanearthleadexceptfortheareaovertheleadsheath.Atthispointopenupthewiresandplacethemdirectlyontothetinnedcoppermesh.Wraptherollspringoverthescreenwiresandtwistuptight.

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• CompletelycovertherollspringwithtwolayersofPVCtape.

• Clean,degreaseandabradetheoutersheathsfor150mmfromthesheathcuts.Slidethelargeoutersealingsleeveoverthejointareaandstartshrinkingthetubeatthecentrebeforeworkingtowardseachendinturn.

• Allowthejointtocoolbeforemovingorbackfilling.UNCONTROLL

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4.4.3 Polymeric Pot Ends • Completethestepsinsection4.1.2.

• Laythecopperscreenwiresbackoverontothescreenedblackandredinsulatingsleeveanddistributethemaroundthecircumferenceevenly.

• Wrapthetinnedtinnedcoppermeshwitha50%overlaparoundthepotend,startingattheoutersheathandcontinuingupontothecopperscreenwires,beforecoveringtheinsulatingrod.

Note:Thestresscontroltubingandtherodendmustbeincontactwiththetinnedcoppermesh.

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• Covertheendsofthecopperscreenwiresunderthetinnedcoppermeshwithtwolayers offabrictape.

• Placetheheatshrinkendcapoverthepotendandshrinkitintoplace.Startattheclosedendbeforeworkingtowardsthecablesheath.Duringtheshrinkingprocesscarefullypushtheclosedendofthecapagainsttheinsulatingendwithanappropriatetool.

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• Checkthattheover-sheathiscleananddegreased.Positiontheoutersealingsleeveover thepotendassemblysothatitlinesupwiththeendoftheendcap.

• Shrinkthetubingdown,startingatthecentreworkingtowardseachendinturn.Donotmoveorbackfilluntilthepotendhascooled.

4.4.4 Resin Filled Three-Core Transition Straight Joints (Three-Core Paper to 3 x Single-Core Polymeric Cables)

• Completetheproceduresforinstallingtheconnectorinsulationinsection4.3.3.

• Pullthecorestogetherascloselyaspossibleandwraponelayeroftinnedcoppermesharoundthejointwitha50%overlap.Continueontotheleadsheathfor30mmanduptothescreenwiresontheoppositejointside.

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• Laythecopperwirescreensbackacrossthejointandformthemintothreeseparateearthconductors.Connectthecopperscreenwirestoeachofthethreeearthbraidsusingthemechanicalconnectorsprovided.

• Positionthethreeearthbraidsevenlyaroundtheleadsheathareaontopofthetinnedcoppermesh.Connectthethreeearthbraidstotheleadsheathusingalargerollspring.

• Wraptherollspringoverthebraidsandtwistthespringuptightly.CovertherollspringwithtwolayersofPVCtape.

• Wraptheremainingexposedleadsheathwiththestripsofredsealanttape.This is an important moisture seal. Do not leave out.

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4.4.5 Heatshrink Three-Core Transition Straight Joints (Three-Core Paper to Single-Core Polymeric)

• Completetheproceduresforinstallingtheconnectorinsulationinsection4.3.4.

• Pullthecorestogetherascloselyaspossibleandwraponelayeroftinnedcoppermesharoundthejointwitha50%overlap.Continueontotheleadsheathfor30mmanduptothescreenwiresontheoppositejointside.

• Laythescreenwiresbackacrossthejointandformthemintothreeseparateearthconductors.Connectthecopperwirescreenstothethreeearthbraidsusingthemechanicalconnectorsprovided.

• Laythethreeearthleadsevenlyaroundtheleadsheathontopofthetinnedcoppermesh.Connectthethreeearthbraidstotheleadsheathusingalargerollspring.Wraptherollspringoverthebraidsandtwistthespringuptightly.CoverthespringwithtwolayersofPVCtape.UNCONTROLL

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• Applyonehalflaplayerofwhitefabrictapeoverthesingle-corepolymericendofthejointforadistanceof150mmfromthecableoversheathtoprotectthetinnedcoppermeshtapefromtheheatgeneratedbyshrinkingtheThree-Corebreakout.

• Pulltheheatshrinkbreakoutbackoverthejointasfarasitwillgoandshrinkinplace,startingwiththeturretsbeforemovingontothemainbody.

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• Wraptheremainingexposedleadsheathwiththestripofblackmasticsealanttape.Thisisanimportantmoistureseal.Donotleaveout.

• Positionthewraparoundheatshrinkjointsleevearoundthejointandconnectthetwoendstogetherusingthemaetalchannelandthemetaljoiningclip.

• Shrinkthewraparoundsleeveinplace,startingatthemiddlebeforemovingtowardseachendinturn.Thegreenpaintonthesurfaceofthesleeveshoulddisappearwhenthetubeiscorrectlyshrunk.

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• Extraheatshouldbeappliedtothemetalchanneluntilthewhitemarkerlinecanbe clearlyseenunderit.

• Donotmoveorbackfilluntilthejointhascompletelycooled.

4.4.6 HSL Trifurcating Joints (Three-Core HSL to 3 x Single-Core Polymeric Cables) • Completetheproceduresforinstallingtheconnectorinsulationinsection4.3.5.

• Wraponelayeroftinnedcoppermeshwitha50%overlapovereachinsulatedcorecontinuingacrossthejointedcoresfromthesheathcutonthepolymericcables.Finish50mmontotheleadsheaths.

• Laythecopperscreenwiresbackacrossthejointandformthemintothreeseparateearthconductors.Connectthecopperscreenwirestoeachofthreeearthbraidsusingmechanicalconnectorsprovidedinthekit.UNCONTROLL

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• Connecttheeachearthbraidstoeachoftheindividulleadsheathsusingatwoturnsoftherollsprings.

• Turntheendoftheearthbraidsbackoverthetwoturnsoftherollspringensuringthattheyareflatandeven.Wraptheremainderofthespringlengthoverthebraidsandtwistthespringuptightly.

• CovertherollspringswithtwolayersofPVCtape.

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• Wraptheremainingexposedleadsheathswiththestripsofredsealanttape.This is an important moisture seal. Do not leave out.

4.4.7 Connection of Screen Wires on Indoor and Outdoor Terminations • Completetheproceduresforinstallingtheterminationsdescribedinsection4.1.8.

• ConnectthescreenwirestotheEarthingstudorpositionprovided(outdoorterminations)asapplicableforthegeometryoftheapparatus.

4.4.8 Fitting Plastic Joint Boxes (Trifurcating Joints Only) • Trimofftheendsofthejointboxsuppliedwiththekit,sothatitwillfitoverthecables

enteringthebox.

• Usingtheboxasaguide,offerituptothecableandmarkthestandoffpositionsofthemouldingswithachinagraphpencil.

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• Removethebackingfromtherubberpatchessuppliedinthekitandapplycentrally(overthepreviouslymademarks)withthestickysideout.

• Placethetwohalvesofthejointshelloverthejointandclipthetwohalvestogetherwiththeclipsprovided.Checkenoughclipsareusedtostoptheresinleakingoutwhenitispouredin.

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• TapethejointboxtotheincomingcablewithPVCoranothersuitabletape.Iflargegapsareleftwhentheshellisfitteditmaybenecessarytopacktheendsofthejointshelloutwiththeclaypacksuppliedinsomekits.

• Forextrasecurity,runalengthofPVCtapedowntheseamsofthejointshellandfittheplasticlid.

4.4.9 Mixing and Installation of Polyurethane Resin • All33kVjointsshouldbefilledwith3-partpolyurethaneresin.Checkthatthecorrect

PersonalProtectiveEquipmentiswornatalltimesandtheresinisnotmixedinaconfinedspace.

• Checkthelabelonthebuckettoensurethattheresinhasnotpassedtheusebydate.

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• Emptythecontentsofthebucketandcheckforanydamagetothepackaging.

• Pickupthefoilbagcontainingtheresinandhardenerandapplypressuretothelargeresinpouchsothattheresinbreaksthesealbetweenthetwosectionsandmixeswiththehardener.

• Mixthecontentsofbagbykneadingthefoilbagforaminimumoftwominutes.

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• Carefullycutoneofthecornersoffthefoilbagandpourallthecontentsintothesuppliedplasticbucket.

• Pourapproximatelyhalfofthesandsuppliedintheplasticbagintothebucketandstiruntilitisthoroughlymixedintotheresin.

• Pourtherestofthesandintothebucketandmixuntilnorawsandisvisibleandtheresinhasnolumpsinit.

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• Pourthemixedresinintothejointshell.

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Documents

33kV Jointing Manual Section 4 - Thorne and …...UK POWER NETWORKS 33kV CABLE JOINTING MANUAL I 2012 Section 4 I Page 1 4 INSTALLING HEATSHRINK MATERIALS AND COMPONENTS 4.1 Installing