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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 Materials
4.1.1 Single-Core Paper Insulated Cables in Transition Joints
Preparethecableasdescribedinsection3.2.Useachinagraphpenciltomark20mmontotheleadsheathand10mmontotheinsulationpapers.
Removethereleasepaperfromthemediumlengthofyellowstresscontroltape.Stretchthetapetoabouthalfitsoriginalwidthandwrapitaroundtheleadsheathfor20mm.Removethetwinebinderfromthescreenedgeandcontinuewiththetapeoverthescreenpapersandontotheinsulationfor10mm.
Useachinagraphpenciltomarktheleadsheath20mmbeyondtheyellowstresscontroltape.Positiontheclearbarriertubingoverthecoreendandovertheyellowstresscontroltape,overlappingontotheleadsheathby20mm.UN
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Shrinkthetubingdown,startingontheleadsheathandcontinuingtowardsthecoreend.Oncecompletedthetubingshouldbefullyshrunkandhaveasmoothfinishwithoutwrinklesorcreases.
Positiontheshortblackconductivesleeve220mmfromthecoreendandshrinkthetubingdownstartingattheopencableendbeforeworkingtowardstheleadsheath.
4.1.2 Single-Core Polymeric Pot Ends
Preparethecablesasdescribedinsection3.1uptoandincludingthescreenremovalpoint.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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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,withoneclipeithersideofthesupportringscentralridge.
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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 70mm & 95mm
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 120mm & 150mm
Forcablesbelowtheminimumsizerangespecifiedonthekitlabel,a'shimkit'mustbeused.
Thecableswillbeatthestageofpreparationdescribedinsections4.1.1,4.1.3,4.1.4or 4.1.6.
Applyashortlengthoftheyellowstresscontroltape20mmovertheendoftheconductivetubeandontothecleartubingby10mm.Usesomeoftheyellowtapesuppliedinthemainjointkit.
Positionashortlengthofthestresscontroltubing(54/24)overthecoreend,overlappingtheconductivetubesandtheyellowstresscontrolmasticby40mm.UN
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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 Lugs
4.2.1 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
Followthecablepreparationproceduresforpolymericcablesinsections3.1.1to3.1.3beforeinstallinganymechanicallugs.
Eachkitcomeswiththecorrectsizeandtypeoflugforeachtermination.Removetheconductorinsulationtotheinsertiondepthofthelug.
Placethelugovertheconductorsothatthebottomofthebarrelbuttsupagainstthecoreinsulation.
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Tightentheboltsbyhandandcheckthatthepalmholeslineupwiththeirrespectiveconnectionpoint.
Tightentheboltsuntiltheboltheadsshearoff.
4.3 Installing Connector Stress Control and Heatshrink Insulation
4.3.1 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.
Continuetoshrinkthetubefromthecentretowithin50mmofoneend.
Removetheheatfromthatendandstartshrinkingfromthemiddleagaintowardstheotherendofthetubing.Stopagain50mmfromtheend.Thisensuresairinsidethetubeisexpelledasthetubeshrinks.
Returntoeachtubeendinturntocompletetheshrinkingprocesscompletely.
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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.
Continuetoshrinkthetubefromthecentretowithin50mmofoneend.
Removetheheatfromthatendandstartshrinkingfromthemiddleagaintowardstheotherendofthetubing.Stopagain50mmfromtheend.Thisensuresairinsidethetubeisexpelledasthetubeshrinks.
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Returntoeachtubeendinturntocompletetheshrinkingprocesscompletely.
4.3.4 Heatshrink Three-Core Transition Straight Joints (Three-Core PILC to Single-Core Polymeric)
Fittheconnectoruptothepointasdescribedinsection4.2.4.
Removethereleasepaperfromoneoftheshortyellowstresscontrolmasticstripsandwrapitaroundthepolymericcorescreen,starting20mmfromthescreenedgeandcontinueontotheinsulationfor10mm.Stretchthetapetohalfitsoriginalwidthtoachieveafinethinedgeontheinsulation.
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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Continuetoshrinkthetubesfromthecentretowithin50mmofoneend.
Removetheheatfromthatendandstartshrinkingfromthemiddletowardstheotherendofthetubes.Stop50mmfromtheend.Thisensuresairinsidethetubeisexpelledasthetubeshrinks.
Returntoeachtubeendinturntocompletetheshrinkingprocesscompletely.
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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.
Removethereleasepaperfromoneoftheshortyellowstresscontrolmasticstripsandwrapitaroundthepolymericcorescreen,starting20mmfromthescreenedgeandcontinueontotheinsulationfor10mm.Stretchthetapetohalfitsoriginalwidthtoachieveafinethinedgeontheinsulation.
Repeatthisonthepapercablecore,wrappingtheyellowmasticaroundtheedgeoftheconductivetubing.Cover20mmoftheconductivetubingandcontinueontothecleartubingfor10mm.UN
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Checkthattheboltholesarefilledwiththesuppliedgreyclaytoleaveasmoothprofile. Usealongpieceoftheyellowstresscontrolmastictocoverbothendsoftheconnector, 20mmontheconnectorand10mmontotheinsulation.
Removethereleasepaperfromtheyellowstresscontrolmasticpatchandwrapitcentrallyaroundtheconnector,takingcaretoexcludeanytrappedairasitisapplied.Whenfinishedthepatchshouldbesmoothandwrinklefree.
Slidethestresscontroltubesfrominsidethenestedtubesetsandpositionthemcentrallyovertheconnectorsensuringthattheoverlapovereachtapedscreenedgeisequal.Shrinkthetubesstartinginthecentrebeforeworkingtowardseachendinturn.
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Removethereleasepaperfromonelengthoftheredsealantmastictapeandwrapitaroundbothendsofthestresscontroltube.Overlapthetapeontothetubeby20mmandby10mmontothecore.
Pulltheredinsulatingtubesfromthetubesetsandcentrallypositionthemoverthestresscontroltubes.Shrinkthetubesstartinginthecentrebeforeworkingtowardseachendinturn.Whencompletethetubesshouldbesmoothandwrinklefree.
Note:Continuewiththenextstepwhiletheredinsulatingtubesarestillhot.
Pullthescreenedblackandredinsulatingtubescentrallyovertheredinsulatingtubesandstartshrinkingatthecentrepositionusingequalheatoverthewholesurface.Whenthetubesareproperlyshrunk,theridgesontheouterblacklayerofthetubesshouldnolongerbevisibleandthetubescannolongerbemoved.
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Continuetoshrinkthetubesfromthecentretowithin50mmofoneend.
Removetheheatfromthatendandstartshrinkingfromthemiddleagaintowardstheotherendofthetubes.Stopagain50mmfromtheend.Thisensuresairinsidethetubeisexpelledasthetubeshrinks.
Returntoeachtubeendinturntocompletetheshrinkingprocesscompletely.
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4.4 Installing Mechanical Earth Bonds and Associated Components
4.4.1 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.UN
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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.UN
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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.UN
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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,sothatitwillfitoverthecablesenteringthebox.
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.CheckthatthecorrectPersonalProtectiveEquipmentiswornatalltimesandtheresinisnotmixedinaconfinedspace.
Checkthelabelonthebuckettoensurethattheresinhasnotpassedtheusebydate.
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Emptythecontentsofthebucketandcheckforanydamagetothepackaging.
Pickupthefoilbagcontainingtheresinandhardenerandapplypressuretothelargeresinpouchsothattheresinbreaksthesealbetweenthetwosectionsandmixeswiththehardener.
Mixthecontentsofbagbykneadingthefoilbagforaminimumoftwominutes.
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Carefullycutoneofthecornersoffthefoilbagandpourallthecontentsintothesuppliedplasticbucket.
Pourapproximatelyhalfofthesandsuppliedintheplasticbagintothebucketandstiruntilitisthoroughlymixedintotheresin.
Pourtherestofthesandintothebucketandmixuntilnorawsandisvisibleandtheresinhasnolumpsinit.
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Pourthemixedresinintothejointshell.
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