ECS 02-0033 33kV Jointing Manual PDF

Document Number: ECS 02-0033
Version: 1.0
Date: 29/10/2018
THIS IS AN UNCONTROLLED DOCUMENT, THE READER MUST CONFIRM ITS VALIDITY BEFORE USE
ENGINEERING CONSTRUCTION STANDARD
ECS 02-0033
33KV JOINTING MANUAL
Network(s): EPN, LPN, SPN, UKPN Services
This 33kV jointing manual covers the approved methods and associated jointing
Summary:
kits for use on all non-fluid filled 33kV mains cables within UK Power Networks
Author: Jesse Garcia Date: 29/10/2018
Approver: Paul Williams Date: 23/11/2018
This document forms part of the Company's Integrated Business System and its requirements are mandatory throughout UK
Power Networks. Departure from these requirements may only be taken with the written approval of the Director of Asset
Management. If you have any queries about this document please contact the author or owner of the current version.
Circulation
UK Power Networks External
☒ Asset Management ☒ UK Power Networks Services
☒ Capital Programme ☒ Contractors
☒ Connections ☒ ICPs/IDNOs
☐ Health & Safety ☐ Meter Operators
☐ Legal ☒ G81 Website
☒ Network Operations
☐ Procurement
☐ Strategy & Regulation
☒ Technical Training
33kV Jointing Manual Document Number: ECS 02-0033
Version: 1.0
Date: 29/10/2018
Revision Record
Version 1.0 Review Date 23/11/2023

Date 29/10/2018 Author Jesse Garcia
updated from the 33kV Jointing Manual and transferred onto an engineering document
© UK Power Networks 2018 All rights reserved 2 of 256

Version: 1.0
Date: 29/10/2018
Contents
1 Introduction ............................................................................................................. 7
1.1 Safety, Health, Environment and Quality Statement .................................................. 7
1.2 Glossary and Abbreviations ....................................................................................... 8
2 Jointing Instructions ............................................................................................... 9
2.1 Single-Core Polymeric Straight Joints ..................................................................... 10
2.1.1 Single-Core Straight Joints 185 to 300mm2 Conductors .......................................... 10
2.1.2 Cable Preparation ................................................................................................... 10
2.1.3 Installation of Heatshrink Materials and Components .............................................. 10
2.1.4 Single-Core Straight Joints 300 to 630mm2 Conductors .......................................... 16
2.1.7 Single-Core Straight Joints 630 to 1000mm2 Conductors ........................................ 22
2.2 Single-Core PILC to XLPE Transition Straight Joints ............................................... 28
2.2.1 Single-Core PILC (95 to 400mm2) to Single-Core Polymeric (185 to 500mm2) ........ 28
2.2.4 Single-Core PILC (500 to 630mm2) to Single-Core Polymeric (500 to 630mm2) ...... 38
2.3 Three-Core PILC to Single Core XLPE Transition Straight Joints ............................ 47
2.3.1 Three-Core PILC (95 to 300mm2) to Single-Core Polymeric (185 to 500mm2) ......... 47
2.3.4 Three-Core PILC (185 to 400mm2) to Single-Core Polymeric (500 to 630mm2) ....... 57
2.4 Three-Core HSL Transition Joints ........................................................................... 68
2.4.1 Three-Core HSL PILC (95 to 300mm2) to Single-Core Polymeric (185 to 500mm2) . 68
2.5 Single-Core Polymeric Pot End Joints ..................................................................... 80
2.5.1 Single-Core Polymeric Pot End Joints (300mm2) ..................................................... 80

Version: 1.0
Date: 29/10/2018

2.5.4 Single-Core Polymeric Pot End Joints (500 to 630mm2) .......................................... 86
2.6 Indoor and Outdoor Terminations ............................................................................ 92
2.6.1 Indoor and Outdoor Single-Core Polymeric Cable Terminations (300 to 1200mm2). 92
2.7 Polymeric Single Core Cable Sheath Repair Kit ...................................................... 98
2.8 Type C Seperable Connectors .............................................................................. 102
2.8.1 Type C Seperable Connectors for Single-Core Polymeric Cable (300mm2) ........... 102
2.8.2 Cable Preparation ................................................................................................. 102
2.8.3 Installation of Materials and Components .............................................................. 102
2.8.4 Type C Seperable Connectors for Single-Core Polymeric Cable (400 to 800mm2) 109
2.8.7 Type C Seperable Connectors for Single-Core Polymeric Cable (1000mm2) ......... 116
2.8.10 Type C Seperable Connectors for Single-Core Polymeric Cable (1200mm2) ......... 123
2.9 Inner Cone Size 3 Terminations ............................................................................ 130
2.9.1 Inner Cone Size 3 Terminations for Single-Core Polymeric Cable (300 to
630mm2) ................................................................................................................ 130
3 Standard Procedures for Preparing 33kV Cables ............................................. 137
3.1 Single-Core Wire Screened Polymeric Cables....................................................... 137
3.1.1 Outer Sheath Removal .......................................................................................... 137
3.1.2 Removing the Conductive Layer from the Outer Sheath ........................................ 138
3.1.3 Binder Tape Removal ............................................................................................ 139
3.1.4 Removing and Terminating the Aluminium or Copper Wire Screens ..................... 139
3.1.5 Removing the Bonded Polymeric Screen .............................................................. 141
3.1.6 Installing the Wire Screen Earth Connection ......................................................... 143
3.1.7 Removing the Polymeric Insulation........................................................................ 145

Version: 1.0
Date: 29/10/2018
3.2 Single-Core Lead Covered Cables ........................................................................ 146

3.2.1 Removing the Outer Serving or Sheath ................................................................. 146
3.2.2 Removing the Lead Sheath ................................................................................... 147
3.2.3 Removing the Copper Woven Tape (CWT) ........................................................... 149
3.2.4 Removing the Insulation Screen ............................................................................ 149
3.2.5 Removing the Insulation Papers ............................................................................ 150
3.3 Three-Core Paper Insulated Cables ...................................................................... 151
3.3.1 Removing the Outer Hessian Serving or (PE) Sheath ........................................... 151
3.3.2 Removing the Steel Wire Armour .......................................................................... 151
3.3.3 Removing the Inner Bitumen Layer ....................................................................... 153
3.3.4 Removing the Lead Sheath ................................................................................... 155
3.3.5 Removing the Copper Woven Tapes (CWT).......................................................... 157
3.4 Three-Core HSL Paper Insulated Cables .............................................................. 161
3.4.1 Removing the Outer Serving or Sheath ................................................................. 161
3.4.2 Removing the Steel Wire Armour .......................................................................... 162
3.4.3 Removing the Bitumen Layer ................................................................................ 163
3.4.4 Removing the Lead Sheaths ................................................................................. 165
3.4.5 Removing the Copper Woven Tape (CWT) ........................................................... 166
3.5 Moisture Testing on Paper Insulated Cables ......................................................... 170
4 Installing Heatshrink Materials and Components ............................................. 172
4.1 Installing Stress Control and Insulation Materials .................................................. 172
4.1.1 Single-Core Paper Insulated Cables in Transition Joints ....................................... 172
4.1.2 Single-Core Polymeric Pot Ends............................................................................ 174
4.1.3 Resin Filled Three-Core Transition Straight Joints (Three-Core Paper to 3 x Single-
Core Polymeric Cables) ......................................................................................... 179
4.1.4 Heatshrink Three-Core Transition Straight Joint (Three-Core Paper to 3 x Single- Core
Polymeric Cables) ................................................................................................. 183
4.1.5 HSL Breakout Module ........................................................................................... 188
4.1.6 HSL Cable Core Preparation ................................................................................. 192
4.1.7 Paper Insulation 'Shim Kit' for Cable Cross Sections 70mm² & 95mm² .................. 194
4.1.8 Paper Insulation 'Shim Kit' for Cable Cross Sections 120mm² & 150mm² .............. 196
4.1.9 Paper Insulation 'Shim Kit' for Cable Cross Sections 120mm² & 150mm² .............. 198
4.1.10 Single-Core Polymeric Terminations (Indoor and Outdoor).................................... 199

Version: 1.0
Date: 29/10/2018
4.2 Installing Mechanical Connectors and Lugs ........................................................... 206

4.2.1 Single-Core Polymeric Straight Joints ................................................................... 206
4.2.2 Single-Core Transitional Straight Joints ................................................................. 208
4.2.3 Resin Filled Three-Core Trifurcating Joints (Three-Core Paper to 3 x Single-Core
4.2.4 Heatshrink Three-Core Transition Straight Joint (Three-Core Paper to 3 x Single-Core
4.2.5 HSL Trifurcating Joints (Three-Core HSL to 3 x Single-Core Polymeric Cables) ... 215
4.2.6 Mechanical Lugs for Indoor and Outdoor Terminations ......................................... 218
4.3 Installing Connector Stress Control and Heatshrink Insulation ............................... 220
4.3.2 Single-Core Transition Straight Joints ................................................................... 223
4.3.3 Resin Filled Three-Core Transition Straight Joints (Three-Core Paper to Single-Core
4.3.4 Heatshrink Three-Core Transition Straight Joints (Three-Core PILC to Single-Core
Polymeric) ............................................................................................................. 231
4.4 Installing Mechanical Earth Bonds and Associated Components ........................... 238
4.4.2 Single-Core Transition Joints ................................................................................. 241
4.4.3 Polymeric Pot Ends ............................................................................................... 244
Core Polymeric Cables) ......................................................................................... 246
4.4.5 Heatshrink Three-Core Transition Straight Joints (Three-Core Paper to Single-Core
Polymeric) ............................................................................................................. 247
4.4.7 Connection of Screen Wires on Indoor and Outdoor Terminations ........................ 252
4.4.8 Fitting Plastic Joint Boxes (Trifurcating Joints Only) .............................................. 252
4.4.9 Mixing and Pouring JEM Resin .............................................................................. 254

Version: 1.0
Date: 29/10/2018
1 Introduction
This 33kV Jointing Manual covers the approved methods and associated jointing kits for use
on all non-fluid filled 33kV mains cables within UK Power Networks. This manual is split into
four sections:
 Section 1 Introduction and Safety, Health, Environment and Quality Statement;
 Section 2 Jointing Instructions;
 Section 3 Standard Procedures for Preparing 33kV 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

UK Power Networks requires anyone working on its network to comply fully with its Health,
Safety and Sustainability (HSS) policies and procedures, details of which can be found in the
UK Power Networks’ Document Library (Alfresco/G81 document library). 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.
 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 (PPE) 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 UK Power Networks' 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 specifically authorised to issue such instructions
to them.
 Only competent or authorised persons specifically 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.
 All jointing works shall be carried out in accordance with this document 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.

Version: 1.0
Date: 29/10/2018
1.2 Glossary and Abbreviations
Term Definition
AWS Aluminium Wire Screen

CWS Copper Wire Screen
PPE Personal Protective Equipment
TE TE Connectivity
UK Power Networks UK Power Networks (Operations) Ltd consists of three electricity
distribution networks:
 Eastern Power Networks plc (EPN).
 London Power Network plc (LPN).
 South Eastern Power Networks plc (SPN).
XLPE Cross linked polyethylene

Version: 1.0
Date: 29/10/2018
2 Jointing Instructions
This section contains a complete list of jointing instructions and kit selection tables for all 33kV
joints.
Only joints contained within this section are to be used on the networks within 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.
Imperial Conductor Metric Equivalent

Size (sq. in) Conductor Size (sq.
mm)
0.1 70
0.15 95
0.2 120
0.25 150
0.3 185
0.4 240
0.5 300
0.6 400
0.75 500
1.0 630
1.23 800
1.55 1000
For advice on the jointing of equivalent cable sizes, refer to your supervisor or engineer and
the contents of EDS 02-0034 ‘33kV Single Core XLPE Cables’.

Version: 1.0
Date: 29/10/2018
2.1 Single-Core Polymeric Straight Joints
2.1.1 Single-Core Straight Joints 185 to 300mm2 Conductors
These are all heatshrink joints that contain both phase and wire screen connectors.
Cable Sizes mm2 Joint Kit Description and Part Numbers

TE Part Number SMOE 64545
UKPN Stores Code 02683D
185 185 1 per Joint
185 300 1 per Joint
300 300 1 per Joint
2.1.2 Cable Preparation
Refer to the following sections of this manual for details of the preparation of each type of
cable:
 3.1 Single-Core Wire Screened Cables.
2.1.3 Installation of Heatshrink Materials and Components
Refer to the following sections of this manual for the installation of heatshrink materials and
other components:
 4.2 Installing Mechanical Connectors and Lugs;
 4.2.1 Single-Core Polymeric Straight Joints;
 4.3 Installing Connector Stress Control and Heatshrink Insulation;
 4.4 Installing Mechanical Earth Bonds and Associated Components;
 4.4.1 Single-Core Polymeric Straight Joints.

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018
This all heatshrink joint only contains wire screen connectors.
Cable Sizes Joint Kit Description and Part Numbers

mm2
Description Joint Kit 185/400mm 185/400mm 500mm to 630mm to
to 500mm to 630mm 500mm 630mm
Connector Connector Connector Connector
TE Part Number SMOE BSMB BSMB BSMB 500 BSMB 630
64546 185/400 - 185/400 -
500 630
UKPN Stores 02684N 02665F 02668K 02666Q 02669U
Code
300 400 1 per Joint 1 per Joint
cable:
other components:

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018
This all heatshrink joint only contains wire screen connectors.

mm2
Description Joint Kit 800mm to 630mm to 1000mm to
800mm 1000mm 1000mm
Connector Connector Connector
TE Part Number SMOE BSMB 800 BSMB 630 BSMB
64597 - 1000 1000
UKPN Stores 02693M 02670Q 02690H 02689M
Code
cable:
other components:

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018
2.2 Single-Core PILC to XLPE Transition Straight Joints
2.2.1 Single-Core PILC (95 to 400mm2) to Single-Core Polymeric (185 to 500mm2)
These are all heatshrink joints that are supplied without phase connectors (these come in a
separate kit).

mm2
Description 185mm to 95mm to 300mm 185/400mm to PILC Cable
500mm Joint Connector 500mm Build Up Kit
Kit Connector
TE Part Number SMOE-64548 BSMB 95 – BSMB 185/400- SMOE 62191
300GB 500
UKPN Stores 02687S 02671A 02665F 02651H
Code
PILC POLY
95 185 1 per Joint 1 per Joint 1 per 3 Joints
240 300 1 per Joint

Version: 1.0
Date: 29/10/2018
cable:
 3.1 Single-Core Wire Screened Polymeric Cables;
 3.2 Single-Core Paper Insulated Cables.
other components:
 4.1 Installing Stress Control and Insulation Materials;
 4.1.1 Single-Core Paper Insulated Cables in Transition Joints;
 4.1.7 Paper Insulation Shim Kit for 95mm2 Cables;
 4.1.8 Paper Insulation Shim Kit for 120 and 150mm2 Cables;
 4.2.2 Single-Core Transition Straight Joints;
 4.4.2 Single-Core Transition Straight Joints.

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018
2.2.4 Single-Core PILC (500 to 630mm2) to Single-Core Polymeric (500 to 630mm2)
separate kit).

mm2
Description 500mm to 500mm to 500mm to 630mm to
630mm Joint 500mm 630mm 630mm
Kit Connector Connector Connector
TE Part Number SMOE-64549 BSMB 500 BSMB 500-630 BSMB 630
UKPN Stores 02688C 02666Q 02667A 02669U
Code
PILC POLY

cable:
 3.2 Single-Core Paper Insulated Cables.

other components:
 4.1.1 Single-Core Paper Insulated Cables in Transition Joints;
 4.4.2 Single-Core Transition Straight Joints.

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018
2.3 Three-Core PILC to Single Core XLPE Transition Straight Joints

2.3.1 Three-Core PILC (95 to 300mm2) to Single-Core Polymeric (185 to 500mm2)
These are resin filled heatshrink joints that are supplied without phase connectors (these come
in a separate kit).
Description 185/400mm 95mm to 185/400mm to PILC Cable
to 300mm 500mm Build Up Kit
185/500mm Connector Connector
Joint Kit
TE Part Number SMOE- BSMB 95 – BSMB 185/400- SMOE 62191
64558 300GB 500
UKPN Stores Code 02691S 02671A 02665F 02651H
PILC POLY
95 - 150 185 - 300 1 per Joint 3 per Joint 1 per Joint
185 185 - 300 1 per Joint 3 per Joint
185 - 400 185 - 500 1 per Joint 3 per Joint
Resin Volume = 32 Litres per Joint

cable:
 3.1 Single-Core Wire Screened Cables;
 3.3 Three-Core Paper Insulated Cables.

other components:
 4.1.3 Resin Filled Three-Core Transition Joints;
 4.4.4 Resin Filled Three-Core Transition Joints.

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018
2.3.4 Three-Core PILC (185 to 400mm2) to Single-Core Polymeric (500 to 630mm2)

separate kit).

Description 185/400mm to 185/400mm to PILC Cable
500/630mm 630mm Build Up Kit
Joint Kit Connector
TE Part Number SMOE-64559 BSMB SMOE
185/400 – 630 62191
UKPN Stores Code 02692C 02668K 02651H
PILC POLY
185 630 1 per Joint 3 per Joint 1 per Joint
240 630 1 per Joint 3 per Joint 1 per Joint

cable:

other components:
 4.1.4 Heatshrink Three-Core Transition Joints;
 4.1.7 Paper Insulation 'Shim' Kit for 95mm2 Cables;
 4.1.8 Paper Insulation 'Shim' Kit for 120 and 150mm2 Cables;
 4.4.5 Heatshrink Three-Core Transition Joints.

 Cable Sizes

Version: 1.0
Date: 29/10/2018
mm2 Kit Description and Part

Numb
Tyco OE
637

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018
52

Version: 1.0
Date: 29/10/2018
2.4 Three-Core HSL Transition Joints
2.4.1 Three-Core HSL PILC (95 to 300mm2) to Single-Core Polymeric (185 to 500mm2)
This is a resin filled joint that is supplied without phase connectors (these come in a separate
kit).

Description 185/400mm to 95mm to 185/400mm to PILC Cable HSL
185/500mm 300mm 500mm Build Up Kit Module
Joint Kit Connector Connector
TE Part Number SMOE-64558 BSMB 95 – BSMB SMOE SMOE
300GB 185/400-500 62191 62909
UKPN Stores Code 02691S 02671A 02665F 02651H 02553C
PILC POLY
95 - 150 185 - 300 1 per Joint 3 per Joint 1 per Joint 1 per
Joint
185 185 - 300 1 per Joint 3 per Joint 1 per
Joint
185 - 400 185 - 500 1 per Joint 3 per Joint 1 per
Joint
400 500 1 per Joint 3 per Joint 1 per
Joint
Resin Volume = 32 Litres per Joint
18-
cable:
other components:

Version: 1.0
Date: 29/10/2018
 4.4.6 HSL Transition Joints.

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018
2.5 Single-Core Polymeric Pot End Joints
2.5.1 Single-Core Polymeric Pot End Joints (300mm2)
These are all heatshrink joints containing all the required components.
630SMOE
Cable Sizes mm2 Joint Kit Description and Part
Numbers
Description 300mm Pot End Kit
TE Part Number SMOE-64551
UKPN Stores Code 02685X
300 3 per Joint
cable:
 3.1 Single-Core Wire Screened Polymeric Cables.
other components:
 4.1.2 Single-Core Polymeric Pot End Joints;
 4.4.3 Single-Core Polymeric Pot End Joints.

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018
2.5.4 Single-Core Polymeric Pot End Joints (500 to 630mm2)
630SMOE
Numbers
Description 500/630mm Pot End Kit
TE Part Number SMOE-64552
UKPN Stores Code 02686H
500 3 per Joint
630 3 per Joint
cable:
other components:
 4.1.2 Single-Core Polymeric Pot End Joints;
 4.4.3 Single-Core Polymeric Pot End Joints.

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018
2.6 Indoor and Outdoor Terminations

2.6.1 Indoor and Outdoor Single-Core Polymeric Cable Terminations (300 to 1200mm2)
These are outdoor heatshrink termination kits supplied in sets of three without phase
conductor lugs or wire screen termination kits, which are supplied in a separately. For indoor
terminations use the same kits but reduce the number of sheds from four to two.
mm2
Description 185mm to 1000mm to 185mm to 500mm to 800mm to 1200mm
630mm 1200mm 400mm 630mm 1000mm Mechanical
Termination Termination Mechanical Mechanical Mechanical lug Pack
Kit Kit Lug Pack Lug Pack lug Pack
TE Part SMOE- SMOE- BAH- BAH- BLMT BAH-
Number 64547 64570 038080872 038080873 800/1000-17 024030254
UKPN Stores 02663L 02664V 02675P 02676Y 02678T 02679D
Code
185 1 per Set 1 per Set
800
For a complete outdoor termination assembly use the above kits and the following materials
Description TE Part No UKPN Stores No.
. Code Required
Outdoor Support Bracket EPPA-031 02680Y 1
33kV Surge Arresters OCP2-30M-NFF 09435U 1 Set of 3

cable:

other components:
 4.1.9 Single-Core Polymeric Terminations (Indoor and Outdoor);
 4.2.6 Mechanical Lugs for Indoor and Outdoor Terminations;
 4.4.7 Connection of Copper Wire Screens on Indoor and Outdoor Terminations.

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018
2.7 Polymeric Single Core Cable Sheath Repair Kit
630SMOE
Numbers
Description Polymeric Single Core Cable
Sheath Repair Kit
TE Part Number CRSM 84/20-250/239
UKPN Stores Code 02305F

300 1 per single core
cable:

Version: 1.0
Date: 29/10/2018
K Power

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018
Networks
Stores
Code

Version: 1.0
Date: 29/10/2018
2.8 Type C Seperable Connectors
2.8.1 Type C Seperable Connectors for Single-Core Polymeric Cable (300mm2)
These termination kits are supplied as a set of three, complete with phase conductor lugs. A
separate wire screen termination kit with each kit.

Description 300mm2 Type C Seperable 300mm2 Seperable Connector
Connector Kit AWS Kit
TE Part Number RSTI-6855-GB10 SMOE-64595
UKPN Stores Code 01938C 04198G
300 1 per Termination 1 per Termination
cable:
2.8.3 Installation of Materials and Components
other components:
 4.4.7 Connection of Screen Wires on Indoor and Outdoor Terminations

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018
2.8.4 Type C Seperable Connectors for Single-Core Polymeric Cable (400 to 800mm2)

mm2
Description 400mm2 Type 500/630mm2 800mm2 Type 500/630mm2 1000/1200mm
C Seperable Type C C Seperable Seperable 2 Seperable
Connector Kit Seperable Connector Kit Connector Connector

Connector Kit AWS Kit AWS Kit
TE Part RSTI-6951- RSTI-6952- RSTI-6953- SMOE-64596 SMOE-64608
Number GB10 GB10 GB10
UKPN Stores 01939M 01940H 01941S 04199R 02659L
Code
1 per 1 per
400
Termination Termination
1 per 1 per
500
1 per 1 per
630
1 per 1 per
800
cable:
other components:

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018

Description 1000mm2 Type C Seperable 1000 & 1200mm2 Seperable
Connector Kit Connector AWS Kit
TE Part Number RSTI-6954-GB10 SMOE-64608
UKPN Stores Code 02682T 02659L
cable:
other components:

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018

Description 1200mm2 Type C Seperable Connector 1000 & 1200mm 2
Kit Seperable Connector
AWS Kit
Nexans Part Number 3XM489TB/G-S-56-800.1200-14.5-V CW SMOE-64608
UKPN Stores Code 02694W 02659L
cable:
other components:

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018
2.9 Inner Cone Size 3 Terminations

2.9.1 Inner Cone Size 3 Terminations for Single-Core Polymeric Cable (300 to 630mm2)
Due to the fact that XLPE cable is manufacture to set of minimum standards, dimensions can
vary between individual drums. It is therefore important that cable dimensions are physically
checked before terminations are ordered. The table below provides the details required to
ensure the correct kits are used (All dimension should be measured using a diameter tape):
mm2
Description 400mm2 Type 500/630mm2 800mm2 Type 500/630mm2 1000/1200mm2
C Seperable Type C C Seperable Seperable Seperable
Connector Kit Seperable Connector Kit Connector Connector AWS
Connector Kit AWS Kit Kit
TE Part RSTI-6951- RSTI-6952- RSTI-6953- SMOE-64596 SMOE-64608
Number GB10 GB10 GB10
UKPN Stores 01939M 01940H 01941S 04199R 02659L
Code
400 1 per 1 per
500 1 per 1 per
630 1 per 1 per
800 1 per 1 per
cable:
other components:
 4.2.6Mechanical Lugs for Indoor and Outdoor Terminations;

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018

Version: 1.0
Date: 29/10/2018
3 Standard Procedures for Preparing 33kV Cables

3.1 Single-Core Wire Screened Polymeric Cables
3.1.1 Outer Sheath Removal
 Clean and abrade the outer sheath with an approved abrasive paper for 150mm beyond
the sheath removal point.
 Mark the removal point of the outer sheath as indicated on the relevant jointing instruction
using a Chinagraph pencil.
 Use an approved tool to remove the sheath. check the tool cutting wheel is set to the
correct depth to avoid damaging the copper wire screens below.
 Starting at the removal point make a circular cut around the cable. Cut along the cable to
the position of the sheath removal point, and remove the sheath.
 It is essential that the correct tool is used to remove the outer sheath, as any damage to
the aluminium wires at the point, where they are bent against the sheath can result in them
snapping.
185
630
1
per
Joint
3
per
Joint
1
per
300 630
1 per Joint 3 per Joint

Version: 1.0
Date: 29/10/2018
3.1.2 Removing the Conductive Layer from the Outer Sheath
 Apply four half lap layers of PVC tape to the exposed aluminium wire screen for 50mm
beyond the sheath removal point. To protect the wire during the conductive layer removal
process.
 Remove the semi-conductive layer from the outer sheath using the approved stripping tool
to the dimension shown in the relevant jointing instruction.
 Remove residues of the semi conducting sheath material using either a scraper or shave
hook.
 Using a ruler mark the prepared surface of the outer sheath with a Chinagraph pencil every
20mm along the sheath. Starting from the outer sheath cut for a distance of 100mm.
 Apply a short length of tinned copper mesh or a tinned copper wire binder around the
sheath at each of the marks.
 Using a 500V megger, measure the insulation resistance between each adjacent pair of
wire binders. The measured insulation resistance value should be greater than 100MΩ.
 If the insulation resistance is below 100MΩ, remove more of the outer sheath with the
scraper or shave hook and retest.

Version: 1.0
Date: 29/10/2018
 Abrade the outer sheath with the semi-conductive layer removed using 60/80 grade
aluminium oxide tape to form a water seal.
2651H
3.1.3 Binder Tape Removal
 Remove the fabric or plastic tape wrap from the screen wire using an approved knife,
 taking care not to damage the aluminium or copper wires below.
3.1.4 Removing and Terminating the Aluminium or Copper Wire Screens
 Mark the screen cut point on the aluminium or copper wire screen as indicated on the
relevant jointing instruction, using a Chinagraph pencil.

Version: 1.0
Date: 29/10/2018
 Apply 6 turns of PVC tape around the wire screen on the outer sheath side of the screen
removal position.
 Ring around the wire screen at the wire screen cut position with an insulated junior
hacksaw. Care should be taken to only score the surface of the aluminium wires and not
cut into the insulation screen below.
 Bend the individual aluminium or copper wires back against the previously made score at
the wire screen removal point. The aluminium wires will break at the score position and
can then be removed.

Version: 1.0
Date: 29/10/2018
 Once all the screen wires have been removed, unwind the water swelling tape from the
insulation and tear it off at the screen cut position.
3.1.5 Removing the Bonded Polymeric Screen
 The approved bonded screen stripping tool can be used to remove the black insulation
screen from the outer sheath cut. This measurement varies depending upon the type of
joint or termination being made:
 Smear a thin coating of Silicone grease over the conducting screen layer. Starting at the
open end of the cable, set the tool to the correct cutting depth so that the entire screen is
removed with only the minimum amount of insulation. It is essential that the core is as
straight as possible for this operation otherwise traces of the screen may be left behind.

Version: 1.0
Date: 29/10/2018
 Continue turning the tool until it butts up against the stop position (dependant on the screen
termination point) and continue to turn the tool until a smooth right angled taper is
produced. Test the tool firstly on the overlap section of the core if required.
 The insulation now requires polishing smooth with an appropriate aluminium oxide grit
paper (minimum 150 grade) until smooth and free of ridges. To finish this process, reverse
the paper and 'buff up' with the smooth side.
 Clean and degrease the insulation with an approved solvent wipe to remove all traces of
any remaining loose material. Always wipe from the open core end towards the screen
wires to avoid contaminating the insulation with carbon from the remaining screen.

Version: 1.0
Date: 29/10/2018
3.1.6 Installing the Wire Screen Earth Connection
 Lift the individual aluminium wire screen wire against the sheath cut, so they are at a 90
degree angle to the cable core.
 Using the brass support ring as a guide, make a Chinagraph pencil mark on the inner
bedding paper, level with the end of the support ring.
 Using the brass support ring as a guide, build up the diameter of the cable core, with PVC
tape to match the inside diameter of the support ring. In line with the Chinagraph pencil
mark on the cable core bending tape.

Version: 1.0
Date: 29/10/2018
 Slide the brass support ring over the PVC tape, so it is level with the end of the PVC tape.
 Slide the brass support ring over the PVC tape, so it is level with the end of the PVC tape.
 Bend the individual aluminium wires down onto the surface of the brass support ring.

Version: 1.0
Date: 29/10/2018
 Apply 3 layers of PVC tape around the screen wires to temporarily hold them in place.
3.1.7 Removing the Polymeric Insulation
 Use the approved Alroc tool and set the 'stop gauge' to the connector insertion depth.
 Position the tool at the open core end and adjust the blade to the required depth; just deep
enough so the blade does not damage the conductor.
 Rotate the tool along the core using the spiral cut setting until the stop gauge prevents it
from moving any further.

Version: 1.0
Date: 29/10/2018
 Remove the tool and the insulation spiral. Carefully remove the remaining conductor
screen using an approved knife.
3.2 Single-Core Lead Covered Cables
3.2.1 Removing the Outer Serving or Sheath
 Mark the position of the serving or sheath termination as indicated on the relevant jointing
instruction.
 Make a circular cut at this mark using an appropriate approved tool. Check that the cut is
only three quarters through the sheath thickness.

Version: 1.0
Date: 29/10/2018
 Now make a lengthwise cut along the sheath towards the sheath cut position taking
care not to damage the underlying lead sheath.
 Lift the edge of the sheath and unwrap along its length, tearing off at the circular cut
point. The use of a gas torch may assist this operation if necessary.
3.2.2 Removing the Lead Sheath
 Clean and degrease the lead sheath using the approved solvent wipes. Mark the lead
sheath at the removal point as indicated on the relevant jointing instruction using a
Chinagraph pencil.

Version: 1.0
Date: 29/10/2018
 Use an approved hack knife to make an indented circular cut around the lead sheath,
taking care to only cut part way through the sheath.
 Cut the lead sheath across from the open cable end to the circular cut. Use an appropriate
approved hack knife. Take care not to damage the Copper Woven tape below.
 Open the lead sheath up along the length of the cut and carefully unwrap the lead sheath
against the ring cut.

Version: 1.0
Date: 29/10/2018
3.2.3 Removing the Copper Woven Tape (CWT)
 Unwind the CWT and carefully remove it by cutting it against the lead sheath edge with an
approved knife to leave a smooth finish.
3.2.4 Removing the Insulation Screen
 Mark the screen papers with a Chinagraph pencil at the removal point indicated in the
relevant jointing instruction. Tie a twine binder around the screen at this point.
 Unwrap the screen carefully to the termination point and remove it by neatly tearing against
the twine binder. Remove any carbon paper below the screen to the same termination
position, followed by two of the insulation papers.

Version: 1.0
Date: 29/10/2018
3.2.5 Removing the Insulation Papers
 Only remove the papers after fitting the barrier tubing as described in Section 4.1.1. Mark
the insulation papers at the point of removal as indicated in the appropriate jointing
instruction. Using an approved sharp knife, cut around the core through the papers and
clear barrier tube taking care not to damage the conductor below.
 Remove the clear barrier tube by pulling towards the end with a gentle twisting movement.
 Unwrap the papers up to the cut position and tear off neatly against the barrier tube edge.
 Clean any surplus compound from the cable conductor with an approved solvent wipe.

Version: 1.0
Date: 29/10/2018
3.3 Three-Core Paper Insulated Cables
3.3.1 Removing the Outer Hessian Serving or (PE) Sheath
 Mark the position of the serving or sheath termination as indicated on the relevant
jointing instruction.
 Wear suitable gloves while removing the serving. Place a wire binder around the serving
at the removal point and score in front of the binder using an approved knife.
 Remove the serving with the approved knife and heat from a gas torch if required or in the
case of a polyethylene sheath use the approved tool for this operation.
3.3.2 Removing the Steel Wire Armour
 Place a wire binder around the armour wires at the point of removal as indicated in the
relevant jointing instruction.

Version: 1.0
Date: 29/10/2018
 Using an approved saw, make a circular cut around the armours at the binder position.
Cut through only half the width of the armour to avoid damaging the lead sheath below.
 Wear suitable gloves while removing the armour. Lift and unwrap the armour wires a few
at a time and break them off against the binder by bending them backwards and forwards.
 Remove the binder and lift the armours with a hack knife so they are 90° to the cable.
Clean off all traces of bitumen from the wires using a gas torch and approved solvent
wipes.

Version: 1.0
Date: 29/10/2018
3.3.3 Removing the Inner Bitumen Layer
 Wear suitable gloves for this operation. Score around the inner bedding layers with an
approved knife adjacent to the vertical armours taking great care not to score into the
underlying lead sheath.
 At the open cable end lift the bitumen impregnated textile layer with a knife and unwrap it
back to the vertical armour position, tearing it against the score previously made. The use
of a gas torch may assist this process.
 Apply more heat to the final layer of bitumen on the lead sheath and armours and wipe off
any remaining traces of bitumen with approved solvent wipes. The lead sheath and
armours should be clean and bright after this process.

Version: 1.0
Date: 29/10/2018
 Apply two wraps of black mastic sealant around the lead sheath butting up against the
raised armours.
 Make a mark with a Chinagraph pencil 130mm from the end of the outer sheath. Wrap a
length of copper mesh around the lead sheath up to the 130mm mark.
 Lay the armours down over the mastic, ensuring that none are crossed, and secure the
armours over the copper mesh area with the two worm drive clips provided.

Version: 1.0
Date: 29/10/2018
 Apply a layer of PVC tape to the worm drive clips to cover any sharp edges. Position the
armour sealing sleeve 30mm beyond the armour edge and shrink down starting at the lead
sheath end before proceeding towards the cable over-sheath.
3.3.4 Removing the Lead Sheath
 Clean and degrease the lead sheath using approved solvent wipes. Use a Chinagraph
pencil to mark the lead sheath 430mm from the outer sheath as indicated on the relevant
jointing instruction.

Version: 1.0
Date: 29/10/2018
 Wear suitable gloves for this operation. Use an approved hack knife to make a circular
indented ring cut around the lead sheath at the pencil mark, taking care to only cut part
way through the sheath.
 From the open cable end, cut the lead sheath longitudinally to the circular cut using the
appropriate approved hack knife. Take care not to damage the Copper Woven Tape
(CWT) below.

Version: 1.0
Date: 29/10/2018
3.3.5 Removing the Copper Woven Tapes (CWT)
 Unwind the CWT and remove the core fillers carefully with the side cutters.
 Rewind the CWT tightly around the cable cores at the crutch position for a distance of
20mm from the lead sheath, then cut and tie off. Remove any surplus tape with insulated
side cutters.
 Using an approved solvent wipe, remove any surplus cable compound from the
screened core insulation.
 Mark the screen papers at the removal point indicated in the relevant jointing instruction.
Tie a fine wire binder around the screens at this point.

Version: 1.0
Date: 29/10/2018
 Carefully unwrap the first 50mm of the screen. Secure the end of the core insulation papers
with numbered phase tape matching the numeral paper. Unwind the remainder of the
screen to the termination point and remove it by neatly tearing against the applied binder.
 Remove the numeral paper and one layer of paper below to the same point as the screen
papers, using the same method and marking the cores with the matching numbered phase
tape.
 Note: It is important to mark the cores with the correct phase numbers immediately after
each numeral paper is removed.

Version: 1.0
Date: 29/10/2018
 Only remove the papers after fitting the clear barrier tubes described in Section 4.1.3.
 Mark the clear barrier tube over the core papers at the point of removal as indicated in the
appropriate jointing instruction.
 Using a sharp knife cut around the core and through the papers taking care not to damage
the conductor below.

Version: 1.0
Date: 29/10/2018
 Rounding of the conductor with water pump or similar pliers will assist this operation and
will help prepare the conductor for insertion into the appropriate connector.
 Unwrap the papers to the cut position and tear off against the clear barrier tube edge.
 Clean any surplus compound from the cable conductor with an approved solvent wipe.

Version: 1.0
Date: 29/10/2018
3.4 Three-Core HSL Paper Insulated Cables
3.4.1 Removing the Outer Serving or Sheath
 Mark the position of the serving or sheath termination as indicated on the relevant jointing
Instruction.
 Wear suitable gloves while removing the serving. Place a wire binder around the serving
at the removal point and score in front of the binder using an approved knife.
 Remove the serving with the approved knife and heat from a gas torch if required.

Version: 1.0
Date: 29/10/2018
3.4.2 Removing the Steel Wire Armour
 Place a wire binder around the armour wires at the point of removal as indicated in the
relevant jointing instruction.
 Using an approved depth guarded or junior saw make a circular cut around the armours
at the binder position. Cut through only half the width of the armour to avoid damaging the
lead sheaths below.
 Wear suitable gloves while removing the armour. Lift and unwrap the armour wires a few
at a time and break them off against the binder by bending them backwards and forwards.

Version: 1.0
Date: 29/10/2018
 At the open cable end lift the bitumen impregnated layer with a knife and unwrap it back
to the armour cut position. Remove it at this point, taking care not to damage the underlying
lead sheaths.
 Remove the binder and lift the armours with an approved hack knife so they are 90° to the
cable. Clean off all traces of bitumen from the wires using a gas torch and approved solvent
wipes.
3.4.3 Removing the Bitumen Layer
 Open out the three lead sheaths carefully and remove the bitumen/paper layer and fillers
from all three sheaths up to the point where the under armour bedding remains.

Version: 1.0
Date: 29/10/2018
 Apply more heat to the final layer of bitumen on the lead sheaths and wipe off all traces of
bitumen with the approved solvent wipes.
 The lead sheaths should be free from bitumen on completion of this task.
 Build up the remaining inner bedding using the black mastic from the Three-Core transition
joint and the HSL module to suit the support ring’s inner diameter. Fit the support ring over
the build-up tape, positioning it 60mm from the uplifted armours.

Version: 1.0
Date: 29/10/2018
 Wrap the length of supplied black mastic behind the support ring, butting it against the
armours wires. Lay the armours down onto the ring and secure them with a wire binder.
3.4.4 Removing the Lead Sheaths
 Only remove the lead sheaths after firstly following the necessary steps described in
Section 4.1.5. (HSL module application).
 Clean and degrease the lead sheaths using approved solvent wipes. Use a Chinagraph
pencil to mark the lead sheaths at the removal point as indicated on the relevant jointing
instruction.
 Use an approved hack knife, make a circular indented ring cut around the lead sheath at
the pencil mark, taking care to only cut part way through the sheath.
 Cut the lead sheath across from the open cable end to the circular cut. Use an appropriate
approved hack knife. Take care not to damage the Copper Woven tape below.

Version: 1.0
Date: 29/10/2018
3.4.5 Removing the Copper Woven Tape (CWT)
 Unwind the CWT and carefully remove it by cutting it against the lead sheath edge with an
approved knife to leave a smooth finish.

Version: 1.0
Date: 29/10/2018
 Mark the screen papers with a Chinagraph pencil at the removal point indicated in the
relevant jointing instruction. Tie a twine binder around the screen at this point.
 Unwrap the screen carefully to the termination point and remove it by neatly tearing against
the twine binder. Remove any carbon paper below the screen to the same termination
position, followed by two of the insulation papers.

Version: 1.0
Date: 29/10/2018
 Only remove the papers after fitting the barrier tubing as described in Section 3.1.2. Mark
the insulation papers at the point of removal as indicated in the appropriate jointing
instruction. Using an approved sharp knife, cut around the core through the papers and
clear barrier tube taking care not to damage the conductor below.
 Unwrap the papers up to the cut position and tear off neatly against the barrier tube edge.

Version: 1.0
Date: 29/10/2018
 Clean any surplus compound from the cable conductor with an approved wipe.

Version: 1.0
Date: 29/10/2018
3.5 Moisture Testing on Paper Insulated Cables
 Full Personal Protective Equipment (PPE) shall be worn at all times for this test.
 Gently heat the paraffin wax container on a low heat, insert the thermometer through one
of the rubber grommets in the top and wait until the wax reaches a temperature of 125°C.
 Always handle the papers to be tested with gloves, as moisture from your hands is
enough to give a positive test.
 Lift out the basket and place the paper tapes to be tested in it.
 The samples from the following layers shall be tested:
 Inner and outer belt papers.
 Paper or string fillers.
 Inner and outer core papers.
 Immerse the basket complete with papers in the paraffin wax bath and note the results.
 If there is no reaction from the wax or it froths slightly, the papers are dry and the cable is
fit to be jointed.

Version: 1.0
Date: 29/10/2018
 If the wax froths excessively and a crackling noise is heard, the papers are wet and the
cable should not be jointed.
 Remove the heat from container and leave to cool before moving.
 The wax can be re-used until it starts to discolour and there is no need to dispose of it after
each moisture test.

Version: 1.0
Date: 29/10/2018
4 Installing Heatshrink Materials and Components

4.1 Installing Stress Control and Insulation Materials
4.1.1 Single-Core Paper Insulated Cables in Transition Joints
 Prepare the cable as described in Section 3.2. Use a Chinagraph pencil to mark 20mm
onto the lead sheath and 10mm onto the insulation papers.
 Remove the release paper from the medium length of yellow stress control tape. Stretch
the tape to about half its original width and wrap it around the lead sheath for 20mm.
Remove the twine binder from the screen edge and continue with the tape over the screen
papers and onto the insulation for 10mm.

Version: 1.0
Date: 29/10/2018
 Use a Chinagraph pencil to mark the lead sheath 20mm beyond the yellow stress control
tape. Position the clear barrier tubing over the core end and over the yellow stress control
tape, overlapping onto the lead sheath by 20mm.
 Shrink the tubing down, starting on the lead sheath and continuing towards the core end.
Once completed the tubing should be fully shrunk and have a smooth finish without
wrinkles or creases.
 Position the short black conductive sleeve 220mm from the core end and shrink the tubing
down starting at the open cable end before working towards the lead sheath.

Version: 1.0
Date: 29/10/2018
4.1.2 Single-Core Polymeric Pot Ends
 Prepare the cables as described in Section 3.1 up to and including the screen removal
point. The dimension for the screen is 80mm.
 Remove the insulation for 30mm from the end of the cable.
 Clean and degrease the insulation with an approved solvent wipe to remove all traces of
conducting material. Always wipe from the open cut end towards the screen wires to
avoid contaminating the insulation with carbon from the screen layer.
 Wrap the conductive tape supplied in the jointing kit around the 30mm of exposed
conductor stretching it to about half its original width.

Version: 1.0
Date: 29/10/2018
 Increase the conductor diameter sufficiently so that the insulating rod is a snug fit over the
conductor. Push the insulating rod onto the conductor ensuring that it butts against the
cable insulation.
 Use a short strip of yellow stress control mastic and remove the release papers from a
short strip of yellow stress control mastic tape.
 Wrap it around the edge of the insulation screen starting 20mm from the screen edge,
before continuing for 10mm on to the core insulation.
 Stretch the tape to approximately half its original width to obtain a fine edge onto the
insulation.
 Using a long strip of yellow stress control mastic and remove the release papers.
 Wrap it around the core insulation starting 10mm from the insulation edge, before
continuing on to the insulating rod covering the 'painted area' and 10mm beyond on to
the rod insulation.

Version: 1.0
Date: 29/10/2018
 Use only as much of the yellow stress control mastic as necessary to fill in the step
between the insulation and the rod.
 Using a long strip of yellow stress control mastic and remove the release papers. Wrap it
around the core insulation starting 10mm from the insulation edge, before continuing on
to the insulating rod covering the 'painted area' and 10mm beyond on to the rod
insulation.
 Use only as much of the yellow stress control mastic as necessary to fill in the step
between the insulation and the rod.

Version: 1.0
Date: 29/10/2018
 Wrap one layer of red mastic around the insulating rod 60mm from its end and with a width
of 10mm.
 Position the black stress control tubing over the insulating rod and butt it up against the
cable oversheath cut. Shrink the tubing down starting at the oversheath end before
working towards the insulating rod end.
 Use one layer of red mastic around each end of the installed stress controlled tube 60mm
in from each end and with a width of 10mm.

Version: 1.0
Date: 29/10/2018
 Slide the red insulating tubing over the stress control tube butting it against the cable
oversheath and coinciding with the stress control tubing edge.
 Shrink the tubing down starting at the over-sheath end and working towards the insulating
rod end.
 Place the black and red screened insulating tubing over the assembly and position it to
coincide with the previously installed tubes.

Version: 1.0
Date: 29/10/2018
 Shrink the black and red tube down starting in the centre. When this section is fully shrunk
it should be smooth without ridges and should not move when twisting the tube end.
 Continue the shrinking process, working towards one end and stopping 50mm from the
end. Then shrink towards the opposite end stopping 50mm from the end. Finally, shrink
down the first remaining 50mm of tubing followed by the second 50mm of tubing. This
process ensures that no air is trapped inside the tube.
Core Polymeric Cables)
 Prepare the cables up to the point as described in Section 3.3.

 Protect the Copper Woven Tape (CWT) with nylon tape, starting from 20mm onto the lead
sheath extending 30mm onto the cores. The nylon tape should be applied with tension.

Version: 1.0
Date: 29/10/2018
 At the screen termination position wrap one layer of void filling yellow stress control mastic
around each core, overlapping the screen papers by 20mm and the insulation by 10mm.
Remove the metal binder from the screen edge during the taping process.
 Slide the clear barrier tubing over each core and position 30mm from the end of the metal
sheath. Shrink down the tubing starting at the crutch position working towards the open
core ends. Check the tubing is shrunk down evenly and free from creases or wrinkles.

Version: 1.0
Date: 29/10/2018
 Slide the black conducting tubing over the core ends and position them 50mm from the
end of the metal sheath. Shrink the tubes down at this position starting at the crutch before
working towards the core ends.
 Slide the small yellow mastic wedge into the crutch using the installation tool provided.
Take the larger wedge and insert it into the crutch behind the smaller wedge using the
same tool. Remove the nylon tape after insertion of both wedges.

Version: 1.0
Date: 29/10/2018
 Degrease the cores using approved solvent wipes. Make a Chinagraph pencil mark on the
conductive tubes 70mm from the lead sheath cut and for 20mm onto the lead sheath.
 Wrap strips of yellow mastic around the crutch between the two Chinagraph pencil marks.
Apply sufficient tension to stretch the tape to half its original width until a 'cone' shape is
formed.
 Pass the conductive breakout over the cores and push it well down into the crutch, using
the yellow wedge installation tool. Hold the breakout in place and shrink it down starting at
the centre, before firstly working towards the lead sheath and then towards the breakout
fingers.

Version: 1.0
Date: 29/10/2018
4.1.4 Heatshrink Three-Core Transition Straight Joint (Three-Core Paper to 3 x Single-

 Prepare the cables up to the point as described in Section 3.3.

 Protect the CWT with nylon tape, starting 20mm onto the lead sheath extending 30mm
onto the cores. The nylon tape should be applied with tension.
 At the screen termination position wrap one layer of void filling yellow stress control mastic
around each core overlapping the screen papers by 20mm and the insulation by 10mm.
Remove the metal binder from the screen edge during the taping process.

Version: 1.0
Date: 29/10/2018
 Slide the clear barrier tubing over each core and position 30mm from the end of the metal
sheath. Shrink down the tubing starting at the crutch position before working towards the
open core ends. Check the tubing is shrunk down evenly and is free from creases or
wrinkles.
 Slide the black conducting tubing over the core ends and position them 50mm from the
end of the metal sheath. Shrink the tubes down at this position starting at the crutch
working towards the core ends.

Version: 1.0
Date: 29/10/2018
 Slide the smaller supplied yellow mastic wedge into the crutch using the installation tool
provided. Take the larger wedge and insert it into the crutch behind the smaller wedge
using the same tool. Remove the nylon tape after insertion of both wedges.
 Degrease the cores using approved solvent wipes. Make a Chinagraph pencil mark on the
conductive tubes 70mm from the lead sheath cut and for 20mm onto the lead sheath.

Version: 1.0
Date: 29/10/2018
 Wrap the strips of yellow stress control mastic around the crutch between the two
Chinagraph pencil marks. Apply sufficient tension to stretch the tape to half its original
width until a cone shape is formed.
 Pass the conductive breakout over the cores and push it well down into the crutch, using
the yellow wedge installation tool. Hold the breakout in place and shrink it down, starting
at the centre before working towards the lead sheath and then towards the breakout
fingers.

Version: 1.0
Date: 29/10/2018
 Position the short length of wrap-around heatshrink tube over the paper cable so that it
covers the lead sheath and the three finger break out. Leave a gap of at least 100mm
between the end of the wrap around and the armour sealing sleeve.
 Shrink the wrap-around in place starting in the middle, until the surface paint on the tube
turns from green to black. Then gradually move to each end using the same process. Extra
heat should be applied to the metal channel until the white marker line can be clearly seen
under it.
 Position the short sealing heatshrink tubes over the turrets of the heatshrink breakout,
ensuring they are pushed right into the crutch and shrink in place.

Version: 1.0
Date: 29/10/2018
4.1.5 HSL Breakout Module
 Prepare the cables up to the point as described in Section 3.4.1 to 3.4.3.

 Use a Chinagraph pencil to mark each lead sheath 100mm from the armour cut edge. Fold
a short length of tinned copper mesh in half-length ways.
 Wrap the tinned copper mesh around the lead sheaths centred on the 100mm mark.
 Position one of the lengths of braid over the mesh so that the loose end points away from
the crutch of the cable.

Version: 1.0
Date: 29/10/2018
 Secure a length of earth braid to each lead of the lead sheaths using one turn of the roll
springs directly on to the copper mesh wrap.
 Bend the braids back over the roll spring and then secure in place with the remaining turns.
 Cover each of the roll springs with two layers of PVC tape.

Version: 1.0
Date: 29/10/2018
 Secure the braid ends to the armours and the support ring with a roll of tinned copper
mesh sandwiching the braids between the mesh wraps.
 Finally, secure the mesh and braids to the support ring and armours using the worm drive
clips provided, with one clip either side of the support ring’s central ridge.

Version: 1.0
Date: 29/10/2018
 Cover the worm drive clips with PVC tape to tidy up their loose ends.
 Slide a sealing sleeve over each lead sheath and roll spring connection up to where the
earth braid meets the support ring. Shrink them down starting on the lead sheaths and
continuing towards the armour wires area.
 Wrap a strip of black mastic behind the support ring over the armour wires, filling the space
between the ring and the outer sheath.

Version: 1.0
Date: 29/10/2018
 Pass the breakout over the lead sealing sleeves and pull down into the crutch. Shrink the
breakout down starting in the centre before moving towards the over-sheath and then
shrink the breakout fingers.
 Position the crutch sealing sleeve with one end level with the end of the fingers on the
breakout and shrink into place.
4.1.6 HSL Cable Core Preparation
 Prepare the cables as detailed in Section 4.1.5 and remove the lead sheaths as
described in Section 3.4.4.
 Use a Chinagraph pencil to mark 20mm onto the lead sheath, and 10mm onto the
insulation papers.

Version: 1.0
Date: 29/10/2018
 Remove the release paper from one of the medium lengths yellow stress control tape.
Stretch the tape to about half its original width and wrap it around the lead sheath for
20mm. Remove the twine binder from the screen edge and continue with the tape over the
screen papers and on to the insulation for 10mm.
 Make a mark on the lead sheath using a Chinagraph pencil 20mm beyond the yellow stress
control tape. Position the clear barrier tubing over the core end and the yellow stress
control tape overlapping onto the lead sheath by 20mm.
 Shrink the tubing down, starting on the lead sheath and continuing towards the core end.
Once completed the tubing should be fully shrunk and have a smooth finish without
wrinkles or creases.

Version: 1.0
Date: 29/10/2018
 Position the short black conductive sleeve 220mm from the core end and shrink the tubing
down, starting at the open cable end before working towards the lead sheath.
4.1.7 Paper Insulation 'Shim Kit' for Cable Cross Sections 70mm² & 95mm²
 For cables below the minimum size range specified on the kit label a 'shim kit' must be
used.
 The cables will be at the stage of preparation described in Sections 4.1.1, 4.1.3, 4.1.4 or
4.1.6.
 Apply a piece of the yellow stress control tape 20mm over the end of the conductive tube
and onto the clear tubing by 10mm. Use some of the yellow tape provided in the main joint
kit.
 Position a short length of the smaller diameter stress control tubing (42/16) over the core
end, overlapping the conductive tubes and the yellow stress control mastic by 40mm.

Version: 1.0
Date: 29/10/2018
 Shrink the stress control tubing down, starting from the yellow mastic tape and working
towards the open core end.
 Wrap one of the red mastic strips provided around the end of the stress control tube 30mm
on to the tubing and 10mm on to the core.
 Position a short length of the larger diameter stress control tubing (54/24) directly over the
previously applied stress control tube and shrink down following the same procedure as
before.

Version: 1.0
Date: 29/10/2018
 Apply one of the red mastic strips provided around the end of the stress control tube 30mm
on to the tubing and 10mm on to the previously applied red mastic.
 For cables below the minimum size range specified on the kit label, a 'shim kit' must be
used.
4.1.6.
 Apply a short length of the yellow stress control tape 20mm over the end of the conductive
tube and onto the clear tubing by 10mm. Use some of the yellow tape supplied in the main
joint kit.
 Position a short length of the stress control tubing (54/24) over the core end, overlapping
the conductive tubes and the yellow stress control mastic by 40mm.

Version: 1.0
Date: 29/10/2018
 Wrap one of the red mastic strips provided around each end of the stress control tube
30mm on to the tubing and 10mm on to the core.
 Position a short length of the larger diameter stress control tubing (54/24) directly over the
previously applied stress control tube and shrink down following the same procedure as
before.

Version: 1.0
Date: 29/10/2018
 Apply one of the red mastic strips provided around the end of the stress control tube 30mm
on to the tubing and 10mm on to the previously applied red mastic.
 For cables below the minimum size range specified on the kit label, a 'shim kit' must be
used.
4.1.6.
 Apply a short length of the yellow stress control tape 20mm over the end of the conductive
tube and onto the clear tubing by 10mm. Use some of the yellow tape supplied in the main
joint kit.
 Position a short length of the stress control tubing (54/24) over the core end, overlapping
the conductive tubes and the yellow stress control mastic by 40mm.

Version: 1.0
Date: 29/10/2018
4.1.10 Single-Core Polymeric Terminations (Indoor and Outdoor)
 Follow the cable preparation procedures for polymeric cables as described in Section 3.1.
 Use a Chinagraph pencil to mark the outer sheath 60mm below the sheath cut position.
 Wrap one layer of red sealant tape over the cable sheath down to the Chinagraph pencil
mark.

Version: 1.0
Date: 29/10/2018
 Make a Chinagraph pencil mark onto the core screen 40mm from the sheath cut.
 Remove the core screen down to the 40mm mark using the approved insulation screen
stripping tool.
 Make a mark with a Chinagraph pencil 20mm on to the core screen and 10mm on to the
insulation.

Version: 1.0
Date: 29/10/2018
 Remove the release paper and wrap the yellow stress control mastic around the screen
cut between the two pencil marks. Stretch the tape to half its original width to achieve a
fine thin edge onto the insulation.
 Position the black stress control tubing over the core so that it is level with the outer sheath
cut. Shrink the tubing down, starting at the sheath cut end and working upwards. When
fully shrunk the tubing should be smooth and wrinkle free.
 Remove the insulation from the core end according to the inner dimension of the cable lug
barrel.

Version: 1.0
Date: 29/10/2018
 Fit the cable lug ensuring that the lug butts against the insulation edge and hand tighten
the securing bolts.
 Shear off the bolt heads using the approved tools and fill in the indents with the grey clay
provided.

Version: 1.0
Date: 29/10/2018
 Wrap the red sealant tape around the lug barrel, overlapping onto the insulation. Build up
the diameter difference with the red tape so that a smooth and even profile is achieved.
 Remove the release paper from the red tubing. Place the tubing over the cable end (with
the sealant coated end downwards), level with the bottom of the red mastic.
 Shrink the tubing down starting at the outer sheath end, before working towards the cable
lug.

Version: 1.0
Date: 29/10/2018
 Cut the tubing back onto the cable lug, level with the top of the main body, if necessary.
 Post-heat the palm of the cable lug until a bead of the sealant appears around the top of
the tubing.
 Use a Chinagraph pencil to mark the position for the sheds on the tubing at the dimension
given in the termination instruction.
 Place two skirts over the cable end and position on the previously made marks. Shrink
each shed in place.

Version: 1.0
Date: 29/10/2018
 For outdoor terminations there are four skirts to be fitted to each termination. These should
be placed and shrunk into position at the measurements indicated in the relevant jointing
instruction.

Version: 1.0
Date: 29/10/2018
4.2 Installing Mechanical Connectors and Lugs
4.2.1 Single-Core Polymeric Straight Joints
 The cables will have been prepared up to the point as described in Section 3.1.
 Position the combined stress control, screened insulating tubing and outer sealing sleeve
over one of the cable ends.
 Remove the insulation as described in Section 3.1.3.
 The connector comes with metal inserts to fit small conductors. If the conductor will not fit
the connector, discard the insert and use the connector without it.

Version: 1.0
Date: 29/10/2018
 Fit the conductors into the connector. The insulation should butt against the end of the
connector.
 Using the approved insulated tool to hold the connector, take up the tension on all the bolts
equally without shearing them off.
 Continue to tighten and sheer off all the bolts starting with the bolts at each end followed
by the central bolts.

Version: 1.0
Date: 29/10/2018
 Fill the bolt holes in the connector with the grey clay supplied in the joint kit.
4.2.2 Single-Core Transitional Straight Joints
 The cables will have been prepared up to the point as described in Sections 3.1 and 3.2.
 Slide the five-piece tubing set over the polymeric cable side. Nesting the tube set on the
plastic bag wrapping will keep the inside of the tubes clean. The tube set should be
placed in the order shown.
Note: It is important that the fourth tube (the second largest) is placed within the tube
set so that the uncoated inner edge points towards the joint centre.
 Remove the insulation from both cables using the methods described in Sections 3.1.3
and 3.2.5.

Version: 1.0
Date: 29/10/2018
 The connector is a 'Two Piece' design with the two halves secured together with a central
shear bolt. Each connector half has two conductor securing bolts which are also of the
shear off type.
 Fit the conductors into the connector. The insulation should butt against each end of the
connector.
 Using the approved insulated tool to hold the connector, take up the tension on all the bolts
equally without shearing them off.

Version: 1.0
Date: 29/10/2018
 Continue to tighten and sheer off all the bolts starting with those at each end followed by
the central bolt.
 Fill the bolt holes in the connector with the grey clay supplied in the joint kit.
4.2.3 Resin Filled Three-Core Trifurcating Joints (Three-Core Paper to 3 x Single-Core

Polymeric Cables)
 The cables will have been prepared up to the point as described in Section 3.1 and 4.1.3.
 Slide the plastic trifurcating end of the plastic joint box over the single-core cables and
position it away from the jointing area.

Version: 1.0
Date: 29/10/2018
 Slide the three-piece tubing sets over the polymeric cable side. Nesting the tube sets on
the plastic bag wrapping to keep the inside of the tubes clean. The tube sets should be
 Set the cores in their final jointing position. Check that the conductors have been cut to
allow for any connector central moisture block. Remove the insulation from both
conductors, Sections 3.1.3 and 3.3.7, to the connector insertion depth.
 Insert each end of the core into its respective 'connector half' and finger-tighten the bolts.

Version: 1.0
Date: 29/10/2018
 Align and position the two connector halves so that the central fixing bolt can be inserted
into the central fixing hole. The use of force for this operation should not be necessary.
 Hold the connector with the approved holding tool and tighten the two bolts on one side
until they sheer off.
 Repeat the operation on the other side of the connector. Check that the combined tube
set is located over the single-core cables and sheer off the central fixing bolt.

Version: 1.0
Date: 29/10/2018
 Clean and degrease the connector. Fill the bolt holes with the supplied grey clay to obtain
a smooth finish.
4.2.4 Heatshrink Three-Core Transition Straight Joint (Three-Core Paper to 3 x Single-

 The cables will have been prepared up to the point as described in Sections 3.1 and 4.1.4.
 Slide the outer joint heatshrink sealing breakout over the single-core cables and position
it away from the jointing area.
 Slide the four-piece tubing set over the polymeric cable side. Nesting the tube set on the
plastic bag wrapping will keep the inside of the tubes clean. The tube set should be
 Remove the insulation from both cables using the methods described in Sections 3.1.3
and 3.3.7.

Version: 1.0
Date: 29/10/2018
 Slide the mechanical connector onto the conductor on the paper side of the joint. The
connector is fitted with an insert to accommodate smaller section cables; if the cable
conductor fits into the connector with the insert in place, use it - if not, remove the insert
and use it without.
 Check that the connector butts up against the insulation and finger-tighten the bolts.
 Insert the single-core polymeric cables into the connector ensuring that the connector butts
up against the insulation and finger-tighten the bolts.

Version: 1.0
Date: 29/10/2018
 Hold the connector with the approved holding tool and tighten each bolt half a turn at a
time with a socket until it shears off. Start with the bolt nearest the insulation at each end
before moving on to the other two bolts, working towards the middle.
 Smooth off any sharp edges from the bolts and then clean and degrease the connector.
Fill the bolt holes with the supplied grey clay to obtain a smooth finish.
4.2.5 HSL Trifurcating Joints (Three-Core HSL to 3 x Single-Core Polymeric Cables)
 The cables will have been prepared up to the point as described in Section 3.1 and 4.1.6.
 Slide the plastic trifurcating end of the plastic joint box over the single-core cables and
position it away from the jointing area.

Version: 1.0
Date: 29/10/2018
 Position a combined tube set (stress control, insulating tube and screened insulating) over
each of the single-core polymeric cables.
 Set the cores in their final jointing position. Check that the conductors have been cut to
allow for any connector central moisture block. Remove the insulation from both
conductors (3.1.3 and 3.3.7) to the connector insertion depth.
 Insert each end of the core into its respective 'connector half' and finger-tighten the bolts.

Version: 1.0
Date: 29/10/2018
 Align and position the two connector halves so that the central fixing bolt can be inserted
into the central fixing hole. The use of force for this operation should not be necessary.
 Hold the connector with the approved holding tool and tighten the two bolts on one side
until they sheer off.
 Repeat the operation on the other side of the connector. Check that the combined tube
set is located over the single-core cables and sheer off the central fixing bolt.

Version: 1.0
Date: 29/10/2018
 Clean and degrease the connector. Fill the bolt holes with the supplied grey clay to obtain
a smooth finish.
4.2.6 Mechanical Lugs for Indoor and Outdoor Terminations
 Follow the cable preparation procedures for polymeric cables in Sections 3.1.1 to 3.1.3
before installing any mechanical lugs.
 Each kit comes with the correct size and type of lug for each termination. Remove the
conductor insulation to the insertion depth of the lug.

Version: 1.0
Date: 29/10/2018
 Place the lug over the conductor so that the bottom of the barrel butts up against the core
insulation.
 Tighten the bolts by hand and check that the palm holes line up with their respective
connection point.
 Tighten the bolts until the bolt heads shear off.

Version: 1.0
Date: 29/10/2018
4.3 Installing Connector Stress Control and Heatshrink Insulation
 Fit the connector up to the point as described in Section 4.2.1.

 Use a Chinagraph pencil to mark the black insulation screen of both cables 20mm from
the screen cut.
 Mark a second pencil mark on the insulation 10mm from the screen cut.
 Stretch one of the short yellow stress control mastic supplied in the kit to half its original
width. Wrap it around the core screen and insulation between the two Chinagraph pencil
marks. Repeat for the other cable side.

Version: 1.0
Date: 29/10/2018
 Use the long strip of yellow stress control mastic to wrap the mastic around the connector
with a 50% overlap, stretching the mastic to about half its original width. Cover all the
connector area and overlap to the insulation on each side of the connector by 5mm. Make
sure there is a smooth transition from the connector onto the insulation.
 Position the black stress control tube centrally over the connector area. Each end of the
tube should extend beyond the screen termination points of each cable. Shrink the stress
control tubing down, starting in the centre and working towards each end in turn.
 Position the screened insulating red and black tube centrally over the stress control tube
and start shrinking the sleeve at the centre position using equal heat over the whole
surface.
 When the tubing is properly shrunk, the ridges on the outer black layer of the tube should
no longer be visible.

Version: 1.0
Date: 29/10/2018
 Continue to shrink the tube from the centre to within 50mm of one end.
 Remove the heat from that end and start shrinking from the middle again towards the other
end of the tubing. Stop again 50mm from the end. This ensures that air inside the tube is
expelled as the tube shrinks.
 Return to each tube end in turn to complete the shrinking process completely.

Version: 1.0
Date: 29/10/2018
4.3.2 Single-Core Transition Straight Joints

 Wrap a short piece of the yellow stress control mastic around the paper cable core at the
edge of the short black conducting sleeve. Start 20mm on the conducting tube, continuing
for 10mm onto the clear barrier tube.
 Wrap a shorter piece of the yellow stress control mastic around the polymeric screen,
starting 20mm from the screen edge and continuing for 10mm on to the insulation. Stretch
the tape to half its original width during the taping process.
 Use the long strips of yellow stress control mastic to wrap the mastic around the connector
with a 50% overlap, stretching it to about half its original width. Cover the connector area
and overlap on to the insulation each side of the connector by 5mm. Make sure a minimum
coverage of 2mm is achieved over the connector area.

Version: 1.0
Date: 29/10/2018
 Pull the black stress control tubing from inside the nested tube set and position it centrally
over the connector area, leaving a 20mm gap between the over sheath and the tubing
end.
 Shrink the stress control tubing down starting in the centre, before working towards each
end in turn. When finished the tubing should be fully shrunk and wrinkle free.

Version: 1.0
Date: 29/10/2018
 Wrap a piece of red sealant mastic around each end of the stress control tubing. Start from
10mm on the stress control tubing and extend for 10mm onto the core screen at both ends.
 Pull the red insulating tubing from inside the nested tube set and position it centrally over
the stress control tube. Start shrinking in the centre before working towards each end in
turn.
Note: Continue on to the next step while the red insulating tubing is still hot.
 Pull the black and red screened insulating tubing centrally over the red insulating tube
and start shrinking the sleeve at the centre position using equal heat over the whole
surface. When the tubing is properly shrunk, the ridges on the outer black layer of the
tube should no longer be visible and the tube can no longer be moved.

Version: 1.0
Date: 29/10/2018
 Remove the heat from that end and start shrinking from the middle again towards the
other end of the tubing. Stop again 50mm from the end. This ensures air inside the tube
is expelled as the tube shrinks.
 Pull the black compression sealing sleeve across the joint to the paper cable side and
place it so that at least 50mm of lead sheath is still visible.

Version: 1.0
Date: 29/10/2018
 Shrink the tubing down, starting on the tube set end and working towards the lead sheath.
Once completed there should be approximately 50mm of lead sheath still exposed.
4.3.3 Resin Filled Three-Core Transition Straight Joints (Three-Core Paper to Single-

 Remove the release paper from one of the short yellow stress control mastic strips and
wrap it around the polymeric core screen, starting 20mm from the screen edge and
continue onto the insulation for 10mm. Stretch the tape to half its original width to achieve
a fine thin edge on the insulation.
 Repeat the exercise on the paper cable core, wrapping the yellow stress control mastic
around the edge of the conductive tubing. Cover 20mm of the conductive tubing and
continue on to the clear tubing for 10mm.

Version: 1.0
Date: 29/10/2018
 Ensure that the bolt holes are filled with the supplied grey clay to leave a smooth profile.
Use a long piece of the yellow stress control mastic to fill the ends of the connector and
the insulation cut back continuing 10mm on to the insulation, and 20mm on to the
connector. If there is a step between the body of the connector and the cable insulation
apply yellow stress control mastic to form a smooth the profile.
 Remove the release paper from the yellow stress control mastic patch and wrap it centrally
around the connector, taking care to exclude any trapped air as it is applied. When finished
the patch should be smooth and wrinkle free.
 Slide the stress control tubing from inside the nested tube set and position it centrally
over the connector area. Make sure that the overlap over each taped screen edge is
equal. Shrink the tubing starting in the centre and working towards each end in turn.

Version: 1.0
Date: 29/10/2018
 Remove the release paper from one length of the red sealant tape and wrap it around the
end of the stress control tube. Overlap the tape on to the tube by 20mm and by 10mm on
to the core.
 Pull the red insulating tubes from the tube sets and centrally position them over the stress
control tubes. Shrink the tubing starting in the centre before working towards each end in
turn. When complete the tube should be smooth and wrinkle free.
Note: Continue with the next step while the red insulating tubing is still hot.
 Position the screened red and black insulating tubes centrally over the red insulating tubes.
Start shrinking the sleeves at the centre position using equal heat over the whole surface.
When the tubing is properly shrunk, the ridges on the outer black layer of each tube should
no longer be visible and the tubes can no longer be moved.

Version: 1.0
Date: 29/10/2018
end of the tubing. Stop again 50mm from the end. This ensures air inside the tube is

Version: 1.0
Date: 29/10/2018
4.3.4 Heatshrink Three-Core Transition Straight Joints (Three-Core PILC to Single-Core

Polymeric)

continue onto the insulation for 10mm. Stretch the tape to half its original width to
achieve a fine thin edge on the insulation.
 Repeat the exercise on the paper cable core, wrapping the yellow mastic around the edge
of the conductive tubing. Cover 20mm of the conductive tubing and continue on to the
clear tubing for 10mm.
 Check that the bolt holes are filled with the supplied clay to leave a smooth profile. Using
a long piece of the yellow stress control mastic, fill the ends of the connectors and the
insulation cut backs, continuing 10mm on to the insulation and 20mm on to the connector.
If there is a step between the body of the connector and the cable insulation apply yellow
stress control mastic to form a profile.

Version: 1.0
Date: 29/10/2018
 Remove the release paper from one of the yellow stress control mastic patch and wrap it
centrally around the connector, taking care to exclude the air as it is wrapped. When
finished the patch should be smooth and wrinkle free. Repeat the process with all three
connectors.
 Slide the stress control tubes from inside the nested tube sets and position them centrally
over each connector ensuring that the overlap over each taped screen edge is equal.
Shrink the tubing starting in the centre before working towards each end in turn.
 Remove the release paper from one length of the red sealant mastic tape and wrap it
around the end of the stress control tube. Overlap the tape on to the tube by 20mm and
by 10mm on to the core.

Version: 1.0
Date: 29/10/2018
control tubes. Shrink the tubing starting in the centre before working towards each end in
turn. When complete the tube should be smooth and wrinkle free.
Note: Continue with the next step while the red insulating tubes are still hot.
 Pull the screened red and black insulating tubes centrally over the red insulating tubes and
start shrinking the sleeves at the centre position using equal heat over the whole surface.
When the tubes are properly shrunk, the ridges on the outer black layer of the tubes should
no longer be visible and the tubes can no longer be moved.
 Continue to shrink the tubes from the centre to within 50mm of one end.

Version: 1.0
Date: 29/10/2018
 Remove the heat from that end and start shrinking from the middle towards the other end
of the tubes. Stop 50mm from the end. This ensures air inside the tube is expelled as the
tube shrinks.
 Position the three compression sleeves over the paper end of the joint, so that they equally
overlap the red and black insulation tubes and the core tubes. The uncoated end of the
compression sleeve should be positioned towards the centre of the joint. Shrink in place
starting from the centre of the tubes towards the centre of the joint before finally shrinking
from the centre towards the crutch.

Version: 1.0
Date: 29/10/2018

continue onto the insulation for 10mm. Stretch the tape to half its original width to achieve
a fine thin edge on the insulation.
 Check that the bolt holes are filled with the supplied grey clay to leave a smooth profile.
Use a long piece of the yellow stress control mastic to cover both ends of the connector,
20mm on the connector and 10mm onto the insulation.
 Remove the release paper from the yellow stress control mastic patch and wrap it centrally
around the connector, taking care to exclude any trapped air as it is applied. When finished
the patch should be smooth and wrinkle free.

Version: 1.0
Date: 29/10/2018
 Slide the stress control tubes from inside the nested tube sets and position them centrally
over the connectors ensuring that the overlap over each taped screen edge is equal.
Shrink the tubes starting in the centre before working towards each end in turn.
 Remove the release paper from one length of the red sealant mastic tape and wrap it
around both ends of the stress control tube. Overlap the tape on to the tube by 20mm and
by 10mm on to the core.
control tubes. Shrink the tubes starting in the centre before working towards each end in
turn. When complete the tubes should be smooth and wrinkle free.
Note: Continue with the next step while the red insulating tubes are still hot.

Version: 1.0
Date: 29/10/2018
 Pull the screened black and red insulating tubes centrally over the red insulating tubes and
start shrinking at the centre position using equal heat over the whole surface. When the
tubes are properly shrunk, the ridges on the outer black layer of the tubes should no longer
be visible and the tubes can no longer be moved.
 Continue to shrink the tubes from the centre to within 50mm of one end.
end of the tubes. Stop again 50mm from the end. This ensures air inside the tube is

Version: 1.0
Date: 29/10/2018
4.4 Installing Mechanical Earth Bonds and Associated Components
 Complete the joint as described in Section 4.3.1 before fitting this earth bond arrangement.
 Remove the previously applied PVC from both wire screens and wrap two layers of tinned
copper mesh around both wire screens and tie off with a half hitch.
 Wrap one half-lap layer of copper woven tape over the length of the joint, starting from the
wire screen at one end to the wire screen at the other end, tying off with a half hitch.

Version: 1.0
Date: 29/10/2018
 Position the supplied length of tinned copper braid over the joint, with one end level with
the wire screen termination at one end. Temporarily secure in place with PVC tape.
 Fix one end of the tinned copper braid to the wire screens, using the supplied worm drive
clip.
 Cover the worm drive clip with sufficient layers of cotton tape to cover all the exposed
sharp edges of the worm drive clip.

Version: 1.0
Date: 29/10/2018
 If required cut the tinned copper braid to length, so the other end is directly over the wire
screens at the other end of the joint. Fix the braid to the wire screens using a second wire
drive clip.
 Wrap a second layer of tinned copper mesh round the joint with a 50% overlap. Cover the
complete joint from worm drive clip to worm drive clip.

Version: 1.0
Date: 29/10/2018
 Clean and degrease the outer sheaths of both cables for 150mm from the sheath cut. Slide
the large outer sealing sleeve centrally over the joint area.
 Start shrinking the tube at the centre before working towards each end in turn. Allow to
cool before moving or backfilling the joint.
4.4.2 Single-Core Transition Joints
 Complete the procedures for insulating the connector as described in Section 4.3.2.
 Remove the previously applied PVC from the wire screen on the XLPE side of the joint
and wrap two layers of tinned copper mesh around wire screen and tie off with a half hitch.

Version: 1.0
Date: 29/10/2018
 Wrap two layers of tinned copper mesh at 50% overlap over the joint from the lead sheath
on the paper cable to the over-sheath cut on the polymeric cable, tying off with a half hitch.
 Position the supplied length of tinned copper braid over the joint with one end level with
the wire screen termination at one end. Temporarily secure in place with PVC tape.
 Fix one end of the tinned copper braid to the wire screens, using the supplied worm drive
clip.

Version: 1.0
Date: 29/10/2018
 Wrap the roll spring over the other end of the tinned copper braid, over the lead sheath
and twist up tight.
 Completely cover the roll spring with two layers of PVC tape.

Version: 1.0
Date: 29/10/2018
 Clean, degrease and abrade the outer sheaths for 150mm from the sheath cuts. Slide the
large outer sealing sleeve over the joint area and start shrinking the tube at the centre
before working towards each end in turn.
 Allow the joint to cool before moving or backfilling.
4.4.3 Polymeric Pot Ends
 Complete the steps in Section 4.1.2.

 Remove the previously applied PVC from the wire screen and wrap two layers of tinned
copper mesh around wire screen and tie off with a half hitch.

Version: 1.0
Date: 29/10/2018
 Wrap the tinned copper mesh with a 50% overlap around the pot end, starting at the outer
sheath and continuing up onto the copper screen wires, before covering the insulating rod.
Note: The stress control tubing and the rod end must be in contact with the tinned
copper mesh.
 Check that the over-sheath is clean and degreased. Position the outer sealing sleeve
centrally over the tinned copper mesh area, with one end level with the end of the outer
sheath semi-conducting removal point.
 Shrink the tubing down, starting at the centre working towards each end in turn. Do not
move or backfill until the pot end has cooled.

Version: 1.0
Date: 29/10/2018
 Complete the procedures for installing the connector insulation in Section 4.3.3.
 Pull the cores together as closely as possible and wrap one layer of tinned copper mesh
around the joint with a 50% overlap. Continue on to the lead sheath for 30mm and up to
the screen wires on the opposite joint side.
 Position the three earth braids evenly around the lead sheath area on top of the tinned
copper mesh. Connect the three earth braids to the lead sheath using a large roll spring.
 Wrap the roll spring over the braids and twist the spring up tightly. Cover the roll spring
with two layers of PVC tape.

Version: 1.0
Date: 29/10/2018
 Wrap the remaining exposed lead sheath with the strips of red sealant tape. This is an
important moisture seal. Do not leave out.
4.4.5 Heatshrink Three-Core Transition Straight Joints (Three-Core Paper to Single-Core

Polymeric)
 Pull the cores together as closely as possible and wrap one layer of tinned copper mesh
around the joint with a 50% overlap. Continue on to the lead sheath for 30mm and up to
the screen wires on the opposite joint side.
 Lay the three earth leads evenly around the lead sheath on top of the tinned copper mesh.
Connect the three earth braids to the lead sheath using a large roll spring. Wrap the roll
spring over the braids and twist the spring up tightly. Cover the spring with two layers of
PVC tape.

Version: 1.0
Date: 29/10/2018
 Apply one half lap layer of white fabric tape over the single-core polymeric end of the
joint for a distance of 150mm from the cable oversheath to protect the tinned copper
mesh tape from the heat generated by shrinking the Three-Core breakout.
 Pull the heatshrink breakout back over the joint as far as it will go and shrink in place,
starting with the turrets before moving on to the main body.

Version: 1.0
Date: 29/10/2018
 Wrap the remaining exposed lead sheath with the strip of black mastic sealant tape. This
is an important moisture seal. Do not leave out.
 Position the wraparound heatshrink joint sleeve around the joint and connect the two ends
together using the metal channel and the metal joining clip.
 Shrink the wraparound sleeve in place, starting at the middle before moving towards each
end in turn. The green paint on the surface of the sleeve should disappear when the tube
is correctly shrunk.

Version: 1.0
Date: 29/10/2018
 Extra heat should be applied to the metal channel until the white marker line can be clearly
seen under it.
 Do not move or backfill until the joint has completely cooled.
 Wrap one layer of tinned copper mesh with a 50% overlap over each insulated core
continuing across the jointed cores from the sheath cut on the polymeric cables. Finish
50mm on to the lead sheaths.
 Connect each earth braids to each of the individual lead sheaths using a two turns of the
roll springs.

Version: 1.0
Date: 29/10/2018
 Turn the end of the earth braids back over the two turns of the roll spring ensuring that
they are flat and even. Wrap the remainder of the spring length over the braids and twist
the spring up tightly.
 Cover the roll springs with two layers of PVC tape.
 Wrap the remaining exposed lead sheaths with the strips of red sealant tape.
 This is an important moisture seal. Do not leave out.

Version: 1.0
Date: 29/10/2018
4.4.7 Connection of Screen Wires on Indoor and Outdoor Terminations
 Complete the procedures for installing the terminations described in Section 4.1.8.
 Connect the screen wires to the Earthing stud or position provided (outdoor terminations)
as applicable for the geometry of the apparatus.
4.4.8 Fitting Plastic Joint Boxes (Trifurcating Joints Only)
 Trim off the ends of the joint box supplied with the kit, so that it will fit over the cables
entering the box.
 Using the box as a guide, offer it up to the cable and mark the stand-off positions of the
mouldings with a Chinagraph pencil.
 Remove the backing from the rubber patches supplied in the kit and apply centrally (over
the previously made marks) with the sticky side out.

Version: 1.0
Date: 29/10/2018
 Place the two halves of the joint shell over the joint and clip the two halves together with
the clips provided. Check enough clips are used to stop the resin leaking out when it is
poured in.
 Tape the joint box to the incoming cable with PVC or another suitable tape. If large gaps
are left when the shell is fitted it may be necessary to pack the ends of the joint shell out
with the clay pack supplied in some kits.

Version: 1.0
Date: 29/10/2018
4.4.9 Mixing and Pouring JEM Resin
 All 33kV joints should be filled with 2-part JEM resin. Wear the correct Personal Protective
Equipment at all times and do not mix the resin in a confined space.
 Check the label on the bucket to ensure that the resin has not passed its use-by date.
 Empty the contents of the bucket and check for any damage to the packaging and check
the printed label on each bag to ensure that the compound has not passed its use-by date.
 Pick up each clear bag containing the clear liquid and white powder and check to ensure
that the white powder in the larger bag is free flowing and not stuck in the corners.

Version: 1.0
Date: 29/10/2018
 Apply even pressure to the smaller liquid pouch so that the liquid breaks the seal between
the two sections and mixes with the powder.
 Mix the contents of the bag using a rolling movement, until there are no signs of dry powder
or lumps visible.
 Carefully cut one of the corners off the clear bag and pour all the contents into the joint
shell to be filled.

Version: 1.0
Date: 29/10/2018
 Continue to fill the joint shell until the filling hole is full and then put on the lid to prevent
other materials dropping into the compound.
 Dispose of the used clear bag in normal rubbish and return the clean buckets to the local
depot for recycling.

ECS 02-0033 33kV Jointing Manual PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

ECS 02-0033 33kV Jointing Manual PDF

Uploaded by

Copyright:

Available Formats

Document Number: ECS 02-0033

33KV JOINTING MANUAL

Network(s): EPN, LPN, SPN, UKPN Services

Author: Jesse Garcia Date: 29/10/2018

Approver: Paul Williams Date: 23/11/2018

Version 1.0 Review Date 23/11/2023

© UK Power Networks 2018 All rights reserved 2 of 256

© UK Power Networks 2018 All rights reserved 3 of 256

2.5.3 Installation of Heatshrink Materials and Components .............................................. 80

© UK Power Networks 2018 All rights reserved 4 of 256

3.2 Single-Core Lead Covered Cables ........................................................................ 146

© UK Power Networks 2018 All rights reserved 5 of 256

4.2 Installing Mechanical Connectors and Lugs ........................................................... 206

© UK Power Networks 2018 All rights reserved 6 of 256

1.1 Safety, Health, Environment and Quality Statement

© UK Power Networks 2018 All rights reserved 7 of 256

1.2 Glossary and Abbreviations

AWS Aluminium Wire Screen

© UK Power Networks 2018 All rights reserved 8 of 256

All sizes apply to both copper and aluminium conductor sizes.

Imperial Conductor Metric Equivalent

© UK Power Networks 2018 All rights reserved 9 of 256

2.1 Single-Core Polymeric Straight Joints

2.1.1 Single-Core Straight Joints 185 to 300mm2 Conductors

Cable Sizes mm2 Joint Kit Description and Part Numbers

2.1.2 Cable Preparation

 3.1 Single-Core Wire Screened Cables.

2.1.3 Installation of Heatshrink Materials and Components

 4.2 Installing Mechanical Connectors and Lugs;

 4.2.1 Single-Core Polymeric Straight Joints;

 4.3 Installing Connector Stress Control and Heatshrink Insulation;

 4.3.1 Single-Core Polymeric Straight Joints;

 4.4 Installing Mechanical Earth Bonds and Associated Components;

 4.4.1 Single-Core Polymeric Straight Joints.

© UK Power Networks 2018 All rights reserved 10 of 256

© UK Power Networks 2018 All rights reserved 11 of 256

© UK Power Networks 2018 All rights reserved 12 of 256

© UK Power Networks 2018 All rights reserved 13 of 256

© UK Power Networks 2018 All rights reserved 14 of 256

© UK Power Networks 2018 All rights reserved 15 of 256

2.1.4 Single-Core Straight Joints 300 to 630mm2 Conductors

This all heatshrink joint only contains wire screen connectors.

Cable Sizes Joint Kit Description and Part Numbers

2.1.5 Cable Preparation

 3.1 Single-Core Wire Screened Cables.

2.1.6 Installation of Heatshrink Materials and Components

 4.2 Installing Mechanical Connectors and Lugs;

 4.2.1 Single-Core Polymeric Straight Joints;

 4.3 Installing Connector Stress Control and Heatshrink Insulation;

 4.3.1 Single-Core Polymeric Straight Joints;

 4.4 Installing Mechanical Earth Bonds and Associated Components;

 4.4.1 Single-Core Polymeric Straight Joints.

© UK Power Networks 2018 All rights reserved 16 of 256

© UK Power Networks 2018 All rights reserved 17 of 256

© UK Power Networks 2018 All rights reserved 18 of 256

© UK Power Networks 2018 All rights reserved 19 of 256

© UK Power Networks 2018 All rights reserved 20 of 256

© UK Power Networks 2018 All rights reserved 21 of 256

2.1.7 Single-Core Straight Joints 630 to 1000mm2 Conductors

This all heatshrink joint only contains wire screen connectors.

Cable Sizes Joint Kit Description and Part Numbers

2.1.8 Cable Preparation

 3.1 Single-Core Wire Screened Cables.