NS 0129 Network Standards Volume 1
Construction Standards for High Voltage Cable Joints and Terminations 1 October 1997
Amendments included from CIA 1087, 21 Dec 1999; CIA 1094, 1 Mar 2000, CIA 1114, 15 June 2000, CIA 1170, 15 May 2001, CIA 1188, 25 July 2001, CIA 1226, 27 Mar 2002 and CIA 1242, 23 April 2002
SUMMARY Network Standard NS 0129 provides the requirements for making joints and terminations on high voltage cables.
GENERAL This Standard is subject to amendment by EnergyAustralia at any time. Any proposed deviation from this Standard must be submitted to EnergyAustralia for approval before it is implemented.
ISSUE EnergyAustralia staff: This Standard is for issue to all staff involved with high voltage cable jointing work, and for general reference by technical and engineering staff.
Where this document is issued as a controlled document replacing an earlier edition; remove and destroy the superseded document. Accredited Service Providers and Contractors: This document is issued on an uncontrolled basis. It is the user’s responsibility to ensure that the document being used is current and includes any amendments issued since the date on the document.
EnergyAustralia offers a subscription service which provides for updates and amendments to standards on payment of an annual fee. Current network standards are also available on EnergyAustralia’s Internet site at www.energy.com.au.
DISCLAIMER This Standard has been developed using information available from field and other sources and is suitable for most situations encountered in EnergyAustralia. Particular conditions, projects or localities may require special or different practices. It is the responsibility of all persons involved to ensure that a safe system of work is employed and that statutory requirements are met. EnergyAustralia will not accept any liability for work carried out to a superseded standard. EnergyAustralia may not accept work carried out which is not in accordance with current standard requirements. EnergyAustralia’s standards are subject to ongoing review. It is possible that conflict may exist between standard documents. In this event, the most recent standard is to prevail.
INTERPRETATION In the event that any user of this Standard considers that any of its provisions is uncertain, ambiguous or otherwise in need of interpretation, the user should request EnergyAustralia to clarify the provision. EnergyAustralia’s interpretation shall then apply as though it were included in the Standard, and is final and binding. No correspondence will be entered into with any person disputing the meaning of the provision published in the Standard or the accuracy of EnergyAustralia’s interpretation.
SUMMARY Network Standard NS 0129 provides the requirements for making joints and terminations on high voltage cables.
GENERAL This Standard is subject to amendment by EnergyAustralia at any time. Any proposed deviation from this Standard must be submitted to EnergyAustralia for approval before it is implemented.
ISSUE EnergyAustralia staff: This Standard is for issue to all staff involved with high voltage cable jointing work, and for general reference by technical and engineering staff.
Where this document is issued as a controlled document replacing an earlier edition; remove and destroy the superseded document. Accredited Service Providers and Contractors: This document is issued on an uncontrolled basis. It is the user’s responsibility to ensure that the document being used is current and includes any amendments issued since the date on the document.
EnergyAustralia offers a subscription service which provides for updates and amendments to standards on payment of an annual fee. Current network standards are also available on EnergyAustralia’s Internet site at www.energy.com.au.
DISCLAIMER This Standard has been developed using information available from field and other sources and is suitable for most situations encountered in EnergyAustralia. Particular conditions, projects or localities may require special or different practices. It is the responsibility of all persons involved to ensure that a safe system of work is employed and that statutory requirements are met. EnergyAustralia will not accept any liability for work carried out to a superseded standard. EnergyAustralia may not accept work carried out which is not in accordance with current standard requirements. EnergyAustralia’s standards are subject to ongoing review. It is possible that conflict may exist between standard documents. In this event, the most recent standard is to prevail.
INTERPRETATION In the event that any user of this Standard considers that any of its provisions is uncertain, ambiguous or otherwise in need of interpretation, the user should request EnergyAustralia to clarify the provision. EnergyAustralia’s interpretation shall then apply as though it were included in the Standard, and is final and binding. No correspondence will be entered into with any person disputing the meaning of the provision published in the Standard or the accuracy of EnergyAustralia’s interpretation.
Network Standard NS 0129 Construction Standards for High Voltage Cable Joints and Terminations 1 October 1997 CONTENTS 1.
INTROD INTRODUCT UCTION.... ION........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ....... ... 1
2.
RESPON RESPONSIB SIBILI ILITIE TIES S ........ ............ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ...... 2 2.1 2.1 Clie Client nts s ...... ........ ..... ...... ...... ...... ...... ...... ...... ...... ...... ..... ..... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ......2 ...2 2.2 2.2 Ener Energy gyAu Aust stra rali lia a Repr Repres esen enta tativ tives es ...... ......... ..... ..... ...... ...... ..... ..... ...... ...... ..... ..... ...... ...... ..... .. 2 2.3 2.3 Elec Electr tric ical al Safe Safety ty Rule Rules s ...... ......... ...... ...... ...... ...... ...... ...... ...... ..... ..... ...... ...... ..... ..... ...... ...... ..... ..... ......2 ...2 2.4 2.4 Admi Admitt ttan ance ce to to Ener Energy gyAu Aust stra rali lia a Prem Premis ises es .... ...... .... .... .... .... .... .... .... .... .... .... .... .... ....2 ..2
3.
CONS CONSTR TRUC UCTI TION ON OF OF UND UNDER ERGR GROU OUND ND TO TO OVE OVERH RHEA EAD D (UG/ (UG/OH OH)) PILC CABLE TERMINATIONS............... TERMINATIONS............................ .......................... .......................... ..................... ........ 4
4.
CONN CONNEC ECTI TION ON OF OF UNDE UNDERG RGRO ROUN UND D MUL MULTI TI-C -COR ORE E CABL CABLE E TO TO HV ABC............................ ABC....................................... ....................... ....................... ....................... ....................... ...................... .................. ....... 8 4.1 4.1 HV ABC ABC to to Und Under ergr grou ound nd Cabl Cable e Con Const stru ruct ctio ion... n..... .... .... .... .... .... .... .... .... .... .... 10
5.
Suburb Suburban an Type Type Transf Transform ormer er Cable Cable Termi Terminat nation ion (HV1-2 (HV1-20)... 0)....... ........ ........ ...... .. 11
6.
INDO INDOOR OR COLD COLDSH SHRI RINK NK TERM TERMIN INAT ATIO ION, N, PAPE PAPER R INS INSUL ULAT ATED ED CABLES CABLES ..................... ................................. ....................... ....................... ....................... ...................... ....................... ................ .... 12
7.
OUTD OUTDOO OOR R COL COLDS DSHR HRIN INK K TER TERMI MINA NATI TION ON,, PAPE PAPER R INSU INSULA LATE TED D CABLES CABLES ..................... ................................. ....................... ....................... ....................... ...................... ....................... ................ .... 16
8.
(Delet (Deleted ed by CIA 1170, 1170, 15 May 2001) 2001) ........ ............ ........ ........ ........ ........ ........ ........ ........ ........ ........ ...... .. 18
9.
INDO INDOOR OR AND AND OUTD OUTDOO OOR R SING SINGLE LE-C -COR ORE E HEAT HEATSH SHRI RINK NK TERMINATIONS, XLPE-INSULATED CABLES (HV1-27) .................. ................ .. 19 9.1 9.1 Gene Genera rall ...... ......... ...... ...... ...... ...... ..... ..... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... .... .. 19 9.2 9.2 Spec Specia iall Requ Requir irem emen ents ts ..... ........ ...... ..... ..... ...... ...... ..... ..... ...... ...... ..... ..... ...... ...... ..... ..... ...... ...... ..... .... .. 20
10. TRANSF TRANSFORM ORMER ER HEATSH HEATSHRIN RINK K TERMINAT TERMINATION ION SINGLE SINGLE-CO -CORE, RE, PAPER-INS PAPER-INSULAT ULATED ED CABLES CABLES (HV1-28) (HV1-28) ...................... ................................. ...................... ........... 26 11.
POT END (LIVE END SEAL) SEAL) HEATSH HEATSHRINK RINK TERMINATI TERMINATION ON SINGLESINGLECORE, PAPER-INSULATED CABLES (HV1-35) ........................... .............. .................. ..... 29
12. POT END (LIVE (LIVE END END SEAL) SEAL) HEAT HEATSHR SHRINK INK TERM TERMINA INATIO TION N MULTICORE, PAPER-INSULATED CABLES (HV1-36) ..................... .............. ....... 31 13. STRAIG STRAIGHT HT THROU THROUGH GH HEATS HEATSHRI HRINK NK JOINT JOINT SING SINGLELE-COR CORE, E, PAPER-INS PAPER-INSULAT ULATED ED CABLES CABLES (HV2-2) (HV2-2) ...................... ................................. ...................... ............. .. 33 14. STRAIG STRAIGHT HT THRO THROUGH UGH HEATSH HEATSHRIN RINK K JOINT JOINT UP UP TO 300m 300mm m2 MULTICORE MULTICORE,, PAPER-INSU PAPER-INSULATE LATED D CABLES CABLES (HV2-3) (HV2-3) ..................... ....................... .. 35 14.1 14.1 Appr Approv oved ed Hea Heats tshr hrin ink k Join Jointt Kits Kits ...... ......... ...... ...... ...... ...... ..... ..... ...... ...... ..... ..... ...... ...... ..... .. 35 14.2 14.2 Core Core Conn Connec ecto tors rs ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... ..... ...... ...... ...... ...... ..... ..... ...... ......35 ...35 14.3 14.3 Earth Earth Contin Continuit uity....... y........... ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ...... .. 36
14.4 14.5
Stripping Dimensions ............................................................ 37 Other Requirements.............................................................. 37
15. STRAIGHT THROUGH HEATSHRINK JOINT MULTICORE, PAPERINSULATED CABLES 300 TO 500mm2 (HV2-4) ................................ 39 15.1 Approved Heatshrink Joint Kits ............................................. 39 15.2 Core Connectors ...................................................................39 15.3 Earth Continuity..................................................................... 40 15.4 Stripping Dimensions ............................................................ 40 15.5 Other Requirements.............................................................. 41 16. THREE-TO-ONE HEATSHRINK TRANSITION JOINT PAPERINSULATED CABLES (HV2-5)............................................................ 42 16.1 Approved Heatshrink Joint Kits ............................................. 42 16.2 Core Connectors ...................................................................43 16.3 Earth Continuity..................................................................... 44 16.4 Stripping Dimensions ............................................................ 44 16.5 Other Requirements.............................................................. 44 17. STRAIGHT THROUGH JOINT (STUB TEE) SCREENED AND BELTED PAPER INSULATED MULTI-CORE CABLES (HV 2-72) .... 46 17.1 Core Connectors ...................................................................46 17.2 Paper Insulation and Insulating Tapes .................................. 46 17.3 Stress Cones......................................................................... 47 17.4 Earth Continuity..................................................................... 47 17.5 Stripping Dimensions ............................................................ 48 17.6 Troughing-in of Completed Joints.......................................... 48 17.7 Commissioning of Joints........................................................ 48 18. LAY-ON TEE JOINTS FOR SCREENED AND BELTED PAPER INSULATED CABLES ......................................................................... 53 18.1 Core Connectors ...................................................................53 18.2 Paper Insulation and Insulating Tapes .................................. 53 18.3 Stress Cones......................................................................... 54 18.4 Earth Continuity..................................................................... 54 18.5 Stripping Dimensions ............................................................ 55 18.6 Troughing-in of Completed Joints.......................................... 55 18.7 Commissioning of Joints........................................................ 55 19. QUALITY OF WORK...........................................................................61 19.1 Warranty and Public Liability ................................................. 61 20. STORES AND MATERIALS................................................................ 61 21.
REFERENCES.................................................................................... 62 21.1 EnergyAustralia Drawings .....................................................62 21.2 Acts and Regulations ............................................................ 62
APPENDICES
A
Cable Description Codes..................................................................... 63
B
Installation Instruction HV 1-41 ........................................................... 65
C
Installation Instruction HV 1-42 ........................................................... 75
D
Installation Instruction HV 1-43 ........................................................... 86
E
Installation Instruction HV 1-44 ........................................................... 98
1
1.
1 October 1997
INTRODUCTION This Network Standard specifies EnergyAustralia’s construction requirements for High Voltage (HV) cable joints, terminations, and Underground to Overhead (UG/OH) connections. Although there are many types of HV joints, terminations and UGOH connections on EnergyAustralia’s reticulation system, only the approved construction standards currently in use are detailed in this document. The requirements of this standard must always be adhered to. Any deviations from this standard must be submitted to EnergyAustralia for approval prior to being implemented. In general, EnergyAustralia’s current policy provides for the contestability of customer connections, recoverable works and some system augmentations. Work on EnergyAustralia’s supply system can only be performed by accredited contractors. Details of the accreditation procedure may be obtained from any of EnergyAustralia’s Customer Service centres. This Network Standard should be read in conjunction with EnergyAustralia’s documents NS 0127 - Specification for Low Voltage Cable Joints and Terminations and NS 0130 - Specification for Underground Cable Laying for URD. Construction details for joints, terminations, and UG/OH connections which are not covered in this standard should be sought from EnergyAustralia as required.
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
1 October 1997
2.
RESPONSIBILITIES
2.1
Clients
2
It is the responsibility of clients to ensure that only accredited personnel are engaged on the design and construction of electricity reticulation installations. The construction of electricity reticulation installations undertaken by clients must be managed by accredited Project Managers.
2.2
EnergyAustralia Representatives A representative will be appointed by EnergyAustralia for each project undertaken by accredited contractors. The representatives will be responsible for organising audits and will act as liaison between the Client and EnergyAustralia. Audits will be carried out either progressively or at the completion of the work depending on the specific requirements of each project.
2.3
Electrical Safety Rules All accredited personnel will be required to be appropriately trained for the work concerned, and will need to have a thorough knowledge of EnergyAustralia’s Electrical Safety Rules. In particular, they shall have a full understanding of the procedures and documentation associated with Equipping Permits and high and low voltage access permits before they commence work on any part of EnergyAustralia’s reticulation system. EnergyAustralia’s Electrical Safety Rules are designed to ensure compliance with the Electrical (Worker’s Safety) Regulation 1992, which applies to all work on high and low voltage electrical apparatus or near exposed high voltage conductors and to persons who enter electrical stations or generating stations. The regulation applies to people employed by electricity supply authorities, customers taking supply at high voltage, electrical contractors and accredited contractors working on electrical apparatus, and to any other employee or person including visitors.
2.4
Admittance to EnergyAustralia Premises Admission to EnergyAustralia’s premises is granted to accredited contractors only under EnergyAustralia’s supervision and at the accredited contractors’ cost under the following conditions: •
EnergyAustralia does not hold itself responsible to the accredited contractor or anyone claiming through the accredited contractor in respect of any loss, damage or injury which may be suffered or received during or arising from their presence upon EnergyAustralia’s premises or any part thereof or any other premises or works connected therewith.
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
3
•
•
•
•
1 October 1997
The accredited contractor accepts all risks involved in making any visit to the said premises and works whether there are concealed dangers or otherwise and whether such dangers are known to EnergyAustralia or not. EnergyAustralia does not guarantee that the premises or works are free from concealed dangers or risks. EnergyAustralia shall not be liable for or be bound by any of the liabilities or duties to or by which it would otherwise be liable or bound under the law relating to the liability and/or responsibility of an owner or occupier of premises to or in relation to licensees and/or invitees. Accredited contractors agree to safeguard any person who may accompany them or be under their control or direction and shall acquaint any such person with the terms upon which admission is granted by EnergyAustralia to its premises or work sites.
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
1 October 1997
3.
4
CONSTRUCTION OF UNDERGROUND TO OVERHEAD (UG/OH) PILC CABLE TERMINATIONS This specification provides the requirements for the construction of 11kV underground-to-overhead (UG/OH) PILC cable terminations. This specification should be read in conjunction with the installation instructions for Outdoor Coldshrink Terminations. There are two types of 11kV underground-to-overhead (UG/OH) PILC cable terminations, they are the Type K2 and Type K3. The Type K2 UG/OH is a single core cable termination used for terminating 500 mm2 multicore cables by first trifurcating the multicore cable approximately 3 metres away from the foot of the UG/OH pole; or when a UG/OH termination is to be constructed within 25 metres of the substation it is supplying. The Type K3 UG/OH is for terminating multicore cables less than 500 mm2. The construction of pole mounted 11kV underground-to-overhead (UG/OH) cable terminations must be completed to the requirements of Drawing 62103 11kV Underground to Overhead (UG/OH) Construction for Single Core PILC Cables Type K2 for single core cables and Drawing 119643 11kV Underground to Overhead (UG/OH) Construction for Multicore PILC Cables Type K3 for multicore cables. Copies of these drawings are included in this Standard. Larger prints may be obtained from EnergyAustralia. The cables must be erected on the side of the pole away from oncoming traffic (except if the mains terminate on the traffic side of the pole, or there are problems such as a driveway or underground obstructions). The cable shall not be bent tighter than the manufacturer’s specified minimum internal bending radius, both during installation and after it has been set in position. The erection and termination of the cable on the pole should be completed together wherever possible to minimise the number of outages required. Where it is intended to terminate the UG/OH cable at a later date, the cable should: •
•
•
•
Be cut long enough to allow construction of the termination at the correct height. This would normally require the cable to extend 300mm above the UG/OH support bracket. Above ground joints on UG/OH cables are not allowed. Be shorted and sealed in accordance with the requirements of NS 0130 Specification for Underground Cable Laying Be securely saddled to the pole. The cable should not be coiled or excessively bent - refer to the manufacturer’s specification for minimum internal bending radius. Have sufficient electrical clearance from the overhead mains if these mains are intended to be energised before the cable termination is completed.
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
5
1 October 1997
Drawings 62103 and 119643 provide an alternative arrangement for UG/OH terminations which involves using polymeric surge arresters to provide protection against electrical surges as well as mechanical support for the terminated cores. This arrangement must be used wherever possible. Where an earth fault indicator (EFI) is required to be installed on UG/OH cable, the pole must be appropriately dressed to suit the current transformer (CT) before the cable is erected on the pole. Mounting and wiring details for the CT and EFI will be provided by EnergyAustralia as required. The earth down lead must be kept clear of all metalwork, braces, coach screws, etc, on the pole.
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
1 October 1997
6
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
7
1 October 1997
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
1 October 1997
4.
8
CONNECTION OF UNDERGROUND MULTI-CORE CABLE TO HV ABC This specification provides the requirements for constructing connection points between underground cables and overhead aerial bundled cables (HV
TYPICAL HV ABC TO UNDERGROUND CABLE CONSTRUCTION
ABC). Figure 3.1 Front View of HV ABC to underground cable construction
The construction of pole mounted 11kV underground-to-overhead (UG/OH) multicore cable terminations type K3 must be completed to the requirements of Section 3 of this Network Standard.
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
9
1 October 1997
Figure 3.2 Side view of HV ABC to underground cable construction
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
1 October 1997
4.1
10
HV ABC to Underground Cable Construction
Item
Description
Stockcode
Drawing
1
Helically split tube 1 m long (note 2)
71290
2
Copper link plate
56937
3
19/2.00 GI preformed termination
-
4
Clevis thimble for GI catenary
-
5
M20 eyebolt with link plate-length to suit
-
A3-13837
6
Pole cap
-
A2-21852
7
Plastic coated steel cable ties
-
8
Copper crimp link
9
Screen bonding cable
35 mm2
57091
120 mm2
57158
35 mm2
59535
120 mm2
60111
10
Bimetallic earthing tee clamp
91165
11
Split bolt clamp type C
61374
18908
12
UGOH mounting bracket
66365
A1-62011
13
Cantilever standoff insulator 11kV
14
ABC heatshrink termination 11 kV
90225 2
35 mm
74252 2
120 mm 15
Compression lug (bimetallic)
2
35 mm
74260 58347
2
120 mm
58321
16
M12 x 35 SS bolt and nut
45021
17
M12 flat and spring washers
49429, 143859
18
Termination plate (item 3 on drawing)
91132
19
UG cable heatshrink termination 11 kV
-
20
Earth-wire (19/2.00 Cu)
21
Support assy of ABC suspension clamp
A2-116989
35 mm
2
63040 2
120 mm
63016
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
11
5.
1 October 1997
SUBURBAN TYPE TRANSFORMER CABLE TERMINATION (HV1-20) Note: Heatshrink glands must not be used on gland entry transformers, as there are no suitable heatshrink glands currently available for an oil vapour environment. Brass glands must be used, in accordance with the following diagram.
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
1 October 1997
6.
12
INDOOR COLDSHRINK TERMINATION, PAPER INSULATED CABLES This specification provides the requirements for constructing coldshrink pressure sealing terminations on indoor 11kV single core and multicore paper insulated, screened, metal sheathed, polymeric oversheathed cables. The design of this termination is such that it is capable of withstanding high internal pressures. Only personnel who have been trained and assessed as being competent in the installation of 3M pressure rated coldshrink terminations can install these terminations. Either EnergyAustralia or 3M can perform this training.
Approved Coldshrink Kits Currently, the only approved supplier of coldshrink pressure sealing termination kits suitable for this application is 3M, in accordance with the technical kit specification for the stockcodes listed below. Other coldshrink pressure sealing termination kit designs or other suppliers for similar designs must not be used unless specifically approved by EnergyAustralia. Earthing kits for single core cables are progressively being incorporated in the termination kits. Contact 3M on 1300 363 787 if the earthing kits have not been supplied. Coldshrink Kit Description
Coldshrink Kit Stockcode No.
3 x single core indoor coldshrink termination kit (including earthing) suitable for 11 kV 95mm² - 185mm² paper insulated, screened, lead sheathed, polymeric oversheathed cables – 3M’s part number EAIT-11-1C-P-S-95/185
175341
3 x single core indoor coldshrink termination kit (including earthing) suitable for 11 kV 240mm² - 300mm² paper insulated, screened, lead sheathed, polymeric oversheathed cables – 3M’s part number EAIT-11-1C-P-S-240/300
175343
Multicore indoor coldshrink termination kit (including earthing) suitable for 11kV 95 mm² paper insulated, screened, lead sheathed, polymeric oversheathed cables 3M's part number EAIT-11-3C-P-S-95 Multicore indoor coldshrink termination kit (including earthing) suitable for 11kV 185 mm² - 300 mm² paper insulated, screened, lead sheathed, polymeric oversheathed cables – 3M's part number EAIT-11-3C-P-S-185/300
175883
175884
Cable Lugs
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
1 October 1997
13
The lugs used can be of the sweated type or the compression type. In either case, the lugs must have sealed palms and barrels (except for the cable entry end). Compression lugs must be installed in strict compliance with the manufacture’s recommendations for crimping dies, and the number and position of crimps. EnergyAustralia’s stockcodes of approved lugs are provided in the table below. Stockcode of Crimp Lugs for Indoor Terminations Cable Size
Copper Cables
Aluminium Cables
95 mm²
175531
H102442
185 mm²
175532
57927
240 mm²
175533
H107706
300 mm²
175534
57687
Requirements The following requirements must be satisfied when constructing coldshrink pressure sealing terminations: •
•
•
•
•
•
•
The cables must not be bent tighter than the manufacturers’ specified minimum bending radii during the termination process or after they have been set in position. The termination shall be constructed in accordance with the installation instruction supplied in the termination kit. The installation instruction supplied is Version 1, dated 12th April 2001. Refer to Appendix B for single core cables and Appendix D for multicore cables. No jagged edges shall be left on terminated screen papers. Paper insulation must be tested for moisture. If moisture is found, the relevant EnergyAustralia representative must be immediately notified. Tapes will be applied over the lug barrels and the cable metal sheath to prevent water entry into the termination area. These areas must be properly cleaned and degreased before the tapes are applied.. The design of multicore terminations incorporates the use of resin to provide for a high cable operating pressure. This resin is best applied using a resin gun. So, it is highly recommended that a resin gun be used to inject resin into the cable crotch. This gun can be obtained from EnergyAustralia’s Logistics Branch on stockcode 175885 or purchased directly from 3M (Part No. E4 Resin Gun). Coldshrink tubings must be properly and evenly shrunk and must be free of voids.
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
1 October 1997
•
14
Restriction tape is used to improve the pressure sealing abilities of the termination. This tape does not stretch and will break if over tensioned. Avoid creasing when applying this tape.
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
1 October 1997
15
Earth Fault Indicator (EFI) CT Support Bracket Some of the designs for indoor heatshrink terminations utilised wiped copper bangles for earthing of the cable sheaths. These bangles were also used to support EFI CTs where appropriate. The new coldshrink termination design incorporates the use of roll springs and copper braids for earthing, but is not suitable for supporting the EFI CTs. To support the EFI CT, a cable mounting bracket is installed on each of the outer single core cables, with the EFI CT resting on top of the mounting brackets (refer to Figure 1 below). The cable mounting brackets are available on stockcode 177066 for 95 mm2 PILC cables, and stockcode 177067 for 185 mm2 to 300 mm2 PILC cables.
Endbox (if applicble)
80mm below the gland plate of the cable endbox
100mm below the outer Silicon Tubing for terminations in free air (no end box) Upper oversheath cut 100mm min
EFI CT
Mounting bracket
EFI CT arrangement if required
Cable Oversheath
To Main Earthing Point
Figure 1 - EFI CT Arrangement If Required
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
1 October 1997
7.
16
OUTDOOR COLDSHRINK TERMINATION, PAPER INSULATED CABLES This specification provides the requirements for constructing coldshrink pressure sealing terminations on outdoor 11kV single core and multicore paper insulated, screened, metal sheathed, polymeric oversheathed cables. This specification should be read inconjuction with Section 4 (construction of UG/OH Multicore Cable Termination Type K3) and Construction of UG/OH Single Core Cable Termination Type K2 of NS 0129 Construction Standards for HV Cable Joints and Terminations . The design of this termination is such that it is capable of withstanding high internal pressures. Only personnel who have been trained and assessed as being competent in the installation of 3M pressure rated coldshrink terminations can install these terminations. Either EnergyAustralia or 3M can perform this training.
Approved Coldshrink Kits Currently, the only approved supplier of coldshrink pressure sealing termination kits suitable for this application is 3M, in accordance with the technical kit specification for the stockcodes listed below. Other coldshrink pressure sealing termination kit designs or other suppliers for similar designs must not be used unless specifically approved by EnergyAustralia. Earthing kits for single core cables are progressively being incorporated in the termination kits. Contact 3M on 1300 363 787 if the earthing kits have not been supplied. Coldshrink Kit Description 3 x single core outdoor coldshrink termination kit (including earthing) suitable for 11 kV 95mm² - 185mm² paper insulated, screened, lead sheathed, polymeric oversheathed cables – 3M’s part number EAOT-11-1C-P-S-95/185 3 x single core outdoor coldshrink termination kit (including earthing) suitable for 11 kV 240mm² - 300mm² paper insulated, screened, lead sheathed, polymeric oversheathed cables – 3M’s part number EAOT-11-1C-P-S-240/300 Multicore outdoor coldshrink termination kit (including earthing) suitable for 11kV 95 mm² paper insulated, screened, lead sheathed, polymeric oversheathed cables 3M's part number EAOT-11-3C-P-S-95 Multicore outdoor coldshrink termination kit (including earthing) suitable for 11kV 185 mm² - 300 mm² paper insulated, screened, lead sheathed, polymeric oversheathed cables 3M's part number EAOT-11-3C-P-S-185/300
Kit Stockcode No.
175342
175344
175881
175882
Cable Lugs
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
1 October 1997
17
The lugs used can be of the sweated type or the compression type. In either case, the lugs must have sealed palms and barrels (except for the cable entry end). Compression lugs must be installed in strict compliance with the manufacture’s recommendations for crimping dies, and the number and position of crimps. EnergyAustralia’s stockcodes of approved lugs are provided in the table below. Stockcode of Crimp Lugs for Outdoor Terminations Cable Size
Copper Cables
Aluminium Cables
95 mm²
151050
H102442
185 mm²
90183
57927
240 mm²
H95901
H107706
300 mm²
57695
57687
Requirements The following requirements must be satisfied when constructing coldshrink pressure sealing terminations: •
•
•
•
•
•
•
The cables must not be bent tighter than the manufacturers’ specified minimum bending radii during the termination process or after they have been set in position. The termination shall be constructed in accordance with the installation instruction supplied in the termination kit. The installation instruction supplied is Version 1, dated 12th April 2001. Refer to Appendix C for single core cables and Appendix E for multicore cables. No jagged edges shall be left on terminated screen papers. Paper insulation must be tested for moisture. If moisture is found, the relevant EnergyAustralia representative must be immediately notified. Tapes will be applied over the lug barrels and the cable metal sheath to prevent water entry into the termination area. These areas must be properly cleaned and degreased before the tapes are applied. The design of multicore terminations incorporates the use of resin to provide for a high cable operating pressure. This resin is best applied using a resin gun. So, it is highly recommended that a resin gun be used to inject resin into the cable crotch. This gun can be obtained from EnergyAustralia’s Logistics Branch on stockcode 175885 or purchased directly from 3M (Part No. E4 Resin Gun). Coldshrink tubings must be properly and evenly shrunk and must be free of voids.
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
1 October 1997
•
•
8.
18
Restriction tape is used to improve the pressure sealing abilities of the termination. This tape does not stretch and will break if over tensioned. Avoid creasing when applying this tape. The earth braids used on outdoor terminations must be covered. All new earthing kits will be supplied with covered earth braids, in the interim the earth braids in the existing earthing kits must be covered with VM tape.
(DELETED BY CIA 1170, 15 MAY 2001)
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
1 October 1997
19
9.
INDOOR AND OUTDOOR SINGLE-CORE HEATSHRINK TERMINATIONS, XLPE-INSULATED CABLES (HV1-27) This specification provides the requirements for terminating 11 kV XLPE insulated wire screened single-core cables for indoor and outdoor applications.
9.1
General This termination design is not suitable for installation in environments subject to transformer oil or heavy transformer oil vapour contamination, such as inside oil transformer tanks. Current approved suppliers of heatshrink termination kits suitable for this application are Raychem and Sigmaform, in accordance with the technical kit specifications for the stockcodes listed below. Other termination kit designs or other suppliers for similar designs must not be used unless specifically approved by EnergyAustralia. Table 1
Termination Kits and LV Heatshrink Tubing STOCKCODES
Cable size
35 mm2
120 mm2
630 mm2
Termination type
Termination kit stockcode
LV Heatshrink tubing
Bimetal Crimp lug
Indoor
74278
60186
58347
Outdoor
74252
60186
58347
Indoor
74286
60186
58321
Outdoor
74260
60186
58321
Indoor
60038
60319
-
Outdoor
60053
60319
-
The termination construction details, including stripping dimensions for the approved Raychem and Sigmaform termination kits are shown in figures 8.1 to 8.5. The cable connectors used can be of the sweated type or the compression type. In either case, the connectors must be of the sealed type to safeguard against the ingress of moisture into the core conductors. The barrel of the connectors must be long enough to allow the outer heatshrink tubing of the termination to overlap them by a minimum of 30mm on 35mm2 cables and 60mm on 120mm2 and larger cables.
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
1 October 1997
20
Compression type connectors must be installed in strict compliance with the manufacturer’s recommendations for crimping dies, and the number and position of crimps. The following requirements must be satisfied when constructing heatshrink cable terminations on XLPE cables: •
•
•
•
•
•
•
9.2
The termination kit contents and the prepared cable ends must be kept free of foreign matter, and must not be damaged during the termination process Cables must not be bent tighter than their manufacturers’ specified minimum bending radii, either during the termination process or after they have been set in position. The insulation semi-con shall be neatly terminated. Special care must be taken to ensure that the XLPE insulation is not damaged while removing the semi-con. Cable connectors must be preheated prior to installation All components involved in the termination (including cable components) which will come into contact with either mastic tape or adhesive sealants must be thoroughly cleaned prior to the application of such sealing agents. Cleaning must only be done using lint-free cloth. Heatshrink tubings must be properly and evenly shrunk, free of voids, and must not be damaged due to overheating. Heatshrink components with adhesive sealant coatings must provide effective sealing against moisture ingress when installed The specified stripping dimensions must be adhered to.
Special Requirements The Electricity Reticulation Designer will specify the type of cable connector to be used on the terminations, and the earth screens termination requirements. If EFI CTs (Earth Fault Indicator Current Transformers) are required, two additional rain-sheds (stockcode 141564) per phase will be required to support the CT (see Detail C of Figure 8.1). (These rain-sheds are larger than the standard termination rain-sheds included in the termination kit.) If the wire screens are not required to be earthed LV heatshrink tubings are used (see Detail B of Figure 8.1). EFI CTs must not be installed where the wire screens are not earthed.
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
21
1 October 1997
connector
Figure 8.1 Special Construction Requirements
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
1 October 1997
22
Cable Components
*
1
Conductor
2
XPLE Insulation
3
Semiconducting Screen
4
Wire Screens Note: where earthing of wire screens is not required, see Detail B of Figure 8.1 for details of wire screen termination.
5
Polymeric Sheath
Heatshrink Kit Components
6
Mastic Tape (red)
7
Non-tracking, weather resistant tubing (red)
8
Stress control tubing (black)
9
Void-filling Tape (yellow)
*Refer to Clause 8.1 for details
Figure 8.2 Construction requirements for approved Raychem Indoor XLPE Cable Terminations
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
1 October 1997
23
Cable Components
*
1
Conductor
2
XPLE Insulation
3
Semiconducting Screen
4
Wire Screens Note: where earthing of wire screens is not required, see Detail B of Figure 8.1 for details of wire screen termination.
5
Polymeric Sheath
Heatshrink Kit Components
6
Mastic Tape (red)
7
Non-tracking, weather resistant tubing (red)
8
Stress control tubing (black)
9
Void filling Tape (yellow)
10
Rain-shed
*Refer to Clause 8.1 for details
Figure 8.3 Construction requirements for approved Raychem outdoor XLPE Cable Terminations
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
1 October 1997
24
Cable Components
*
1
Conductor
2
XPLE Insulation
3
Semiconducting Screen
4
Wire Screens Note: where earthing of wire screens is not required, see Detail B of Figure 8.1 for details of wire screen termination.
5
Polymeric Sheath
Heatshrink Kit Components
6
Mastic Tape (red)
7
Non-tracking, weather resistant tubing (red)
8
Stress control tubing (black)
*Refer to clause 8.1 for details
Figure 8.4 Construction requirements for approved Sigmaform Indoor XLPE Cable Terminations
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
1 October 1997
25
Cable Components
*
1
Conductor
2
XPLE Insulation
3
Semiconducting Screen
4
Wire Screens Note: where earthing of wire screens is not required, see Detail B of Figure 8.1 for details of wire screen termination.
5
Polymeric Sheath
Heatshrink Kit Components
6
Mastic Tape (red)
7
Non-tracking, weather resistant tubing (red)
8
Stress control tubing (black)
9
Rainshet
*Refer to clause 8.1 for details
Figure 8.5 Construction requirements for approved Sigmaform Outdoor XLPE Cable Terminations
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
1 October 1997
10.
26
TRANSFORMER HEATSHRINK TERMINATION SINGLE-CORE, PAPER-INSULATED CABLES (HV1-28) This specification provides the details for a heatshrink termination on 11 kV 95mm2, single-core, paper-insulated, metal-sheathed cables. The termination is suitable for installation above the oil inside the tank of gland-entry transformers. Currently, the only approved supplier of heatshrink termination kits suitable for this application is Raychem, in accordance with the technical kit specification for the stockcode listed below. Other termination kit designs or other suppliers for similar designs must not be used unless specifically approved by EnergyAustralia. HEATSHRINK KIT DESCRIPTION
3 x single core cable heatshrink terminations suitable for 95mm2 screened paper insulated cables
HEATSHRINK KIT STOCKCODE NO.
157081
The termination construction details, including stripping dimensions for the approved Raychem termination kit are shown in figure 9.1. The lugs used can be of the sweated type or the compression type. In either case, the lugs must have sealed palms and barrels (except for the cable entry end). The barrels of the lugs must be long enough to allow the outer heatshrink tubing of the termination to overlap them by a minimum of 50mm. Compression lugs must be installed in strict compliance with the manufacturer’s recommendations for crimping dies, and the number and position of crimps. CABLE SIZE
STOCKCODE OF CRIMP LUGS FOR COPPER CABLES
95mm2
151050
The following requirements must be satisfied when constructing heatshrink cable terminations inside transformer tanks. •
•
The termination kit contents and the prepared cable ends must be kept free of foreign matter, and must not be damaged during the termination process. The transformer oil must not be contaminated with foreign matter during the termination process.
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
27
•
•
•
•
•
•
•
1 October 1997
The cables and their individual cores must not be bent tighter than the manufacturers’ specified minimum bending radii, either during the termination process or after they have been set in position. No jagged edges shall be left on terminated screen papers Lugs must be preheated prior to installation All components involved in the termination (including cable components) which will come into contact with either mastic tape or adhesive sealants must be thoroughly cleaned prior to the application of such sealing agents. Cleaning must only be done using lint-free cloth. Heatshrink tubings must be properly and evenly shrunk, free of voids, and must not be damaged due to overheating. Heatshrink components with adhesive sealant coatings must provide effective sealing against moisture ingress when installed. The outer heatshrink tubing must overlap the barrel of the lug by a minimum of 50mm The specified stripping dimensions must be adhered to.
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
1 October 1997
28
Cable Components
1
Conductor
2
Paper Insulation
3
Screen Papers
4
Lead Sheath
Kit Components
5
Void-filling Tape (yellow)
6
Non-tracking, oil resistant tubing
7
Stress Control Tubing
Other Components
8
Lug
Abrade metal sheath before installing outer tubing
Figure 9.1 Raychem Heatshrink Termination for installation inside transformer tanks
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
1 October 1997
29
11.
POT END (LIVE END SEAL) HEATSHRINK TERMINATION SINGLE-CORE, PAPER-INSULATED CABLES (HV1-35) This jointing instruction specifies the requirements for a pot end (live end seal) termination on 11 kV, single-core, paper-insulated, screened, metal sheathed, polymeric oversheathed cables. Currently, the only approved supplier of heatshrink termination kits suitable for this application is Raychem, in accordance with the technical kit specification for the stockcode listed below. Other termination kit designs or other suppliers for similar designs must not be used unless specifically approved by EnergyAustralia. HEATSHRINK KIT DESCRIPTION
HEATSHRINK KIT STOCKCODE NO.
1 single core cable heatshrink pot end (live seal) suitable for 185 mm2 screened paper insulated cables
152116
1 single core cable heatshrink pot end (live seal) suitable for 300 mm2 screened paper insulated cables
152124
The pot end construction details, including stripping dimensions for the approved Raychem termination kits are shown in figures 10.1.
Figure 10.1 Stripping dimensions for approved Raychem Pot end Termination kits
The following requirements must be satisfied when constructing heatshrink cable pot ends: •
•
•
The termination kit contents and the prepared cable ends must be kept free of foreign matter, and must not be damaged during the termination process. The cable must not be bent tighter than its manufacturers’ specified minimum bending radius, either during the termination process or after it has been set in position. No jagged edges shall be left on terminated screen papers
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
1 October 1997
•
•
•
•
•
30
All components involved in the termination (including cable components) which will come into contact with either mastic tape or adhesive sealants must be thoroughly cleaned prior to the application of these sealing agents. Cleaning must only be done using lint-free cloth. Heatshrink tubings must be properly and evenly shrunk, free of voids, and must not be damaged due to overheating. Heatshrink components with adhesive sealant coatings must provide effective sealing against moisture ingress when installed The outer heatshrink tubing must overlap the cable oversheath by a minimum of 100 mm The specified stripping dimensions must be adhered to The completed termination must be allowed to cool before applying mechanical load to it
Figure 10.2 Completed View of Single Core Cable Pot End Terminations
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
1 October 1997
31
12.
POT END (LIVE END SEAL) HEATSHRINK TERMINATION MULTICORE, PAPER-INSULATED CABLES (HV1-36) This specification provides the requirements for a pot end (live end seal) termination on 11 kV, multicore, paper-insulated, screened, metal sheathed, polymeric oversheathed cables. Currently, the only approved supplier of heatshrink kits suitable for this application is Raychem, in accordance with the technical kit specification for the stockcode listed below. Other kit designs or other suppliers for similar designs must not be used unless specifically approved by EnergyAustralia.
HEATSHRINK KIT DESCRIPTION
HEATSHRINK KIT STOCKCODE NO.
1 multicore cable heatshrink pot end (live end seal) suitable for 95 mm2 screened paper insulated cables 1 multicore cable heatshrink pot end (live end seal) suitable for 185 mm2 screened paper insulated cables 1 multicore cable heatshrink pot end (live end seal) suitable for 300 mm2 screened paper insulated cables
152132
152140
152157
The pot end construction details, including stripping dimensions for the approved Raychem termination kits are shown in figure 11.1.
Armour (if any)
Metal Sheath
Screen Papers
Paper Insulation
Figure 11.1 Stripping Dimensions
The following requirements must be satisfied when constructing heatshrink cable pot ends: •
•
The termination kit contents and the prepared cable ends must be kept free of foreign matter, and must not be damaged during the termination process. The cable cores must not be bent tighter than the manufacturers’ specified minimum bending radii, either during the termination process or after it has been set in position.
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
1 October 1997
•
•
•
•
•
•
32
No jagged edges shall be left on terminated screen papers All components involved in the termination (including cable components) which will come into contact with either mastic tape or adhesive sealants must be thoroughly cleaned prior to the application of these sealing agents. Cleaning must only be done using lint-free cloth. Heatshrink tubings must be properly and evenly shrunk, free of voids, and must not be damaged due to overheating. Heatshrink components with adhesive sealant coatings must provide effective sealing against moisture ingress when installed The outer heatshrink tubing must overlap the cable oversheath by a minimum of 100 mm The specified stripping dimensions must be adhered to The completed termination must be allowed to cool before applying mechanical load to it.
Figure 11.2 Completed Pot End Termination on Multicore Cable
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
1 October 1997
33
13.
STRAIGHT THROUGH HEATSHRINK JOINT SINGLE-CORE, PAPER-INSULATED CABLES (HV2-2) This specification provides the requirements for a straight through heatshrink joint on 11 kV single-core, paper-insulated, screened, metal-sheathed, polymeric oversheathed cables. Currently, the only approved supplier of heatshrink straight through joint kits suitable for this application is Raychem, in accordance with the technical kit specification for the stockcodes listed below. Other joint kit designs or other suppliers for similar designs must not be used unless specifically approved by EnergyAustralia. STOCKCODE NO. Heatshrink Kit Description
1 single core cable heatshrink straight through joint kit suitable for screened paper insulated cables in the size range 95-185 mm2 1 single core cable heatshrink straight through joint kit suitable for 300 mm2 screened paper insulated cables
Heatshrink Kit
Copper Compression Links
90316
150268-95mm2 57141-120 mm2 150250-185 mm2
148155
80929
Aluminium Compression Links −
148320
The stripping dimensions and construction details of the joint shall be strictly in accordance with Raychem’s installation specification. Heatshrink tubings referred to by Raychem as “compression sleeves” are not used by EnergyAustralia and so they will not be supplied in the above kits. The outer tubing of 300 mm2 cable joint kits shall be replaced with a reinforced wrap-around sleeve (stockcode 148395) for all joints which are made in pits within the Sydney CBD, and for joints made in pits outside the Sydney CBD where they would be subject to regular disturbance. The cable connectors used can be of the sweated type or the compression type. The connector material shall match the conductor material on which to be used; i.e. for copper cables the connectors shall be copper, and for aluminium cables the connectors shall be aluminium. For transition joints from copper to aluminium, the connectors shall be of the bi-metal type. For size transition joints the connectors shall match both the transition sizes and the conductor materials. All connectors shall be of the blocked type. Where compression connectors are used, they shall be installed strictly in accordance with the manufacturer’s specification for crimping dies, number of crimps, and position
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
1 October 1997
34
of crimps. Installed connectors shall not diminish either the load current carrying capacity or the fault current carrying capacity of the jointed cables. Joints shall have tinned copper sheath continuity braids installed with earth fault current capacities matching those of the cables being jointed. The minimum cross sectional area of the braids shall be: •
25mm2 for 95mm2 , 120 mm2 , and 185 mm2 cables; and
•
30mm2 for 300mm2 cables
Installed sheath continuity braids shall not limit the earth fault rating of the jointed cables. The following requirements must be satisfied when constructing heatshrink straight through joints: •
•
•
•
•
•
•
•
The joint kit contents and the prepared cable ends must be kept free of foreign matter, and must not be damaged during the termination process. No jagged edges shall be left on terminated screen papers All metal sheath terminations must be belled The cable cores must not be bent tighter than the manufacturers’ specified minimum bending radii during the jointing process. The completed joint and the first 500mm of each associated cable must be straight when set in position. All components involved in the joint (including cable components) which will come into contact with either mastic tape or adhesive sealants must be thoroughly cleaned and degreased prior to the application of these sealing agents. Cleaning must only be done using lint-free cloth. Heatshrink tubings must be properly and evenly shrunk, free of voids, and must not be damaged due to overheating. Heatshrink components with adhesive sealant coatings must provide effective sealing against moisture ingress when installed The outer heatshrink tubing (and the reinforced wrap-around sleeve where used) must overlap the cable oversheaths by a minimum of 100 mm each. The completed joint must be allowed to cool down before applying mechanical load to it
Figure 12.1 Completed 11 kV heatshrink straight through joint on singlecore, paper-insulated screened, metal-sheathed cables.
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
1 October 1997
35
14.
STRAIGHT THROUGH HEATSHRINK JOINT UP TO 300mm 2 MULTICORE, PAPER-INSULATED CABLES (HV2-3) This specification provides the requirements for straight-through heatshrink joints on 11kV multi-core paper insulated, screened, metal sheathed, polymeric oversheathed, armoured and unarmoured cables. The design of the joints covered by this specification is only suitable for cables up to 300 mm2 in cross sectional area. For joints on 300-500mm2 cables, refer to the relevant section of this Network Standard.
14.1
Approved Heatshrink Joint Kits Currently, the only approved supplier of heatshrink straight-through joint kits suitable for this application is Raychem, in accordance with the technical kit specification for the stockcodes listed below. Other joint kit designs or other suppliers for similar designs must not be used unless specifically approved by EnergyAustralia. STOCKCODE NO. Heatshrink Kit Description
1 multi-core cable heatshrink straight-through joint kit suitable for screened paper insulated cables in the size range 50-95 mm2 1 multi-core cable heatshrink straight-through joint kit suitable for screened paper insulated cables in the size range 185 - 300 mm2 Notes:
14.2
Special Heatshrink Kit (See Note 1)
Standard Heatshrink Kit (See Note 2)
−
109496
148312
148304
The special kit has a re-enforced wrap-around outer sleeve for environmental protection in lieu of the standard tubular sleeves. It shall be used in pits and other open space installations where joints are likely to be physically disturbed and/or where they are not given adequate side support. 2. The standard kit has two tubular outer sleeves for environmental protection. It shall be used where joints are intended to be buried, and in open space installations where joints are given adequate side support and where they are not likely to be physically disturbed while in service.
1.
Core Connectors The cable connectors used can be of the sweated type or the compression type. Certain mechanical connectors were under evaluation at the time of preparing this Standard. Where mechanical connectors are intended to be used, they shall be submitted to EnergyAustralia first for approval.
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
1 October 1997
36
Sweated type connectors shall be made of high conductivity copper. They shall be tinned and suitable for the cable size(s) to be jointed. For compression type connectors, the connector material shall match the conductor material on which they are used; ie for copper cables the connectors shall be copper, and for aluminium cables the connectors shall be aluminium. For transition joints from copper to aluminium, the connectors shall be of the bi-metal type. For size transition joints the connectors shall match both the transition sizes and the conductor materials. Where compression connectors are used, they shall be installed strictly in accordance with the manufacturer’s specification for crimping dies, number of crimps, and position of crimps. Jointed cores shall be of the same length (ie. bird-caging of cores will not be accepted). Installed connectors shall maintain the load current carrying capacity of the jointed cores. EnergyAustralia’s stockcodes of approved connectors are provided in the table below. STOCKCODES NO. Cable Size
14.3
Sweated WeakBack Ferules
Copper Compression Links
Aluminium Compression Links
50 mm2
−
57174
−
95 mm2
63818
150268
−
185 mm2
63826
150250
−
240 mm2
−
−
−
300 mm2
63834
80929
148320
Earth Continuity The metal sheaths of jointed cables shall be made continuous by joining them with tinned copper braids of the appropriate size. The installed braids on each joint shall collectively have a 1 second earth fault current carrying capacity matching that of the cables being jointed. Where the cables being jointed vary in size, the larger cable shall be used to determine the appropriate size of braids to be used. The minimum total cross sectional area of the copper braids used shall be: 43 mm2 for 95 mm2 multi-core cables; 62 mm2 for 185 mm2 multi-core cables; 72 mm2 for 240 mm2 multi-core cables; and 85 mm2 for 300 mm2 multi-core cables. Tinned copper braids shall be attached either by wiping or by means of approved mechanical connectors. Installed sheath continuity braids shall not limit the earth fault rating of the jointed cables. NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
37
14.4
1 October 1997
Stripping Dimensions The stripping dimensions and construction details of the joint shall be strictly in accordance with Raychem’s installation specification. Where jointing space is restricted, the stripping dimensions for cables in the size range 185 - 300 mm2 may be reduced to the minimum dimensions shown in the sketch below. These dimensions must only be used where jointing space is restricted. Where a joint involves cables of different sizes, the larger cable shall be on the longer side of the joint.
Figure 13.1 Reduced Stripping Dimensions for 2 2 185mm -300mm joints only
14.5
Other Requirements The following requirements must be satisfied when constructing heatshrink straight-through joints:
•
•
•
•
•
•
The joint kit contents and the prepared cable ends must be kept free of foreign matter, and must not be damaged during the jointing process. No jagged edges shall be left on terminated screen papers. All metal sheaths terminations must be belled. The cable cores must not be bent tighter than the manufacturers’ specified minimum bending radii during the jointing process. The completed joint and the first 500 mm of each associated cable must be straight when set in position. All components involved in the joint (including cable components) which will come into contact with either mastic tape or adhesive sealants must be thoroughly cleaned and degreased prior to the application of these sealing agents. Cleaning must only be done using lint-free cloth. Heatshrink tubings must be properly and evenly shrunk, free of voids, and must not be damaged due to overheating. Heatshrink components with
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
1 October 1997
38
adhesive sealant coatings must provide effective sealing against moisture ingress when installed. •
•
The outer heatshrink tubings (and the reinforced wrap-around sleeve where used) must overlap the cable oversheaths by a minimum of 100 mm each. Where standard heatshrink kits are used, the outer tubular sleeves must overlap each other by a minimum of 100 mm. The completed joint must be allowed to cool down before applying mechanical load to it
Figure 13.2 Completed joint with tubular sleeves
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
39
15.
1 October 1997
STRAIGHT THROUGH HEATSHRINK JOINT MULTICORE, PAPER-INSULATED CABLES 300 TO 500mm 2 (HV2-4)
This specification provides the requirements for straight-through heatshrink joints on 11kV multi-core paper insulated, screened, metal sheathed, polymeric oversheathed, armoured and unarmoured cables. The design of the joint covered by this specification is only suitable for cables in the size range 300mm2-500mm2 in cross sectional area. For joints on cables up to 300mm2 in cross sectional area, refer to the relevant section of this Network Standard.
15.1
Approved Heatshrink Joint Kits
Currently, the only approved supplier of heatshrink straight through joint kits suitable for this application is Tyco Electronics, in accordance with the technical kit specification for the stockcode listed below. Other joint kit designs or other suppliers for similar designs must not be used unless specifically approved by EnergyAustralia. Heatshrink Kit Description
1 multi-core cable heatshrink straight through joint kit suitable for screened paper insulated cables in the size range 300 - 500 mm2 *
Stockcode No. of Heatshrink Kit
152884*
The insulation shims included in the heatshrink kit (stockcode 152884) are to be used on 500 mm2 cable when the step between the connector and the core insulation is greater than 5 mm (see Figure 15.1). Three additional shims will be required for a 500 mm2 to 500 mm2 straight through joint and are available direct from Tyco Electronics by quoting Tyco Electronics Part No AUST- SY114.
Figure 15.1 Straight Through Joint Compression Link
15.2
Core Connectors
The cable connectors used can be of the sweated type or the compression type. Certain mechanical connectors were under evaluation at the time of preparing this Standard. Where mechanical connectors are intended to be used, they shall be submitted to EnergyAustralia first for approval. Sweated type connectors shall be made of high conductivity copper. They shall be tinned and suitable for the cable size(s) to be jointed. For compression type connectors, the connector material shall match the conductor material on which they are used; ie for copper cables the connectors shall be copper, and for aluminium cables the connectors shall be aluminium. For transition joints from copper to aluminium, the connectors shall be of the bi-metal type. For size NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
1 October 1997
40
transition joints the connectors shall match both the transition sizes and the conductor materials. Where compression connectors are used, they shall be installed strictly in accordance with the manufacturer’s specification for crimping dies, number of crimps, and position of crimps. Jointed cores shall be of the same length (ie. birdcaging of cores will not be accepted). Installed connectors shall maintain the load current carrying capacity of the jointed cores. EnergyAustralia’s stockcodes of approved connectors are provided in the table below. Stockcodes No. Cable Size
Sweated Copper Weak-Back Compression Ferrules Links
Aluminium Compression Links
Bimetal Compression Links
300 mm2
63834
80929
148320
−
500 mm2
63891
−
176372
−
−
−
−
152603
500 mm2 Al 300 mm2 Cu
The dimensions of the connectors to be used shall not exceed those specified in the table below. Maximum Connector Dimensions Before Installation
15.3
Cable Size
Diameter (mm)
Length (mm)
300
36
190
500
48
190
Earth Continuity
The metal sheaths of jointed cables shall be made continuous by joining them with tinned copper braids of the appropriate size. The installed braids on each joint shall collectively have a 1 second earth fault current carrying capacity matching that of the cables being jointed. Where the cables being jointed vary in size, the larger cable shall be used to determine the appropriate size of braids to be used. The minimum total cross sectional area of the copper braids used shall be: 85 mm2 for 300 mm2 multi-core cables; and 117 mm2 for 500 mm2 multi-core cables. Tinned copper braids shall be attached either by wiping or by means of approved mechanical connectors. Installed sheath continuity braids shall not limit the earth fault rating of the jointed cables.
15.4
Stripping Dimensions
The stripping dimensions and construction details of the joint shall be strictly in accordance with Raychem’s installation specification. Where a joint involves cables of different sizes, the larger cable shall be on the longer side of the joint.
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
41
15.5
1 October 1997
Other Requirements
The following requirements must be satisfied when constructing heatshrink straightthrough joints: The joint kit contents and the prepared cable ends must be kept free of foreign matter, and must not be damaged during the jointing process. No jagged edges shall be left on terminated screen papers. All metal sheaths terminations must be belled. The cable cores must not be bent tighter than the manufacturers’ specified minimum bending radii during the jointing process. The completed joint and the first 500 mm of each associated cable must be straight when set in position. All components involved in the joint (including cable components) which will come into contact with either mastic tape or adhesive sealants must be thoroughly cleaned and degreased prior to the application of these sealing agents. Cleaning must only be done using lint-free cloth. Heatshrink tubings must be properly and evenly shrunk, free of voids, and must not be damaged due to overheating. Heatshrink components with adhesive sealant coatings must provide effective sealing against moisture ingress when installed. The outer heatshrink tubings (and the reinforced wrap-around sleeve where used) must overlap the cable oversheaths by a minimum of 100 mm each. Where standard heatshrink kits are used, the outer tubular sleeves must overlap each other by a minimum of 100 mm. The completed joint must be allowed to cool down before applying mechanical load to it. •
• • •
•
•
•
•
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
1 October 1997
16.
42
THREE-TO-ONE HEATSHRINK TRANSITION JOINT PAPER-INSULATED CABLES (HV2-5) This specification provides the requirements for a transition joint from multicore, paper-insulated, screened, metal sheathed, polymeric oversheathed, armoured and unarmoured cabled to three single core, paper insulated, screened, metal sheathed, polymeric oversheathed cables. This design is suitable for cables up to 500 mm2 in cross sectional area.
16.1
Approved Heatshrink Joint Kits
Currently, the only approved supplier of heatshrink joint kits suitable for this application is Tyco Electronics, in accordance with the technical kit specification for the stockcodes listed below. Other joint kit designs or other suppliers for similar designs must not be used unless specifically approved by EnergyAustralia. Transition joint from multicore to single-core
Heatshrink kit Stockcode
185 mm2
95 mm2
*
185 mm2
185 mm2
151290
300 mm2
95 mm2
151290**
300 mm2
185 mm2
151290
300 mm2
300 mm2
151290
500 mm2
185 mm2
500 mm2
300 mm2
500 mm2
500 mm2
152215 and 175804 152215 152215***
*
Not a standard EnergyAustralia stock item. It may be purchased directly from Tyco Electronics by quoting Tyco Electronics part number AUSTSY81.
**
Additional components are required for a 300mm2 to 95mm2 transition joint and are available direct from Tyco Electronics by requesting the following: Three BBIT 40/16-300/U red shim sleeves, and three OBTF35/12-300/U transparent barrier tubings. These transparent barrier tubings must replace the barrier tubings supplied in the kit (stockcode 151290).
*** Three additional shims will be required for a 500mm2 to 500mm2 transition joint if the step between the connector and the core insulation is greater than 5 mm. These shims are available direct from Tyco Electronics by quoting Tyco Electronics part number AUST-SY114.
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
1 October 1997
43
16.2
Core Connectors
The cable connectors used can be of the sweated type or the compression type. Certain mechanical connectors were under evaluation at the time of preparing this Standard. Where mechanical connectors are intended to be used, they shall be submitted to EnergyAustralia first for approval. Sweated type connectors shall be made of high conductivity copper. They shall be tinned and suitable for the cable size(s) to be jointed. For compression type connectors, the connector material shall match the conductor material on which they are used; ie for copper cables the connectors shall be copper, and for aluminium cables the connectors shall be aluminium. For transition joints from copper to aluminium, the connectors shall be of the bi-metal type. For size transition joints the connectors shall match both the transition sizes and the conductor materials. Where compression connectors are used, they shall be installed strictly in accordance with the manufacturer’s specification for crimping dies, number of crimps, and position of crimps. Installed connectors shall maintain the load current carrying capacity of the jointed cores. EnergyAustralia’s stockcodes of approved connectors are provided in the tables below. Stockcodes No. Cable Size
Sweated WeakBack Ferules
Copper Compression Links
Aluminium Compression Links
95 mm2
63818
150268
−
185 mm2
63826
150250
−
240 mm2
−
−
−
300 mm2
63834
80929
148320
500 mm2
63891
−
176372
Cable Sizes
Bimetal Compression Lugs for Size Transitions Stockcode No.
185 mm2 Al - 185 mm2 Cu
57018
300 mm2 Al - 95 mm2 Cu
Utilux No. H15424X11 (BK 300/95)*
300 mm2 Al - 185 mm2 Cu
56994
500 mm2 Al - 185 mm2 Cu
Links included in heatshrink kit (stockcode 175804)
500 mm2 Al - 300 mm2 Cu
152603
* Other links may be used but must be submitted to EnergyAustralia for approval.
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
1 October 1997
44
The dimensions of the connectors to be used shall not exceed those specified in the table below. Maximum Connector dimensions (mm) before installation
16.3
Cable Size
Diameter
Length
95 mm2
28
140
185 mm2
36
190
300 mm2
36
190
500 mm2
48
190
Earth Continuity
The metal sheaths of the single core cables shall be made continuous with the metal sheath of the multi-core cable by joining them with tinned copper braids of the appropriate size. One tinned copper braid shall be used for each single core cable. Each braid shall have a minimum 1 second earth fault rating equivalent to 1/3 the 1 second earth fault rating of the multi-core cable. Tinned copper braids shall be attached to the metal sheath of single core cables using the roll springs supplied in the kit. Attaching the tinned copper braids to the multicore cable shall be either by wiping or by means of approved mechanical connectors. Installed sheath continuity braids shall not limit the earth fault rating of the jointed cables.
16.4
Stripping Dimensions
The stripping dimensions and construction details of the joint shall be strictly in accordance with Raychem’s installation specification.
16.5
Other Requirements
The following requirements must be satisfied when constructing heatshrink straightthrough joints: The joint kit contents and the prepared cable ends must be kept free of foreign matter, and must not be damaged during the jointing process. No jagged edges shall be left on terminated screen papers. All metal sheaths terminations must be belled. The cable cores must not be bent tighter than the manufacturers’ specified minimum bending radii during the jointing process. The completed joint and the first 500 mm of each associated cable must be straight when set in position. All components involved in the joint (including cable components) which will come into contact with either mastic tape or adhesive sealants must be thoroughly cleaned and degreased prior to the application of these sealing agents. Cleaning must only be done using lint-free cloth. Heatshrink tubings must be properly and evenly shrunk, free of voids, and must not be damaged due to overheating. Heatshrink components with adhesive sealant coatings must provide effective sealing against moisture ingress when installed. •
• • •
•
•
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
45
•
1 October 1997
The insulation shims included in the heatshrink kit for 500 mm2 cables are to be used when the step between the connectors and the core insulation is greater than 5 mm (See Figure 16.1).
Figure 16.1 Straight Through Joint Compression Connector.
•
•
The outer tubular heatshrink tubings must overlap each other and the cable oversheaths by a minimum of 100 mm each. The completed joint must be allowed to cool down before applying mechanical load to it.
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
1 October 1997
17.
46
STRAIGHT THROUGH JOINT (STUB TEE) SCREENED AND BELTED PAPER INSULATED MULTI-CORE CABLES (HV 2-72)
This specification provides the requirements for constructing straight through taped joints (stub tee) on paper insulated, screened or belted, metal sheathed, polymeric oversheathed, armoured and unarmoured cables.
17.1
Core Connectors
The cable connectors shall be of the sweated type (ie. weak back ferrules). Mechanical connectors may be used, however they shall be submitted to EnergyAustralia first for approval. EnergyAustralia’s stockcodes of approved connectors are provided in the table below. Cable Sizes
Stockcode of weak-Back Ferrule
185-185 mm2
UFO 190 6 3842
185-300 mm2
UFO 194 6 3891
300-300 mm2
UFO 196 6 3917
Installed connectors shall be free of sharp edges and burrs, and shall maintain the load current carrying capacity of the jointed cores.
17.2
Paper Insulation and Insulating Tapes
The paper insulation on all cores must be tapered over a 6 mm length as shown in Figure 2. The full length of exposed paper insulation, including the tapered section, must be free of dust and moisture, and must not be touched with bare hands. The crepe paper jointing tapes approved by EnergyAustralia for 11kV jointing are impregnated with rosin/oil compound, and packed in sealed tins. Tins of insulating paper tapes must be examined prior to opening. If a tin is damaged or any compound leakage is evident, the contents must not be used. Tins must not be opened until the tapes are ready to be used. Insulating tapes must be tested for moisture content before they are used. Tapes which appear to contain any amount of moisture must not be used. Insulating tapes must be applied with an overlap of approximately 50% either direct from the roll or from a former. Surplus tapes must be discarded - they must never be used. EnergyAustralia’s stockcodes of approved insulating paper tapes are provided in the table below. Details
Stockcode
Tin of crepe paper rolls each containing: 18 rolls x 50mm wide, 8 rolls x 20mm wide, and 8 rolls x 10mm wide. All rolls are 35mm OD x 3m long
58024
Tin of crepe paper rolls each containing: 25 rolls x 50mm wide, 8 rolls x 20mm wide, and
76018
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
47
1 October 1997
4 rolls x 10mm wide. All rolls are 35m OD x 3m long
17.3
Stress Cones
Some joints will require the construction of stress cones. Where required, construction of stress cones shall comply with the following requirements: 1. The screens must be removed to 90mm from the metal sheath termination. Where carbon impregnated paper is used as screen, the outer layer of paper insulation must also be removed to the screen termination. 2. Two half lapped layers of crepe paper tape must be applied to the exposed core paper insulation following the same direciton of lay as the core paper insulation. 3. A stress cone foundation must be built using crepe paper tape. The foundation must start at the end of the screen, and must gradually reach a maximum diameter of 13mm larger than the diameter of the core insulation. The maximum diameter must occur 13mm from the end of the screen. 4. A half lapped layer of tinned copper mesh (25 mm wide) must be applied over the stress cone foundation starting onto the metal sheath. The mesh must be stretched to less than half its width while it is being applied. 5. The tinned copper mesh must be soldered to the metal sheath, and the return spiral must be tack soldered to the stress cone. 6. Any sharp projections must be smoothed off. Any metal dust resulting from this operation must be carefully removed.
17.4
Earth Continuity
The metal sheath of the jointed cables shall be made continuous by wiping the lead sleeve directly onto them. The tinning and wiping of the sleeve and metal sheaths shall provide water tight seals and durable contacts capable of withstanding earth fault currents of the same magnitude as the fault ratings of the cable sheaths involved. EnergyAustralia’s stockcodes of approved lead sleeves for 11kV joints are provided in the table below. Details
Stockcode
1500mm long lead sleeve, copperized, 28mm ID x 3mm wall thickness
80150
1500mm long lead sleeve, copperized, 32mm ID x 3mm wall thickness 1500mm long lead sleeve, copperized, 40mm ID x 3mm wall thickness 1500mm long lead sleeve, copperized, 50mm ID x 3mm wall thickness 1500mm long lead sleeve, copperized, 65mm ID x 3mm wall thickness
68700
1700mm long lead sleeve, copperized, 75mm ID x 3mm wall thickness 1500mm long lead sleeve, copperized, 90mm ID x 3mm wall thickness 1500mm long lead sleeve, copperized,
68767
68809 68791 68783
68817 68759
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
1 October 1997
48
100mm ID x 3mm wall thickness 1500mm long lead sleeve, copperized 125mm ID x 3mm wall thickness 1800mm long lead sleeve, copperized, 150mm ID x 5mm wall thickness 1700mm long lead sleeve, copperized, 175mm ID x 5mm wall thickness 1800mm long lead sleeve, copperized, 200mm ID x 5mm wall thickness
17.5
68742 68734 68833 68726
Stripping Dimensions
The stripping dimensions and construction details shall be strictly in accordance with the construction requirements provided in Figures 1 and 2.
17.6
Troughing-in of Completed Joints
Completed joints intended to be directly buried shall be placed in suitable troughings and completely encapsulated with either approved polyurethane compound or troughing-in bitumen. The stockcodes of approved troughing-in bitumen is 52811.
17.7
Commissioning of Joints
Taped joints shall not be commissioned before the joint filling and troughing-in compounds have set. Completed joints and associated cable installations shall be tested prior to commissioning in accordance with the requirements of NS 0161 - Testing Cables After Installation.
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
49
1 October 1997
Figure 1 - 11kV Screeened Cable STJ (Stubtee) Construction Details
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
1 October 1997
50
Figure 2 - 11kV Screened Cables Stub Tee Joints Sectional Details
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
51
1 October 1997
Figure 3 - 11kV Belted - Screened S.T.J. (Stubtee) Construction Details
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
1 October 1997
52
Figure 4 - 11kV Belted/Belted or Belted/Screened Stubtee Sectional Details
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
1 October 1997
53
18.
LAY-ON TEE JOINTS FOR SCREENED AND BELTED PAPER INSULATED CABLES
This specification provides the requirements for constructing the following lay-on tee joints: Single core tee cable (paper insulated, screened, metal sheathed, polymeric oversheathed) to single core main cable (paper insulated, screened, metal sheathed, polymeric oversheathed). 3 Single core tee cables (paper insulated, screened, metal sheathed, polymeric oversheathed) to multi-core main cable which may be either screened, or belted, or a joint between a screened and a belted paper cable. The multi-core cable can be armoured or unarmoured. Multi-core cable tee (which may be either belted or screened) to multi-core cable main (which may be either belted or screened). Both cables may be armoured or unarmoured. •
•
•
18.1
Core Connectors
The cable connectors shall be of the sweated type (ie. weak back ferrules). Mechanical connectors may be used, however they shall be submitted to EnergyAustralia first for approval. EnergyAustralia’s stockcodes of approved connectors are provided in the table below. Cable Sizes
Stockcode of weak-Back Ferrule
185-185 mm2
63842
185-300 mm2
63891
300-300 mm2
63917
Installed connectors shall be free of sharp edges and burrs, and shall maintain the load current carrying capacity of the jointed cores.
18.2
Paper Insulation and Insulating Tapes
The paper insulation on all cores must be tapered over a 6 mm length as shown in Figure 2. The full length of exposed paper insulation, including the tapered section, must be free of dust and moisture, and must not be touched with bare hands. The crepe paper jointing tapes approved by EnergyAustralia for 11kV jointing are impregnated with rosin/oil compound, and packed in sealed tins. Tins of insulating paper tapes must be examined prior to opening. If a tin is damaged or any compound leakage is evident, the contents must not be used. Tins must not be opened until the tapes are ready to be used. Insulating tapes must be tested for moisture content before they are used. Tapes which appear to contain any amount of moisture must not be used. Insulating tapes must be applied with an overlap of approximately 50% either direct from the roll or from a former. Surplus tapes must be discarded - they must never be used. EnergyAustralia’s stockcodes of approved insulating paper tapes are provided in the following table.
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
1 October 1997
18.3
54
Details
Stockcode
Tin of crepe paper rolls each containing: 18 rolls x 50mm wide, 8 rolls x 20mm wide, and 8 rolls x 10mm wide. All rolls are 35mm OD x 3m long
58024
Tin of crepe paper rolls each containing: 25 rolls x 50mm wide, 8 rolls x 20mm wide, and 4 rolls x 10mm wide. All rolls are 35mm OD x 3m long
76018
Stress Cones
Some joints will require the construction of stress cones. Where required, construction of stress cones shall comply with the following requirements: 1. The screens must be removed to 90 mm from the metal sheath termination. Where carbon impregnated paper is used as screen, the outer layer of paper insulation must also be removed to the screen termination. 2. Two half lapped layers of crepe paper tape must be applied to the exposed core paper insulation following the same direction of lay as the core paper insulation. 3. A stress cone foundation must be built using crepe paper tape. The foundation must start at the end of the screen, and must gradually reach a maximum diameter of 13mm larger than the diameter of the core insulation. The maximum diameter must occur 13mm from the end of the screen. 4. A half lapped layer of tinned copper mesh (25mm wide) must be applied over the stress cone foundation starting onto the metal sheath. The mesh must be stretched to less than half its width while it is being applied. 5. The tinned copper mesh must be soldered to the metal sheath, and the return spiral must be tack soldered to the stress cone. 6. Any sharp projections must be smoothed off. Any metal dust resulting from this operation must be carefully removed.
18.4
Earth Continuity
The metal sheath of the jointed cables shall be made continuous by wiping the lead sleeve directly onto them. The tinning and wiping of the sleeve and metal sheaths shall provide water tight seals and durable contacts capable of withstanding earth fault currents of the same magnitude as the fault ratings of the cable sheaths involved. EnergyAustralia’s stockcodes of approved lead sleeves for 11kV joints are provided in the table below. Details
Stockcode
1500mm long lead sleeve, copperized, 28mm ID x 3mm wall thickness
80150
1500mm long lead sleeve, copperized, 32mm ID x 3mm wall thickness
68700
1500mm long lead sleeve, copperized, 40mm ID x 3mm wall thickness 1500mm long lead sleeve, copperized, 50mm ID x 3mm wall thickness
68809 68791
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
55
18.5
1 October 1997
1500mm long lead sleeve, copperized, 65mm ID x 3mm wall thickness 1700mm long lead sleeve, copperized, 75mm ID x 3mm wall thickness
68783
1500mm long lead sleeve, copperized, 90mm ID x 3mm wall thickness
68817
1500mm long lead sleeve, copperized, 100mm ID x 3mm wall thickness 1500mm long lead sleeve, copperized 125mm ID x 3mm wall thickness 1800mm long lead sleeve, copperized, 150mm ID x 5mm wall thickness
68759
1700mm long lead sleeve, copperized, 175mm ID x 5mm wall thickness 1800mm long lead sleeve, copperized, 200mm ID x 5mm wall thickness
68833
68767
68742 68734
68726
Stripping Dimensions
The stripping dimensions and construction details shall be strictly in accordance with the construction requirements provided in Figures 1, 2, 3, 4, and 5.
18.6
Troughing-in of Completed Joints
Completed joints intended to be directly buried shall be placed in suitable troughings and completely encapsulated with either approved polyurethane compound or troughing-in bitumen. The stockcodes of approved troughing-in bitumen is 52811.
18.7
Commissioning of Joints
Taped joints shall not be commissioned before the joint filling and troughing-in compounds have set. Completed joints and associated cable installations shall be tested prior to commissioning in accordance with the requirements of NS 0161 - Testing Cables After Installation.
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
1 October 1997
56
Figure 1 - Lay On Tee Joint - Single Core to Single Core Screened Cables
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
57
1 October 1997
Figure 2 - 11kV Lay on Tee Joint - Screened Single Core onto Multi-Core Cables
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
1 October 1997
58
Figure 3 - 11kV Lay on Tee Joint - Multicore Screened/Belted Cables
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
59
1 October 1997
Figure 4 - Lay On Tee Joints - 11kV Screened Cable Sectional Details
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
1 October 1997
60
Figure 5- Lay On Tee Joints - 11kV Belted/Belted and Belted/Screened Cables Sectional Details
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
61
19.
1 October 1997
QUALITY OF WORK Supply of electricity will not be made available until all specified work is satisfactorily completed. The responsibility for correcting any defects will be that of the client.
19.1
Warranty and Public Liability The client is to warrant any undertaken electrical work which will become part of EnergyAustralia’s reticulation systems to be free of defects for a period of 36 calender months after the date of acceptance, and will be required to pay for or carry out any required repairs within that period. The client is required to have and keep a $10,000,000 (ten million dollars) public liability insurance policy for the duration of the construction work and until ownership is officially transferred to EnergyAustralia. the client must provide a certificate of currency of the insurance policy on request.
20.
STORES AND MATERIALS Contractors must only use approved products on the network. EnergyAustralia should be contacted regarding approved products. Alternative products may be submitted to EnergyAustralia for approval. A fee for the approval of alternative products for use on the network will be negotiated. To purchase materials from EnergyAustralia, the Project Manager must contact the "Project Officer Network Procurement" on telephone number (02) 9394 6034. All materials will be made available for the Client to pick up from: Central Warehouse 2 Mayvic Street Chullora NSW 2190
Alternatively, the client may obtain material from other sources provided the quality assurance and environmental management system requirements are met. Materials must comply with EnergyAustralia's relevant specifications. All materials used for network projects must be new.
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
1 October 1997
62
21.
REFERENCES
21.1
EnergyAustralia Drawings
119643
21.2
11kV Overhead Construction - Pole Mounting of Multicore Cable Terminations Type K3
Acts and Regulations This is not a full listing but should be used as a guide only. Electricity Act 1945 Construction Safety Regulations 1950 Reg No. 133A Work Cover Certificate of Exemption 5099 Electricity (Workers’ Safety) Regulation 1992 Occupational Health & Safety (Confined Space) Regulation Construction Safety Act
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
1 October 1997
63
APPENDIX A CABLE DESCRIPTION CODES This is what the code letters mean: 415 V | Voltage Rating
240 | Conductor (Size (mm2)
AL3 | Conductor Type and No. of Cores
XQ | Insulation
CU (NW) | Neutral (if applicable)
Z | Sheath
/SAC | Other Information (if applicable)
Before slash/ Phase-to-phase Voltage, Cross-sectional Area (mm2), Number of Cores
AL
Aluminium
(N)
Concentric Neutral
AW
Alumoweld
(NW)
Wavewound Concentric Neutral
BR
Butyl Rubber
NY
Nylon Insulation
CDCU
Cadmium Copper
P
Paper Insulation
CM
Cambric
PR
Pair
CQ
Cellular Polythene
Q
Polythene Insulation
CU
Copper
R
Rubber Insulation
CW
Copper Weld
SF
Single Fibre-reinforced Plastic Rod Armour
DB
Double Brass Tape
SL
Single Lead Sheath
DRT
Double Steel Reinforcing Tape
ST
Single Steel Tape Armour
DT
Double Steel Tape Armour
SW
Single Steel Wire Armour
DW
Double Steel Wire Armour
TR
Tough Rubber Insulation
F
Filter Core
(TS)
Taped Screen
FE
Steel
(WS)
Stranded Wire Screen
H
Hochstadter Screen
XQ
Cross-linked Polythene
J
Jute or Hessian Sheath
YQ
High-density Polythene
L
Lead Sheath
Z
PVC Sheath
MB
Moisture Barrier
Examples: 415V 240 AL3 XQ CU(NW)Z/SAC
415 volts phase-to-phase, 240 mm2 3-core solid aluminium conductors, crosslinked polyethylene insulation, copper wavewound concentric neutral, PVC sheath. 415V 240 AL4 XQ Z/SAC
415 volts phase-to-phase, 240 mm2 4-core solid aluminium conductors, crosslinked polyethylene insulation, PVC sheath.
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
1 October 1997
64
11kV 500 AL3 PHL SWJ
11 kV phase-to-phase, 500 mm 3-core stranded aluminium conductors, paper insulated, screened, lead alloy sheathed, single wire armoured, jute sheathed. ²
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
1 October 1997
65
APPENDIX B INSTALLATION INSTRUCTION HV 1-41 Installation Procedure for 3M Coldshrink Pressure Sealing Terminations on Indoor Single Core Paper Lead Cables Version 1, 12th April 2001 This installation instruction HV 1-41 details the installation procedure of 3M coldshrink pressure sealing terminations on 11kV indoor single core screened paper cables that are made in accordance with AS1026. This instruction is not applicable to any other type of termination. Installation instruction HV 1-41 has been prepared for use by EnergyAustralia staff, contractors employed by EnergyAustralia and Accredited Service Providers, exclusively for work on EnergyAustralia’s network assets. This instruction is to be read in EnergyAustralia’s Network Standards.
conjunction
with
the
relevant
CONTENTS 1. General 2. Termination Procedure 3. Completed Termination 4. Earthing the Termination 5. Typical Earthing Arrangement
3M
Approved By: P.Broderick
Date: 12/4/01
EnergyAustralia
Approved By: N.Issa
Date: 12/4/01
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
1 October 1997
66
General 1. Keep the coldshrink kit in its packaging until the components are required in order to minimise exposure to dust contamination. After opening the packaging, components which are not immediately required must be protected against potential dust contamination. 2. Tapes will be applied over the lug barrels and the cable metal sheath to prevent water entry into the termination area. These areas must be properly cleaned and degreased before the tapes are applied. 3. The tapes referred to in this instruction are proprietary 3M tapes, and are supplied as part of the termination kit. No substitution for these tapes shall be made without Network's prior approval. The tapes involved are: Self amalgamating tape Restriction tape Stress control tape Mastic sealant tape
Scotch no. 23 Scotch no. 20 Scotch no. 2220 Scotch no. 2900R
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
67
1 October 1997
Prepare Cable 1
Set the cables into position after determining the phasing requirements.
2
Cut the cables to the required length after allowing for fitting of the sealed terminal lugs.
3
Remove the polymeric oversheath from the end of each of the cables to a distance of 220 mm plus the internal depth of the sealed terminal lug.
4
Clean the metal sheath, and then abrade it for a distance of 50 mm above the polymeric oversheath cut.
5
Clean the polymeric oversheath, and then abrade it for a distance of 60 mm below the metal sheath.
6
Remove the metal sheath to a distance of 40 mm above the polymeric oversheath cut.
7
Bell the metal sheath
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
1 October 1997
68
Install Terminal Lugs 1
Remove the paper screens and insulation from the end of each cable for a distance equal to the length of the lug barrel + 15 mm.
2
Test the paper insulation for moisture content. If moisture exists, notify the relevant field coordinator/supervisor for immediate action.
3
Unwind 30 mm off the paper screens to allow completion of the next step.
4
Install sealed terminal lugs in accordance with manufacturer's specification. If using solder lugs, the cables must be suitably protected against excessive heat or flame. If using compression lugs, remove excess grease after installation, and de-grease the barrel of each of the lugs. Note:
5
The lug must comply with the specified maximum dimensions.
Using self amalgamating tape (Scotch No. 23), smoothly profile the barrel of each of the lugs in order to facilitate achieving a good oil seal. Ensure that at least two half-lapped layers of tape are applied to the lower 30 mm of the barrel and the exposed conductor between the lug and the paper insulation. Also extend the tape for 10 mm onto the paper insulation to stop it from unwinding. Stretch the tape to 50% of its original width while applying it.
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
69
1 October 1997
Install Stress Control Tape 1
Using a twine binder, remove the paper screens down to 25 mm above the edge of the metal sheath. Ensure that the screen cut is neat and free of any jagged edges.
2
Apply two half-lapped layer of Stress Control Tape (Scotch No. 2220) at the edge of the metal sheath, working towards the cable end for a distance of 70 mm. Leave an even front edge, then tape back to the starting point.
Note:
3
Scotch tape No. 2220 should be applied silver side out, and stretched to 3/4 of its original width. Remove the liner before stretching the tape.
Apply one half-lapped layer of White Restriction Tape (Scotch No. 20) at the metal sheath end of the stress control tape to protect it from any damage while shrinking the black oil barrier tubing. Start the restriction tape 10 mm onto the metal sheath and finish it 25 mm onto the stress control tape.
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
1 October 1997
70
Install Oil Barrier Tubing 1
Slide a black oil barrier tubing over one of the cables, and position it 20 mm onto the metal sheath.
2
Shrink the tubing into position by pulling and unwinding the pull-tab of the tubing in an anticlockwise direction.
3
Check that the tubing overlaps the lug barrel by a minimum of 20 mm. Carefully trim any excess tubing (portion of tubing extending beyond the barrel of the lug), making sure that the cut starts and finishes at the same spot (ie. a uniform cut) to avoid tearing of the tubing.
4
If the tubing is trimmed, apply three full turns of self amalgamating tape (Scotch No. 23) to the end of the tubing to ensure that it does not tear.
5
Apply self amalgamating tape (Scotch No. 23) over the black oil barrier tubing at the gap between the paper insulation and the terminal lug, making sure the black tubing is pulled down into the gap. Fill the gap up to the level of insulation, and then apply two extra half-lapped layers, overlapping the lug barrel and the insulation by 15 mm each. Stretch the tape to 50% of its original width while applying it.
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
71
1 October 1997
Install Oil Barrier Tubing 6
Apply four half-lapped layers of White Restriction Tape (Scotch No. 20) to cover the full length of the black oil barrier tubing + 10 mm either side. Caution:
The white restriction tape DOES NOT STRETCH. So avoid creasing when applying it.
Install Silicon Tubing 1
Apply four full turns of self amalgamating tape (Scotch No.23) over the lug barrel at the end of the white restriction tape.
2
Apply two half-lapped layers of self amalgamating tape (Scotch No. 23) over the remaining exposed portion of the metal sheath and continue for 30 mm onto the polymeric oversheath.
3
Slide the grey silicon tubing over the cable and position the silicon tubing to overlap the polymeric oversheath by 50 mm. Shrink the tubing into position by pulling and unwinding the pull-tab in an anti-clockwise direction.
4
This tubing should fully cover the band of self amalgamating tape applied over the lug. If it is too long, carefully trim any excess tubing, making sure that the cut starts and finishes at the same point to avoid tearing of the tubing.
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
1 October 1997
72
Completed Termination
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
73
1 October 1997
Earthing the Termination 1
Remove 80 mm of the polymeric oversheath on each cable starting 80 mm below the gland plate of the cable endbox. If the terminations are in free air (ie. no cable endbox), remove 80 mm of the polymeric oversheath on each cable starting 100 mm below the outer silicon tubing.
2
Clean, degrease and abrade the full length of each exposed metal sheath and 30 mm of the polymeric oversheath at each end.
3
Apply one half-lapped layer of tinned copper mesh over each exposed metal sheath starting and finishing 10 mm clear of the corresponding polymeric oversheath cuts.
4
Wrap two full turns of sealant tape (Scotch No. 2900R) over the polymeric oversheath on each cable, either side of the exposed metal sheath. Determine the length of tinned copper braid required for each cable, allowing for the braid to be folded back on itself at the roll spring position, plus an extra length of approximately 30 mm. Flatten out the braid at the roll spring end by pulling on it sideways in order to achieve maximum surface area coverage.
5
6
7
Position the braid over the tinned copper mesh so that there is sufficient length to be folded back over the roll spring.
8
Starting on the opposite side of the cable, wrap the roll spring twice over the copper braid in the direction of the copper braid. Position the roll spring centrally over the exposed metal sheath.
9
Fold the braid back over the roll spring then wrap the rest of the roll spring around the core.
10
Tighten the roll spring with a twisting action, and then apply four full turns of self amalgamating tape (Scotch No.23) over the roll spring to hold it in position.
11
Apply two full turns of sealant tape (Scotch No.2900R) over the earth braid at the lower oversheath cut.
12
Apply the supplied vinyl mastic tape over the earth connection on each cable, fully covering the two bands of sealant tape (Scotch No.2900R). Half-lap the tape while applying it.
13
Connect the lower end of the earth braid to the main earthing point using M12 bolt, nut and washers.
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
1 October 1997
74
Install Silicon Tubing
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
75
1 October 1997
APPENDIX C INSTALLATION INSTRUCTION HV 1-42 Installation Procedure for 3M Coldshrink Pressure Sealing Terminations on Outdoor Single Core Paper Lead Cables Version 1, 12th April 2001 This installation instruction HV 1-42 details the installation procedure of 3M coldshrink pressure sealing terminations on 11kV outdoor single core screened paper cables that are made in accordance with AS1026. This instruction is not applicable to any other type of termination. Installation instruction HV 1-42 has been prepared for use by EnergyAustralia staff, contractors employed by EnergyAustralia and Accredited Service Providers, exclusively for work on EnergyAustralia’s network assets. This instruction is to be read in conjunction with the relevant EnergyAustralia’s Network Standards and EnergyAustralia’s Drawing 62103, 11 kV Underground-to-Overhead (UG/OH) Construction for Single Core PILC Cables, Type K2.
CONTENTS 1. General 2. Termination Procedure 3. Completed Termination 4. Earthing the Termination 5. Typical Earthing Arrangement
3M
Approved By: P.Broderick
Date: 12/4/01
EnergyAustralia
Approved By: N.Issa
Date: 12/4/01
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
1 October 1997
76
General 1. Keep the coldshrink kit in its packaging until the components are required in order to minimise exposure to dust contamination. After opening the packaging, components which are not immediately required must be protected against potential dust contamination. 2. Tapes will be applied over the lug barrels and the cable metal sheath to prevent water entry into the termination area. These areas must be properly cleaned and degreased before the tapes are applied. 3. The tapes referred to in this instruction are proprietary 3M tapes, and are supplied as part of the termination kit. No substitution for these tapes shall be made without Network's prior approval. The tapes involved are: Self amalgamating tape Restriction tape Stress control tape Mastic sealant tape
Scotch no. 23 Scotch no. 20 Scotch no. 2220 Scotch no. 2900R
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
1 October 1997
77
Prepare Cable 1
Set the cables into position after determining the phasing requirements.
2
Cut the cables to the required length after allowing for fitting of the sealed terminal lugs.
3
Remove the polymeric oversheath from the end of each of the cables to a distance of 305 mm plus the internal depth of the sealed terminal lug. Clean the metal sheath, and then abrade it for a distance of 50 mm above the polymeric oversheath cut.
4
5
Clean the polymeric oversheath, and then abrade it for a distance of 60 mm below the metal sheath.
6
Remove the metal sheath to a distance of 40 mm above the polymeric oversheath cut.
7
Bell the metal sheath.
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
1 October 1997
78
Prepare Install Terminal Lugs 1
Remo Remove ve the paper paper screen screenss and and insula insulati tion on from from the end of each cable for a distance equal to the length of the lug barrel + 15 mm.
2
Test Test the paper paper insula insulatio tion n for for moist moisture ure conten content. t. If moisture exists, notify the relevant field coordinator/supervisor coordinator/supervisor for immediate action.
3
Unwi Unwind nd 30 30 mm mm off off the the pap paper er scr scree eens ns to all allow ow completion of the next step.
4
Instal Installl seal sealed ed termi terminal nal lugs lugs in in acco accorda rdance nce with with manufacturer's specification. If using solder lugs, the cables must be suitably protected against excessive heat or flame. If using compression lugs, remove excess grease after installation, and de-grease the barrel of each of the lugs.
5
Usin Using g sel selff ama amalg lgam amat atin ing g tap tapee (Sc (Scot otch ch No. 23), smoothly profile the barrel of each of the lugs in order to facilitate achieving a good oil seal. Ensure that at least two half-lapped layers of tape are applied to the lower 30 mm of the barrel and the exposed conductor between the lug and the paper insulation. Also extend the tape for 10 mm onto the paper insulation to stop it from unwinding. Stretch the tape to 50% of its original width while applying it.
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
79
1 October 1997
Install Stress Control Tape 1
Using Using a twi twine ne binder binder,, rem remove ove the paper paper screen screenss down to 25 mm above the edge of the metal sheath. Ensure that the screen cut is neat and free of any jagged edges.
2
Apply Apply two two half half-la -lappe pped d lay layer er of Stres Stresss Cont Control rol Tape (Scotch No. 2220) at the edge of the metal sheath, working towards the cable end for a distance of 70 mm. Leave an even front edge, then tape back to the starting point. Note:
3
Scotch tape No. 2220 should be applied silver side out, and stretched to 3/4 of its original width. Remove the liner before stretching the tape.
Apply Apply one halfhalf-lap lapped ped layer layer of of Whit Whitee Rest Restric rictio tion n Tape (Scotch No. 20) at the metal sheath end of the stress control tape to protect it from any damage while shrinking the black oil barrier tubing. Start the restriction tape 10 mm onto the metal sheath and finish it 25 mm onto the stress control tape.
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
1 October 1997
80
Install Oil Barrier Tubing 1
Slide Slide a blac black k oil oil barrie barrierr tubi tubing ng over over one one of the cables, and position it 20 mm onto the metal sheath.
2
Shrin Shrink k the the tubing tubing into into posit position ion by pulli pulling ng and unwinding the pull-tab of the tubing in an anti-clockwise direction.
3
Chec Check k that that the the tub tubin ing g over overla laps ps the the lug lug bar barre rell by a minimum of 20 mm. Carefully trim any excess tubing (portion of tubing extending beyond the barrel of the lug), making sure that the cut starts and finishes at the same spot (ie. a uniform cut) to avoid tearing of the tubing.
4
If the the tubi tubing ng is is trim trimme med, d, apply apply three three full full turns turns of self amalgamating tape (Scotch No. 23) to the end of the tubing to ensure that it does not tear.
5
Appl Apply y self self ama amalg lgam amat atin ing g tape tape (Sc (Scot otch ch No. No. 23) over the black oil barrier tubing at the gap between the paper insulation and the terminal lug, making sure the black tubing is pulled down into the gap. Fill the gap up to the level of insulation, and then apply two extra halflapped layers, overlapping the lug barrel and the insulation by 15 mm each. Stretch the tape to 50% of its original width while applying it.
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
81
6
1 October 1997
Apply four half-lapped layers of White Restriction Tape (Scotch No. 20) to cover the full length of the black oil barrier tubing + 10 mm either side. Caution:
The white restriction tape DOES NOT STRETCH. So avoid creasing when applying it.
Install Silicon Tubing 1
Apply four full turns of self amalgamating tape (Scotch No.23) over the lug barrel at the end of the white restriction tape.
2
Apply two half-lapped layers of self amalgamating tape (Scotch No. 23) over the remaining exposed portion of the metal sheath and continue for 30 mm onto the polymeric oversheath.
3
Slide the grey silicon tubing over the cable and position the silicon tubing to overlap the polymeric oversheath by 50 mm. Shrink the tubing into position by pulling and unwinding the pull-tab in an anti-clockwise direction.
4
This tubing should fully cover the band of self amalgamating tape applied over the lug. If it is too long, carefully trim any excess tubing, making sure that the cut starts and finishes at the same point to avoid tearing of the tubing.
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
1 October 1997
82
Install Skirt Tubing 1
Slide a Silicon Skirt Tubing over the track resistant tubing and shrink it approximately mid way along the termination.
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
83
1 October 1997
Completed Termination
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
1 October 1997
84
Earthing the Termination 1
Remove 80 mm of the polymeric oversheath on each cable starting 100 mm below the outer silicon tubing.
2
Clean, degrease and abrade the full length of each exposed metal sheath and 30 mm of the polymeric oversheath at each end.
3
Apply one half-lapped layer of tinned copper mesh over each exposed metal sheath starting and finishing 10 mm clear of the corresponding polymeric oversheath cuts.
4
Wrap two full turns of sealant tape (Scotch No. 2900R) over the polymeric oversheath on each cable, either side of the exposed metal sheath.
5
Determine the length of tinned copper braid required for each cable, allowing for the braid to be folded back on itself at the roll spring position, plus an extra length of approximately 30 mm.
6
Flatten out the braid at the roll spring end by pulling on it sideways in order to achieve maximum surface area coverage.
7
Position the braid over the tinned copper mesh so that there is sufficient length to be folded back over the roll spring.
8
Starting on the opposite side of the cable, wrap the roll spring twice over the copper braid in the direction of the copper braid. Position the roll spring centrally over the exposed metal sheath.
9
Fold the braid back over the roll spring then wrap the rest of the roll spring around the core.
10
Tighten the roll spring with a twisting action, and then apply four full turns of self amalgamating tape (Scotch No.23) over the roll spring to hold it in position.
11
Apply two full turns of sealant tape (Scotch No.2900R) over the earth braid at the lower oversheath cut.
12
Slide the sealing sleeve over the earth connection, with the loose pull-tab pointing away from the end of the cable.
13
Position the sleeve to fully cover the section between the two bands of sealant tape. Shrink the sleeve into position by pulling and unwinding the pull-tab in a clockwise direction.
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
85
1 October 1997
Typical Earthing Arrangement
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
1 October 1997
86
APPENDIX D INSTALLATION INSTRUCTION HV 1-43 Installation Procedure for 3M Coldshrink Pressure Sealing Terminations on Indoor Multicore Paper Lead Cables Version 1, 12th April 2001 This installation instruction HV 1-43 details the installation procedure of 3M coldshrink pressure sealing terminations on 11kV indoor multicore screened paper cables that are made in accordance with AS1026. This instruction is not applicable to any other type of termination.. Installation instruction HV 1-43 has been prepared for use by EnergyAustralia staff, contractors employed by EnergyAustralia and Accredited Service Providers, exclusively for work on EnergyAustralia’s network assets. This instruction is to be read in EnergyAustralia’s Network Standards.
conjunction
with
the
relevant
CONTENTS 1. General 2. Special Tools 3. Safety Information when using Resin 4. Termination Procedure 5. Earthing the Termination 6. Completing the Termination
3M
Approved By: P.Broderick
Date: 12/4/01
EnergyAustralia
Approved By: N.Issa
Date: 12/4/01
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
1 October 1997
87
General 1. Keep the coldshrink kit in its packaging until the components are required in order to minimise exposure to dust contamination. After opening the packaging, components which are not immediately required must be protected against potential dust contamination. 2. Tapes will be applied over the lug barrels and the cable metal sheath to prevent water entry into the termination area. These areas must be properly cleaned and degreased before the tapes are applied. 3. The tapes referred to in this instruction are proprietary 3M tapes, and are supplied as part of the termination kit. No substitution for these tapes shall be made without Network's prior approval. The tapes involved are: Self amalgamating tape Restriction tape Silicon rubber tape Stress control tape Rubber mastic tape Mastic sealant tape Vinyl mastic tape
Scotch no. 23 Scotch no. 20 Scotch no. 70 Scotch no. 2220 Scotch no. 2228 Scotch no. 2900R
Special Tools The design of this range of terminations incorporates the use of resin to provide for a high cable operating pressure. This resin is best applied using a resin gun. So, it is highly recommended that a resin gun be used to inject resin into the cable crotch. This gun can be obtained from EnergyAustralia's Logistics Branch on stockcode 175885 or purchased directly from 3M (Part No. E4 Resin Gun).
Safety Information when using Resin Refer to the manufacture’s safety information sheet supplied in this kit for details on safety precautions, spillage procedures and disposal methods for the resin contained in this kit.
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
1 October 1997
88
Prepare Cable 1
Set the cable up-straight and in line with the centre phase bushing.
2
Mark the centre line of the lug-mounting holes on the cable as a reference line.
3
Remove the polymeric oversheath to 820 mm below this reference line.
4
Clean the metal sheath, then abrade it for a distance of 230 mm above the polymeric oversheath cut.
5
Remove the metal sheath to a distance of 220 mm above the polymeric oversheath cut.
6
Bell the metal sheath.
7
Unwind the core binding fabric tape down to the metal sheath cut. Apply a few turns of this tape around the three cores immediately above the metal sheath cut, covering a distance of not more than 20 mm. Remove the excess fabric tape.
8
Remove all cable fillers level with the applied fabric tape.
9
Cut the cores 650 mm from the metal sheath cut for easier handling within the endbox.
10
Test the paper insulation for moisture content. If moisture exists, notify the relevant Field Coordinator / Supervisor for immediate action.
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
1 October 1997
89
Install Lower Oil Barrier Tubings 1
Gently spread the cores apart ensuring that they are not over-bent.
2
Wipe off any cable compound on the surface of the cores with a clean rag. Do Not use solvents.
3
Slide a black oil barrier coldshrink tubing over one of the three cores. Position it 45 mm above the metal sheath cut and shrink it down by pulling and unwinding the pull-tab in an anti-clockwise direction.
4
Repeat for the other two cores.
5
Apply two half-lapped layers of White Restriction Tape (Scotch No. 20) firmly over each of the black oil barrier tubings. Start 20 mm below the top end of each tubing and work towards the lower end, then turn back to the starting point. Caution:
The white restriction tape DOES NOT STRETCH. So avoid creasing when applying it.
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
1 October 1997
90
Install Glove and Inject Resin 1
2 For 95 mm cables only: Apply a 25 mm wide band of rubber mastic tape (Scotch No. 2228) around the metal sheath. Position the tape 50 mm below the metal sheath cut, and build it up to a thickness of 8 mm. Moderately stretch the tape while applying it.
2 2 For 185 mm to 300 mm cables only: Apply a 50 mm wide band of rubber mastic tape (Scotch No. 2228) around the metal sheath. Position the tape 50 mm below the metal sheath cut, and build it up to a thickness of 8 mm. Moderately stretch the tape while applying it.
2
Prepare the 3-way glove for installation by carefully unwinding the pull-tab in each finger until the pull-tab core is level with the bottom of the finger.
3
Carefully position the glove over the three cable cores at the lug end, ensuring that the main body pull-tab runs straight down the side of the glove (ie. It does not pass between the cable cores).
4
While holding the main body pull-tab firm to the body of the glove, ease the glove over the cable cores towards the crotch area. Push the glove as far down as it goes. The body of the glove should fully cover the applied rubber mastic tape.
5
While holding the glove in this position, shrink the main body by pulling and unwinding the main body pull-tab in an anti-clockwise direction.
6
Shrink down two of the glove fingers by pulling and unwinding their pull-tabs in an anticlockwise direction.
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
91
1 October 1997
7
Apply silicon grease to the plastic filling tube, and insert it into the third finger. Position the tube on the inner side of the cable core (ie. close to the other cable cores). This will ensure that when the resin is applied it will fill the crotch of the cable.
8
Shrink down the third finger to hold the filling tube firm in position.
9
Thoroughly mix the resin as per the instructions on the pack.
10
Inject resin gently into the cable crotch area through the filling tube. Keep injecting resin until the glove is full (ie. until the resin starts to escape through the gap between the filling tube and the finger of the glove). More than one mix pack might be required to fill the crotch area. Note:
A resin gun is highly recommended for this purpose.
11
Carefully remove the filling tube from the finger.
12
Clean off any excess resin using solvent pads.
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
1 October 1997
92
Earthing the Termination Note:
The earthing kit is separately packaged within the termination kit.
1
Ensure that the metal sheath has been degreased and fully abraded.
2
Apply one half-lapped layer of tinned copper mesh to the exposed metal sheath.
3
Apply two full turns of sealant tape (Scotch No. 2900R) at the top end of the polymeric oversheath.
4
Position the earth braid(s) onto the metal sheath so that they overlap the glove by 80 mm (the end fitted with a lug should point away from the glove). Use a temporary binder (tie or tape) to hold the earth braid(s) in position.
Note:
Only 1 braid (39 mm2) is required for 95 mm2 cables, and two braids (2x39 mm 2) for 185-300 mm 2 cables. If using two braids, position them directly opposite each other.
5
Position a roll spring 20 mm below the bottom of the glove and wrap two full turns over the earth braid(s).
6
Position a second roll spring 30 mm below the first roll spring, and wrap two full turns over the earth braid(s).
7
Fold the earth braid(s) back over the roll springs (after removing the temporary binder), and wrap the remaining lengths of both roll springs over the earth braid(s).
8
Tighten both roll springs with a twisting action, and then apply four full turns of self amalgamating tape over each of them to hold them in position. This tape is not provided with the earthing kit; use the tape supplied with the main termination kit.
9
Apply two full turns of sealant tape (Scotch No. 2900R) at the lower end of the glove.
10
Apply two full turns of sealant tape (Scotch No. 2900R) over the earth braid(s) at the top end of the polymeric oversheath (ie. where previously applied).
11
Apply the supplied vinyl mastic tape over the earth connection fully covering the two bands of sealant tape (Scotch No. 2900R). Half-lap the tape while applying it.
12
Connect the lower end of the earth braid(s) to the main earthing point using M12 bolt, nut and washers.
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
93
1 October 1997
Install Terminal Lugs 1
Attach a lug to each of the terminal posts inside the endbox.
2
Determine the phasing and position of each core.
3
Set one core at a time into its final position and, mark and remove the excess core length.
4
Remove the paper screens and insulation from the end of each core for a distance equal to the length of the lug barrel + 15 mm.
5
Unwind 30 mm off the paper screens to allow completion of the next step.
6
Install sealed terminal lugs in accordance with manufacturer's specification. If using solder lugs, the cable cores must be suitably protected against excessive heat or flame. If using compression lugs, remove excess grease after installation, and de-grease the barrel of the lugs.
7
Using self amalgamating tape (Scotch No. 23), smoothly profile the barrel of each of the lugs in order to facilitate achieving a good oil seal. Ensure that at least two half-lapped layers of tape are applied to the lower 30 mm of the barrel and the exposed conductor between the lug and the paper insulation. Also extend the tape for 10 mm onto the paper insulation to stop it from unwinding. Stretch the tape to 50% of its original width while applying it.
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
1 October 1997
94
Install Stress Control Tape 1
Using a twine binder, remove the paper screens down to 25 mm above the black oil barrier tubings. Ensure that the screen cut is neat and free of any jagged edges. The screen cutback should be at least 220 mm from the end of the paper insulation.
2
Apply two half-lapped layers of Stress Control Tape (Scotch No. 2220) at the end of the black oil barrier tubing, working towards the core end for a distance of 70 mm. Leave an even front edge, then tape back to the starting point. Note:
3
Scotch tape No. 2220 should be applied silver side out, and stretched to 3/4 of its original width. Remove the liner before stretching the tape.
Apply one half-lapped layer of White Restriction Tape (Scotch No. 20) at the black tubing end of the stress control tape to protect it from any damage while shrinking the second oil barrier tubing. Start the Restriction Tape 10 mm onto the black oil barrier tubing and finish it 25 mm onto the stress control tape.
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
95
1 October 1997
Install Upper Oil Barrier Tubings 1
Slide a second black oil barrier tubing over one of the outer phases and position it to overlap the tubing already installed by 20 mm (ie. at the end of the white restriction tape previously applied).
2
Check that the tubing overlaps the lug barrel by at least 15 mm. The tubing will grow in length by approximately 15 mm when shrunk. If after allowing for this growth, the tubing does not overlap the lug barrel by 15 mm, contact the relevant Field Coordinator/ Supervisor for instructions. If, on the other hand the tubing is too long, position it so that the overlap with the lug barrel before shrinking is approximately 25 mm.
3
Shrink the tubing into position by pulling and unwinding the pull-tab in an anti-clockwise direction.
4
Apply self amalgamating tape (Scotch No. 23) over the black oil barrier tubing at the gap between the paper insulation and the terminal lug, making sure the black tubing is pulled down into the gap. Fill the gap up to the level of insulation, and then apply two extra half-lapped layers, overlapping the lug barrel and the insulation by 15 mm each. Stretch the tape to 50% of its original width while applying it.
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
1 October 1997
96
5
Apply two half-lapped layers of White Restriction Tape (Scotch No. 20) to cover the full length of the upper black oil barrier tubing + 30 mm of the lower oil barrier tubing.
6
Repeat the above procedure for the remaining cores.
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
97
1 October 1997
Install Outer Silicon Tubings 1
Slide a short outer silicon tubing over one of the outer phases and push it down to fully overlap the finger of the glove. Shrink it into place by pulling and unwinding the pull-tab in an anticlockwise direction.
2
Slide a long outer silicon tubing over the same cable core and position it to overlap the short tubing by 20 mm. Check that the tubing will fully cover the remaining length of the core after allowing for 15 mm of growth in length. If it requires a slight adjustment to achieve full coverage, the overlap with the short tubing can be reduced to 15 mm. If the shortfall is more than 15 mm, two half-lapped layers of silicone rubber tape (Scotch No. 70) can be used. On the other hand, if the tubing is too long, the overlap with the short tubing can be increased accordingly.
3
Shrink the tubing into place.
4
Repeat for the other two cores.
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
1 October 1997
98
APPENDIX E INSTALLATION INSTRUCTION HV 1-44 Installation Procedure for 3M Coldshrink Pressure Sealing Terminations on Outdoor Multicore Paper Lead Cables Version 1, 12th April 2001 This installation instruction HV 1-44 details the installation procedure of 3M coldshrink pressure sealing terminations on 11kV outdoor multicore screened paper cables that are made in accordance with AS1026. This instruction is not applicable to any other type of termination. Installation instruction HV 1-44 has been prepared for use by EnergyAustralia staff, contractors employed by EnergyAustralia and Accredited Service Providers, exclusively for work on EnergyAustralia’s network assets. This instruction is to be read in conjunction with the relevant EnergyAustralia’s Network Standards and EnergyAustralia’s Drawing 119643, 11 kV Underground-to-Overhead (UG/OH) Construction for Multicore PILC Cables, Type K3.
CONTENTS 1. General 2. Special Tools 3. Safety Information when using Resin 4. Termination Procedure 5. Earthing the Termination 6. Completing the Termination
3M
Approved By: P.Broderick
Date: 12/4/01
EnergyAustralia
Approved By: N.Issa
Date: 12/4/01
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
1 October 1997
99
General 1. This installation instruction assumes that: •
•
•
The multicore cable has been pulled up the pole and saddled into position. The UGOH mounting bracket, standoff insulators/surge arresters and termination plates are properly installed. Note 1: The slots in the termination plates must be centred onto the standoff insulators, and the lower end of the plates must point towards the trifurcating point of the cable, which is approximately 1 metre below the standoff insulators. Note 2: The standoff insulators must be installed strictly in accordance with the details given in drawing A1-119643. Adequate clearance exists above the OHLV to allow the Elevated Working Platform to be manoeuvred comfortably (clearances are detailed in drawing A1-119643).
2. Keep the coldshrink kit in its packaging until the components are required in order to minimise exposure to dust contamination. After opening the packaging, components which are not immediately required must be protected against potential dust contamination. 3. Tapes will be applied over the lug barrels and the cable metal sheath to prevent water entry into the termination area. These areas must be properly cleaned and degreased before the tapes are applied. 4. The tapes referred to in this instruction are proprietary 3M tapes, and are supplied as part of the termination kit. No substitution for these tapes shall be made without Network's prior approval. The tapes involved are: Self amalgamating tape Restriction tape Silicon rubber tape Stress control tape Rubber mastic tape Mastic sealant tape Vinyl mastic tape
Scotch no. 23 Scotch no. 20 Scotch no. 70 Scotch no. 2220 Scotch no. 2228 Scotch no. 2900R
Special Tools The design of this range of terminations incorporates the use of resin to provide for a high cable operating pressure. This resin is best applied using a resin gun. So, it is highly recommended that a resin gun be used to inject resin into the cable crotch. This gun can be obtained from EnergyAustralia's Logistics Branch on stockcode 175885 or purchased directly from 3M (Part No. E4 Resin Gun).
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
1 October 1997
100
Safety Information when using Resin Refer to the manufacture’s safety information sheet supplied in this kit for details on safety precautions, spillage procedures and disposal methods for the resin contained in this kit.
Prepare Cable 1
Cut the multicore cable 100 mm above the top of the UGOH mounting bracket.
2
Attach a lug to the termination plate on the centre phase.
3
Using the removed length of cable, test the paper insulation for moisture content. If moisture exists, notify the relevant Field Coordinator / Supervisor for immediate action.
Remove Polymeric Oversheath 1
Set the multicore cable into the position of the centre phase to allow the stripping dimensions to be marked.
2
Mark the position of the polymeric oversheath cut (point A) 870 mm from the lower end of the lug barrel.
3
Remove the polymeric oversheath to point A.
4
Clean the metal sheath, then abrade it for a distance of 230 mm above the polymeric oversheath cut.
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
101
1 October 1997
Remove Metal Sheath and Prepare Crotch 1
Remove the metal sheath to a distance of 220 mm above point A (polymeric oversheath cut).
2
Bell the metal sheath.
3
Unwind the core binding fabric tape down to the metal sheath cut. Apply a few turns of this tape around the three cores immediately above the metal sheath cut, covering a distance of not more than 20 mm. Remove the excess fabric tape.
4
Remove all cable fillers level with the applied fabric tape.
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
1 October 1997
102
Install Lower Oil Barrier Tubings 1
Gently spread the cores apart ensuring that they are not over-bent.
2
Wipe off any cable compound on the surface of the cores with a clean rag. Do Not use solvents.
3
Slide a black oil barrier coldshrink tubing over one of the three cores. Position it 45 mm above the metal sheath cut and shrink it down by pulling and unwinding the pull-tab in an anticlockwise direction.
4
Repeat for the other two cores.
5
Apply two half-lapped layers of White Restriction Tape (Scotch No. 20) firmly over each of the black oil barrier tubings. Start 20 mm below the top end of each tubing and work towards the lower end, then turn back to the starting point. Caution:
The white restriction tape DOES NOT STRETCH. So avoid creasing when applying it.
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
103
1 October 1997
Install Glove and Inject Resin 1
2 For 95 mm cables only: Apply a 25 mm wide band of rubber mastic tape (Scotch No. 2228) around the metal sheath. Position the tape 50 mm below the metal sheath cut, and build it up to a thickness of 8 mm. Moderately stretch the tape while applying it.
2 2 For 185 mm to 300 mm cables only: Apply a 50 mm wide band of rubber mastic tape (Scotch No. 2228) around the metal sheath. Position the tape 50 mm below the metal sheath cut, and build it up to a thickness of 8 mm. Moderately stretch the tape while applying it.
2
Prepare the 3-way glove for installation by carefully unwinding the pull-tab in each finger until the pull-tab core is level with the bottom of the finger.
3
Carefully position the glove over the three cable cores at the lug end, ensuring that the main body pull-tab runs straight down the side of the glove (ie. It does not pass between the cable cores).
4
While holding the main body pull-tab firm to the body of the glove, ease the glove over the cable cores towards the crotch area. Push the glove as far down as it goes. The body of the glove should fully cover the applied rubber mastic tape.
5
While holding the glove in this position, shrink the main body by pulling and unwinding the main body pull-tab in an anti-clockwise direction.
6
Shrink down two of the glove fingers by pulling and unwinding their pull-tabs in an anticlockwise direction.
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
1 October 1997
104
7
Apply silicon grease to the plastic filling tube, and insert it into the third finger. Position the tube on the inner side of the cable core (ie. close to the other cable cores). This will ensure that when the resin is applied it will fill the crotch of the cable.
8
Shrink down the third finger to hold the filling tube firm in position.
9
Thoroughly mix the resin as per the instructions on the pack.
10
Inject resin gently into the cable crotch area through the filling tube. Keep injecting resin until the glove is full (ie. until the resin starts to escape through the gap between the filling tube and the finger of the glove). More than one mix pack might be required to fill the crotch area. Note:
A resin gun is highly recommended for this purpose.
11
Carefully remove the filling tube from the finger.
12
Clean off any excess resin using solvent pads.
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
1 October 1997
105
Earthing the Termination Note:
The earthing kit is separately packaged within the termination kit.
1
Ensure that the metal sheath has been degreased and fully abraded.
2
Apply one half-lapped layer of tinned copper mesh to the exposed metal sheath.
3
Apply two full turns of sealant tape (Scotch No. 2900R) at the top end of the polymeric oversheath.
4
Position the earth braid(s) onto the metal sheath so that they overlap the glove by 80 mm (the end fitted with a lug should point away from the glove). Use a temporary binder (tie or tape) to hold the earth braid(s) in position.
Note:
Only 1 braid (39 mm 2) is required for 95 mm2 cables, and two braids (2x39 mm 2) for 185-300 mm 2 cables. If using two braids, position them directly opposite each other.
5
Position a roll spring 20 mm below the bottom of the glove and wrap two full turns over the earth braid(s).
6
Position a second roll spring 30 mm below the first roll spring, and wrap two full turns over the earth braid(s).
7
Fold the earth braid(s) back over the roll springs (after removing the temporary binder), and wrap the remaining lengths of both roll springs over the earth braid(s).
8
Tighten both roll springs with a twisting action, and then apply four full turns of self amalgamating tape over each of them to hold them in position. This tape is not provided with the earthing kit; use the tape supplied with the main termination kit.
9
Apply two full turns of sealant tape (Scotch No. 2900R) at the lower end of the glove.
10
Apply two full turns of sealant tape (Scotch No. 2900R) over the earth braid(s) at the top end of the polymeric oversheath (ie. where previously applied).
11
Apply the supplied vinyl mastic tape over the earth connection fully covering the two bands of sealant tape (Scotch No. 2900R). Half-lap the tape while applying it.
12
Connect the other end of the earth braid(s) to the main earth using two split bolt clamps.
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
1 October 1997
106
Install Terminal Lugs 1
Attach a lug to each of the termination plates on the outer phases.
2
Determine the phasing and position of each core.
3
Set one core at a time into its final position and, mark and remove the excess core length.
4
Remove the paper screens and insulation from the end of each core for a distance equal to the length of the lug barrel + 15 mm.
5
Unwind 30 mm off the paper screens to allow completion of the next step.
6
Install sealed terminal lugs in accordance with manufacturer's specification. If using solder lugs, the cable cores must be suitably protected against excessive heat or flame. If using compression lugs, remove excess grease after installation, and de-grease the barrel of the lugs.
7
Using self amalgamating tape (Scotch No. 23), smoothly profile the barrel of each of the lugs in order to facilitate achieving a good oil seal. Ensure that at least two half-lapped layers of tape are applied to the lower 30 mm of the barrel and the exposed conductor between the lug and the paper insulation. Also extend the tape for 10 mm onto the paper insulation to stop it from unwinding. Stretch the tape to 50% of its original width while applying it.
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
107
1 October 1997
Install Stress Control Tape 1
Using a twine binder, remove the paper screens down to 25 mm above the black oil barrier tubings. Ensure that the screen cut is neat and free of any jagged edges. The screen cutback should be at least 220 mm from the end of the paper insulation.
2
Apply two half-lapped layers of Stress Control Tape (Scotch No. 2220) at the end of the black oil barrier tubing, working towards the core end for a distance of 70 mm. Leave an even front edge, then tape back to the starting point. Note:
3
Scotch tape No. 2220 should be applied silver side out, and stretched to 3/4 of its original width. Remove the liner before stretching the tape.
Apply one half-lapped layer of White Restriction Tape (Scotch No. 20) at the black tubing end of the stress control tape to protect it from any damage while shrinking the second oil barrier tubing. Start the Restriction Tape 10 mm onto the black oil barrier tubing and finish it 25 mm onto the stress control tape.
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
1 October 1997
108
Install Upper Oil Barrier Tubings 1
Slid Slidee a seco second nd blac black k oil oil barr barrie ierr tub tubin ing g ove overr one one of the outer phases and position it to overlap the tubing already installed by 20 mm (ie. at the end of the white restriction tape previously applied).
2
Chec Check k tha thatt the the tubi tubing ng over overla laps ps the the lug lug barr barrel el by at least 15 mm. The tubing will grow in length by approximately 15 mm when shrunk. If after allowing for this growth, the tubing does not overlap the lug barrel by 15 mm, contact the relevant Field Coordinator/ Supervisor for instructions. If, on the other hand the tubing is too long, position it so that the overlap with the lug barrel before shrinking is approximately 25 mm.
3
Shri Shrink nk the the tub tubin ing g int into o pos posit itio ion n by by pul pulli ling ng and and unwinding the pull-tab in an anti-clockwise direction.
4
Appl Apply y sel selff am amalga algam matin ating g tap tapee (S (Scotc cotch h No. No. 23) 23) over the black oil barrier tubing at the gap between the paper insulation and the terminal lug, making sure the black tubing is pulled down into the gap. Fill the gap up to the level of insulation, and then apply two extra half-lapped layers, overlapping the lug barrel and the insulation by 15 mm each. Stretch the tape to 50% of its original width while applying it.
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
109
1 October 1997
5
Appl Apply y two two half half-l -lap appe ped d lay layer erss of of Whi White te Rest Restri rict ctio ion n Tape (Scotch No. 20) to cover the full length of the upper black oil barrier tubing + 30 mm of the lower oil barrier tubing.
6
Repe Repeat at the the abo above ve proc proced edur uree for for the the rem remai aini ning ng core cores. s.
Install Outer Silicon Tubings 1
Slide lide a sho short rt oute outerr sil silic icon on tubi tubing ng over over one one of of the the outer phases and push it down to fully overlap the finger of the glove. Shrink it into place by pulling and unwinding the pull-tab in an anti-clockwise direction.
2
Slide lide a lon long g out outer er sili silico con n tub tubin ing g ove overr the the sam same cable core and position it to overlap the short tubing by 20 mm. Check that the tubing will fully cover the remaining length of the core after allowing for 15 mm of growth in length. If it requires a slight adjustment to achieve full coverage, the overlap with the short tubing can be reduced to 15 mm. If the shortfall is more than 15 mm, two half-lapped layers of silicone rubber tape (Scotch No. 70) can be used. On the other hand, if the tubing is too long, the overlap with the short tubing can be increased accordingly.
3
Shrink the tubing into place.
4
Repeat for the other two co cores.
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242
1 October 1997
110
Install Skirt Tubings 1
Slide lide a ski skirt rt tubi tubing ng over over one one of of the the core coress and and position it 170 mm from the top of the long silicon tubing.
2
Shrin hrink k the the tubi tubing ng into into plac placee by by pull pullin ing g and and unwinding the pull-tab in an anti-clockwise direction.
3
Repeat for the other two co cores.
NS 0129 plus CIAs 1087, 1094, 1114, 1170, 1188, 1226 & 1242