Technical department Approved | Review | write | 1 Ae pr (MeCaen [BPng 220kV GIS terminal installation instructions ‘SHOWA-TBEA (SHANDONG) CABLE ACCESSORIES CO., LTD. 1TBEA e swecc Contents. 1. General Instruction ... 2, Assembly Instruction... 2-1 Pre homework check... 2-2 Epoxy bushing installation 2-3 Joint processing and connection.... 3. Attention after Installation... SHOWA-TBEA (SHANDONG) CABLE ACCESSORIES CO.,LTD. 2TBEA « swec L. General Instruetion + This manual is only applicable to the installation of 220kV GIS cable termination (Short ‘Types Short type + lengthening rod). + Part ofthe installation process should be performed in a dustproof environment, Suitable installing temperature 0 °635._{CHumidity below 70%. + Keep the dimensions exactly correct according to this instruction. if this instruction does not match the installation drawing, the installation drawing shall prevail + All dimensions in this assembly instrdction are given by millimeter (mm). + In advance of assembly, confirm that required assembly materials, tools and consumables are available, (See Table 1 and 2). + Inadvance of assembly, confirm and distinguish the phase of cable termination. + The sizeof cable treatment need more than 2 people to confirm at the same time. Table| Too! list, - No. Item Specifications Photo _| 1 | Tore 10-100N'm ae ‘wrench ‘Torque socket Torque wrench 3 MS-MI6 hexagon socket Diagonal width 240mm?—-38mm 42mm 42mm a=" 42mm tar? 1 | Compression — «| ice we /! 1800mm?---82mm, 2000mm?-—-86mm SHOWA-TBEA (SHANDONG) CABLE ACCESSORIES CO.,LTD. 3TBEA e swcc No. | item Specifications Photo Hydraulic S| compression | - holder | Hysauti fr. f compressor 4 7 [Bleetic | Temperature | heating bet |max.i60 °C | | | pliers Adjustable 9 | angle - wrench | compression gj Compression) a a 7s Industrial, above 1000W 10 | Electric drier 11 | Blectrie saw | - ‘SHOWA-TBEA (SHANDONG) CABLE ACCESSORIES CO.,LTD. 4TBEA @ swece ‘Temperature 2 pea’ 50. % controller Peel 3 " machine pos ' 14 | Bumer Lshape | = Is * steel 16 | Ruter Non-magnetic 17 | Scissors Table2: Consumable list + Glass plate (for peeling-off of outer semi-conductive layer) + Metal foil + Teflon tape + Adhesion heat resistance tape + Kerosene (Paraffin) + Cloth for cleaning + Specified cotton for cleaning + Dehydrated ethanol (purity: >99.5%) + Nylon glove + PE film SHOWA-TBEA (SHANDONG) CABLE ACCESSORIES CO., LTD. 5TBEA (S swecc 2._Assembly Instruction Assembly procedure Epoxy bushing installtion 7 + | Cle processing F L Connector ‘compression 1 ‘Semi-conduetive layer moldin, 1 Stress relief cone Cable insertion 2:1 Inspection before operations Check that the materials and tools required for the assembly are available. SHOWA-TBEA (SHANDONG) CABLE ACCESSORIES CO., LTD. 6TBEA 3) swec 2:2 Assembly of bushing No. tem Specifications + Installing conductor extensi “+ Remove seal cover and install t bushing, Note * Confirm the conductor surface state, no foreign body, scratches, metal debris and so on. position. The lower edge of the casing is standard position (Fig. 1) + Installing fixing metal + Tighten the bolts t0 the wy [Asem specified torque, of bushing + When installing the bushing, do not collide with the air chamber, scratches, ete, $0 as not to cause damage to the epoxy bushing 2.3 Cable processing No. | item Note Confirm the allowable bending radius of the + The cable bending radius should be more than | cable with the the permissible radius during the cuble Cable handing. (Fig. 1) ‘manufacturer. @ + Cut the cable atthe pre-cutting position that | Take into account the pre-cutting | is more than 500mm from the cable cuting retraction of the cable when inserted, the cable is SHOWA-TBEA (SHANDONG) CABLE ACCESSORIES CO., LTD. 7TBEA (iS swoc Fig. 1: Cable preparation No. Item, Specifications Note @) ~ Remove the outer sheath atthe postion (Fi a 2 + Confirm the dimension from the standard position, Be careful not to damage the cable materials, when heating it + In the process of stripping the outer sheath, do not damage the metal sheath, Outer sheath removal @ * Confirm the dimension from the standard position, Be careful not to damage Metal sheath the cable materials, when heating it. jernoval + When cutting the metal sheath, be careful not to damage the inside of the cable SHOWA-TBEA (SHANDONG) CABLE ACCESSORIES CO., LTD. 8TBEA 3) swcc + Wear gloves when using glass to prevent hand injury. Graphite | - According to the installation drawing, remove (5) [layer | the graphite layer on the outer sheath of the | ble and record it into the contimation form. removal soni Asfcschesing // / ‘Aluminium fol / ‘Waterblocking tape, Figure 2 heating straightening Isuition ieiding [lescmaroeene |[ouaraee | [ose tem | Fig.3:Cable treatment Standard position Fidge of cable conductor ————————— + Ifthe cut surface becomes inclined, length shall be measured from the edge able conductor of eable conductor, Fig. SHOWA-TBEA (SHANDONG) CABLE ACCESSORIES CO., LTD. 9TBEA 3) swec sreeth tsteps) ° x Figure 5:slope appearance inspection x No. | _ Item Specifications Note (Geo Fig. 3) * Wrap it in Metal fils. + Wind up a ribbon-heater. ( one-way) + Wrap it in Metal foils. + Heat it for 4 hours with controlling temperature at 80°C, + After heating, straighten the cable and fix it by | + Don’t eoot down by such as L-shape stel force + Keep straight for more than 12 hours, and cool down. (by natural coolin + Pay attention to the Straighten a expansion and © | ing ‘bending ofthe cable during heating, + Don't move the cable during heating, SHOWA-TBEA (SHANDONG) CABLE ACCESSORIES CO., LTD. 10TBEA @ swec No. Item Specifications Note - ~ Peeling off semi-conduetive water-proof Peeling-off Afier Peeling ofl co _|smibcondutine semi-conduetive water-proof water-proof tap to the distance from the tap metal sheath is 30mm ~ Confirm distance to standard position. + Cut the eable perpendicularly 5 . (Figs Cutting of = Cut the cable at the actual cutting | ftheeable axis. CFig.s) © | ote postion shown in Fig 4 99.5%) and | gloves, cone and cable Cleaning of specified cleaning clothes or cleaning papers. | ' pre-molded | — (Fig.14) Po not reuse the viet clothes which were once stress. rele 20) used for cleaning of cone and = semi-conductive cable ‘material to prevent insulation conductive materials from sticking to insulation, + Finally, clean insulation part with new clothes and check it very clean Cleaning stress relief cone SHOWA-TBEA (SHANDONG) CABLE ACCESSORIES CO., LTD. 18THEA é swec ‘Cleaning cable insulation + Confirm that there is no wound and contamination after cleaning. Drying of stress reliet * Dry the surface of the stress relief cone and cable insulation with a drier. Drying is performed not to leave dehydrated ethanol + Do not let the hot mouth Of drier touch the cable and stress relief eone. an) |coneans Drying stress relief cone ase ssulaton + (Maximum permissible temperature of cable insulation and stess relief cone is90 °C) Drying cable insulation ~ Apply the silicone oil to the surface of the cable insulation and the pre-molded stress | + Apply the silicone oil relief cone. with clean bare hand or + Insert the fixing metal to pre-molded stress | nylon gloves relief cone, + Open the lid of silicone “Insert stress relief cone to the specified | oil just before the Insertion of Position on the cable. application work since it | stessreliet is highly hygroscopic, cone + Do not use the remaining silicone oil + Be careful not to wound cable surface. “Don’t use silicone Cable insulation Stress relief cone erease, Apply the silicone oil SHOWA-TBEA (SHANDONG) CABLE ACCESSORIES CO., LTD, 19TBEA (L9 swec gs Insertion _ stress relief cone Clean stopper, stopper and stress relief cone contact surface coated with grease + Stopper and stress relief cone tight, extra ‘grease must be clean with paper towels. + Remove PVC tape on the connector. ! stopper i | fom4— Dotted line part apply slicone of i Insertion of| + Extruded grease need to @3) Stress relief stopper re be clean. ‘Remove PVC tape “Remove ie A wit shal and non-woven |. iean he conector A + Insert the conneetion B to the conneetion A. | and ensure that there are + Fixing the connection B withthe C ring no impurities. such as silicone oil on the surface. Connection + connection B prevents (24) |B slipping out installation +C type retaining ring should be fixed with special tools to prevent damage to silver plated surface If there is no insulation bol, the serews must | * The screws must be Removal of | be loosened evenly and the sealing cover | evenly loosened at the should be removed. 25) casing seal | When the insulating bolt is preset, the | angle cover insulating bot is removed, «The sealing ring of the sealed cover is not to be: TBEA (i swec used again, + Be careful not to cause bushing damage, + Do not touch the metal part of the bushing when cleaning, just + Observe the leading end of the conductor lead-out bar on the other side of the bushing and insert the cable straight Check and | Check that there is no damage on the inside | clean the white epoxy cleaning of | of bushing and clean the surface with 29) | inside of dlebydrated ethanol and specified cleaning | Patt bushing clothes or cleaning papers + Confirm that there is no wound and contamination on the inside of bushing. = Diy the inside of bushing by drier. T 0 me E Drying the + Do not let the hot mouth inner of drier touch the eable on fe oe and sess eli cone the bushing + Do not overheat. ~ Confirm that theres + Sligone oil evenly applied to the outer | no foreign matter on surface of the stress cone and the inner | the surface, moisture surface of the bushing and other electrical + hazards. + Apply silicone oi pol = with clean hands oF wear clean gloves 28 © | sittone oi + Be careful not 0 misuse silicone grease “Pay attention to the connection A t0 avoid silicone oil pollution. ~ Pay attention fo the allowable bending , radius of the cable while inserting the cable Confirm that the head into the casing connector surface is 29). | Insert cable clean before insertion, + Work carefully by more SHOWA-TBEA (SHANDONG) CABLE ACCESSORIES CO., LTD. 21TBEA e swec ~ Once the conductor leads out ofthe rod, than 4 persons. ‘grab the leading end of the conductor and + Measure the distance from the leading end of the rod to the front end of the epoxy bushing to confirm that itis within the requirements of the assembly drawn into the bushing. damage the surface of bushing inside the bushing. G0) ‘move the eable to the designated position. +The cable is fed straight + Confirm the connector for stopper does not Do not over-impact the connecting contacts | + Clean the compression fiting flanges and + Visual confirmation seals. seal grooves shall + Apply a thin layer of silicone grease to the have no foreign body, seal and secure it in the seal groove. moisture, etc Remove hexagonal long nuts pre-assembled | Silicone oil daub on shaft C (12) should clean their + Push the compression fittings to touch the hands or use clean stress cone and push it once. gloves. Use 10 bolts (M10 * 35L,) to fix the + Must be diagonal compression fittings onto the epoxy sleeves evenly tighten bolt and tighten bolts in diagonal direction. + Tightening ‘Smear anti - death torque :20N-m spray. + After confirm the size, PVC tape must Install be removed compression unit and confirm cable insertion + Reinstall the long nut back to the shaft C and adjust the compression spring until the compression support moves to the Cred line mark + Afler installation to confirm size M and L. If does not meet the prescribed scope, must unload stress cone compression fittings, pull out the cable head, to insert Confirm spring compression length. Pre-compression spring length: I hour. After compression, refum the long nut to the red SHOWA-TBEA (SHANDONG) CABLE ACCESSORIES CO., LTD. 22,TBEA ee swec ‘mark on the compression shaft. basing sock tape a Fig.16 Insert cable Jf Fig.17:_Install compression unit No, Item Specifications Note * Be careful not to * Four tin-plated soft copper braided wires ee Internal | (10mm2) are crimped at one end with crimp crimping cable terminals and the crimp terminals are evenly. + To prevent the inner (G1) _| grounding | secured to the shaft C. The other end of the surhuce of the tin-plated soft copper braided wire, together rotective fixture ‘treatment | with the shielded metal mesh, is fixed on a fon being scratched, Corrugated aluminum sheath, pay attention to the direction and angle of SHOWA-TBEA (SHANDONG) CABLE ACCESSORIES CO., LTD. 23TBEA (DS swec we the erimp terminal + When fixing the tinned soft copper braided wire, the tinned soft copper braided wire should be properly relaxed, ‘The tin-plated soft copper braiding line is fully tightened and then moved upwards by 30-50mm. eons, Fig.19:_Intemal grounding treatment No. Item Specifications Note ‘Wrap self bonding insulation tape, the outer diameter of the metal sheath matches the inner diameter of the protective metal + Before winding the seladhesive tape, apply ‘one-component adhesive Base ms (32) on the metal sheath, winding + Winding diameter: The diameter of protective cover Imm ~ Clean the flange of protective cover, « Tighteni ue xs isl canaetiooe Tightening tong protective | + Apply grease evenly to the gasket and press it_| _10N “m SHOWA-TBEA (SHANDONG) CABLE ACCESSORIES CO., LTD. 24TBEA ({% swee a Tnto the gasket groove of the protective cover. + Protective cover and compression unit connected. After screwing the bolt in by hand, tighten the bolt diagonally to the specified torque. \ ean Nanaia econo Fig.20: Base winding “Tightening must be diagonal uniform, Confirm that the Mange surface isin full contact, “After fixing the protective cover, fully secure the cables, and do not impose unnatural external forces on the product. SHOWA-TBEA (SHANDONG) CABLE ACCESSORIES CO., LTD. 25noses / depen) mimes, 28 fy Fig.2I: Install protective cover No. Item Specifications Note ~ After applying the one component adhesive ~ Pay altention fo the to the part contacted with the insulating shape while winding self-adhesive tape, tape Insulation | + Winding insulating self-adhesive tape. (1/2 | + The insulation self cover, filled) adhesive tape is self-adhesi stretched to 2 times G4) the original length and ve tape then wind. winding Two component use methods: ~ Pay attention fo the + First, knead the material in the bag until it is shape of the tape uniform, then remove the metal clamp and during the winding, mix the two liquids in the bag evenly. + The adhesive tape + Apply two component adhesive on the side ‘must be applied ‘and wrap around the glass belt (I /2 cover, 3 evenly to each layer Winding | back and of glass belt. 69 forth), glass belt After winding, heat the glass belt and the SHOWA-TBEA (SHANDONG) CABLE ACCESSORIES CO., LTD. 26TBEA é swecc Dinder with a hot air gun. + The distance between the outlet of the hot air ‘gun and the heating surface is more than Tem. ‘To be evenly heated, no local overheating. Two component binders are initially solidified before the next operation can be ccartied out. 7 Move heat-shrinkable tubing to cover protective hardware and cable jackets as per dimensions. Use a heat gun or liquid gas spray gun to heat the heat-shrinkable tube, When heating, should be heated slowly from one end to the other, or heated from the middle to the ends. Do not heat from both ends to avoid air bubbles and swelling. When heating, the heat ‘gun or liguid gas spray gun should be evenly moved to make the heat shrinkable tube evenly heated. When heating, local temperature should not be too high to prevent ~ Shrink evenly + Do not over-heat. * Check heat shrinkable tube surface without cracks, foreign objects. + Affer the processing, if the surface of the heat-shrinkable tube ig found to be smudged, wipe it with a rag (if necessary, take alcoho! that does Shrinking | — the heat shrinkable tube being scorched.The not affect the heat shrinkable tube is heated to make all insulation ofheat | parts evenly heat shrinked, ensuring thatthe performance of the G6) inner layer of rubber can be heated to reach heat-shrinkable tube). shrinkable | the bonding surface. After heating and shrinking, it must be obvious overflow at tube | both ends of heat shrinkable tube to achieve the best seating. Wrapping |” Wrap PVC tape around the edge ofthe Take care of the 1 | of Pvc tape shrinkable tube (1/2 overlap 1 back and forth) appearance while winding, SHOWA-TBEA (SHANDONG) CABLE ACCESSORIES CO., LTD. a7TBEA @é swecc 12 cena gw) eames = ylnaiatete Widenig Tamar — steed copper ad oe ‘SI ‘Ses Tighe by crrero Eero repeal ‘ers me 12 omc ekeeaTe Fig.21: Anticorrosive processing 3._Attention after Installation + Check the cable is fixed securely with cable clamp. + Check the earthing circuit. + After the assembly finished, leave the sealing end for 8 hours at least. During the time, do not apply voltage. + The cable assembly environment rust be less than 90% in humidity. SHOWA-TBEA (SHANDONG) CABLE ACCESSORIES CO.,LTD. 28