2011 U N C O N T R O L L E D UK POWER NETWORKS 11KV JOINTING MANUAL I 2011 Section Index I Page 1 CONTENTS 1 INTRODUCTION 2 JOINTING INSTRUCTIONS 2.1 Single Core Polymeric Straight Joints 4 2.1.1 EPN/LPN/SPN Single Core Straight Joints (Copper Wire Screen Cables) 4 2.1.2 EPN Single Core Straight Joints (Copper Wire Screen to Polylam Cables) 4 2.1.3 EPN Single Core Straight Joints (Polylam to Polylam Cables) 4 2.1.4 Cable Preparation 4 2.1.5 Installing Heatshrink Materials and Components 5 2.2 Triplex Polymeric Straight Joints 11 2.2.1 EPN/LPN/SPN Triplex Straight Joints (Copper Wire Screen Cables) 11 2.2.2 EPN Triplex Straight Joints (Copper Wire Screen to Polylam Cables) 11 2.2.3 EPN Triplex Core Straight Joints (Polylam to Polylam Cables) 11 2.2.4 Cable Preparation 12 2.2.5 Installing Heatshrink Materials and Components 12 2.3 Single Core/Triplex Polymeric Branch Joints 18 2.3.1 EPN/LPN/SPN Single Core/Triplex Branch Joints (Copper Wire Screen Cables) 18 2.3.2 EPN Single Core/Triplex Branch (Copper Wire Screen to Polylam Cables) 18 2.3.3 EPN Single Core (Three Polylam Cables) 18 2.3.4 Cable Preparation 19 2.3.5 Installing Heatshrink Materials and Components 19 2.4 Three-Core Transition Straight Joints (Polymeric to Paper) 26 2.4.1 EPN Triplex or Single Core Polymeric (CWS) to PILC Straight Joints 26 2.4.2 EPN Polylam to PILC Straight Joints 26 2.4.3 LPN/SPN Triplex or Single Core Polymeric (CWS) to PILC Straight Joints 27 2.4.4 SPN Triplex to PICAS Straight Joints 27 1.1 Safety, Health, Environment and Quality Statement 1 U N C O N T R O L L E D UK POWER NETWORKS 11KV JOINTING MANUAL I 2011 Section Index I Page 2 2.4.5 EPN/LPN/SPN Triplex to Three-Core Polymeric Cable Joints 27 2.4.6 Cable Preparation 28 2.4.7 Installing Heatshrink Materials and Components 28 2.5 Three-Core Paper Cable Straight Joints (PICAS and PILC) 38 2.5.1 EPN PILC to PILC Straight Joints 38 2.5.2 LPN PILC to PILC Straight Joints 38 2.5.3 SPN PILC to PILC Straight Joints 39 2.5.4 Cable Preparation 39 2.5.5 Installing Heatshrink Materials and Components 39 2.6 Three-Core Paper Cable Vertical Straight Joints (PILC) 48 2.6.1 EPN/LPN/SPN Vertical Straight Joints (PILC) 48 2.6.2 Cable Preparation 48 2.6.3 Installing Heatshrink Materials and Components 48 2.7 Three-Core Transition Branch Joints (Polymeric to Paper) 60 2.7.1 EPN PILC Main with Triplex or Single Core Polymeric (CWS) Branch Joints 60 2.7.2 EPN PILC Main to Polylam Branch Joints 60 2.7.3 LPN/SPN PILC Main with Triplex or Single Core Polymeric (CWS) Branch Joints 61 2.7.4 SPN PICAS Main with Triplex Branch Joints 61 2.7.5 EPN Triplex or Single Core Polymeric (CWS) Main PILC Branch Joints 62 2.7.6 EPN Polylam Main PILC Branch Joints 62 2.7.7 LPN/SPN Triplex or Single Core Polymeric (CWS) Main PILC Branch Joints 63 2.7.8 SPN Triplex Polymeric Main PICAS Branch Joints 64 2.7.9 Triplex or Single Core Polymeric Main with a Triplex or Single Core Polymeric Branch Joints 64 2.7.10 EPN Polylam Main with a Polylam Branch Joints 65 2.7.11 EPN Polylam Main with Triplex or Single Core Polymeric Branch Joints 65 2.7.12 EPN Triplex or Single Core Polymeric Main with a Polylam Branch Joints 66 2.7.13 Cable Preparation 66 2.7.14 Installing Heatshrink Materials and Components 67 2.8 Single Core Polymeric Pot Ends 77 2.8.1 EPN/LPN/SPN Triplex or Three Single Core Pot End Joints (CWS Cables) 77 2.8.2 EPN Polylam Pot End Joints 77 2.8.3 Cable Preparation 77 2.8.4 Installing Heatshrink Materials and Components 77 2.9 Three-Core Paper Cable Pot Ends (PICAS and PILC) 83 2.9.1 EPN/LPN/SPN Three-Core PILC/PICAS Pot End Joints 83 2.9.2 Cable Preparation 83 2.9.3 Installing Heatshrink Materials and Components 83 U N C O N T R O L L E D UK POWER NETWORKS 11KV JOINTING MANUAL I 2011 Section Index I Page 3
2.10 New Single Core Polymeric Indoor Terminations 91 2.10.1 EPN/LPN/SPN Triplex or Three Single Core Termination Kits (CWS Cables) 91 2.10.2 EPN Polylam Termination Kits 91 2.10.3 Cable Preparation 91 2.10.4 Installing Heatshrink Materials and Components 91 2.11 Single Core Polymeric Terminations in to Existing Compound End Boxes 96 2.11.1 Kit Selection Tables 96 2.11.2 EPN/LPN/SPN Triplex or Three Single Core Termination Kits (CWS Cables) 96 2.11.3 EPN Polylam Termination Kits 97 2.11.4 Cable Preparation 97 2.11.5 Installing Heatshrink Materials and Components 97 2.12 T1 Transformer End Box Terminations 102 2.12.1 EPN/LPN/SPN Triplex or Three Single Core Terminations into T1 Transformer End Box 102 2.12.2 Cable Preparation 102 2.12.3 Installing Heatshrink Materials and Components 102 2.13 Single Core Polymeric Pole Terminations 108 2.13.1 EPN/SPN Triplex Pole Termination Kits (CWS Cables) 108 2.13.2 EPN Polylam Pole Termination Kits 108 2.13.3 Cable Preparation 108 2.13.4 Installing Heatshrink Materials and Components 108 2.14 13kA PILC Cable Earth Kit 113 2.14.1 LPN and SPN 13kA PILC Cable Earth Kit 113 2.14.2 Cable Preparation 113 2.14.3 Installing Heatshrink Materials and Components 113 2.15 Three-Core Loop and Transitional Loop Joints 120 2.15.1 EPN Transitional Loop Joint PILC to Triplex or Single Core Polymeric (CWS) 120 2.15.2 EPN Transitional Loop Joint PILC to Polylam 120 2.15.3 LPN/SPN Transitional Loop Joint PILC to Triplex or Single Core Polymeric (CWS) 121 2.15.4 SPN Transitional Loop Joint PICAS Main to Triplex 121 2.15.5 EPN Polylam to Polylam Loop Joint 122 2.15.6 EPN PILC to PILC Loop Joint 122 2.15.7 LPN/SPN PILC to PILC Loop Joint 123 2.15.8 Cable Preparation 123 2.15.9 Installing Heatshrink Materials and Components 124 2.16 Polymeric Single Core Cable Sheath Repair Kit 133 2.16.1 EPN/LPN/SPN Polymeric Single Core Cable Sheath Repair Kit 133 2.16.2 Cable Preparation 133 U N C O N T R O L L E D UK POWER NETWORKS 11KV JOINTING MANUAL I 2011 Section Index I Page 4 3.1 Single Core Copper Wire Screened Polymeric Cables 1 3.1.1 Removing the Outer Sheath 1 3.1.2 Removing the Bonded Polymeric Screen 3 3.1.3 Removing the Easy Strip Insulation Screen 6 3.1.4 Removing the Polymeric Insulation 8 3.2 Single Core Polylam Cables 9 3.2.1 Removing the Outer Sheath and Aluminium Foil Layer 9 3.2.2 Installing Cheese-Grater Earth Connection 10 3.2.3 Removing the Easy-Strip Insulation Screen 13 3.2.4 Removing the Polymeric Insulation 15 3.3 Three-Core Polymeric Cables 16 3.3.1 Removing the Outer Sheath 16 3.3.2 Preparation of Plastic Cable Sheath 17 3.3.3 Preparation of Steel Wire Armour (Steel Wire Armour Cables) 18 3.3.4 Preparation of Copper Wire Screen (Copper Wire Screened Cables) 21 3.3.5 Removing the Inner Bedding Layer 26 3.3.6 Removing the Fillers 27 3.3.7 Removing the Insulation Screen 27 3.3.8 Removing the Polymeric Insulation 29 3.4 PICAS Paper Insulated Corrugated Aluminium Sheathed Cables 30 3.4.1 Removing the Outer PVC Sheath 30 3.4.2 Removing the Bitumen Layer 32 3.4.3 Removing the Corrugated Aluminium Sheath 32 3.4.4 Preparation of PVC Sheath 33 3.4.5 Removing the Copper Woven Tapes (CWT) and Core Fillers 34 3.4.6 Removing the Insulation Screen (Screened Cables Only) 35 3.4.7 Removing the Conducting and Belt Papers 36 3.4.8 Removing the Insulation Papers 38 3.5 PILC Paper Insulated Lead Sheathed Cables 40 3.5.1 Removing the Outer Serving or Sheath 40 3.5.2 Preparation of Plastic Cable Sheath 41 3.5.3 Removing the Steel Wire Armour 41 3.5.4 Removing the Steel Tape Armour 43 3.5.5 Removing the Inner Bitumen Layer 44 3 STANDARD PROCEDURES FOR PREPARING 11KV AND 6.6KV MAINS CABLES U N C O N T R O L L E D UK POWER NETWORKS 11KV JOINTING MANUAL I 2011 Section Index I Page 5 3.5.6 Removing the Lead Sheath 46 3.5.7 Removing the Conducting and Belt Papers 47 3.5.8 Removing the Core Fillers from Belted Cables 49 3.5.9 Removing the Copper Woven Tapes (CWT) (Screened Cables Only) 50 3.5.10 Removing the Insulation Screen (Screened Cables Only) 50 3.5.11 Removing the Insulation Papers 52 3.6 Moisture Testing on Paper Insulated Cables 54 4 STANDARD PROCEDURES FOR INSTALLING MATERIALS AND COMPONENTS 4.1 Installing Stress Control and Insulation Materials 1 4.1.1 Belted Paper Cables 1 4.1.2 Build-Up Kit for Small Section Paper Cables 5 4.1.3 Screened Paper Cables 6 4.1.4 Single Core Polymeric Cables in Single and Triplex Straight/Branch Joints 9 4.1.5 Single Core Polymeric Cables in Transitional Straight or Branch Joints 11 4.1.6 Single Core Polymeric Cable Terminations 15 4.1.7 Three-Core Polymeric Cables 20 4.2 Installing Mechanical Connectors and Lugs 22 4.2.1 Single Core and Triplex Straight Joints 22 4.2.2 Three-Core Transition and Three-Core PICAS/PILC Joints 24 4.2.3 Single Core Branch Joints 26 4.2.4 Three-Core Transition Branch Joints 30 4.2.5 Mechanical Lugs for Indoor and Outdoor Terminations 33 4.2.6 Mechanical Thimbles for use in T1 Transformer End Boxes 35 4.3 Installing Connector Stress Control and Heatshrink Insulation 36 4.3.1 Single Core and Triplex Straight/Branch Joints 36 4.3.2 Transition and Paper to Paper Straight Joints 39 4.3.3 Single Core Branch Joints 42 4.3.4 3-Core Transition Branch Joints 46 4.3.5 Polymeric and Paper Pot End Joints 50 4.4 Installing Bushing Boots 55 4.4.1 Cold Applied Switchgear Boots 55 4.4.2 Heat Shrink Boots 58 4.5 Installing Mechanical Earth Bonds and Associated Components 60 U N C O N T R O L L E D UK POWER NETWORKS 11KV JOINTING MANUAL I 2011 Section Index I Page 6 4.5.1 Single Core Straight Joints 60 4.5.2 Triplex Straight Joints 62 4.5.3 Single Core Branch Joints 64 4.5.4 Triplex Cables into Transition Joints Using a Support Ring 66 4.5.5 Standard PILC Earth Steel Wire Armour Cables (EPN and Pot Ends Only) 69 4.5.6 PICAS Earth (SPN Only) 70 4.5.7 13kA PILC Earth Kit Steel Wire Armoured Cables (LPN and SPN Areas Only) 71 4.5.8 13kA PILC Earth Kit Steel Tape Armoured Cables (LPN and SPN Areas Only) 76 4.5.9 Installing Aluminium Cages 79 4.5.10 Connections of Earth Screens on Indoor and Outdoor Terminations 81 4.6 Fitting Plastic Joint Boxes 83 4.7 Mixing and Installing Polyurethane Resin 85 4.8 Mixing and Installing Gurufex 88 4.9 Removing Gurufex 88 U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 1 I Page 1 This 11kV J ointing Manual covers the approved methods and associated jointing kits for use on 11kV and 6.6kV mains cables within UK Power Networks. This 11kV J ointing Manual is split into four sections: Section 1 Introduction and Safety, Health, Environment and Quality Statement Section 2 J ointing Instructions Section 3 Standard Procedures for Preparing 11kV and 6.6kV Mains Cables Section 4 Standard Procedures for Installing Materials and Components Every attempt has been made to cover all the types of joint required. If the joint that you are required to make is not covered, refer either to the Craft Training Centres at Bury St Edmunds and Sundridge or to Asset Management. 1.1 Safety, Health, Environment and Quality Statement It is paramount that all jointing activities are carried out in strict compliance with all Safety, Health, Environmental and Quality policies and procedures. It is not intended to list all the detailed procedures and guidance that apply to jointing as they would quickly become out of date. This is intended to highlight the overall requirements, details of which can be found in the UK Power Networks Central Document Library (CDL). The requirements of the Distribution Safety Rules and associated approved procedures and codes of practice shall be followed at all times. Appropriate Personal Protective Equipment shall be worn. An on-site risk assessment shall be carried out using the UK Power Networks standard on-site risk assessment sheet at the start of every job and reviewed at the start of every subsequent day of the job. Only approved materials shall be used. Materials and substances which have not been assessed by UK Power Networks under its COSHH procedure shall not be used without assessment. Only approved tools designed for the type of cable shall be used, and the condition of these shall be checked each day before use. Only persons who have been trained and assessed to a level acceptable to UK Power Networks may carry out jointing on the network owned by UK Power Networks. People shall only carry out work for which they have the necessary skills and training. Work may only be carried out in accordance with network procedures and, where appropriate, the agreement of network control. Work may only be carried out if an appropriate task or job instruction has been issued for that work, unless the person concerned is specically authorised to issue such instructions to them. Only competent or authorised persons specically appointed to do so may carry out jointing work, receive Permits to Work and carry out the operational activities associated with jointing such as linking and fusing. The work site shall be kept tidy. Environmental risks created by the work and disposal of waste shall be managed in accordance with UK Power Networks Environmental procedures. 1 I NTRODUCTI ON U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 1 I Page 2 All jointing works shall be carried out in accordance with this manual and other guidance issued by UK Power Networks. All work carried out shall be recorded in the approved manner and details returned for inclusion on the records management system. Any incidents or near misses that occur, and any hazards that come to light shall be reported to the AIRline reporting system. This section is intended only as a summary of HSS requirements. Persons carrying out jointing works on the network, shall ensure they are up to date with all relevant HSS procedures and guidance before carrying out work. If in doubt, ask. U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 3 This section contains a complete list of jointing instructions and kit selection tables for all 6.6kV and 11kV joints. Only joints contained within this section are to be used in UK Power Networks. No other joint kits or combinations of joint kit shall be used without the approval of UK Power Networks Asset Management. To simplify the kit selection tables only metric cable sizes are used. To convert from imperial to metric conductor sizes refer to the comparison table below: All sizes apply to both copper and aluminium conductor sizes. 2 J OI NTI NG I NSTRUCTI ONS Imperial Conductor Size (sq. in) Metric Equivalent Conductor Size (sq. mm) 0.007 4 0.0225 16 0.04 25 0.06 35 0.1 70 0.15 95 0.2 120 0.25 150 0.3 185 0.4 240 0.5 300 For advice on the jointing of equivalent cable sizes, refer to your supervisor or engineer and the contents of EDS 02-0027 11kV Triplex Cables. U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 4 2.1 Single Core Polymeric Straight Joints The tables below detail the joint kits required to complete this joint for the cable sizes listed. Any jointing requirements for cable sizes not shown here shall be referred to one of the UK Power Networks J ointing Schools. 2.1.1 EPN/LPN/SPN Single Core Straight J oints (Copper Wire Screen Cables) 2.1.2 EPN Single Core Straight J oints (Copper Wire Screen to Polylam Cables) 2.1.3 EPN Single Core Straight J oints (Polylam to Polylam Cables) 2.1.4 Cable Preparation Refer to the following sections of this manual for details of the preparation of each type of cable: 3.1 Single Core Copper Wire Screened Polymeric Cables. 3.2 Single Core Polylam Cables. Cable Sizes mm 2 J oint Kit Description and Part Numbers Single Core Straight J oint 35 to 95mm 2 Single Core Straight J oint 150 to 300mm 2 Tyco Part No. SMOE 63401 SMOE 63402 Stores Code 04100A 04101K 70 95 70 95 1 per Phase 150 300 150 300 1 per Phase Cable Sizes mm 2 J oint Kit Description and Part Numbers Single Core Straight J oint 150-300mm 2 Polylam Earth Kit Tyco Part No. SMOE 63402 SMOE 63409 Stores Code 04101K 04108D Triplex Polylam 95 300 150 240 1 per Phase 1 for 3 Phases Cable Sizes mm 2 J oint Kit Description and Part Numbers Single Core Straight J oint 150-300mm 2 Polylam Earth Kit Tyco Part No. SMOE 63402 SMOE 63409 Stores Code 04101K 04108D 150 240 150 240 1 per Phase 2 for 3 Phases U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 5 2.1.5 Installing Heatshrink Materials and Components Refer to the following sections of this manual for the installation of heatshrink materials and other components: 4.1 Installing Stress Control and Insulation Materials. 4.1.4 Single Core Polymeric Cables in Single and Triplex Straight/Branch J oints. 4.2 Installing Mechanical Connectors and Lugs. 4.2.1 Single Core and Triplex Straight J oints. 4.3 Installing Connector Stress Control and Heatshrink Insulation. 4.3.1 Single Core and Triplex Straight/Branch J oints. 4.5 Installing Mechanical Earth Bonds and Associated Components. 4.5.1 Single Core Straight J oints. U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 6 Installation Instruction
11kV Single Core XLPE Straight Joint
For Cable Sizes: 35-95mm 2
SMOE 63401 UK Power Networks Stores Code 04100A For Cable Sizes: 150-300mm 2
SMOE 63402 UK Power Networks Stores Code 04101K
U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 7 Cable Overlap Overlap the cables as shown in Figure 1. Mark the reference line. 1 Cable Preparation Remove the oversheath to dimension shown in Table 1. Clean the remaining oversheath for about 1m. Bend back the shield wires onto the oversheath. Fix the ends of the shield wires temporarily in place. 2 Core Preparation Cut the cores at the reference line using a hacksaw (refer to Table 1). Thoroughly remove the core screen to the dimensions given in the drawing, so that the insulation surface is free from all traces of conductive material. Clean and degrease the insulation. Note: Do not nick the insulation reference line reference line a a 500 Measure the conductor bore depth of the connector and remove the insulation on both cores equal to the insert depth l (refer to Table 1).
4 l l 3 40 a reference line insulation core screen 50 Table 1 Dimensions in mm Cable Size mm 2 a I 35 to 95 140 30 150 to 300 170 60 5 20 10 Take the yellow void filling strip from the aluminium foil packet. Remove the release papers from the strip with the pointed ends. Wrap the void filler around the core screen starting 20mm from the end of the screen and continue onto the insulation for 10mm. Stretch the strip to half of its original width and apply under tension to achieve a fine thin edge. U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 8 Completion of Joint
Slide a combined tubing set over one XLPE cable core. 1 - Black and red screened insulation sleeve. 2 - Black outer sleeve. Slide the black stress control tubing over the XLPE cable core level with the end of the insulation cut back. Shrink down starting from the insulation cut back before working towards the oversheath as shown in drawing. Fit the conductors into the connector. There should be no gap left between the connector and the insulation. Take up the tension equally on all bolts (do not shear bolt heads at this stage). Starting at the connector ends, tighten the bolts until the heads shear off. In the case of a proud edge showing after removal of the bolts, this edge should be removed with a suited tool. Re-align cables if necessary. Note: If required (small cross sections) use a connector holding tool avoiding conductor bending. 9 6 Installation of Mechanical Connector The connector is supplied with insert half shells or centralising rings, which have to be used on small cross sections. Check before installation if the conductor fits the centralising ring or if it is insertable into the connector with the half shells installed. The fit of the centralising rings is tight and requires complete insertion. 8 insert shells 7 2 1 10 Clean and degrease the cable cores and the connector. Fill the bolt holes with Raychem clay to obtain a smooth finish. U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 9 Remove the release paper from the black stress grading patch. Position the patch centrally over the connector area. Note: In the case of a rectangular patch apply the long side across the connector. Wrap the patch over the connector area starting at the connector bolts. Note: Do not stretch the patch. Position the black and red screened insulating sleeve centrally over the connector area. a. Start shrinking the sleeve in the centre (1). b. Continue shrinking by working towards one side (2), stopping 50mm from the end. Shrink the other half in the same way (3). c. Shrink down the first end (4) and finally the second (5). The sleeve should be fully shrunk without leaving ridges. Cable side with long shield wires: Bend the shield wires back over the joint area. Form the shield wires into two equal groups. Cable side with the short shield wires: Bend the shield wires back over the joint area close to the copper mesh.
Gather the wires together and cut them centrally above the 50mm copper mesh overlap on the cable oversheath. 11 Starting with a 50mm overlap onto the oversheath of the ca- ble side with the short shield wires, wrap one layer of copper mesh round the joint with a 50% overlap. 13 50 Copper mesh 14 50 cut b 50 2 3 4 5 c 12 a 1 15 Form two earth leads of the shield wires and insert into the mechanical shield connectors supplied. Tighten the bolts until the heads shear off.
U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 10 J oint completed. Allow the joint to cool before applying any mechanical strain. 18 Clean and degrease the ends of the oversheath for a length of about 150mm. Centre the black outer sleeve over the copper mesh area. Start shrinking in the centre, working towards the ends. 17 2 Wrap a second layer of copper mesh round the joint with a 50% overlap. Cover the complete joint area including the mechanical shield connector.
16 Copper mesh U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 11 2.2 Triplex Polymeric Straight Joints The tables below detail the joint kits required to complete this joint for the cable sizes listed. Any jointing requirements for cable sizes not shown on this table shall be referred to one of the UK Power Networks J ointing Schools. 2.2.1 EPN/LPN/SPN Triplex Straight J oints (Copper Wire Screen Cables) Cable Sizes mm 2 J oint Kit Description and Part Numbers Triplex Straight J oint 35-95mm 2 Triplex Straight J oint 150-300mm 2 Tyco Part No. SMOE 63403 SMOE 63404 Stores Code 04102U 04103E 70 95 70 95 1 per J oint 150 300 150 300 1 per J oint Resin Volume 6.0 Litres 2.2.2 EPN Triplex Straight J oints (Copper Wire Screen to Polylam Cables) Cable Sizes mm 2 J oint Kit Description and Part Numbers Triplex Straight J oint 35-95mm 2 Triplex Straight J oint 150-300mm 2 Polylam Earth Kit Tyco Part No. SMOE 63403 SMOE 63404 SMOE 63409 Stores Code 04102U 04103E 04108D Triplex Polylam 70 300 150 240* 1 per J oint 1 for 3 phases Resin Volume 6.0 Litres 6.0 Litres 2.2.3 EPN Triplex Core Straight J oints (Polylam to Polylam Cables) Cable Sizes mm 2 J oint Kit Description and Part Numbers Triplex Straight J oint 35-95mm 2 Triplex Straight J oint 150-300mm 2 Polylam Earth Kit Tyco Part No. SMOE 63403 SMOE 63404 SMOE 63409 Stores Code 04102U 04103E 04108D 150 240 150 240 1 per J oint 2 for 3 phases Resin Volume 6.0 Litres 6.0 Litres U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 12 2.2.4 Cable Preparation Refer to the following sections of this manual for the cable preparation details: 3.1 Single Core Copper Wire Screened Polymeric Cables. 3.2 Single Core Polylam Cables. 2.2.5 Installing Heatshrink Materials and Components Refer to the following sections of this manual for the installation of heatshrink materials and other components: 4.1 Installing Stress Control and Insulation Materials. 4.1.4 Single Core Polymeric Cables in Single and Triplex Straight/Branch J oints. 4.2 Installing Mechanical Connectors and Lugs. 4.2.1 Single Core and Triplex Straight J oints. 4.3 Installing Connector Stress Control and Heatshrink Insulation. 4.3.1 Single Core and Triplex Straight/Branch J oints. 4.5 Installing Mechanical Earth Bonds and Associated Components. 4.5.2 Triplex Straight J oints. 4.6 Fitting Plastic J oint Boxes. 4.7 Mixing and Installing Polyurethane Resin. U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 13 Installation Instruction
11kV Triplex XLPE Straight Joint
For Cable Sizes: 35-95mm 2
SMOE 63403 UK Power Networks Stores Code 04102A For Cable Sizes: 150-300mm 2
SMOE 63404 UK Power Network Stores Code 04103E
U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 14 Cable Overlap Overlap the cables to be jointed by 200mm. Mark the reference line. Core Preparation Cut the cores at the reference line using a hacksaw (refer to Table 1). Thoroughly remove the core screen to the dimensions given in the Figure 3, so that the insulation surface is free from all traces of conductive material. Clean and degrease the insulation. Note: Do not nick the insulation! 3 Remove the insulation from both cores equal to the insert depth l (refer to Table 1).
4 l l 40 a reference line insulation core screen 1 reference line 200 200 a a 2 Stripping Dimensions Carefully remove the cable oversheath to the dimension a shown in the Table 1 below. Degrease the outer cable sheaths for a distance of 200mm. Table 1 Dimensions in mm Cable size mm 2 a I 35 to 95 140 30 150 to 300 170 60 U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 15 5 Completion of Joint
Slide the black and red screened insulation sleeve over one of the XLPE cable core.
Check that these tubes are in place before fitting the mechanical connector.
7 Slide the black stress control tubing over the XLPE cable core level with the end of the insulation cut back. Shrink down starting from the insulation cut back before working towards the oversheath as shown in drawing. 6 9 Take the yellow void filling strip from the aluminium foil packet. Remove the release papers from the strip with the pointed ends. Wrap the void filler around the core screen starting 20mm from the end of the screen and continue onto the insulation for 10mm. Stretch the strip to half of its original width and apply under tension to achieve a fine thin edge. 20 10 Installation of Mechanical Connector The connector is supplied with insert half shells or centralising rings, which have to be used on small cross sections. Check before installation if the conductor fits the centralising ring or if it is insertable into the connector with the half shells installed. The fit of the centralising rings is tight and requires complete insertion. 8 insert shells Fit the conductors into the connector. There should be no gap left between the connector and the insulation. Take up the tension equally on all bolts (do not shear bolt heads at this stage). Starting at the connector ends, tighten the bolts until the heads shear off. In the case of a proud edge showing after removal of the bolts, this edge should be removed with a suited tool. Re-align cables if necessary. Note: If required (small cross sections) use a connector holding tool avoiding conductor bending. U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 16 b 50 2 3 4 5 c 11 12
13 Form the copper wire screens into two groups and connect them together using the mechanical connector. Position the connector in the gap between two insulating sleeves. a Bring all three cables together in trefoil formation. Wrap two layers of tinned copper mesh around all three cores. 1 10 14 Clean and degrease the cable cores and the connector. Fill the bolt holes with Raychem clay to obtain a smooth finish. Remove the release paper from the black stress grading patch. Position the patch centrally over the connector area. Note: In the case of a rectangular patch apply the long side across the connector. Wrap the patch over the connector area starting at the connector bolts. Note: Do not stretch the patch. Position the black and red screened insulating sleeve centrally over the connector area. a. Start shrinking the sleeve in the centre (1). b. Continue shrinking by working towards one side (2), stopping 50mm from the end. Shrink the other half in the same way (3). c. Shrink down the first end (4) and finally the second (5). The sleeve should be fully shrunk without leaving ridges. U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 17 Fit and support the plastic shell, seal the ends using the mastic provided with the kit.
Mix the resin following the manufacturers instructions and fill the joint.
16 Degrease the cable oversheaths and wrap the centre of the joint with the rubber sheet at the shell stand off position, adhesive side outwards. Flame brush the cable oversheaths for a distance of 100mm.
15 50 U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 18 2.3 Single Core Polymeric Branch Joints The tables below detail the joint kits required to complete this joint for the cable sizes listed. This joint is primarily to be used as a single core repair joint. Any jointing requirements for cable sizes not shown on this table shall be referred to one of the UK Power Networks J ointing Schools. 2.3.1 EPN/LPN/SPN Single Core Branch J oints (Copper Wire Screen Cables) 2.3.2 EPN Single Core Branch (Copper Wire Screen to Polylam Cables) 2.3.3 EPN Single Core (Three Polylam Cables) Cable Sizes mm 2 J oint Kit Description and Part Numbers Single Core Branch J oint 95-150mm 2 Single Core Branch J oint 185-300mm 2 Tyco Part No. SMOE 63405 SMOE 63406 Stores Code 04104P 04105Y 95 150 95 150 1 per Phase 95 185 300 1 per Phase 150 300 185 185 1 per Phase Cable Sizes mm 2 J oint Kit Description and Part Numbers Single Core Branch J oint 95-150mm 2 Single Core Branch J oint 185-300mm 2 Polylam Earth Kit Tyco Part No. SMOE 63405 SMOE 63406 SMOE 63409 Stores Code 04104P 04105Y 04108D Triplex Polylam 95 150 150 1 per Phase 1 for 3 Polylam ends 185 300 150 240 1 per Phase 1 per Phase 1 for 3 Polylam ends Cable Sizes mm 2 J oint Kit Description and Part Numbers Single Core Branch J oint 95-150mm 2 Single Core Branch J oint 185-300mm 2 Polylam Earth Kit Tyco Part No. SMOE 63405 SMOE 63406 SMOE 63409 Stores Code 04104P 04105Y 04108D 150* 150* 1 per Phase 1 per J oint 150* 240* 1 per Phase 1 per J oint 240* 240* 1 per Phase 1 per J oint U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 19 2.3.4 Cable Preparation Refer to the following sections of this manual for the preparation of each cable type: 3.1 Single Core Copper Wire Screened Polymeric Cables. 3.2 Single Core Polylam Cables. 2.3.5 Installing Heatshrink Materials and Components Refer to the following sections of this manual for the installation of heatshrink materials and other components: 4.1 Installing Stress Control and Insulation Materials. 4.1.4 Single Core Polymeric Cables in Single and Triplex Straight/Branch J oints. 4.2 Installing Mechanical Connectors and Lugs. 4.2.3 Single Core Branch J oints. 4.3 Installing Connector Stress Control and Heatshrink Insulation. 4.3.3 Single Core Branch J oints. 4.5 Installing Mechanical Earth Bonds and Associated Components. 4.5.3 Single Core Branch J oints. U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 20 Installation Instruction
11kV Single Core XLPE Branch Joint
For Cable Sizes: 95-150mm 2
SMOE 63405 UK Power Networks Stores Code 04104P For Cable Sizes: 185-300mm 2
SMOE 63406 UK Power Networks Stores Code 04105Y
U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 21 Cable Overlap Overlap the branch cable by about 300mm. Mark the reference line on the cable. Cut the main cable at the reference line.
1 300 reference line 2 dimensions in mm reference line 60 60 160 160 60 60 core screen oversheath shield wires All Cable Ends Remove the release paper from the short lengths of yellow void filling mastic with the pointed end, wrap it around the core starting 20mm from the end of the screen and continuing onto the insulation for 10mm. Stretch the mastic to half of its original width and apply under tension to achieve a thin edge on the insulation. 3 10 20 Cable Preparation Remove the oversheaths to the dimensions given in the Figure 2, measured from the reference line. Clean all the remaining oversheaths for about 800mm on both cable sides. Fold back the copper wires and hold the ends in place with PVC tape. Cut the branch cable at the reference line. Remove the core screen to the dimensions given in the Figure 2, so that the insu- lation surface is free from all traces of conductive material. Remove the insulation to the dimension given in Figure 2. Note: Do not nick the insulation. STRESSCONTROL Position the black stress control tubing level with the insulation cutback. Shrink the tubing into position starting at the insulation cutback before working towards the oversheath as shown in Figure 4. 4 U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 22 Single Cable Side Only Position the red insulation build up sleeve level with the end of stress control tubing. Shrink the tubing into position, starting at the insulation cutback before working towards the oversheath as shown in Figure 5. 5 Completion of Joint
Slide the combined tubing set and the outer sleeve over the single cable end. The plastic bag of the tubing set can be used as additional protection by placing it under the tubing set.
1. Black stress control tubing. 2. Black and red screened insulating sleeve.
Check that these tubes are in place before fitting the mechanical connector.
6 Insert the black rubber profile (1) and the red mastic profile (2) between the cores. Position the red mastic profile so that it is level with the insulation cutback as shown in Figure 7. The black rubber profile must butt up against the red mastic profile. 7 2 1 1 2
Install the conductors in to the mechanical connector. The insulation cutback must butt on the connector body. Tighten the bolt set alternatively in several steps, starting with the outer bolts, until the heads shear off.
Note: In the event of a proud edge showing after removal of the bolt heads, this edge should be removed. 9 Installation of Mechanical Connector The connector is supplied with a centralising insert for use on smaller cross sections on the single cable side. Check if the conductor will fit through the hole in the plastic insert provided with the connector. If the conductor fits through the hole in the insert place it into the single cable bore of the connector. The insert is not required if it does not fit the conductor. The fitting is tight and requires complete insertion. 8 insert U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 23 Remove one release paper from the long yellow void filling mastic strip and roll it up. Starting from the single core side, wrap it around the core with a 50% overlap. The mastic should be stretched to about half of its original width and applied under tension. Carefully fill all gaps. Continue across the connector. 11 Apply a total of two thin layers of yellow void filling mastic over the connector, forming a smooth profile between the end of the stress control tubing on the single core side and the red mastic profile on the other side. Overlap the stress control tubing and the red mastic profile for 5mm. Lubricate the void filling mastic with the silicone tissue provided. 12 Fill each of the remaining holes with clay to obtain a smooth finish. 10 clay 150 a b c d 1 2 3 4 Pull the black stress control tubing from inside the tubing set and position it with 10mm overlap of the rubber profile. Start shrinking from the branch cable side working towards the single core side. The tubing should be fully shrunk and wrinkle free. 13 Position the black and red screened insulating sleeve centrally over the stress control tube. a. Start shrinking the sleeve in the centre over the connector (1). Shrink carefully and slowly. b. Check if fully shrunk down, preferably by looking inside from the single core end. No gap should be visible around the connector. c. Continue slowly shrinking by working towards the single core end (2) stopping 150mm from the end. Then slowly shrink the other side completely (3). d. Finally shrink down the second end (4). The sleeve should be fully shrunk without leaving ridges. 14 Check Attention! It is important to shrink slowly and to use plenty of heat whilst following the steps below. 10 1 2 U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 24 Starting from the branch side, apply the tinned copper mesh with a 50% overlap. around the previously installed tube, so that the whole joint is covered. 15 Bend the copper wires back over the joint area and cut the wires of the main cable to the required length. On the single core side insert the shielding wires into the mechanical connector and tighten the bolts finger tight.
For small section branches, check that the size of long length of copper wire screen, matches the size of the copper wire screen on the main. 16 On the branch side insert main and branch wires into the second mechanical connector. The copper wires of the branch cable should extend beyond the first connector. Tighten the bolts finger tight. 17 Cut the copper wires of the branch cable to the required length and insert them in the first connector. Tighten the bolts on both connectors until the heads shear off to provide the earth connection.
18 Degrease the cable oversheaths. Flame brush the oversheaths until they have a shiny appearance for a distance of 100mm. 19 U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 25 b c c a b Offer the bottom of the plastic joint shell up to the joint . Mark on the tinned copper mesh the centre of the stand off positions in the shell. Wrap the rubber strips around the joint on top of the previously marked positions, sticky side out.
20 a. Assemble the joint half shells around the joint and clip together. b. Fill any gaps around the cable entry holes as required. c. Fill the joint with the approved resin following the manufacturers instructions and safety data sheet. The joint is now complete. Allow the resin to set before applying any mechanical strain. 21 U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 26 Cable Sizes mm 2 J oint Description and Part Numbers Three Core Transition Straight J oint 95-185mm 2 Three Core Transition Straight J oint 240-300mm 2 PILC Build Up Kit 16-70mm 2 Tyco Part No. SMOE 63410 SMOE 63411 SMOE 63429 Stores Code 04120S 04121C 04125R PILC POLY 16 70 95 1 per J oint 1 per J oint 95 185 95 185 1 per J oint 240 300 240 300 1 per J oint Resin Volume 13.0 Litres 15.0 Litres Cable Sizes mm 2 J oint Description and Part Numbers Three Core Transition Straight J oint 95-185mm 2 Three Core Transition Straight J oint 240-300mm 2 PILC Build Up Kit 16-70mm 2 Polylam Earth Kit Tyco Part No. SMOE 63410 SMOE 63411 SMOE 63429 SMOE 63409 Stores Code 04120S 04121C 04125R 04108D PILC POLY 16 70 150 1 per J oint 1 per J oint 1 per J oint 95 185 150 1 per J oint 1 per J oint 240 300 240 1 per J oint 1 per J oint Resin Volume 13.0 Litres 15.0 Litres 2.4 Three Core Transition Straight Joints (Polymeric to Paper) The tables below detail the joint kits required to complete this joint for the cable sizes listed. Any jointing requirements for cable sizes not shown on this table shall be referred to one of the UK Power Networks J ointing Schools. 2.4.1 EPN Triplex or Single Core Polymeric CWS to PILC Straight J oints 2.4.2 EPN Polylam to PILC Straight J oints U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 27 2.4.3 LPN/SPN Triplex or Single Core Polymeric CWS to PILC Straight J oints Cable Sizes mm 2 J oint Description and Part Numbers Three Core Transition Straight J oint 95-185mm 2 Three Core Transition Straight J oint 240-300mm 2 13.1kA Earth Kit PILC Build Up Kit 16-70mm 2 Tyco Part No. SMOE 63410 SMOE 63411 SMOE 63414 SMOE 63429 Stores Code 04120S 04121C 04124G 04125R PILC POLY 16 70 95 1 per J oint 1 per J oint 95 95 1 per J oint 120 185 185 1 per J oint 1 per J oint 240 300 240 300 1 per J oint 1 per J oint Resin Volume 13.0 Litres 15.0 Litres Cable Sizes mm 2 J oint Kit Description and Part Numbers Three Core Transition Straight J oint 95-185mm 2 Three Core Transition Straight J oint 240-300mm 2 Tyco Part No. SMOE 63410 SMOE 63411 Stores Code 04120S 01421C PICAS POLY 95 185 95 185 1 per J oint 300 300 1 per J oint Resin Volume 13.0 Litres 15.0 Litres Cable Sizes mm 2 J oint Kit Description and Part Numbers Three Core Transition Straight J oint 95-185mm 2 Three Core Transition Straight J oint 240-300mm 2 Three Core Poly Conversion Kit Tyco Part No. SMOE 63410 SMOE 63411 SMOE 63439 Stores Code 04120S 01421C 04134Q Triplex POLY 95 185 95 185 1 per J oint 1 per J oint 240 300 240 300 1 per J oint 1 per J oint Resin Volume 15.0 Litres 2.4.4 SPN Triplex or PICAS Straight J oints 2.4.5 EPN/LPN/SPN Triplex to Three Core Polymeric Cable J oints U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 28 2.4.6 Cable Preparation Refer to the following sections of this manual for the preparation of each cable type: 3.1 Single Core Copper Wire Screened Polymeric Cables. 3.2 Single Core Polylam Cables. 3.3 Three Core Polymeric Cables. 3.4 PICAS Paper Insulated Corrugated Aluminium Sheathed Cables. 3.5 PILC Paper Insulated Lead Sheathed Cables. 2.4.7 Installing Heatshrink Materials and Components Refer to the following sections of this manual for the installation of heatshrink materials and other components: 4.1 Installing Stress Control and Insulation Materials. 4.1.1 Belted Paper Cables. 4.1.2 Build Up Kits for Small Section Paper Cables. 4.1.3 Screened Paper Cables. 4.1.5 Single Core Polymeric Cables in Transitional Straight/Branch J oints. 4.1.7 Three Core Polymeric Cables. 4.2 Installing Mechanical Connectors and Lugs. 4.2.2 Three Core Transition and Three Core PICAS/PILC. 4.3 Installing Connector Stress Control and Heatshrink Insulation. 4.3.2 Transition and Paper to Paper Straight J oints. 4.5 Installing Mechanical Earth Bonds and Associated Components 4.5.4 Triplex Cables into Transition J oints Using a Support Ring. 4.5.5 Standard PILC Steel Wire Armour Cables. 4.5.6 PICAS Earth. 4.5.7 13kA PILC Earth Kit Steel Wire Armoured Cables. 4.5.8 13kA PILC Earth Kit Steel Tape Armoured Cables. 4.5.9 Installing Aluminium Cages. 4.6 Fitting Plastic J oint Boxes. 4.7 Mixing and Installing Polyurethane Resin. U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 29 Instal lati on Instruction
11kV Three Core Transition Straight Joint
For Cable Sizes: 95-185mm 2
SMOE 63410 UK Power Networks Stores Code 04120S For Cable Sizes: 240-300mm 2
SMOE 63411 UK Power Networks Stores Code 04121C
U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 30 belt papers/fabric tape Cable Overlap
Plastic Cable with Copper Wire Screen Overlap the cables to be jointed by about 200 mm. Mark the reference line.
Strip the cables to the dimensions given below. reference line 200 Pol ymeri c Pl astic lead sheath wire amour reference line core screen wire screen 60 140 20 200 b 220 40 PICAS Cabl e, screened belt paper / fabric tape Paper Pol ymeri c Pl astic metal sheath oversheath 140 20 c 220 40 PILC Cable, Steel Wire or Tape Armoured a b Table 1 Conductor size Cut-back dimensi ons given below mm a b c 95 - 500 300 450 - 300 550 350 490 Paper oversheath For three core pol ymeri c cabl es use the 185 to 300mm joint and the paper cable dimensions below. U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 31 The 13A earth clip may need to be installed at thi s stage of the joint
Paper Cables
Remove the armours according to the dimensions shown in the drawing on the previous page. Stand the armour wires upright and remove all traces of compound from them and the cable lead sheath. Thoroughly clean and abrade the lead sheath for 200mm from the cable armour. 1 Wrap the short length of tinned copper mesh around the lead sheath so that its edge just protrudes beyond the armour wires when they are laid back down. 2 Relay the armour wires over the mesh and secure with a worm drive clip. 3 4B Belted Paper Cables Tie a twine binder around the carbon paper 5mm from the end of the lead sheath and tear the layers of paper off against. Tie a second twine binder around the belt papers 20mm from the end of the metal sheath and tear off the belt papers against it. Remove the fillers level with the belt papers. Secure the paper insulation at the end of each core using PVC tape. Using a clean, dry cloth, remove any excess cable compound from the cores. 4A Screened Paper Cables Unwind the copper woven fabric tape and remove the fillers. Rewind the tape around the crutch of the cable and tie it off 20mm from the end of the metal sheath. Tie a twine binder around the screen papers at the dimension given in the Figure 4B. Tear off the screen papers level with the twine binder. Remove the top two paper tapes to the same position as the screen papers. Using a clean, dry cloth, remove any excess cable compound from around the cores.
tape binder 5 20 20 reference line 180 U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 32 Three Core Pol ymeric Cables Remove the semi conducting screen layer from the insulation to the dimension shown in Figure 4C using approved tools and jointing techniques. Do not nick the insulation layer.
4C reference line 180 7 6 8 40 20 20 10 50 5 Push the yellow mastic wedge carefully into the crutch until the tip is just below the belt paper or fabric tape. The wedge will deform and partly extrude between the cores.
Slide the red insulating tubes over the cores on each cable end, pushing then well down into the crutch.
Shrink the tubes, starting from the crutch and working towards the core ends. Ensure that the tubes are shrunk down evenly and are free from air or grease pockets.
For cable sizes below those shown in Table 1, the core tubes should be substituted for those in the build up kit.
Remove the release paper from a 400mm yellow mastic tape strip. Wrap the tape around the crutch, overlapping onto the lead sheath by 20 mm and continue onto the red insulating tubes for 20mm. Wrap a second strip of the yellow mastic over the first layer. The mastic tape should be stretched to half its original width and applied under tension.
Screened Paper Cables Onl y Cut a 50mm long piece from the yellow void filling mastic tape as shown in Figure 5. Wrap the yellow mastic around the screen papers starting 20mm from the end of the screen and continuing onto the insulation for 10mm. Stretch the mastic to half its original width and apply under tension to achieve a fine thin edge. Note: The yellow mastic should be applied in the same direction as the lay of the screen papers. U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 33 Position the red crutch sealing sleeve centrally over the yellow void filling mastic tape and shrink into position.
Note: For cable sizes below 95mm 2 ,the crutch sealing sleeve should be substituted for that in the PILC cable build up kit. 9 Seal ant Tape Wrap one layer of red sealant tape around the cable oversheath for 60mm from the sheath cut with slight tension and a one third overlap. Screen Wires Bend the screen wires back onto the red sealant tape ensuring the wires are straight and do not cross. Use a wire binder to keep them tight against the red sealant tape.
Semi Conducting Layer Remove the semi conducting screen layer from the insulation to the dimension shown in Figure 13 using approved tools and jointing techniques. Do not nick the insulation layer.
Insulation Remove the insulation to the internal depth of the connector, dimension L in the drawing.
Single Core XLPE Sheath Removal Lay the single core XLPE cables in to their final jointing position. Mark the reference line and cut to length. Slide the large support ring over all three single core cables. Carefully remove the oversheaths. Thoroughly degrease the outer cable sheath for a distance of 200mm from the sheath cut.
11 60 10 200 Moisture Seal Wrap one layer of red sealant tape over the previously applied 60mm red tape to sandwich the screen wires to form a moisture seal. Continue onto the semi-conducting layer for 15mm. Degrease the insulation.
13 60 15 12 40 L U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 34 14 30 Stress Relieving Tape Remove one release paper from the short pointed yellow void filling mastic strips. Starting 20mm on the semi-con layer, continue taping on to the insulation for 10mm to form a smooth taper. Stretch the tape to approx. half its original width and apply under tension to ensure a smooth fine edge. Remove the second release paper during this taping operation.
Connector Installation Reset the cores into their final jointing position. Ensure that conductors have been cut to allow for the moisture block in the centre of the connector. Screw the shear head bolts into the connector body until the tip is level with the inside surface of the connector
Note: The bolts should not be removed once they have been screwed into the connector. Position the connector on the short side of the joint and tighten the shear head bolts, until they are finger tight. The connectors should be positioned with the bolt heads facing away from the centre of the joint.
Note: Do not remove the centre fixing bolt at this time.
Hold the connector with the recommended holding tool and tighten the two shear head bolts sequentially until they shear off. 16 reference line shear head bolts shear head bolts holding tool 17 Remove the centre fixing bolt and position the other half of the connector onto the corresponding core on the long side of the joint.
At this time do not tighten the shear head bolts. 18 Core Tubing Position the red core tubing over the cable core so it is level with the end of the insulation cutback. Shrink down starting from the cutback before moving towards the oversheath.
Using plastic tape or poly bags, cover the single core cables beyond the red BPTM tubes and park the black and red insulation tubes over them. Cover the tubes to protect them from dust or moisture splashes.
Note: If the insulating tubes are a tight fit over the red BPTM tubing, lubricate the tubing with a smear of silicone grease from the sachet provided.
15 U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 35 19 holding tool Bring the two halves of the connector together and insert the centre fixing bolt. Finger tighten the centre fixing bolt to join two V shapes together. Hold the connector with the recommended connector holding tool and tighten the two shear head bolts sequentially until they shear off. Hold the connector with the recommended connector holding tool and tighten the centre fixing bolt until it shears off.
Repeat this procedure for all connectors. holding tool 20 Clean and degrease the ends of the red insulating tubing and the connector. Remove one release paper from the yellow mastic patch and wrap it around the connector. Apply the patch centrally over the connector, taking care to exclude air voids as it is applied. Ensure the patch seam is located over the bolts of the mechanical connector. Repeat the procedure on the remaining connectors. Leave the release papers in position until all three patches are in place. 22 Remove the release paper from all three connectors. The surplus yellow patch material extending over the connector ends should be folded back and used to fill up the steps between the core and connector body. 21 yellow mastic Position the red and back screened insulation sleeves centrally over the connectors. Start shrinking the sleeves in the centre. 23 U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 36 50 check a b c d 1 2 3 4 5 24 a. Shrink the sleeves in the centre (1). b. Check if fully shrunk by twisting the sleeve ends. The sleeves should not move from its position. If the sleeve rotates continue shrinking until it locks in place. c. Continue shrinking by working towards one side (2), stopping 50mm from the end. Shrink the other half in the same way (3). d. Shrink down the first end (4) and finally the second (5). The sleeves should be fully shrunk without leaving ridges. Fold the 1050mm length of tinned copper mesh in half for its full length, so that its width is reduced to 30mm. Wrap two layers of the copper mesh around the edge of the support ring. Lay all the copper wires of the single core cables on to the copper mesh. Continue to wrap the copper mesh over the copper wires, clamp the copper mesh and wire down on to the support ring, tap and tighten as the worm drive is tightened, and trim off the excess copper wires. Clean and degrease the space between the cage fingers and the copper mesh. Using the red mastic tape, wrap it in the space on the support ring. 28 Pol ymeric Cables Form the 300mm length of the serrated contact strip into a circle and position it on to the support ring edge, nearest to the body of the joint. Slide the support ring along the cables until the screen fingers cover the full width of the contact strip. Use one worm drive clip only and clamp down the fingers of the screen on to the contact strip. Remove any excess clip length once fully tightened.
Note: Lightly tap the fingers of the aluminium cage while tightening. 27 Metallic Earth Screen Connections Fold the length of tinned copper mesh in half along its length. Wrap the mesh around the lead sheath behind the black cable breakout. Trim the length of contact strip to fit around the sheath and secure. Fit the metallic cage centrally around the joint, apply a temporary tape binder around the centre, ensuring the overlap along the cage length remains equal. Position the cage fingers over the contact strop and secure with the worm drive clip.
Alumi nium Sheaths Discard the tinned copper mesh. Position the serrated strip over two adjacent crests. 26 Pull the cores together so that the black and red screened insulation sleeves are in close contact with each other. Wrap the length of tinned copper mesh around all three sleeves and secure.
Post heat the joint at the crutch positions. 25 U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 37 29 Paper Cable Moisture Seal Clean and degrease the metallic sheath. Wrap the remaining space, approximately 60mm, between the armours and the cage with two half lap layers of red mastic sealant tape. This is an important moisture seal do not leave it out.
c c b b a 30 31 rubber patches Degrease and flamebrush the MDPE oversheaths for a distance of 100mm. Trim the ends of the joint shell halves to accommodate the cable being used. Place the bottom half of the joint shell under the joint and mark the position of the two stand-off mouldings on the earth cage. Wrap a rubber patch around the cage centrally over these marks and secure. The patch should be wrapped with the white adhesive side facing outwards. a. Assemble the joint shells around the joint and clip together. b. Fill any gaps around the cable entry holes as required. Support the joint before filling with resin. c. Fill the joint with the approved resin following the manufacturers instructions and safety data sheet.
U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 38 2.5 Three Core Paper Cable Straight Joints (PICAS and PILC) The tables below detail the joint kits required to complete this joint for the cable sizes listed. Any jointing requirements for cable sizes not shown on this table shall be referred to one of the UK Power Networks J ointing Schools. 2.5.1 EPN PILC to PILC Straight J oints 2.5.2 LPN/SPN PILC to PILC Straight J oints Cable Sizes mm 2 J oint Kit Description and Part Numbers PILC/PICAS Straight J oint 95-185mm 2 PILC/PICAS Straight J oint 240-300mm 2 PILC Build Up Kit 16-70mm 2 Tyco Part No. SMOE 63417 SMOE 63418 SMOE 63429 Stores Code 04131L 04132V 04125R 16 70 16 70 1 2 70 95 1 1 95 185 95 185 1 185 300 240 300 1 Resin Volume 12.0 Litres 25.0 Litres Cable Sizes mm 2 J oint Kit Description and Part Numbers PILC/PICAS Straight J oint 95-185mm 2 PILC/PICAS Straight J oint 240-300mm 2 13.1kA Earth Kit PILC Build Up Kit 16-70mm 2 Tyco Part No. SMOE 63417 SMOE 63418 SMOE 63414 SMOE 63429 Stores Code 04131L 04132V 04124G 04125R 70 70 1 2 70 95 1 1 95 95 1 95 120 1 1 120 185 120 185 1 2 185 300 240 300 1 2 Resin Volume 12.0 Litres 25.0 Litres U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 39 2.5.3 SPN PICAS to PICAS Straight J oints 2.5.4 Cable Preparation Refer to the following sections of this manual for the preparation of each cable type: 3.4 PICAS Paper Insulated Corrugated Aluminium Sheathed Cables. 3.5 PILC Paper Insulated Lead Sheathed Cables. 2.5.5 Installing Heatshrink Materials and Components Refer to the following sections of this manual for the installation of heatshrink materials and other components: 4.1 Installing Stress Control and Insulation Materials. 4.1.1 Belted Paper Cables. 4.1.2 Build-Up Kits for Small Section Paper Cables. 4.1.3 Screened Paper Cables. 4.2 Installing Mechanical Connectors and Lugs. 4.2.2 Three Core Transition and Three Core PICAS/PILC. 4.3 Installing Connector Stress Control and Heatshrink Insulation. 4.3.2 Transition and Paper to Paper Straight J oints. 4.5 Installing Mechanical Earth Bonds and Associated Components. 4.5.6 PICAS Earth. 4.5.7 13kA PILC Earth Kit Steel Wire Armoured Cables. 4.5.8 13kA PILC Earth Kit Steel Tape Armoured Cables. 4.5.9 Installing Aluminium Cages. 4.6 Fitting Plastic J oint Boxes. 4.7 Mixing and Installing Polyurethane Resin. Cable Sizes mm 2 J oint Kit Description and Part Numbers PILC/PICAS Straight J oint 95-185mm 2 PILC/PICAS Straight J oint 240-300mm 2 Tyco Part No. SMOE 63417 SMOE 63418 Stores Code 04131L 04132V 95 95 185 1 95 300 1 185 185 1 185 300 300 1 Resin Volume 12.0 Litres 25.0 Litres U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 40 Instal lati on Instruction
11kV PILC / PICAS Strai ght Joint
For Cable Sizes 95-185mm SMOE 63417 UK Power Networks Stores Code = 04131L For Cable Sizes 240-300mm SMOE 63418 UK Power Networks Stores Code = 04132V
U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 41 Cable Preparation
Overlap the cables to be jointed by approximately 300mm. Mark the centre of the overlap as a reference line.
Remove the oversheath and armour to the dimensions shown in Tables 1-3 depending on the cable types.
Clean, degrease and abrade the metal sheaths before the cores are exposed.
Corrugated aluminium sheaths should be cut at the top of a corrugation.
13kA Earth Clips wi ll be required for PILC cables in the LPN and SPN Areas - SMOE 63425 (SAP Code 04124G) 300 reference line Paper Cable with Armour belt paper / fabric tape metal sheath wire armour oversheath reference line c a 180 20 60 d b 180 20 60 120 120 Table 1 Conductor Size Stripping Dimensi ons (mm) (mm 2 ) a b c d 95 - 185 630 480 450 300 185 - 300 780 530 600 350 U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 42 Paper Cable without Armour reference line Armoured to Unarmoured Paper Cable reference line belt paper / fabric tape metal sheath oversheath belt paper / fabric tape metal sheath wire armour oversheath 120 e c b 180 20 60 20 120 d belt paper / fabric tape metal sheath oversheath c e 120 f d 20 20 120 The 13kA earth clip must be install ed at this point before proceeding with the joint install ation. Table 2 Conductor Size Stripping Dimensi ons (mm) (mm 2 ) c d e f 95 - 185 450 300 570 420 185 - 300 600 350 620 470 Table 3 Conductor Size Stripping Dimensi ons (mm) (mm 2 ) c d e f 95 - 185 450 300 570 420 185 - 300 600 350 620 470 U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 43 1b 180 reference line 20 20 10 2 50 3 4 formed yellow wedge 1a 20 tape binder 5 Belted Cables Tie a twine binder around the carbon paper 5mm from the end of the lead sheath and tear the layers of paper off against. Tie a second twine binder around the belt papers 20mm from the end of the metal sheath and tear off the belt papers against it. Remove the fillers level with the belt papers. Secure the paper insulation at the end of each core using PVC tape. Using a clean, dry cloth, remove any excess cable compound from the cores. Screened Cables Unwind the copper woven fabric tape and remove the fillers. Rewind the tape around the crutch of the cable and tie it off 20mm from the end of the metal sheath. Tie a twine binder around the screen papers at the dimension given in the Figure 1B. Tear off the screen papers level with the twine binder. Remove the top two paper tapes to the same position as the screen papers. Using a clean, dry cloth, remove any excess cable compound from around the cores.
Screened Cables Onl y Cut a 50mm long piece from the yellow void filling mastic tape as shown in Figure 5. Remove the twine binder from the end of the screen papers. Wrap the yellow mastic around the screen papers starting 20mm from the end of the screen and continuing onto the insulation for 10mm. Stretch the mastic to half its original width and apply under tension to achieve a fine thin edge. Note: The yellow mastic should be applied in the same direction as the lay of the screen papers. Slide the red insulating tubes over the cores on each cable end, pushing then well down into the crutch.
Shrink the tubes, starting from the crutch and working towards the core ends. Ensure that the tubes are shrunk down evenly and are free from air or grease pockets.
For cable sizes below those shown in Table 1, the core tubes should be substituted for those in the build-up kit.
Cut a 50mm long piece of the yellow void filling mastic, remove the release paper and roll it up to form a wedge. Push the formed mastic wedge carefully into the crutch until the tip is just below the belt paper or fabric tape. The wedge will deform and partly extrude between the cores. U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 44 5 20 20 6 7 red/black insulation sleeve I reference line 8 reference line shear head bolts shear head bolts holding tool 9 Clean and degrease the exposed metal sheath. Remove one release paper from the yellow mastic strip. Wrap the mastic strip around the crutch of the cable overlapping the metal sheath by 20mm and continue onto the red insulating tubings for 20mm. Wrap the remaining strip of yellow mastic over the first. Position the red crutch sealing sleeve centrally over the yellow mastic strips. Shrink the sleeve starting from the metal sheath. Completion of Joint Set the cores into their final jointing position, cores should only be crossed on the long side of the joint. Cut the cores to length allowing for the length of the centre block in the mechanical connectors. Remove the insulation for the depth of the connector barrel I. Slide one red/black screened insulating sleeve over each core on the long side of the joint. Connector Installation Reset the cores into their final jointing position. Check that conductors have been cut to allow for the moisture block in the centre of the connector.
Screw the shear head bolts into the connector body until the tip is level with the inside surface of the connector.
Note: The bolts should not be removed once they have been screwed into the connector. Position the connector on short side of the joint and tighten the Shear Head Bolts finger tight. The connectors should be positioned with the bolt heads facing away from the centre of the joint.
Note: Do not remove the centre fixing bolt at this time.
Hold the connector with the recommended holding tool and tighten the two Shear Head Bolts sequentially until they shear off. U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 45 10 holding tool holding tool 11 12 13 14 yellow mastic patch Remove the centre fixing bolt and position the other half of the connector onto the corresponding core on the long side of the joint. At this time do not tighten the Shear Head Bolts. Bring the two halves of the connector together and insert the centre fixing bolt. Finger tighten the centre fixing bolt allowing the two V shapes to nest together. Hold the connector with the recommended holding tool and tighten the two Shear Head Bolts sequentially until they shear off. Hold the connector with the recommended holding tool and tighten the centre fixing bolt until it shears off.
Repeat this procedure for all connectors. Clean and degrease the ends of the red insulating tubing in the connector area and the connector. Remove one release paper from the yellow mastic patch and wrap it around the connector. Apply the patch centrally over the connector, taking care to exclude air voids as it is wrapped. Check that the patch seam is located over the bolts of the mechanical connector. Repeat the procedure on the remaining connectors. Leave the release paper in position until all three are completed. Remove the release paper from over all three connectors. The surplus yellow patch material extending over the connector ends should be folded back and used to fill up the steps between the core and connector body. U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 46 15 16 17 18 contact strip 19 red mastic tape 10mm edge of contact strip Position the red and black screened insulation sleeves centrally over the connectors. Start shrinking the sleeves in the centre. a. Shrink the sleeves in the centre (1). b. Check if fully shrunk by twisting the sleeve ends. The sleeve should not move from its position. If the sleeve rotates continue shrinking until it locks in place. c. Continue shrinking by working towards one side (2), stopping 50mm from the end. Shrink the other half in the same way (3). d. Shrink down the first end (4) and finally the second (5). The sleeves should be fully shrunk without leaving ridges. Pull the cores together so that the red/black screened insulation sleeves are in close contact with each other. Wrap the length of tinned copper mesh around all three sleeves and secure.
Post heat the joint at the crutch positions. Earth Cage Installation
Alumi nium Sheathed Cables Cut the serrated contact strip into two and form piece into a circle. Place each piece around the aluminium sheath bridging the crests of two of the sheath corrugations. Note: Ensure the contact strip ends do not overlap. Check that a 10mm gap is maintained between edges.
Armoured Cables The contact strip should be positioned over the ends of the wraparound copper sheet. Alumi nium Sheathed Cables Clean and degrease the exposed aluminium sheath. Starting 10mm over the end of the outer cable sheath apply one half lapped layer of the red mastic tape over the end of the cable sheath and the exposed aluminium sheath, up to the edge of the contact strip.
Note: Do not tape over the contact strip. U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 47 22 rubber patches 20 worm drive clips tape binder tape binder Worm drive drive clips 21 red mastic sealant strip 24 23 Clean, degrease and abrade the outer cable sheath for a distance of 100mm on each side of the joint. Position the earth cage around the joint, taking care to space the fingers equally over the previously installed contact strips. Apply a temporary tape binder around the cage to hold it in position and clamp the earth cage at each end with worm drive clips provided. Armoured Cables Wrap the remaining space between the ends of the rmours and the fingers of the earthing cage with two half lapped layers of the red mastic sealant strip.
Note: This is an important moisture seal do not leave it out. Trim the ends of the joint half shells to accommodate the cable being used. Place the bottom half of the joint shell under the joint and mark the position of the two joint shell stand-off mouldings on the earth cage. Wrap a rubber patch around the cage centrally over these marks and secure. The patch should be wrapped with the white adhesive side facing outwards. . Assemble the joint shells around the joint and clip Together (a). . Fill any gaps around the cable entry holes as required. Support the joint before filling with resin (b). . Fill the joint with the approved resin following the manufacturers instructions and safety data sheet (c). The joint is now complete. Allow the resin to set before applying any mechanical strain. U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 48 2.6 Three Core Paper Cable Vertical Straight Joints (PILC) The table below details the joint kits required to complete this joint for the cable sizes listed. Any jointing requirements for cable sizes not shown on this table shall be referred to one of the UK Power Networks J ointing Schools. 2.6.1 EPN/LPN/SPN Vertical Straight J oints (PILC) 2.6.2 Cable Preparation Refer to the following sections of this manual for the preparation of each cable type: 3.1 Single Core Copper Wire Screened Polymeric Cables. 3.5 PILC Paper Insulated Lead Sheathed Cables. 2.6.3 Installing Heatshrink Materials and Components. Refer to the following sections of this manual for the installation of heatshrink materials and other components: 4.1 Installing Stress Control and Insulation Materials. 4.1.1 Belted Paper Cables. 4.1.2 Build-Up Kits for Small Section Paper Cables. 4.1.3 Screened Paper Cables. 4.1.4 Single Core Polymeric Cables in Single and Triplex Straight/Branch J oints. 4.2 Installing Mechanical Connectors and Lugs. 4.2.1 Single Core and Triplex Straight J oints. 4.3 Installing Connector Stress Control and Heatshrink Insulation. 4.3.2 Transition and Paper to Paper Straight J oints. Cable Sizes mm 2 J oint Description and Part Numbers Vertical Transition Straight J oint 120-300mm 2 PILC Build-Up Kit 70mm 2 PILC Build-Up Kit 95mm 2 Tyco Part No. SMOE 63410 SMOE 63411 SMOE 63429 Stores Code 04126B 04127L 04128V PILC POLY 70 185 300 1 per J oint 1 per J oint 95 185 300 1 per J oint 1 per J oint 120 300 185 300 1 per J oint U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 49 Instal lati on Instruction
Vertical Transition Joint for -Core PILC to 3 x 1 Core Flame Retardant Pol ymeric 11kV Cables
For Cable sizes 120-300mm 2
SMOE-62667 UK Power Networks Stores Code 04126B For smaller PILC Cables use the following additional ki ts: 70mm 2 SMOE 62900 UK Power Networks Stores Code 04127L 95mm 2 SMOE 62901 UK Power Networks Stores 04128V BEFORE JOINTING CHECK THAT YOU HAVE THE CORRECT KIT OR KITS REQUIRED FOR THE SIZE OF THE CABLES TO BE JOINTED U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 50 wire binder Preparation of Cables
Cut the paper cable to length, allowing an extra 50mm for core setting.
Overlap the cables as shown in the drawing, ensuring the polymeric cables overlap the paper cable by 100mm. Paper Cable Preparation
Remove the oversheath, armour and bedding according to the dimensions shown in the drawing.
Pol ymeric Cable Paper Cabl e Wrap a wire binder around the armour wires level with end of the oversheath.
Mark a line on the lead sheath 200mm from the wire binder.
Note: The lead sheath will be removed at this mark.
Clean the wire armours and lift them vertically. Thoroughly clean the metal sheath.
100 5 80 20 120 380 50 550 oversheath SWA armour lead sheath carbon paper bel t paper Insulation papers reference l ine 200 1 U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 51 IMPORTANT Separate the cores carefull y so as not to damage the bel t or core i nsulation papers. Slide the oil barrier tubing over the cores and position them 50mm from the end of the belt papers. Shrink down the oil barrier tubing starting at the crutch. Shrink down the first 30mm of the tubing, twisting the tubing around the core to ensure the tubing is fully shrunk. When all three tubes are fully shrunk, push the tubes into the crutch butting them as close to the belt papers as possible. Continue to shrink all three tubes working towards the core ends. Wrap the second roll of tinned copper mesh (EPPA-009-1050) over the three copper earth braids inline with the end of the wire armour.
Fill the gap between the lifted armours and the mesh with layer of black mastic. Mark a line on the lead sheath 80mm from the end of the cable sheath (inline with the end of the wire armour). Wrap one of the rolls of tinned copper mesh (EPPA-009-1050) around the lead sheath level with the mark. Lay the three earth braids over the tinned copper mesh. Position them at 9, 12 and 3 clock.
Note: Check that the solder blocks in the earth braids sit over the lead sheath close to the armours. Lay the wire armours back over the lead sheath, earth braids and copper mesh and black mastic. Secure the armours with the wire drive clip.
For PILC Cable sizes of 70mm 2 use SMOE 62900 (SAP Code 04127L) and for 95mm 2 use SMOE 62901 (SAP Code 04128V) Substitute the armour clamp provided in the main joint kit with the smaller clamp provided in the build up kit. Fold the three copper earth braids back over the cable and temporarily secure with tape. Remove the metal sheath at the position marked in step 1, in such a way that a slight bell is formed. Tie a twine binder around the carbon paper (if any) 5mm from the end of the lead sheath. Tear off the carbon paper level with the twine binder. Tie a twine binder around the belt papers 20mm from the end of the lead sheath. Tear off the belt papers level with the twine binder. Remove the fillers level with belt papers. Protect the belt papers with PVC tape before setting the cores. Start taping 20mm onto the lead sheath and continue over the belt papers. Apply the tape under tension. 6 copper mesh (EPPA-009-1050) 3 2 80 copper earth braids copper mesh (EPPA-009-1050) 4 Worm drive clip 5 end of lead sheath 20 5 protection tape oil barrier tubing black mastic tape U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 52 Slide the conductive tubes (CNTM) over the cores and position them 150mm in from the reference line. Shrink the tubes starting from the reference line working, before working towards the cable crutch.
For PILC Cable sizes of 70mm 2 use SMOE 62900 (SAP Code 04127L) Substitute the conductive tubes provided in the main joint kit with the smaller conductive tubes provided in the build up kit. Insert the yellow void filling wedge into the crutch of the cable. Push the wedge into the crutch until the tip is level with end of the belt papers.
Note: Remove the protection tape after inserting the yellow void filling wedge. Remove the release paper from the long yellow void filling astic strip and roll up the mastic. Apply the void filling mastic with a 50% overlap, stretching it to about half its original width and applying it under tension. Overlap the lead sheath by 20mm and continue over the conductive tubing for a distance of 10mm. Apply the second and third strip over the first forming a cone shape. Clean and degrease the lead sheath and conductive tubing. Pass the conductive cable breakout over the cores and pull it well down into the cable crutch. Shrink the breakout into place starting at the centre (1), work first towards the lead sheath (2), then shrink the turrets onto the cores (3). The numbers in the drawing indicate the shrink sequence.
Note: Post heat the breakout to ensure all expansion lines have disappeared.
For PILC Cable sizes 70mm 2 use SMOE 62900 (SAP Code 04127L) Substitute the conductive breakout provided in the main joint kit with the small conductive breakout provided in the build up kit. Set the cores into their final joint position. Cut the cores to length allowing for the centre block in the mechanical connector. Remove the insulation papers and clear oil barrier tubing for a distance of: I = the depth of connector barrel plus 5mm.
CNTM CNTM CNTM 8 10 7 reference line 150 mm CNTM CNTM CNTM yellow void filling wedge protection tape 9 10 20 Yellow void filling mastic 11 conductive cable breakout 1. 2. 3. reference line. U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 53 Remove the release paper from the short angled strips of yellow void filling mastic. Wrap the mastic around the end of the conductive tubing covering it by 10mm and 10mm of the clear oil barrier tubing. Stretch the mastic to half its original width and apply under tension to achieve a fine thin edge onto the clear barrier tubing. Position the black stress control tubing (J SCR) over the cores so that the end of the tube is approximately 2mm from the end of the insulation cut. Shrink the tube starting from the core end working towards the cable crutch. Clean and degrease the cable breakout turrets and conductive tubing. Position the short black sealing sleeves (MWTM) over the cores and onto the turrets of the cable breakout. Shrink the sleeves starting from the cable breakout working along the cores. Note: The sleeves are coated with an adhesive sealant. During shrinking the sleeves will begin to slide along the turrets of the breakout, so it is advised that a low flame is used during installation of these tubes. Preparation of paper cable complete. For PILC Cable sizes of 70mm 2 use SMOE 62900 (SAP Code 04127L) or for 95mm 2 use SMOE 62901 (SAP Code 04128V) Install an additional stress control tube directly over the previously installed stress control tube. Shrink the tubes starting from the core end working towards the crutch. 12 15 16 10 10 13 2mm J SCR J SCR J SCR MWTM MW TM M W TM
sealing sleeves yellow void filling mastic 14 2mm J SCR J SCR J SCR U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 54 Cut the cores to length allowing for the thickness of the moisture block in the centre of the connector.
Remove the semi-con core screen up to the position marked in the previous step.
Note: Do not nick the insulation. Remove the insulation to the depth of the connector (I). There should be no gap left between the connector and the insulation.
Clean and degrease the insulation.
Remove the release paper from the short angled strips of yellow void filling mastic. Wrap the mastic around the end of the semi-con, covering 10mm of the semi-con and 10mm of the insulation. Stretch the mastic to half its original width an apply under tension to achieve a fine thin edge onto the insulation. Mark a line on the semi-conductive screen 30mm from the edge of the yellow void filling mastic. Wrap one turn of the red (S1085) mastic sealant around the cable screen level with this mark. Position the stress control tubing (J SCR) over the polymeric cables, so that the tube is 2mm from the end of the insulation cut. Shrink the tubes starting from the insulation cut. Pol ymeric Cable Preparation Fold the copper wires back over the cable jackets and temporary secure with tape.
Mark the reference line (centre of joint) on the single-core cables, 220mm from the end of the cable jacket.
Mark the semi-conductive core screen removal position 150mm from the reference line. 18 19 20 21 17 150 70 220 semi-con removal position 70 150 reference line yellow void filling mastic 10 10
yellow void filling mastic red sealant mastic 30 J SCR 2 mm U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 55 Installation of the mechanical connector The connector is supplied with insert half shells which have to be used on small cross section cables. Check before installation if the conductor can be inserted into the connector with the half shells installed. Remove the inserts from the connector if the conductor does not fit into the connector. Fit the conductors into the connector. There should be no gap left between the connector and the insulation. Take up the tension equally on all bolts (do not shear bolt heads at this stage). Starting at the connector ends, tighten the bolts until the heads shear off. In the case of a proud edge showing after removal of the bolts, this edge should be removed with a suited tool. Re-align cables if necessary. Note: For small cross section cables use a connector holding tool to support the connector as you shear off the bolts. Remove any sharp edges from the connector. Clean and degrease the connector.
From the centre of the connector, mark a line 180mm on the stress control tubing (J SCR). Wrap one turn of the red mastic sealant (S1085) around each stress control tubing with the outside edge level with the mark.
Slide the large cable breakout over the three single core polymeric cables. Ensure the fingers of the cable breakout face away from joint.
Position the cable breakout away from the jointing area. Slide the three black and red (ECIT) screened insulation sleeves over the single core cables and position them away from the jointing area. 24 25 26 red sealant mastic (S1085) 180 180 centre of connector JSCR JSCR insert shells 22 23 cable breakout JSCR JSCR JSCR JSCR JSCR JSCR ECIT ECIT ECIT U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 56 29 30 31 screened insulation tubes ECIT Copper mesh EPPA 009-4000 50 end of cable breakout mastic folded back JSCR JSCR 27 Yellow stress control patch Position the black and red screened (ECIT) insulation tubes centrally over connectors. Start shrinking the tubes in the centre. a. Continue shrinking the tubes in the centre. b. Before moving towards the ends, check that the tubes are fully shrunk by twisting one end. If the tube rotates apply more heat. When the tube is locked in place continue shrinking towards one end. c. Continue shrinking towards one of the ends, stopping approximately 50mm from the end. d. Shrink the other half of the tube in the same way, stopping 50mm from the end. Move back to the first end and shrink the remaining 50mm. Finally, shrink the remaining 50mm on the other end of the joint. The tubes should be fully shrunk, leaving no ridges. Relay the cores and pull them together. Starting 50mm in from the end of the cable breakout wrap one layer of the tinned copper mesh (EPPA 009-4000) with a 50% overlap over the joint continuing up to the ends of the cable jackets of the single core cables.
Note: Ensure the tinned copper mesh is wrapped around the exposed semi-conductive layer of the single core polymeric cables. The surplus patch material extending over the stress control tubing ends should be folded back and used to fill up the steps between the core and connector body. 28 Remove the release paper from the yellow stress control patch and wrap it around the connector. Apply the patch centrally over the connector, ensuring the patch overlap is located over the bolt heads.
For PILC Cable sizes of 70mm 2 use SMOE 62900 (SAP Code 04127L) or for 95mm 2 use SMOE 62901(SAP Code 04128V) Using the yellow void filling strips taken from the build up kit, apply the tape around the paper core forming a smooth profile up onto the end of the connector. U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 57 Lay the three earth braids back over the joint and connect them to the three conductors formed from the wire shields with the mechanical tunnel connectors. Secure the three copper earth braids to the lead sheath with the large constant force roll spring. Secure the roll spring with four turns of PVC tape.
Form the copper wires of the single core cables into single conductors and lay them back over the joint.
Wrap two to three turns of the tinned copper mesh (EPPA 009-650) around the exposed lead sheath between the end of the armours and cable breakout skirt. 33 34 35 tunnel connector constant force roll spring PVC tape 32 formed conductors tinned copper mesh EPPA 009-650 U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 58 Position the wraparound joint sleeve centrally over the joint. Pass the retention clip over the rails of the wraparound to keep it in place. Push the metal channels over the rails of the wraparound. The ends of the metal channels should butt up and equally overlap the retention clips. After all channels have been pushed on they should overlap the ends of the wraparound equally. retention clip metal channel 39 Always wear suitable protective gloves to protect your hands against loose glass fibres. Position the coated fibre glass blanket centrally over the joint with its long dimension along the cable axis and the grey coating facing inwards (detail a). Wrap the blanket tightly around the joint and secure it in place. Starting in the centre section of the joint, using the tinned copper mesh. Work towards each end of the joint, folding the blanket to fit closely to the joint shape and secure in place with tinned copper mesh. Wrap one layer of the tinned copper mesh (EPPA 009-4000) with a 50% overlap across the joint, starting from the constant force spring continuing up to the cable jackets of the single core cables.
Wrap two layers of black mastic sealant around the armours behind the worm drive clip over the previously installed black mastic. Clean, degrease and abrade the single core cable jackets for a distance of 75mm from the ends of the cable jacket cut.
Position the cable breakout over the joint, pulling the skirt as far as possible over the joint.
Shrink the breakout starting at the fingers, before working towards the joint. 36 tinned copper mesh EPPA 009-4000 38 cable breakout 37 a black mastic sealant U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 59 Shrink the wraparound sleeve into place starting at the middle of the joint. When the colour of the paint on the wraparound has completely changed to black, progressively move towards the ends of the sleeve.
Note: Extra heat is required on the metal channel. Heat until the white marking line can be seen under the channels. Joint complete.
Allow the joint to cool before applying any mechanical strain.
Note: If the joint is installed in any position other than horizontal the cable should be supported by stand off brackets and cable cleats. On completion fix the fire resi stant information label onto the joint wraparound. 42 40 41 White marking line ire rest i at n klh al sdf asl kfjlaj fj fsdfsdf sdfsdf ffffffff asdf ffffff fffff sdfasdf asdfasdf asdfasd sd asdfasd U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 60 2.7 Three Core Transition and Polymeric to Polymeric Branch Joints The tables below detail the joint kits required to complete this joint for the cable sizes listed. Any jointing requirements for cable sizes not shown on this table shall be referred to one of the UK Power Networks J ointing Schools. 2.7.1 EPN PILC Main with Triplex or Single Core Polymeric CWS Branch J oints 2.7.2 EPN PILC Main to Polylam Branch J oints Cable Sizes mm 2 J oint Description and Part Numbers Three Core Transition Branch J oint 95-185mm 2 Three Core Transition Branch J oint 240-300mm 2 PILC Build-Up Kit 16-70mm 2 Tyco Part No. SMOE 63412 SMOE 63413 SMOE 63429 Stores Code 04122M 04123W 04125R Main Branch 16 70 95 1 per J oint 2 per J oint 95 120 95 1 per J oint 120 150 95 185 1 per J oint 150 240 300 1 per J oint 185 95 185 1 per J oint 185 300 95 300 1 per J oint Resin Volume 36.0 Litres 45.0 Litres Cable Sizes mm 2 J oint Description and Part Numbers Three Core Transition Branch J oint 95-185mm 2 Three Core Transition Branch J oint 240-300mm 2 PILC Build-Up Kit 16-70mm 2 Polylam Earth Kit Tyco Part No. SMOE 63412 SMOE 63413 SMOE 63429 SMOE 63409 Stores Code 04122M 04123W 04125R 04108D Main Branch 16 70 150 1 per J oint 2 per J oint 1 per J oint 95 185 150 1 per J oint 1 per J oint 16 70 240 1 per J oint 2 per J oint 1 per J oint 95 300 240 1 per J oint 1 per J oint Resin Volume 36.0 Litres 45.0 Litres U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 61 2.7.3 LPN/SPN PILC Main with Triplex or Single Core Polymeric CWS Branch J oints 2.7.4 SPN PICAS Main with Triplex Branch J oints Cable Sizes mm 2 J oint Description and Part Numbers Three Core Transition Branch J oint 95-185mm 2 Three Core Transition Branch J oint 240-300mm 2 13.1kA Earth Kit PILC Build-Up Kit 16-70mm 2 Tyco Part No. SMOE 63412 SMOE 63413 SMOE 63414 SMOE 63429 Stores Code 04122M 04123W 04124G 04125R Main Branch 16-70 95 1 per J oint 2 per J oint 95 95 1 per J oint 120 95 185 1 per J oint 2 per J oint 120 240 300 1 per J oint 2 per J oint 150 95 185 1 per J oint 2 per J oint 150 240 300 1 per J oint 2 per J oint 185 95 185 1 per J oint 2 per J oint 185 240 300 1 per J oint 2 per J oint 240 95 300 1 per J oint 2 per J oint Resin Volume 36.0 Litres 45.0 Litres Cable Sizes mm 2 J oint Kit Description and Part Numbers Three Core Transition Branch J oint 95-185mm 2 Three Core Transition Branch J oint 240-300mm 2 Tyco Part No. SMOE 63412 SMOE 63413 Stores Code 04122M 04123W PICAS Triplex 95 95 1 per J oint 95 185 1 per J oint 95 300 1 per J oint 185 185 1 per J oint 185 300 1 per J oint 300 300 1 per J oint Resin Volume 36.0 Litres 45.0 Litres U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 62 2.7.5 EPN Triplex or Single Core Polymeric CWS Main PILC Branch J oint 2.7.6 EPN Polylam Main PILC Branch J oints Cable Sizes mm 2 J oint Description and Part Numbers Three Core Transition Branch J oint 95-185mm 2 Three Core Transition Branch J oint 240-300mm 2 PILC Build Up Kit 16-70mm 2 Polymeric Preparation Kit 95- 150mm 2 Polymeric Preparation Kit 185- 300mm 2 Tyco Part No. SMOE 63412 SMOE 63413 SMOE 63429 SMOE 63415 SMOE 63416 Stores Code 04122M 04123W 04125R 04129F 01430B Poly Main PILC Branch 95 16 70 1 per J oint 1 per J oint 1 per J oint 95 95 150 1 per J oint 1 per J oint 95 185 1 per J oint 1 per J oint 95 240 300 1 per J oint 1 per J oint 150 16 70 1 per J oint 1 per J oint 1 per J oint 150 95 185 1 per J oint 1 per J oint 150 240 300 1 per J oint 1 per J oint 185 16 70 1 per J oint 1 per J oint 185 95 150 1 per J oint 185 185 1 per J oint 1 per J oint 185 240 300 1 per J oint 1 per J oint 240 16 70 1 per J oint 1 per J oint 1 per J oint 240 95 300 1 per J oint 1 per J oint 300 16 70 1 per J oint 1 per J oint 1 per J oint 300 95 300 1 per J oint 1 per J oint Resin Volume 36.0 Litres 45.0 Litres Cable Sizes mm 2 J oint Description and Part Numbers Three Core Transition Branch J oint 95-185mm 2 Three Core Transition Branch J oint 240-300mm 2 PILC Build Up Kit 16- 70mm 2 Polylam Earth Kit Polymeric Preparation Kit 95- 150mm 2 Polymeric Preparation Kit 185- 300mm 2 Tyco Part No. SMOE 63412 SMOE 63413 SMOE 63429 SMOE 63409 SMOE 63415 SMOE 63416 Stores Code 04122M 04123W 04125R 04108D 04129F 01430B Main Branch 150 16 70 1 per J oint 1 per J oint 2 per J oint 1 per J oint 150 95 185 1 per J oint 2 per J oint 1 per J oint 240 16 70 1 per J oint 1 per J oint 2 per J oint 1 per J oint 240 95 300 1 per J oint 2 per J oint 1 per J oint Resin Volume 36.0 Litres 45.0 Litres U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 63 Cable Sizes mm 2 J oint Description and Part Numbers Three Core Transition Branch J oint 95-185mm 2 Three Core Transition Branch J oint 240-300mm 2 PILC Build Up Kit 16- 70mm 2 13kA Earth Clip Polymeric Preparation Kit 95- 150mm 2 Polymeric Preparation Kit 185- 300mm 2 Tyco Part No. SMOE 63412 SMOE 63413 SMOE 63429 SMOE 63414 SMOE 63415 SMOE 63416 Stores Code 04122M 04123W 04125R 04124G 04129F 01430B Main Branch 95 19 70 1 per J oint 1 per J oint 1 per J oint 95 95 1 per J oint 1 per J oint 95 120 300 1 per J oint 1 per J oint 1 per J oint 185 16 35 1 per J oint 1 per J oint 1 per J oint 1 per J oint 185 70 1 per J oint 1 per J oint 1 per J oint 185 95 1 per J oint 1 per J oint 185 120 185 1 per J oint 1 per J oint 1 per J oint 185 240 300 1 per J oint 1 per J oint 1 per J oint 240 16 70 1 per J oint 1 per J oint 1 per J oint 240 95 1 per J oint 1 per J oint 240 120 300 1 per J oint 1 per J oint 1 per J oint 300 16 95 1 per J oint 1 per J oint 300 120 300 1 per J oint 1 per J oint 1 per J oint Resin Volume 36.0 Litres 45.0 Litres 2.7.7 LPN/SPN Triplex or Single Core Polymeric CWS Main PILC Branch J oint U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 64 2.7.8 SPN Triplex Polymeric Main PICAS Branch J oints 2.7.9 Triplex or Single Core Polymeric Main with a Triplex or Single Core Polymeric Branch J oints Cable Sizes mm 2 J oint Description and Part Numbers Three Core Transition Branch J oint 95-185mm 2 Three Core Transition Branch J oint 240-300mm 2 Polymeric Preparation Kit 95-150mm 2 Polymeric Preparation Kit 185-300mm 2 Tyco Part No. SMOE 63412 SMOE 63413 SMOE 63415 SMOE 63416 Stores Code 04122M 04123W 04129F 04130B Triplex Main PICAS Branch 95 95 1 per J oint 1 per J oint 95 185 1 per J oint 1 per J oint 95 300 1 per J oint 1 per J oint 185 185 1 per J oint 1 per J oint 185 300 1 per J oint 1 per J oint 300 300 1 per J oint 1 per J oint Resin Volume 36.0 Litres 45.0 Litres Cable Sizes mm 2 J oint Description and Part Numbers Three Core Transition Branch J oint 95-185mm 2 Three Core Transition Branch J oint 240-300mm 2 Polymeric Preparation Kit 95-150mm 2 Polymeric Preparation Kit 185-300mm 2 Tyco Part No. SMOE 63412 SMOE 63413 SMOE 63415 SMOE 63416 Stores Code 04122M 04123W 04129F 04130B Triplex Main PICAS Branch 70 95 95 185 1 per J oint 2 per J oint 70 95 240 300 1 per J oint 2 per J oint 185 70 185 1 per J oint 2 per J oint 185 300 185 300 1 per J oint 2 per J oint 240 300 70 95 1 per J oint 1 per J oint 1 per J oint Resin Volume 36.0 Litres 45.0 Litres U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 65 2.7.10 EPN Polylam Main with a Polylam Branch J oints 2.7.11 EPN Polylam Main with Triplex or Single Core Polymeric Branch J oints Cable Sizes mm 2 J oint Description and Part Numbers Three Core Transition Branch J oint 95-185mm 2 Three Core Transition Branch J oint 240-300mm 2 Polylam Earth Kit Polymeric Preparation Kit 95- 150mm 2 Polymeric Preparation Kit 185- 300mm 2 Tyco Part No. SMOE 63412 SMOE 63413 SMOE 63409 SMOE 63415 SMOE 63416 Stores Code 04122M 04123W 04108D 04129F 01430B Main Branch 150 150 1 per J oint 3 per J oint 2 per J oint 150 240 1 per J oint 3 per J oint 2 per J oint 240 150 1 per J oint 3 per J oint 1 per J oint 1 per J oint 240 240 1 per J oint 3 per J oint 2 per J oint Resin Volume 36.0 Litres 45.0 Litres Cable Sizes mm 2 J oint Description and Part Numbers Three Core Transition Branch J oint 95-185mm 2 Three Core Transition Branch J oint 240-300mm 2 Polylam Earth Kit Polymeric Preparation Kit 95- 150mm 2 Polymeric Preparation Kit 185- 300mm 2 Tyco Part No. SMOE 63412 SMOE 63413 SMOE 63409 SMOE 63415 SMOE 63416 Stores Code 04122M 04123W 04108D 04129F 01430B Main Branch 150 70 185 1 per J oint 2 per J oint 2 per J oint 150 240 300 1 per J oint 2 per J oint 2 per J oint 240 70 95 1 per J oint 2 per J oint 1 per J oint 1 per J oint 240 185 300 1 per J oint 2 per J oint 2 per J oint Resin Volume 36.0 Litres 45.0 Litres U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 66 2.7.12 EPN Triplex or Single Core Polymeric Main with a Polylam Branch J oints 2.7.13 Cable Preparation Refer to the following sections of this manual for the preparation of each cable type: 3.1 Single Core Copper Wire Screened Polymeric Cables. 3.2 Single Core Polylam Cables. 3.4 PICAS Paper Insulated Corrugated Aluminium Sheathed Cables. 3.5 PILC Paper Insulated Lead Sheathed Cables. Cable Sizes mm 2 J oint Description and Part Numbers Three Core Transition Branch J oint 95-185mm 2 Three Core Transition Branch J oint 240-300mm 2 Polylam Earth Kit Polymeric Preparation Kit 95- 150mm 2 Polymeric Preparation Kit 185- 300mm 2 Tyco Part No. SMOE 63412 SMOE 63413 SMOE 63409 SMOE 63415 SMOE 63416 Stores Code 04122M 04123W 04108D 04129F 01430B Main Branch 70 185 150 1 per J oint 1 per J oint 2 per J oint 240 300 150 1 per J oint 1 per J oint 1 per J oint 1 per J oint 70 95 240 1 per J oint 1 per J oint 2 per J oint 185 300 240 1 per J oint 1 per J oint 2 per J oint Resin Volume 36.0 Litres 45.0 Litres U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 67 2.7.14 Installing Heatshrink Materials and Components Refer to the following sections of this manual for the installation of heatshrink materials and other components: 4.1 Installing Stress Control and Insulation Materials. 4.1.1 Belted Paper Cables. 4.1.2 Build Up Kits for Small Section Paper Cables. 4.1.3 Screened Paper Cables. 4.1.5 Single Core Polymeric Cables in Transitional Straight/Branch J oints. 4.2 Installing Mechanical Connectors and Lugs. 4.2.4 Three Core Transition Branch J oints. 4.3 Installing Connector Stress Control and Heatshrink Insulation. 4.3.4 Three Core Transition Branch J oints. 4.5 Installing Mechanical Earth Bonds and Associated Components. 4.5.4 Triplex Cables into Transition J oints Using a Support Ring. 4.5.5 Standard PILC Steel Wire Armour Cables. 4.5.6 PICAS Earth. 4.5.7 13kA PILC Earth Kit Steel Wire Armoured Cables. 4.5.8 13kA PILC Earth Kit Steel Tape Armoured Cables. 4.5.9 Installing Aluminium Cages. 4.6 Fitting Plastic J oint Boxes. 4.7 Mixing and Installing Polyurethane Resin. U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 68 Instal lati on Instruction
11kV Three-Core Transitional Branch Joint
95-185mm Tyco El ectronics Part No: SMOE 63412 UK Power Networks Stores Code: 04122M 240-300 mm Tyco El ectronics Part No: SMOE 63413 UK Power Networks Stores Code: 04123W
U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 69 reference line Stripping Dimensions Branch Joint with Paper Main with Polymeric Branch using standard kit. Stripping Dimensions for Al ternative joint combinations These will requi re additional cable preparation kits as detail ed in section 2.7 of the UK Power Networks 11kV Jointing Manual belt papers screen papers wire armour reference line oversheath metal sheath belt paper / fabric tape 100 350 600 60 140 PILC PICAS POLYMERIC PILC PICAS 350 600 100 POLYMERIC 140 60 overlap overlap 180 POLYMERIC PILC 180 180 For an all pol ymeric cable joint, replace the PILC cable with a pol ymeric cable stripped to the dimensions below. U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 70 The 13KA earth clip may be requi red. If so omit Steps 1 to 3.
PILC Cable Preparation
Remove the armours according to the dimensions shown on page 68. Stand the armour wires upright and remove all traces of compound from them. Thoroughly clean and abrade the lead sheath for 200mm from the cable armour. 1 Wrap the short length of copper mesh (EPPA-009-850) around the lead sheath so that its edge just protrudes beyond the armour wires when they are laid back down. 2 Relay the wires over the mesh and secure with a worm drive clip. 3 4B IMPORTANT: Separate the cores carefull y so as not to damage the bel t or core i nsulation papers.
Belted Cables Onl y Tie a twine binder around the carbon paper 5mm from the end of the metal sheath and tear off the carbon paper against the twine binder. Tie a twine binder around the belt papers 20mm from the end of the metal sheath and tear off the belt papers level with the twine binder. Remove the fillers level with the belt papers. Secure the paper insulation at the end of each core using a tape binder. Using a clean, dry cloth, remove any excess cable compound from around the cores. Move on to step 5. 4A Screened Cables Onl y Unwind the fabric tape and remove the fillers. Rewind the tape around the crutch of the cable and tie off 20mm from the end of the metal sheath. Tie a twine binder around the screen papers at the dimension given in the drawing. Tear off the screen papers level with the twine binder. Remove the top two paper tapes to the same position as the screen papers. Using a clean, dry cloth, remove any excess cable compound from around the cores.
tape binder 5 20 20 reference line 180 U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 71 Push the yellow mastic wedge carefully into the crutch until the tip is just below the belt paper or fabric tape. The wedge will deform and partly extrude between the cores.
6 Slide the red insulating tubes over the cores on each cable end, pushing them well down into the crutch.
Shrink the tubes, starting from the crutch and working towards the core ends. Ensure that the tubes are shrunk down evenly and are free from air or grease pockets.
For cable sizes below 95mm 2 the core tubes should be substituted for those in the appropriate build up kit.
4C Remove the twine binder from the crutch on belted cables. Remove the release paper from a 400mm yellow mastic void filling tape strip. Wrap the tape around the crutch, overlapping onto the lead sheath by 20mm and continue onto the red insulating tubes for 20mm. Wrap a second strip of the yellow mastic over the first layer.
7 40 20 180 reference li ne 20 5 20 10 50 4D Unwind the fabric tape and remove the fillers. Rewind the tape around the crutch of the cable and tie off 20mm from the end of the metal sheath. Tie a twine binder around the screen papers at the dimen- sion given in the drawing. Tear off the screen papers level with the twine binder. Remove the top two paper tapes to the same position as the screen papers. Using a clean, dry cloth, remove any excess cable compound from around the cores.
Cut a 50mm piece from the yellow mastic void filling tape as shown in the drawing. Remove the twine binder from the end of the screen papers. Wrap the yellow mastic around the screen papers starting 20mm from the end of the screen and continuing onto the insulation for 10mm. Stretch the mastic to half its original width and applied under tension to achieve a fine thin edge. Note: The yellow mastic should be applied in the same direction as the screen papers. U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 72 Position the crutch red sealing sleeve centrally covering the yellow mastic tape. Shrink it into position.
Note: For cable sizes below 95mm 2 the crutch sealing sleeve should be substituted for one in the build up kit. 8 Seal ant Tape Wrap one layer of red sealant tape for 60mm from the sheath cut with slight tension and a one third overlap. 10 Screen Wires Bend back the screen wires onto the red sealant tape ensuring the wires are straight and do not cross. Use a wire binder or cable tie to keep them tight against the red sealant tape.
Semi-Conducting Layer Remove the semi-conducting screen layer from the insulation to the dimension as shown, using the approved tools and methods as applicable. Do not nick the insulation layer.
Moisture Block Wrap one layer of red sealant tape over the previously applied 60mm red tape to sandwich the screen wires giving a moisture block. Continue onto the semi-conducting layer for 15mm. Degrease the insulation.
Stress Relieving Tape Remove one release paper from the short pointed yellow mastic strips. Starting 20mm on the semi-con layer, continue taping on to the insulation foil for 10mm to form a smooth taper. Stretch the tape to half its original width and apply under tension to ensure a fine neat edge. Remove the second release paper during this taping operation. Single-Core Cable Sheath Removal Lay the single core plastic cables in their final jointing position. Mark the reference line and cut to length. Slide the large support ring over all three single core cables. Carefully remove the outer jacket. Thoroughly abrade and degrease the outer cable sheaths for a distance of 200mm from the sheath cut.
IT IS IMPORTANT THAT THIS OPERATION IS CARRIED OUT AT THIS STAGE. DO NOT LEAVE OUT. 9 60 200 11 180 12 60 15 Moisture block Yellow void filling mastic tape 40 U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 73 Core Tubing Position the red core tubing (BPTM-50/20) over the cable to coincide with the red mastic tape. Shrink into place starting at the oversheath end. Strip back the tubing and insulation to suit the depth of the bore of the type of connectors used. Using plastic tape or poly bags, cover the single core cables beyond the red BPTM tubes and park the black and red insulation tubes over them. Cover the tubes to protect against dust or moisture splashes.
Note: If the insulating tubes are a tight fit over the red BPTM tubing, lubricate the tubing with a smear of silicone grease from the sachet provided.
13 Fitting Mechanical Connectors Arrange the core of the branch cable to the core of the main cable and cut to length. Remove the core insulation +5mm. Use the cable ties to bind together each pair of cores on the branch side as close to the crutch as possible. Slide the mechanical connector over the core ends. Position the cable core on the single side of the joint against the connector mark and cut to length. Remove the core insulation +5mm. Slide the connector collar over the core. Place the core end into the open channel. Position the insert over the conductor at the channel position. Slide the collar over the insert, locking the insert to the connector body. 16 Cut each core to length. Remove the conductor insulation to a length equal to the hole depth in the connector +5mm. Note: Allow for the water block in the connector when cutting the cores and insulation. Use the cable ties to bind together each pair of cores on the branch side as close to the crutch as possible. Slide the black and red tubes (2) over each pair of cores on the branch side, taking care not to scratch the inside of the tubing on the exposed conductor. Fit the appropriate bolts in the connector and tighten them up (hand tight) using a 19mm socket. Repeat the same method on the other two connectors. The configuration of the cores and connector positions are shown in the drawing opposite. No other arrangement is allowed. Tighten up each bolt one full turn each time before moving on to the next bolt. Repeat the operation to ensure that all the bolts are evenly tightened. Shear off the bolts at the centre of the connector first and followed by the bolts at each end last. Check that you have all the bolt heads before continuing with the joint, so that none have gone inside any of the tubes. Completion of Joint Position the short (TWJ S) build up sleeves over each core on the single side of the main cable as shown in the drawing. Lay back away from the jointing area.
Note: Where the joints are designed for cables in excess of 185 mm there are two tubes per core. These tubes are of different sizes and can be nested inside each other for easy positioning. 14 1 15 2 2 2 U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 74 2 3 5 1 4 Pull the cores together and wrap the length of tinned copper mesh around all three insulation sleeves in the centre and secure. Remove the cable ties holding the branch cores together. 21 Apply a thin smear of grease over the yellow mastic. Position the three black and red screened insulating sleeves centrally over the connector. Use cable ties to bind together each pair of cores on the branch side. Shrink the tubes starting on the branch side of the connector (1). Shrink to within 50mm of the end (2) and then switch to the single side stopping 50mm from the end (3). Then finish off the first end (4) and then the second end (5). 20 The connectors should be covered with the yellow mastic patches using the following procedure. There are three patches per connector. The first patch is located over the single end of the connector as shown with the overlap located over the bolts area. The two remaining patches should be formed into one long patch by sticking them together, overlapping each other by 50mm. Wrap this long patch around the double end of the connector, with the double 50mm thickness over the bolt area of the connector. 19 Roll up lengthways the wide (S1251) red mastic strips and insert them top and bottom between the parallel cores of the branch side. Firmly press into place butting against the connector edge. Now cut the 600mm piece of yellow void filling mastic into 6x100mm pieces. Remove the release paper from both sides of one piece, fold it in half lengthways and roll up to form a rod shape 50mm long. Position one piece at each end of the connector where the step is at its largest, as shown in the drawing. 18 yellow mastic red mastic patch 2+3 50 patch 1 Position the short (TWJ S) build up sleeve, up to the insulation cut, and shrink down starting at the insulation cut end and continuing towards the cable crutch.
For joints where two sleeves are used, the smaller of the two should be shrunk first. The second sleeve should be then be positioned over the first and shrunk down in a similar manner. 17 1 U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 75 Wrap one piece of the serrated metal contact strip around the copper mesh. Do not overlap the ends of the contact strip.
Corrugated Aluminium Sheaths Fit the serrated strip over two adjacent crests of the aluminium sheath.
23 Using the short length of tinned copper mesh, fold it in half and wrap it around the lead sheath.
Corrugated Aluminium Sheaths Discard the tinned copper mesh. 22 50 Fold the 1050mm length of tinned copper mesh in half for its full length, so that its width is reduced to 30mm. Wrap two layers of the copper mesh around the edge of the support ring, lay all the copper wires of the single core cables on to the copper mesh, continue to wrap the copper mesh over the copper wires. Clamp the copper mesh and wire down on to the support ring, tap and tighten as you go, and trim off the excess copper wires. Clean and degrease the space between the cage fingers and the copper mesh. Apply two half lap layers of red mastic tape to the space on the support ring between the copper wires and the aluminium age. 26 Pol ymeric Cables Form the 300mm length of the serrated contact strip into a circle and position it on to the support ring edge nearest the joint. Slide the support ring along the cables until the screen fingers cover the full width of the contact strip. Use one worm drive clip only and clamp the fingers of the screen down on to the contact strip. Remove any excess clip length once fully tightened. 25 Position the earth cage around the joint, taking care to space the fingers equally over the support ring ends and the cable lead sheath. Apply a temporary tape binder around the cage to hold it in position. On the branch side of the joint, divide the cage fingers equally and shape them so that they lie flat on top of the serrated strip. Clamp the earth cage at each end using the worm drive clips, over the serrated strips. Remove any excess clip length after fully tightening. Note: Lightly tap the fingers of the aluminium cage while tightening. 24 U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 76 Clean and degrease the lead sheath. Using the thin red mastic tape, wrap the remaining space approximately 30mm, between the armours and the cage with two half lap layers. Note: This tape is important as it provides a major moisture seal. DO NOT LEAVE IT OUT. 27 red mastic c c b b a Degrease and abrade the plastic cable outer sheath where applicable, for a distance of 100mm. Trim the ends of the joint half shells to accommodate the cables used. Place the bottom half of the joint shell under the joint and mark the position of the shell stand-off mouldings on the earth cage. Wrap a rubber patch around the cage centrally over these marks and secure. The patch should be wrapped with the adhesive side outwards. 28 a. Assemble the joint half shells around the joint and clip together.
b. Fill any gaps around the cable entry holes as required.
29 C. Fill the joint with the approved resin following the manufacturer's instructions and safety data sheet.
The joint is now complete.
Allow the resin to set before applying any mechanical strain.
30 rubber patches U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 77 2.8 Single Core Polymeric Pot Ends The tables below detail the joint kits required to complete this joint for the cable sizes listed. Any jointing requirements for cable sizes not shown on this table shall be referred to one of the UK Power Networks J ointing Schools. 2.8.1 EPN/LPN/SPN Triplex or Three x Single Core Pot End J oints (CWS Cables) 2.8.2 EPN Polylam Pot End J oints 2.8.3 Cable Preparation Refer to the following sections of this manual for the preparation of each cable type: 3.1 Single Core Copper Wire Screened Polymeric Cables. 3.2 Single Core Polylam Cables. 2.8.4 Installing Heatshrink Materials and Components Refer to the following sections of this manual for the installation of heatshrink materials and other components: 4.1 Installing Stress Control and Insulation Materials. 4.1.4 Single Core Polymeric Cables in Single and Triplex Straight/Branch J oints. 4.3 Installing Connector Stress Control and Heatshrink Insulation. 4.3.5 Polymeric and Paper Pot End J oints. 4.5 Installing Mechanical Earth Bonds and Associated Components. 4.5.9 Installing Aluminium Cages. 4.6 Fitting Plastic J oint Boxes. 4.7 Mixing and Installing Polyurethane Resin. Cable Sizes mm 2 J oint Kit Description and Part Numbers Triplex Pot End J oint 95-150mm 2 Triplex Pot End J oint 185-300mm 2 Tyco Part No. SMOE 63407 SMOE 63408 Stores Code 04106J 04107T 95 185 1 per J oint 240 -300 1 per J oint Resin Volume 14.0 Litres 14.0 Litres Cable Sizes mm 2 J oint Kit Description and Part Numbers Triplex Pot End J oint 95-150mm 2 Triplex Pot End J oint 185-300mm 2 Polylam Earth Kit Tyco Part No. SMOE 63407 SMOE 63408 SMOE 63409 Stores Code 04106J 04107T 04108D 150 1 per J oint 1 per J oint 240 1 per J oint 1 per J oint Resin Volume 14.0 Litres 14.0 Litres U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 78 InstaIIation Instruction
11kV SingIe Core or TripIex CabIe Pot End
For cabIe sizes 95-185mm SMOE 63407 UK Power Networks Stores Code = 04106J For cabIe sizes 240-300mm SMOE 63408 UK Power Networks Stores Code = 04107T
U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 79 1 2 60 200 CabIe Preparation Slide the support ring over the three single cables. Lay the cables in to their final position and mark the reference line. Cut the cables to length and remove the outer sheath. SeaIant Tape Wrap one layer of red sealant tape for 60mm from the sheath cut with slight tension and a one third overlap.
Screen Wires Bend the screen wires back onto the red sealant tape ensuring the wires are straight and do not cross. Use a wire binder or cable tie to keep them tight against the red sealant tape. Semi-Conducting Layer Remove the semi-conducting screen layer from the insulation to the dimension shown using the approved tools and methods as applicable. Do not nick the insulation layer.
3 40 Moisture BIock Wrap one layer of red sealant tape over the previously applied 60mm red tape to sandwich the screen wires giving a moisture block. Continue onto the semi-conducting layer for 15mm. Degrease the insulation.
4 Stress ReIieving Tape Remove one release paper from the short pointed yellow mastic void filling tape. Starting from 20mm on the semi-con layer and continue taping onto the insulation for 10mm to form a smooth taper. Stretch the tape to half its original width and apply under tension to ensure a fine neat edge. Remove the second release paper during this taping operation. 5 15 60 30 75 220 U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 80 Core Tubing Position the red core tubing over the cable onto the end of the red mastic tape. Shrink down starting from the oversheath end. Trim the red core tubing level with the cable end.
6 30 yellow mastic star 40 end caps ECIC 7 8 9 10 Cut one of the 150mm yellow void filling mastic strips into three equal pieces. Arrange the strips in the shape of a star. Position the centre of the star against the core end as shown in the drawing. Apply a 150mm strip of the yellow void filling mastic around the last 40mm of the core end securing the previously installed yellow star. Position over each core end a small black heatshrink end cap. Shrink down each cap, using a hammer shaft pressing against the end of the cap to ensure the cap does not slide off the core end. Slide onto each core a black and red screened insulation tube (ECIC). Position the tubes so that they overlap the ends of the cable caps by 30mm. U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 81 Degrease and abrade the plastic cable sheath for a distance of 100mm. Trim the ends of the joint half shells to accommodate the cables used. Place the bottom half of the joint shell under the joint and mark the position of the two shell stand-off mouldings on the earth cage. Wrap a rubber patch around the cage centrally over these marks and secure. The patch should be wrapped with the white adhesive outwards. Fold the 1050mm length of tinned copper mesh in half for its full length, so that its width is reduced to 30mm. Wrap two layers of the tinned copper mesh around the end of the support ring, lay all the copper wires of the single core cables on to the copper mesh, continue to wrap the tinned copper mesh over the copper wires, clamp the copper mesh and wires down on to the support ring, tap and tighten, and trim off the excess copper wires. Clean and degrease the space between the cage fingers and the copper mesh. Using the red mastic tape, wrap it in the space on the support ring.
13 14 15 Rubber Patches Position the support ring 250mm from the cable end of the black and red insulating tubes. Wrap and secure the serrated strip around the support ring. Wrap the cage around the joint and temporary secure. Space the cage fingers equally around the support ring and the cage using the worm drive clip. 50 check a b c d 1 2 3 4 5 a. Shrink the sleeves in the centre (1). b. Check if fully shrunk by twisting the sleeve ends. The sleeves should not move from their position. If the sleeves rotate continue shrinking until they lock in place. c. Continue shrinking by working towards one side (2), stopping 50mm from the end. Shrink the other half in the same way (3). d. Shrink down the first end (4) and finally the second (5). The sleeves should be fully shrunk without leaving ridges. 11 12 CompIetion of Joint
Wrap the roll of tinned copper mesh around the centre of the black and red tubes. U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 82 c a b J oint complete. Allow the resin to set before applying any mechanical strain. a. Assemble the joint shells around the joint and clip together. b. Fill any gaps around the cable entry hole as required. c. Fill the joint with the approved resin following the manufacturer's instructions and data sheet. 16 17 U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 83 2.9 Three Core Paper Cable Pot Ends (PICAS and PILC) The table below details the joint kits required to complete this joint for the cable sizes listed. Any jointing requirements for cable sizes not shown on this table shall be referred to one of the UK Power Networks J ointing Schools. 2.9.1 EPN/LPN/SPN Three Core PILC/PICAS Pot End J oints 2.9.2 Cable Preparation Refer to the following sections of this manual for the preparation of each cable type. 3.4 PICAS Paper Insulated Corrugated Aluminium Sheathed Cables. 3.5 PILC Paper Insulated Lead Sheathed Cables. 2.9.3 Installing Heatshrink Materials and Components Refer to the following sections of this manual for the installation of heatshrink materials and other components: 4.1 Installing Stress Control and Insulation Materials. 4.1.4 Single Core Polymeric Cables in Single and Triplex Straight/Branch J oints. 4.3 Installing Connector Stress Control and Heatshrink Insulation. 4.3.5 Polymeric and Paper Pot End J oints. 4.5 Installing Mechanical Earth Bonds and Associated Components. 4.5.9 Installing Aluminium Cages. 4.6 Fitting Plastic J oint Boxes. 4.7 Mixing and Installing Polyurethane Resin. Cable Sizes mm 2 J oint Kit Description and Part Numbers Three Core PILC/PICAS Pot End J oint 95-300mm 2 PILC Build-Up Kit 16-70mm 2 Tyco Part No. SMOE 61757 SMOE 63429 Stores Code 04133F 04125R 16 70 1 per J oint 1 per J oint 95 300 1 per J oint Resin Volume 14.0 Litres U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 84 Instal lati on Instruction
11kV Three-Core PILC/PICAS Pot End
For cable sizes 95-300mm SMOE 61757 UK Power Networks Stores Code = 04133F
U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 85 belt papers/fabric tape wire or tape armour reference line 60 140 20 360 belt paper / fabric tape aluminum sheath oversheath 140 20 Paper Cable with Armour 360 oversheath Cable Preparation
Stripping Dimensions Paper Cable with Alumini um Sheath reference line lead sheath U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 86 Paper Cables
Remove the armours according to the dimensions shown on page 84. Stand the armour wires upright and remove all traces of compound from them. Thoroughly clean and abrade the lead sheath for 200mm from the cable armour. 1 Wrap the short length of tinned copper mesh (EPPA-009- 850) around the lead sheath so that its edge just protrudes beyond the armour wires when they are laid back down. 2 Relay the wires over the mesh and secure with a worm drive clip. 3 4 B Belted Cables Onl y Tie a twine binder around the carbon paper 5mm from the end of the lead sheath and tear off the carbon paper against the twine binder. Tie a twine binder around the belt papers 20mm from the end of the lead sheath and tear off the belt papers level with the twine binder. Remove the fillers level with the belt papers. Secure the paper insulation at the end of each core using a PVC tape binder. Using a clean, dry cloth, remove any excess cable compound from around the cores. 4 A Screened Cables Unwind the fabric tape and remove the fillers. Rewind the tape around the crutch of the cable and tie off 20mm from the end of the metal sheath. Tie a twine binder around the screen papers at the dimension given in the drawing. Tear off the screen papers level with the twine binder. Remove the top two paper tapes to the same position as the screen papers. Using a clean, dry cloth, remove any excess cable compound from around the cores.
tape binder 5 20 20 reference line 180 U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 87 Push the mastic wedge carefully into the crutch until the tip is just below the belt paper or fabric tape. The wedge will deform and partly extrude between the cores.
7 IMPORTANT - Separate the cores carefull y so as not to damage the bel t or core i nsulation papers. Slide the red insulating tubes over the cores on each cable end, pushing them well down into the crutch.
Shrink the tubes, starting from the crutch and working towards the core ends. Ensure that the tubes are shrunk down evenly and are free from air or grease pockets.
For cable sizes below 95mm 2 , the core tubes should be substituted for those in the build up kit.
6 Position the red crutch sealing sleeve centrally covering the yellow mastic tape. Shrink it into position.
9 Remove the twine binder from the crutch on belted cables. Remove the release paper from a 400mm length of yellow void filling mastic tape. Wrap the tape around the crutch, overlapping onto the lead sheath by 20mm and continue onto the red insulating tubes for 20mm. Stretch the mastic to half its original width and apply under tension to achieve a fine thin edge. Wrap a second strip of the yellow mastic over the first layer.
8 40 20 Screened Cables Onl y Cut a 50mm piece from the yellow void filling mastic tape as shown in the figure 5. Remove the twine binder from the end of the screen papers. Wrap the yellow mastic around the screen papers starting 20mm from the end of the screen and continuing onto the insulation for 10mm. Stretch the mastic to half its original width and apply under tension to achieve a fine thin edge. Note: The yellow mastic should be applied in the same direction as the screen papers. 20 10 50 5 U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 88 30 yellow mastic star 40 end caps ERIC 10 11 12 13 Set the cores into their final jointing position. Cut the cores to the dimensions given in the drawing.
Cut one of the 150mm yellow void filling strips into three equal pieces. Arrange the strips in the shape of a star. Position the centre of the star against the core end as shown in the drawing. Apply a 150mm strip of the yellow void filling mastic around the last 40mm of the core end securing the previously installed yellow star. Position over each core end a small black end cap. Shrink down each cap, using a hammer shaft pressing against the end of the cap to ensure the cap does not slide off the core end. Slide onto each core a red and black screened insulation tube (ERIC). Position the tubes so that they overlap the ends of the cable caps by 30mm. 50 check a b c d 1 2 3 4 5 14 a. Shrink the sleeves in the centre (1). b. Check if fully shrunk by twisting the sleeve ends. The sleeves should not move from their positions. If a sleeve rotates continue shrinking it, until it locks in place. c. Continue shrinking by working towards one side (2), stopping 50mm from the end. Shrink the other half in the same way (3). d. Shrink down the first end (4) and finally the second (5). The sleeves should be fully shrunk without leaving ridges. U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 89 Compl etion of Joint
Wrap the roll of tinned copper mesh around the centre of the black and red tubes. 15 Earthing Cage Instal lation
Alumi nium Sheathed Cables Cut the serrated contact strip into two and form each of them into circles. Place each piece around the aluminium sheath bridging the crests of two of the sheath corrugations. Note: Ensure the contact strip does not overlap. Check that a 10mm gap is maintained between edges.
Clean and degrease the exposed aluminium sheath. Starting 10mm over the end of the outer cable sheath, apply one half lapped layer of the red mastic tape over the end of the cable sheath and the exposed aluminium sheath, up to the edge of the contact strip.
Note: Do not tape over the contact strip. red mastic tape 10 edge of contact strip 17 contact strip 16 Lead Sheathed cables Fold the length of tinned copper mesh in half along its length. Wrap the mesh around the lead sheath behind the red crutch sealing sleeve. Trim the length of contact strip to fit around the sheath and secure.
Metallic Earth Screen Connections Fit the metallic cage centrally around the joint, apply a temporary tape binder around the centre, ensuring the overlap along the cage length remains equal. Position the cage fingers over the contact strip and secure with the worm drive clip.
18 19 rubber patches Clean, degrease and abrade the plastic cable sheath as applicable for a distance of 100mm. Trim the ends of the joint half shells to accommodate the cables used. Place the bottom half of the joint shell under the joint and mark the position of the two shell stand-off positions on the earth cage. Wrap a rubber patch around the cage centrally over these marks and secure. The patch should be wrapped with the white adhesive side outwards. U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 90 J oint complete. Allow the resin to set before applying any mechanical strain. a. Assemble the joint shells around the joint and clip together. b. Fill any gaps around the cable entry hole as required. c. Fill the joint with the approved resin following the manufacturer's instructions and data sheet. c a b 20 21 U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 91 2.10 New Single Core Polymeric Indoor Terminations The tables below detail the termination kits required to complete this termination for the cable sizes listed. Any jointing requirements for cable sizes not shown on this table shall be referred to one of the UK Power Networks J ointing Schools. 2.10.1 EPN/LPN/SPN Triplex or Three Single Core Termination Kits (CWS Cables) 2.10.2 EPN Polylam Termination Kits 2.10.3 Cable Preparation Refer to the following sections of this manual for the preparation of each cable type: 3.1 Single Core Copper Wire Screened Polymeric Cables. 3.2 Single Core Polylam Cables. 2.10.4 Installing Heatshrink Materials and Components Refer to the following sections of this manual for the installation of heatshrink materials and other components: 4.1 Installing Stress Control and Insulation Materials. 4.1.6 Single Core Polymeric Cable Terminations. 4.2 Installing Mechanical Connectors and Lugs. 4.2.5 Mechanical Lugs for Indoor and Outdoor Terminations. 4.4 Installing Bushing Boots. 4.4.1 Cold Applied Switchgear Boots. 4.5 Installing Mechanical Earth Bonds and Associated Components. 4.5.10 Connection of Earth Screens on Indoor and Outdoor Terminations. Cable Sizes mm 2 Joint Kit Description and Part Numbers Single Core Indoor Termination Kit 95-185mm 2 Single Core Indoor Termination Kit 240-300mm 2 Polylam Earth Kit Right Angle/In-Line Boot Kit 95-300mm 2 Tyco Part No. SMOE 63419 SMOE 63420 SMOE 63409 SMOE 62803 Stores Code 04150T 04151D 04108D 04155S 150 1 per End Box 1 per End Box 1 Set per End Box 240 1 per End Box 1 per End Box 1 Set per End Box Cable Sizes mm 2 J oint Kit Description and Part Numbers Single Core Indoor Termination Kit 95-185mm 2 Single Core Indoor Termination Kit 240-300mm 2 Right Angle/In-Line Boot Kit 95-300mm 2 Tyco Part No. SMOE 63419 SMOE 63420 SMOE 62803 Stores Code 04150T 04151D 04155S 95 185 1 per End Box 1 Set per End Box 240 300 1 per End Box 1 Set per End Box U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 92 Installation Instruction
11KV Single-Core XLPE Indoor Termination
For Cable sizes 95-185mm 2
SMOE 63419 UK Power Networks Stores Code 04150T For Cable sizes 240-300mm 2
SMOE 63420 UK Power Networks Stores Code 04151D
When Bushing Boots are required use: For Cable sizes 95-300 mm 2 SMOE 62803 UK Power Networks Stores Code 04155S U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 93 Cut back the insulation according to dimension K = depth of cable lug barrel hole. Install the cable lug. Degrease and clean the core insulation and the lug.
Thoroughly remove the core screen to within 40mm of the oversheath cut. The surface of the insulation should be free from all traces of conductive material. Smooth out any irregularities. Note: Do not nick the insulation. Fit the cable lug onto the bushing and mark on each single cable the end of the conductor position inside the barrel of the lug. Cut the cable to the required length. Remove the oversheath according to the dimension given in the Figure 2. Degrease and clean the end of the oversheath for about 100mm. Wrap the red sealant tape around the end of the oversheath.
Bend the shielding wires back onto the oversheath. Avoid crossing the individual wires. Fix the shielding wires with a wire binder 60mm from the end of the oversheath. Gather the shielding wires together to form an earth lead. Remove the release paper and wrap the void filling strip around the end of the core screen. Cover 20mm of the core screen and 10mm of the insulation, stretching it to about half its original width and applying it under tension.
2 3 240 wire binder 60 sealant tape clean 100 mm K 5 6 4 40 insulation 20 10 void filler (yellow) core screen 1 Pass the gland sealing sleeve over the three single core cables and position away from the jointing area. Secure the cable gland to the base plate. Slide the base plate over the single cables and set each cable to the relevant bushing stem. Check that the copper wire shields will reach the base plate mechanical connector. U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 94 Note: After installation the termination must be post-heated as well as the palm of the cable lug until a bead of sealant (green) appears around the top of the tubing. Allow the termination to cool before applying any mechanical strain. Preheat the cable lug slightly before placing the tubing over the core. The bottom end of the tubing should be level with the wire binder.
Clean and degrease the termination and bushing. Slide the boots over the completed terminations. Fasten the connectors to the bushings. Shrink the tubing down starting at the screen cut using a soft yellow flame. Heat the area well but avoid scorching of surface. Continue shrinking towards the cable lug. Finally shrink down the bottom end of the tubing. The numbers in the drawing indicate the shrink sequence.
Diameter of cable lug barrel: Use additional red sealant tape to build up the diameter of the cable lug barrel for small cross section cable sizes.
7 Completion of Termination 8 9 2 1 3 10 11 Apply a thin layer of silicone grease 50mm onto the termination as shown and slide the insulating boot down over the termination. 12 50 U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 95 18 r D Min. 15 mm Note: Clean the bushing before the installation of the bushing boot. Apply a thin layer of silicone grease onto the bushing. Connect the cable lug to the bushing. Push the boot upwards over the bushing as far as possible. Installation of the RCAB is now complete.
13 14 Terminations complete. Check that the minimum spacing between the terminations and terminations to any earthed metal work are maintained:
b. phase to earth =15mm c. phase to phase =20mm
Degrease the terminations and the boots. Fit the front cover of the box and secure.
Position the sealing sleeve over the cable gland and shrink down the sleeve, starting from the top of the gland, before working down towards the cables. Termination completed. 16 17 15 Secure the base plate and gather the copper wire shields from each cable together. Connect them to the plate using the provided mechanical connector. Minimum bending radius Minimum bending radius (r) = 15 x D U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 96 2.11 Single Core Polymeric Terminations into Existing Compound End Boxes In most cases, it is possible to install single core polymeric cables into existing bitumen or oil lled end boxes. The only issue is whether standard cold applied bushing boots can be used. The table below details the minimum clearance dimensions that can be used for this type of bushing protection. If the above clearances cannot be achieved within the end box, it shall be sealed and lled with Guruex. 2.11.1 Kit Selection Tables The tables below and overleaf detail the termination kits required to complete this termination for the cable sizes listed. Any jointing requirements for cable sizes not shown on this table shall be referred to one of the UK Power Networks J ointing Schools. 2.11.2 EPN/LPN/SPN Triplex or Three Single Core Termination Kits (CWS Cables) x y y y Operating Voltage (kV) 6.6 11 Minimum clearance between bushing centre (x) mm 100 100 Minimum clearance between bushing centre and ground (y) mm 60 60 Minimum clearance between cold applied bushing boots mm 12 12 Cable Sizes mm 2 J oint Kit Description and Part Numbers Single Core Indoor Termination Kit 95-185mm 2 Single Core Indoor Termination Kit 240-300mm 2 Tyco Part No. SMOE 63419 SMOE 63420 Stores Code 04150T 04151D 95 185 1 per End Box 240 300 1 per End Box Guruflex Supplied in 10 litre kits (Stores Code =02204N) use sufficient to fill box to the existing compound level U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 97 2.11.3 EPN Polylam Termination Kits 2.11.4 Cable Preparation Refer to the following sections of this manual for the preparation of each cable type: 3.1 Single Core Copper Wire Screened Polymeric Cables. 3.2 Single Core Polylam Cables. 2.11.5 Installing Heatshrink Materials and Components Refer to the following sections of this manual for the installation of heatshrink materials and other components: 4.1 Installing Stress Control and Insulation Materials. 4.1.6 Single Core Polymeric Cable Terminations. 4.2 Installing Mechanical Connectors and Lugs. 4.2.5 Mechanical Lugs for Indoor and Outdoor Terminations. 4.5 Installing Mechanical Earth Bonds and Associated Components. 4.5.10 Connection of Earth Screens on Indoor and Outdoor Terminations. 4.8 Mixing and Installing Guruex. Cable Sizes mm 2 J oint Kit Description and Part Numbers Single Core Indoor Termination Kit 95-185mm 2 Single Core Indoor Termination Kit 240-300mm 2 Polylam Earth Kit Tyco Part No. SMOE 63419 SMOE 63420 SMOE 63409 Stores Code 04150T 04151D 04108D 150 1 per End Box 1 per End Box 240 1 per End Box 1 per End Box Guruflex Supplied in 10 litre kits use sufficient to fill box to existing compound level U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 98 Installation Instruction
11KV Single-Core XLPE Indoor Termination
For Cable sizes 95-185mm 2
SMOE 63419 UK Power Networks Stores Code 04150T For Cable sizes 240-300mm 2
SMOE 63420 UK Power Networks Stores Code 04151D
When Bushing Boots are required use: For Cable sizes 95-300 mm 2 SMOE 62803 UK Power Networks Stores Code 04155S U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 99 Cut back the insulation according to dimension K = depth of cable lug barrel hole. Install the cable lug. Degrease and clean the core insulation and the lug.
Thoroughly remove the core screen to within 40mm of the oversheath cut. The surface of the insulation should be free from all traces of conductive material. Smooth out any irregularities. Note: Do not nick the insulation. Fit the cable lug onto the bushing and mark on each single cable the end of the conductor position inside the barrel of the lug. Cut the cable to the required length. Remove the oversheath according to the dimension given in the Figure 2. Degrease and clean the end of the oversheath for about 100mm. Wrap the red sealant tape around the end of the oversheath.
Bend the shielding wires back onto the oversheath. Avoid crossing the individual wires. Fix the shielding wires with a wire binder 60mm from the end of the oversheath. Gather the shielding wires together to form an earth lead. Remove the release paper and wrap the void filling strip around the end of the core screen. Cover 20mm of the core screen and 10mm of the insulation, stretching it to about half its original width and applying it under tension.
2 3 240 wire binder 60 sealant tape clean 100 mm K 5 6 4 40 insulation 20 10 void filler (yellow) core screen 1 Pass the gland sealing sleeve over the three single core cables and position away from the jointing area. Secure the cable gland to the base plate. Slide the base plate over the single cables and set each cable to the relevant bushing stem. Check that the copper wire shields will reach the base plate mechanical connector. U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 100 Note: After installation the termination must be post-heated as well as the palm of the cable lug until a bead of sealant (green) appears around the top of the tubing. Allow the termination to cool before applying any mechanical strain. Preheat the cable lug slightly before placing the tubing over the core. The bottom end of the tubing should be level with the wire binder.
Clean and degrease the termination and bushing. Slide the boots over the completed terminations. Fasten the connectors to the bushings. Shrink the tubing down starting at the screen cut using a soft yellow flame. Heat the area well but avoid scorching of surface. Continue shrinking towards the cable lug. Finally shrink down the bottom end of the tubing. The numbers in the drawing indicate the shrink sequence.
Diameter of cable lug barrel: Use additional red sealant tape to build up the diameter of the cable lug barrel for small cross section cable sizes.
7 Completion of Termination 8 9 2 1 3 10 11 Apply a thin layer of silicone grease 50mm onto the termination as shown and slide the insulating boot down over the termination. 12 50 U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 101 18 r D Min. 15 mm Note: Clean the bushing before the installation of the bushing boot. Apply a thin layer of silicone grease onto the bushing. Connect the cable lug to the bushing. Push the boot upwards over the bushing as far as possible. Installation of the RCAB is now complete.
13 14 Terminations complete. Check that the minimum spacing between the terminations and terminations to any earthed metal work are maintained:
b. phase to earth =15mm c. phase to phase =20mm
Degrease the terminations and the boots. Fit the front cover of the box and secure.
Position the sealing sleeve over the cable gland and shrink down the sleeve, starting from the top of the gland, before working down towards the cables. Termination completed. 16 17 15 Secure the base plate and gather the copper wire shields from each cable together. Connect them to the plate using the provided mechanical connector. Minimum bending radius Minimum bending radius (r) = 15 x D U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 102 2.12 T1 Transformer End Box Terminations The table below details the termination kits required to complete this termination for the cable sizes listed. Any jointing requirements for cable sizes not shown on this table shall be referred to one of the UK Power Networks J ointing Schools. 2.12.1 EPN/LPN/SPN Triplex or Three Single Core Terminations into T1 Transformer End Box 2.12.2 Cable Preparation Refer to the following sections of this manual for the preparation of each cable type: 3.1 Single Core Copper Wire Screened Polymeric Cables. 2.12.3 Installing Heatshrink Materials and Components Refer to the following sections of this manual for the installation of heatshrink materials and other components: 4.1 Installing Stress Control and Insulation Materials. 4.1.6 Single Core Polymeric Cable Terminations. 4.2 Installing Mechanical Connectors and Lugs. 4.2.6 Mechanical Thimbles for use in T1 Transformer End Boxes. 4.4 Installing Bushing Boots. 4.4.2 Heat Shrink Boots. 4.5 Installing Mechanical Earth Bonds and Associated Components. 4.5.10 Connection of Earth Screens on Indoor and Outdoor Terminations. Cable Sizes mm 2 J oint Kit Description and Part Numbers Single Core Indoor Terminations TX End Box 95mm 2 Tyco Part No. SMOE 62831 Stores Code 04154H 95 1 Set per End Box U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 103 Installation Instruction
11V Si ngle-Core XLPE Indoor Termination for T1 Transformer End Box
For 95mm 2 Single-core XLPE or Triplex SMOE 62831 UK Power Networks Stores Code 04154H U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 104 Transformer oop 95mm 2 Termi nations Cable Preparation
Pass the low voltage sealing sleeve over the three single core cables and position it away from the jointing area.
Fix the cable gland to the gland plate.
Carefully position the three single-core cables through the cable gland and gland plate.
Position one of the Thimble Connectors centrally into the bushing half shells. Mark a line on the cable sheaths 165mm from the bottom of the connector. This line will be the sheath removal position.
Note: On completion of the terminations the wire shields from each single core cable will be passed through the cable gland and clamped to the outside surface of the gland. To ensure a sufficient length of wire shield is maintained the cables should be cut to a length of 650mm. T1 Transformer End Box sealing sleeve 650
165 All dimension in mm U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 105 1 2 3 L K 60 sealant tape wire bi nder 40 Remove the oversheath to dimension shown in drawing. Cut the core to dimension L + K, where L=160mm and K =the depth of cable thimble +5mm.
Clean and degrease the end of the oversheath for approximately 100mm.
Wrap one layer of red sealant tape with a small overlap and tension around the end of the oversheath for 60mm. Bend the copper wires back onto the oversheath. Avoid crossing the individual wires. Fix the wires to the surface o f the sealant tape on the over- sheath with a wire binder. Temporarily secure the copper wires along the cable oversheath. Thoroughly remove the core screen to within 40mm of the oversheath cut. The surface of the insulation should be free from all traces of conductive material and any irregularities should be smoothed out. Note: Do not nick the insulation. 20 10 5 4 6 K Cut back the insulation according to Dimension: K = depth of cable lug barrel hol e + 5mm. Install the cable lug. Note: Ensure a holding tool is used to support the cable lug while the bolts are sheared off. Clean and degrease the core insulation and the lug. Note: Fill any remaining gap between the lug and insulation with red sealant tape. Remove the release paper and wrap the yellow void filling strip around the end of the core screen. Cover 20mm of the core screen and continue onto the insulation for 10mm. Stretch the strip to half of its original width and apply under tension to achieve a fine, thin edge onto the insulation. Preheat the cable lug slightly before placing the tubing over the core. The bottom end of the tubing should be level with the wire binder. U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 106 11 7 9 Clean and degrease the termination and bushings. Slide the right angle boots over the completed terminations. Fasten the connectors to the bushings.
Note: At this stage of the installation check the correct core spacing are as specified in step 13. 10 Drawing A Cut the tubing back onto the cable lug barrel if necessary. Post heat the cable lug until a bead of green sealant appears around the top of the tubing.
Drawing B Cut the tubing level with the end of the cable insulation. Clean the surface of the mechanical Connector. Allow the termination to cool before applying any mechanical strain. 8 Shrink the tubing starting at the bottom, before working towards the cable lug.
Remove the release paper from the black mastic tape. Wrap the strips of mastic around the bushing nut and the exposed parts of the connector, covering all sharp edges. To ease the installation of the right angle boots, one layer of PVC tape can be applied over the black mastic tape. The PVC tape must not be applied over the bushing or termination.
Position the right angle boots over the bushing as shown. A B Shrink the boots in place starting at the inside angle of the boot. Shrink the top of the boot onto the bushing first and continue downwards over the core. 12 U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 107 a a b b 14 13 Bend the individual wire shields over the outside of the cable gland and secure with the two worm drive clips provided. The shielding wires should overlap the cable gland by at least 75mm. Cover the screw clamps with strips of the black sealant mastic and position the sealing sleeve over the cable gland. Shrink the sealing sleeve starting from the top of the cable gland before working towards the cables. Termination complete. Check that the minimum spacing between terminations and to any earth plane are maintained.
a. between phase and ground =15mm b. between phases =20mm
Transformer end box complete. 75mm sealing sleeve shi eld wi res 15 U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 108 2.13 Single Core Polymeric Pole Terminations The tables below detail the termination kits required to complete this termination for the cable sizes listed. Any jointing requirements for cable sizes not shown on this table shall be referred to one of the UK Power Networks J ointing Schools. 2.13.1 EPN/SPN Triplex Pole Termination Kits (CWS Cables) 2.13.2 EPN Polylam Pole Termination Kits 2.13.3 Cable Preparation Refer to the following sections of this manual for the preparation of each cable type: 3.1 Single Core Copper Wire Screened Polymeric Cables. 3.2 Single Core Polylam Cables. 2.13.4 Installing Heatshrink Materials and Components Refer to the following sections of this manual for the installation of heatshrink materials and other components: 4.1 Installing Stress Control and Insulation Materials. 4.1.6 Single Core Polymeric Cable Terminations. 4.2 Installing Mechanical Connectors and Lugs. 4.2.5 Mechanical Lugs for Indoor and Outdoor Terminations. 4.5 Installing Mechanical Earth Bonds and Associated Components. 4.5.10 Connection of Earth Screens on Indoor and Outdoor Terminations. Cable Sizes mm 2 J oint Kit Description and Part Numbers Single Core Outdoor Termination Kit 95-185mm 2 Stand Off Insulators (set of 3) Surge Arresters (set of 3) Tyco Part No. SMOE 63421 EPBI 1000 OCP2-12S-NFF Stores Code 04152N 04153X 09436E 95 185 1 kit per Termination 1 set per Termination (if required) 1 set per Termination (if required) Cable Sizes mm 2 J oint Kit Description and Part Numbers Single Core Outdoor Termination Kit 95-185mm 2 Polylam Earth Kit Stand Off Insulators (set of 3) Surge Arresters (set of 3) Tyco Part No. SMOE 63421 SMOE 63409 EPBI 1000 OCP2-12S-NFF Stores Code 04152N 04108D 04153X 09436E 150 240 1 per Pole Termination 1 per Pole Termination 1 set per Termination (if required) 1 set per Termination (if required) U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 109 Installation Instruction
11V Single-Core Outdoor Termination
For Cable Sizes 95-185mm SMOE 63421 UK Power Networks Stores Code = 04152N
U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 110 Cable Preparation
Cut the cable to the required length. Remove the oversheath according to the dimension given in the drawing. Degrease and clean the end of the oversheath for about 100mm. Wrap the red sealant tape around the end of the oversheath.
Bend the shielding wires back onto the oversheath. Avoid crossing the individual wires. Fix the shielding wires with a wire binder 60mm from the end of the oversheath. Gather the shielding wires together to form an earth lead. 3 4 240 wire binder 60 sealant tape clean 100 1 2 Secure the metal crucifix onto the pole at a convenient working height. Fix the insulators to the crucifix, positioning the central insulator in the centre of the fixing cut away.
Secure the copper wire shield connector to the crucifix. Fix the mechanical lugs to the insulators. Secure the cables in the cleat on the crucifix. Overlap the cables 400mm beyond the lug fixing bolts. This will allow the copper wire shields to be connected to the crucifix later in the installation. U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 111 Cut back the insulation according to dimension K = depth of cable lug barrel hole. Install the cable lug. Degrease and clean the core insulation and the lug. Note: Do not use cable lugs with barrel holes deeper than 110mm. Thoroughly remove the core screen to within 40mm of the oversheath cut. The surface of the insulation should be free from all traces of conductive material. Smooth out any irregularities. Note: Do not nick the insulation. Remove the release paper and wrap the yellow void filling mastic strip around the end of the core screen. Cover 20mm of the core screen and 10mm of the insulation, stretching it to about half its original width and applying it under tension.
K 6 7 5 40 insulation 20 10 Yellow void filler core screen Preheat the cable lug slightly before placing the tubing over the core. The bottom end of the tubing should be level with the wire binder.
Shrink one heatshrink shed into place at the position shown in the drawing below. Shrink the tubing down starting at the screen cut using a soft yellow flame. Heat the area well but avoid scorching of surface. Continue shrinking towards the cable lug. Finally shrink down the bottom end of the tubing. The numbers in the drawing indicate the shrink sequence.
Completion of Termination 8 9 2 1 3 10 180 U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 112 11 12 Bolt the cable lugs onto the insulators. Gather the copper wire shields into three groups. Secure the wire shields into the connector on the crucifix. U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 113 2.14 13kA PILC Cable Earth Kit The table below details the sizes of cable which shall have a 13kA Earth Clip tted, in conjunction with all the relevant joint kits in the LPN and SPN areas. They are not required for pot end joints. Any jointing requirements for cable sizes not shown on this table shall be referred to one of the UK Power Networks J ointing Schools. 2.14.1 LPN and SPN 13kA PILC Cable Earth Kit 2.14.2 Cable Preparation To install these clips further details for the preparation of each cable type can be found in the following sections of this manual: 3.4 PICAS Paper Insulated Corrugated Aluminium Sheathed Cables. 3.5 PILC Paper Insulated Lead Sheathed Cables. 2.14.3 Installing Heatshrink Materials and Components To complete these joints further details for the installation of components can be found in the following sections of this manual: 4.5 Installing Mechanical Earth Bonds and Associated Components. 4.5.7 13kA PILC Earth Kit Steel Wire Armoured Cables. 4.5.8 13kA PILC Earth Kit Steel Tape Armoured Cables. Cable Sizes mm 2 J oint Kit Description and Part Numbers Three Core PILC/PICAS Pot End J oint 95-185mm 2 Tyco Part No. SMOE 63414 Stores Code 04124G 16 95 Not Required 120 300 1 per PILC Cable in J oint U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 114 Installation Instruction
11kV PILC 13A Earth Kit for Steel Wire and Steel Tape Armoured Cables
For cable Sizes 95-400mm SMOE 63414 UK Power Networks Stores Code = 04124G
U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 115 Steel Wire Armour Cables
Working from the base kit instruction, strip the cable down to the lead sheath leaving 60mm of cleaned lifted armours.
Abrade and degrease the lead sheath for a distance of 20mm from the lifted armours. A1 Apply two layers of the red sealing mastic around the lead sheath starting 100mm from the lifted armours covering 40mm of sheath working back towards the armours. A2 Position the black sealing sleeve onto the lead sheath up to the lifted wire armours. Shrink down the sleeve. A3 A4 Apply two layers of the red sealing mastic around the insulating sleeve for a distance of 40mm, starting at the end furthest away from the armours, before working back towards the lifted armours.
60 40 red sealing mastic black sealing sleeve red sealing mastic lifted armours A5 copper mesh Unwrap and fold in half lengthways one of the tinned copper mesh rolls. Wrap it around the lead sheath at the end of the insulating sleeve. U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 116 Apply a double 18 gauge wire binder around the centre of the clip and dress down the clip to suit the lead sheath profile. Wrap the earth clip around the cable, ensuring the ends of the clip are over the copper mesh fitted on the lead sheath, and the red sealing mastic on the clip is positioned over the sealing mastic previously installed on the insulating sleeve. Remove the release papers from one of the red sealing mastic strips and stick the strip down the centre of the solid earth clip. Note: This is an important moisture seal. Do not leave it out. A8 A7 A6 red sealing mastic wire binder A9 A10 copper mesh worm drive clip Unwrap and fold in half length ways the remaining two rolls of tinned copper mesh, wrap a roll around each end of the clip over the tinned copper petals. Lay down the armours onto the copper mesh and secure with the worm drive clip. Note: Do not cross the armour wires. U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 117 Prior to the fitting of the metallic earth cage, wrap a contact strip around the copper mesh at the end of the earth clip. If the wire binder comes loose remove it. Apply two layers of the red sealing mastic around the exposed earth clip between the ends of both armours and earth cage. A11 A12 40 30 60 contact strip red sealing mastic worm drive clipclip B1 B2 B3 60 50 lead sheath steel tape armour red sealing mastic copper mesh 10 Steel Tape Armour Cables
Working from the base kit instruction, strip the cable down to the lead sheath leaving 60mm of cleaned armours.
Abrade and degrease the lead sheath for a distance of 150mm from the armours. Apply two layers of the red sealing mastic around the lead sheath for 50mm working from the armour cut. Fold two of the tinned copper mesh rolls in half lengthways and wrap one around the lead sheath 10mm from the end of the red mastic. Wrap the second around the armours 10mm from the end. U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 118 Slightly raise the petals of one side of the clip, which will cater for the armours. Wrap the clip around the cable, ensuring the ends of the clip are over the fitted copper mesh on the lead sheath. Check the red mastic sealing tapes are pressed together. Dress down the clip petals onto the sheath armours.
Using one of the red sealing strips, remove one of the release papers and stick the strip down the centre of the solid tinned copper strip, one side only. Note: This is an important moisture seal. Do not leave it out. B5 B4 red sealing mastic B6 B8 B7 wire binder worm drive clip copper mesh worm drive clip Apply a double wire binder around the centre of the clip.
Fold in half lengthways the remaining tinned copper mesh roll. Wrap it around the end of the clip over the petals which are on the lead sheath.
Fit the worm drive clip around the petals on the armours and secure. Before fitting the cage, wrap the serrated strip around the copper mesh at the end of the clip. Secure the cage with the worm drive clip. U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 119 Apply two layers of the red sealing tape, using a slight overlap around the exposed earth clip between the armours and the cage. B9 red sealing mastic U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 120 2.15 Three-Core Loop and Transitional Loop The tables below details the joint kits required to complete this joint for the cable sizes listed. Any jointing requirements for cable sizes not shown on this table shall be referred to one of the UK Power Networks J ointing Schools. 2.15.1 EPN Transitional Loop J oint PILC to Triplex or Single Core Polymeric CWS 2.15.2 EPN Transitional Loop J oint PILC to Polylam Cable Sizes mm 2 J oint Description and Part Numbers Three Core Transition Loop J oint 95-185mm 2 Three Core Transition Loop J oint 240-300mm 2 PILC Build-Up Kit 16-70mm 2 Tyco Part No. SMOE 63440 SMOE 63441 SMOE 63429 Stores Code 04137U 04138E 04125R Paper XLPE 16 70 95 1 per J oint 1 per J oint 95 150 95- 185 1 per J oint 150 240 300 1 per J oint 185 95 185 1 per J oint 185 300 95 300 1 per J oint Resin Volume 21.0 Litres 38.0 Litres Cable Sizes mm 2 J oint Description and Part Numbers Three Core Transition Loop J oint 95-185mm 2 Three Core Transition Loop J oint 240-300mm 2 PILC Build Up Kit 16-70mm 2 Polylam Earth Kit Tyco Part No. SMOE 63440 SMOE 63441 SMOE 63429 SMOE 63409 Stores Code 04137U 04138E 04125R 04108D Paper XLPE 16 70 150 1 per J oint 1 per J oint 1 per J oint 95 185 150 1 per J oint 1 per J oint 16 70 240 1 per J oint 1 per J oint 1 per J oint 95 300 240 1 per J oint 1 per J oint Resin Volume 21.0 Litres 38.0 Litres U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 121 2.15.3 LPN and SPN Transitional Loop J oint PILC to Triplex or Single Core Polymeric CWS 2.15.4 SPN Transitional Loop J oint PICAS Main to Triplex Cable Sizes mm 2 J oint Description and Part Numbers Three Core Transition Loop J oint 95-185mm 2 Three Core Transition Loop J oint 240-300mm 2 Polymeric Preparation Kit 95-150mm 2 Polymeric Preparation Kit 185- 300mm 2 Tyco Part No. SMOE 63440 SMOE 63441 SMOE 63415 SMOE 63416 Stores Code 04137U 04138E 04129F 01430B Poly Main Poly Branch 95 185 95 185 1 per J oint 1 per J oint 95 185 240 300 1 per J oint 1 per J oint 240 300 95 185 1 per J oint 1 per J oint 240 300 240 300 1 per J oint 1 per J oint Resin Volume 21.0 Litres 38.0 Litres Cable Sizes mm 2 J oint Description and Part Numbers Three Core Transition Loop J oint 95-185mm 2 Three Core Transition Loop J oint 240-300mm 2 Polylam Earth Kit Polymeric Preparation Kit 95-150mm 2 Polymeric Preparation Kit 185-300mm 2 Tyco Part No. SMOE 63440 SMOE 63441 SMOE 63409 SMOE 63415 SMOE 63416 Stores Code 04137U 04138E 04108D 04129F 01430B Triplex Polylam 70 185 150 1 per J oint 1 per J oint 1 per J oint 240 300 150 1 per J oint 1 per J oint 1 per J oint 70 185 240 1 per J oint 1 per J oint 1 per J oint 300 240 1 per J oint 1 per J oint 1 per J oint Resin Volume 21.0 Litres 38.0 Litres U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 122 2.15.5 EPN Polylam to Polylam Loop J oint 2.15.6 EPN PILC to PILC Loop J oint Cable Sizes mm 2 J oint Description and Part Numbers Three Core Transition Loop J oint 95-185mm 2 Three Core Transition Loop J oint 240-300mm 2 PILC Build Up Kit 16-70mm 2 PILC Cable Preparation KIt 95-185mm 2 PILC Cable Preparation KIt 240-300mm 2 Tyco Part No. SMOE 63440 SMOE 63441 SMOE 63429 SHSM- 12AL(2) SHSM- 12BL(10 Stores Code 04137U 04138E 04125R 04140K 04141U Paper Paper 16 70 16 70 1 per J oint 2 per J oint 1 per J oint 16 70 95 1 per J oint 1 per J oint 2 per J oint 95 95 1 per J oint 1 per J oint 95 120 185 1 per J oint 1 per J oint 185 185 1 per J oint 1 per J oint 240 300 185 1 per J oint 1 per J oint 240 300 240 300 1 per J oint 1 per J oint Resin Volume 21.0 Litres 38.0 Litres Cable Sizes mm 2 J oint Description and Part Numbers Three Core Transition Loop J oint 95-185mm 2 Three Core Transition Loop J oint 240-300mm 2 Polylam Earth Kit Polymeric Preparation Kit 95-150mm 2 Polymeric Preparation Kit 185-300mm 2 Tyco Part No. SMOE 63440 SMOE 63441 SMOE 63409 SMOE 63415 SMOE 63416 Stores Code 04137U 04138E 04108D 04129F 01430B Polylam Polylam 150 150 1 per J oint 2 per J oint 1 per J oint 150 240 1 per J oint 2 per J oint 1 per J oint 240 240 1 per J oint 2 per J oint 1 per J oint Resin Volume 21.0 Litres 38.0 Litres U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 123 2.15.7 LPN/SPN PILC to PILC Loop J oint 2.15.8 Cable Preparation Refer to the following sections of this manual for the preparation of each cable type: 3.1 Single Core Copper Wire Screened Polymeric Cables. 3.2 Single Core Polylam Cables. 3.4 PICAS Paper Insulated Corrugated Aluminium Sheathed Cables. 3.5 PILC Paper Insulated Lead Sheathed Cables. Cable Sizes mm 2 J oint Description and Part Numbers Three Core Transition Loop J oint 95- 185mm 2 Three Core Transition Loop J oint 240- 300mm 2 PILC Build Up Kit 16- 70mm 2 PILC Cable Preparation Kit 95- 185mm 2 PILC Cable Preparation Kit 240- 300mm 2 13.1kA Earth Kit Tyco Part No. SMOE 63440 SMOE 63441 SMOE 63429 SHSM- 12AL(2) SHSM- 12BL(10 SMOE 63414 Stores Code 04137U 04138E 04125R 04140K 04141U 04124G Paper Paper 16 70 16 70 1 per J oint 2 per J oint 1 per J oint 16 70 95 1 per J oint 1 per J oint 2 per J oint 95 95 1 per J oint 1 per J oint 95 120 185 1 per J oint 1 per J oint 1 per J oint 185 185 1 per J oint 1 per J oint 2 per J oint 240 300 185 1 per J oint 1 per J oint 2 per J oint 240 300 240 300 1 per J oint 1 per J oint 2 per J oint Resin Volume 21.0 Litres 38.0 Litres U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 124 2.15.9 Installing Heatshrink Materials and Components Refer to the following sections of this manual for the installation of heatshrink materials and other components: 4.1 Installing Stress Control and Insulation Materials. 4.1.1 Belted Paper Cables. 4.1.2 Build Up Kits for Small Section Paper Cables. 4.1.3 Screened Paper Cables. 4.1.5 Single Core Polymeric Cables in Transitional Straight/Branch J oints. 4.2 Installing Mechanical Connectors and Lugs. 4.2.4 Three Core Transition Branch J oints. 4.3 Installing Connector Stress Control and Heatshrink Insulation. 4.3.4 Three Core Transition Branch J oints. 4.5 Installing Mechanical Earth Bonds and Associated Components. 4.5.4 Triplex Cables into Transition J oints Using a Support Ring. 4.5.5 Standard PILC Steel Wire Armour Cables. 4.5.6 PICAS Earth. 4.5.7 13kA PILC Earth Kit Steel Wire Armoured Cables. 4.5.8 13kA PILC Earth Kit Steel Tape Armoured Cables. 4.5.9 Installing Aluminium Cages. 4.6 Fitting Plastic J oint Boxes. 4.7 Mixing and Installing Polyurethane Resin. U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 125 Instal lati on Instruction
11kV Three-Core Transitional Loop Joint
95-185mm SMOE 63440 UK Power Networks Stores Code = 04137U 240-300mm SMOE 63441 UK Power Networks Stores Code = 04138E
This base ki ts makes one complete joint for one three core PILC/PICAS cable to three singl e-core pol ymeric cables. Other cable combi nations can be made using cable preparation ki ts.
U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 126 reference line 100 a 60 140 PILC PICAS POLYMERIC 40 PILC Cable Preparation
Remove the armours according to the dimensions shown in Table 1. Stand the armour wires upright and remove all traces of compound from them. Thoroughly clean and abrade the lead sheath for 200mm from the cable armour. 1 Wrap the short length of tinned copper mesh (EPPA-009- 850) around the lead sheath so that its edge just protrudes beyond the armour wires when they are laid back down. 2 If a 13KA earth clip is required install it now and then proceed to step 4. Stripping Dimensions Table 1 Conductor size Cut-back dimensi ons given below mm a 95 - 185 500 240 - 300 600 180 Pol ymeric U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 127 Relay the wires over the mesh and secure with a worm drive clip. 3 4 B Belted Cables Paper Cables Onl y Tie a twine binder around the carbon paper 5mm from the end of the lead sheath and tear off the carbon paper against the twine binder. Tie a twine binder around the belt papers 20mm from the end of the lead sheath and tear off the belt papers level with the twine binder. Remove the fillers level with the belt papers. Secure the paper insulation at the end of each core using a tape binder. Using a clean, dry cloth, remove any excess cable compound from around the cores. 4 A 5 Screened Paper Cables Onl y Unwind the fabric tape and remove the fillers. Rewind the tape around the crutch of the cable and tie off 20mm from the end of the metal sheath. Tie a twine binder around the screen papers at the dimension given in the drawing. Tear off the screen papers level with the twine binder. Remove the top two paper tapes to the same position as the screen papers. Using a clean, dry cloth, remove any excess cable compound from around the cores.
tape binder 5 20 20 reference line 180 Unwind the fabric tape and remove the fillers. Rewind the tape around the crutch of the cable and tie off 20mm from the end of the metal sheath. Tie a twine binder around the screen papers at dimension given in the drawing. Tear off the screen papers level with the twine binder. Remove the top two paper tapes to the same position as the screen papers. Using a clean, dry cloth, remove any excess cable compound from around the cores. 180 reference li ne 20 Screened Cables Onl y Cut a 50mm piece from the yellow mastic void filling tape as shown in the drawing. Remove the twine binder from the end of the screen papers. Wrap the yellow mastic around the screen papers starting 20mm from the end of the screen and continuing onto the insulation for 10mm. Stretch the mastic to half its original width and apply under tension to achieve a fine thin edge. Note: The yellow mastic should be applied in the same direction as the screen papers. 20 10 50 6 U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 128 Push the mastic wedge carefully into the crutch until the tip is just below the belt paper or fabric tape. The wedge will deform and partly extrude between the cores.
8 IMPORTANT - Separate the cores carefull y so as not to damage the bel t or core i nsulation papers. Slide the red insulating tubes over the cores on each cable end, pushing then well down into the crutch.
Shrink the tubes, starting from the crutch and working towards the core ends. Check that the tubes are shrunk down evenly and are free from air or grease pockets.
For cable sizes below 95mm 2 , the core tubes should be substituted for those in the build up kit.
Position the red crutch sealing sleeve centrally covering the yellow mastic tape. Shrink it into position.
Note: For cable sizes below 95mm 2 , the crutch sealing sleeve should be substituted for that in the build up kit. 10 Remove the twine binder from the crutch on belted cables. Remove the release paper from a 400mm yellow mastic tape strip. Wrap the tape around the crutch, overlapping onto the lead sheath by 20mm and continue onto the red insulating tubes for 20mm. Apply the void filling mastic with a 50% overlap, stretching it to about half its original width and applying it under tension. Wrap a second strip of the yellow mastic over the first layer.
9 40 20 7 11 200 Single-Core Pol ymeric Cable Sheath Removal Lay the single core plastic cables in their final jointing position. Mark the reference line and cut to length. Slide the large support ring over all three single core cables. Carefully remove the outer jackets. Thoroughly abrade and degrease the outer cable sheath for a distance of 200mm from the sheath cut.
Note: It is important that this operation is carried out at this stage. Do not leave it out. U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 129 Seal ant Tape Wrap one layer of red sealant tape for 60mm from the sheath cut with slight tension and a one third overlap. Screen Wires Bend the screen wires back onto the red sealant tape, ensuring the wires are straight and do not cross. Use a wire binder or PVC tape to keep them tight against the red sealant tape.
Semi Conducting Layer Remove the semi conducting screen layer from the insulation to the dimension shown using the approved tools and methods as applicable. Do not nick the insulation l ayer.
Core Tubing Position the red core tubing (BPTM-50/20) over the cable to level with the red mastic tape. Shrink into place starting at the oversheath end. Strip back the tubings and insulation to suite the type of connectors used. Check that the cores are correctly identified. Using plastic tape or poly bags, cover the single core cables beyond the red BPTM tubes and park the black and red insulation tubes over the cables onto this protection. Cover the tubes against dust or moisture splash.
Note: If the insulating tubes are a tight fit over the red BPTM tubing, lubricate the tubing with a smear of silicone grease from the sachet provided. Moisture Block Wrap one layer of red sealant tape over the previously applied 60mm of red tape to sandwich the screen wires to provide a moisture block. Continue onto the semi-conducting layer for 15mm. Degrease the insulation.
Stress Relieving Tape Remove one release paper from the short pointed yellow void filling mastic strips. Starting 20mm from on the semi-con layer, continue taping on to the insulation for 10mm to form a smooth taper. Stretch the tape to half its original width and apply under tension to ensure a fine neat edge. Remove the second release paper during this taping operation.
12 13 14 15 60 40 40 60 15 moisture block stress relieving tape 17 Set the cores in to their final joint position. Secure the cores close to the crutch using the cable ties provided. Arrange the cables as shown in the drawing. U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 130 21 20 Roll up a length of the yellow void filling mastic tape and push it into the single entry hole of the connector. There are three patches per connector. The first patch is located over the single end of the connector as shown with the overlap located over the bolts area. The two remaining patches should be formed into one long patch by sticking them together, overlapping each other by 50mm. Wrap this long patch around the double end of the connector, with the double 50mm thickness over the bolts. 19 red mastic 18 Fitting the Mechanical Connectors Cut the cores to length. Remove the insulation from each core and fit the mechanical connectors. Remember to install and shear off the bolts in the empty single end of the connector. yellow mastic patch 2 +3 Roll up lengthways the wide (S1251) red mastic strips and insert them top and bottom between the parallel cores of the branch side. Firmly press into place butting against the connector edge. Now cut the 600mm piece of yellow void filling mastic into 6 x 100mm pieces. Fold it in half lengthways and roll up to form a rod shape 50mm long. Position one piece next to the connector where the step is at its largest, as shown in the drawing. Position the black heatshrink cap over the single end of the connector and shrink down. Hold the cap in position using the shaft of a hammer. Repeat this process for all three cores. black cap yellow mastic 2 3 5 1 4 22 50 Apply a thin smear of grease over the yellow mastic. Position the three black and red screened insulating sleeves centrally over the connector. Use cable ties to bind together each pair cores on the branch side. Shrink the tubes starting on the branch side of the connector. Shrink to within 50mm of the end and then switch to the single side stopping 50mm from the end. Finish off the first then the second ends. U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 131 Pull the cores together and wrap the length of tinned copper mesh around all three insulation sleeves in the centre and secure. Remove the cable ties holding the branch cores together. Wrap one piece of the serrated metal contact strip around the copper mesh. Do not overlap the contact strip ends.
For cables with aluminium sheaths Fit the serrated strip over two adjacent crests of the aluminium sheath.
24 Using the short length of tinned copper mesh, fold it in half along its length and wrap it around the lead sheath.
For cables with aluminium sheaths Do not apply the tinned copper mesh. 23 50 26 Wrap the aluminium earth cage around the joint. Secure the cage using cable ties or a PVC tape binder. Divide the petals of the cage equally between the two cables. Secure the cage down onto the serrated strips of each cable or the support ring using the worm drive clips. 25 27 Pol ymeric Cables Form the 300mm length of the serrated contact strip into a circle and position it on to the support ring edge nearest the joint. Slide the support ring along the cables until the screen fingers cover the full width of the contact strip. Use one worm drive clip only and clamp down the fingers of the screen on to the contact strip. Remove any excess clip length once fully tightened. U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 132 c a b Fold the 1050mm length of tinned copper mesh in half for its full length, so that its width is reduced to 30mm. Wrap two layers of the tinned copper mesh around the edge of the support, lay all the copper wires of the single core cables on to the copper mesh, continue to wrap the copper mesh over the copper wires, clamp the copper mesh and wires down on to the support ring, (tap and tighten), and trim off the excess copper wires. Clean and degrease the space between the cage fingers and the copper mesh. Using the red mastic tape, wrap it in the space on the support ring. a. Assemble the joint half shells around the joint and clip together. b. Fill any gaps around the cable entry holes as required. c. Fill the joint with the approved resin following the manufacturer's instructions and safety data sheet.
The joint is now complete. Allow the resin to set before applying any mechanical strain. 28 Fold the petals of the cage down on the open side of the joint. This will now close the cage and fully shield the internal part of the joint. Degrease and abrade the cable sheaths for a distance of 100mm. Trim the ends of the joint half shells to accommodate the cable used. Place the bottom half of the joint shell under the joint and mark the position of the two shell stand-off mouldings on the earth cage. Wrap a rubber patch around the cage centrally over these marks and secure. The patch should be wrapped with the adhesive (white) side outwards. 29 30 31 rubber patches U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 133 2.16 Polymeric Single Core Cable Sheath Repair Kit The tables below details the materials required to complete this sheath repair for the cable sizes listed. Any jointing requirements for cable sizes not shown on this table shall be referred to one of the UK Power Networks J ointing Schools. 2.16.1 EPN/LPN and SPN Polymeric Single Core Cable Sheath Repair Kit 2.16.2 Cable Preparation Refer to the following sections of this manual for the preparation of each cable type: 3.1 Single Core Copper Wire Screened Polymeric Cables. 3.2 Single Core Polylam Cables. Cable Sizes mm 2 J oint Kit Description and Part Numbers Polymeric Single Core Cable Sheath Repair Kit Tyco Part No. CRSM 84/20-250/239 Stores Code 02305F 95 300 1 per single core U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 134 Installation Instruction
CRSM Wraparound Repair System for Triplex Cable Sheaths
For Cable Sizes 95-300mm CRSM 84/20-250/239 UK Power Networks Stores Code = 02305F
U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 135 1 2 3 4 General Instructions Only use an approved propane gas torch. Adjust the torch until it has a soft blue flame with a yellow tip. Pencil-like blue flames should be not be used.
Cable nspection (before installation) Carefully remove the cable jacket to a maximum length of 75mm either side of the damaged section. Check that the cable layers beneath the oversheath for signs of further damage. If there is no damage to either the copper wires or the insulation, replace the oversheath. If there is damage to the other layers an appropriate repair must be carried out (i.e. straight joints and a new section of cable).
The wrap-around should extend for at least 50mm at each end beyond the area to be protected.
Clean, degrease (using an approved degreasing solvent) and abrade the oversheath, where it comes into contact with the heatshrink wrap-around sleeve. Remove the foil from the adhesive side of the heatshrink wrap-around sleeve. Position the heatshrink wrap-around sleeve centrally around the area of damage oversheath. Slide the steel channel onto the rail (the use of the Raychem pulling tool AD 1608 is recommended for channels above a length of 500mm). U N C O N T R O L L E D UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 2 I Page 136 Installation complete. Allow the wrap-around sleeve to cool before applying any mechanical strain. 7 6 5 Start shrinking in the centre of the heatshrink wrap-around sleeve opposite the channel, before working towards the ends. Continue heating the channel area until adhesive flows out on both ends of the heatshrink wrap-around sleeve and the channel. U N C O N T R O L L E D