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LARSEN & TOUBRO (OMAN) L.L.

CONTRACT No. 11/2008

REPLACING PORTIONS OF 220kV &132kV OVERHEAD


LINES IN MUSCAT GOVERNORATE WITH CABLES,
PHASE-1

OPERATING AND MAINTENANCE


INSTRUCTION MANUAL

CONTRACTOR :
TAIHAN ELECTRIC WIRE CO.,LTD.
LARSEN & TOUBRO (OMAN) L.L.C
CONTRACT No. 11/2008

REPLACING PORTIONS OF 220kV &132kV OVERHEAD


LINES IN MUSCAT GOVERNORATE WITH CABLES,
PHASE-1

CONTENTS

1. Summary of Project

2. Cable Route
2. 1 Schemetic Line Diagram

3. Specification of Cable
3. 1 Specification for 132kV 1C * 2500SQmm XLPE Power Cable

4. Drawings of Accessories
4. 1 Sealing End Termination
4. 2 Premolded Insulated Joint
4. 3 Premolded Normal Joint
4. 4 Cross Bonding Link Box with SVL
4. 5 Solid Bonding Link Box without SVL
4. 6 Sheath Voltage Limiter
4. 7 Concentric Bonding Cable 400SQmm
4. 8 Earthing Cable 400SQmm

5. Testing and Commissioning Test Report


5. 1 Cable Sheath Test Before Jointing
5. 2 Tests After Installation
5. 3 Test Procedure Report
6. Operational Maintenance Instructions of Power Cable
6. 1 Cable Laying Work
6. 2 Jointing Work
6. 3 Maintenance

7. Attached Technical Data


7. 1 Current Carrying Capacity
7. 2 Short Circuit Current For Conductor
7. 3 Short Circuit Current Capacity For Metalic Sheath
7. 4 Sheath Induced Voltage
7. 5 Sequence Impedance

8. Other Site Works Data


8. 1 Cable Laying Supervision Record
8. 2 Pictures of Cable Jointing
1. Summary of Project
Summary of Project

1. Name of Project
Supply & Installation of 132kV XLPE underground cables of accessories
in Muscat, Oman

2. Contract No : 11/2008

3. Contractor : Taihan Electric Wire Co.,Ltd

4. Route

4 1 Cable
4.1 C bl : 132kV 2500
2500sq.mm 1C XLPE P
Power C
Cable
bl

4.2 Route
1) Bawsher S/S ~ Gubrah P/S (GBO 1& 2)
2) Tower-14 ~ Gubrah P/S (GMQ 1& 2)
3) Tower-14 ~ Tower (GMQ 3& 4)

4.3 Installed By : Taihan Electric Wire Co.,Ltd

5. Terms of Project : 2009.09. ~ 2010.11


2. Cable Route

2. 1 Schemetic Line Diagram


3. Specification of Cable

3. 1 Specification for 132kV 1C * 2500SQmm XLPE Power Cable


Messrs : Oman Electricity Transmission Company (OETC) Docu. No.: TAX-K0808-C
Project : Supply of 132kV EHV Cables & Accessories Date : Jan-2009
for Replacing Portions of 220 and 132kV Overhead Lines

SPECIFICATION OF 132kV CABLE


Page: 1 of 3

SPECIFICATION OF 132kV SINGLE CORE 2500SQmm XLPE POWER CABLE

1. General

This specification covers the design, manufacturing, factory testing, marking, packing and shipping of 132kV single-core
2500SQ.mm XLPE insulated underground cable in accordance with IEC publication 60840. The 132kV single-core 2500SQ.mm
XLPE insulated underground cable offered shall be complete in all respects necessary for their effective and trouble
free operation when connected to the system.

2. Cable Construction

2.1 Conductor

The conductor shall be compacted with 5 segments and shall consist of copper wires. The conductor shall be clean and
free from metallic and foreign particles, which may contaminate the insulation or cause high stress points. A moisture
barrier between the strands of the conductor also shall be applied. Maximum D.C resistance at 20 of conductor shall
be 0.0072 [/km]

2.2 Conductor Screen

The conductor screen shall consist of a semi-conducting binder tape applied over the conductor and a layer of black
extruded super-smooth semi-conducting compound which shall be firmly and continuously bonded to the inner surface of
the insulation. The semi-conducting material shall be compatible with the insulation and the semi-conducting tape.
The outer surface of the conductor screen shall be cylindrical, smooth and free of protrusions and irregularities and
shall have no tendency to separate from the insulation due to the effect of bending during installation, load cycling
and short circuit under service conditions.

2.3 Insulation

The insulation shall consist of a homogeneous extrusion of super-clean cross-linked polyethylene (XLPE), which shall
have 20mm nominal thickness.
The cross-linked polyethylene insulation produced shall be free from micro voids, contaminant, protrusion and moisture
content as specified in the above standards.

2.4 Insulation Screen

The insulation screen shall consist of an extruded layer of black, thermosetting semi-conducting super-smooth material
applied directly over the insulation.
The inner surface of the insulation screen shall be smooth and free of protrusions and irregularities and shall be
firmly and continuously bonded to the outer surface of the insulation and shall have no tendency to separate from the
insulation due to the effect of bending during installation, load cycling and short- circuit under service conditions.
Page: 2 of 3

2.5 Manufacturing Process of conductor screen, insulation and insulation screen

The conductor shall be covered with three layers (screen, insulation, screen) the insulation being of super-clean HV
insulation compound, extruded under high pressure and heat treatment.
The conductor screen, the insulation and the insulation screen shall be mutually compatible and shall, in the same
manufacturing process, be continuously extruded and completely dry cured by a common head.

2.6 Water Barrier

Semi-conductive non woven fabric swellable tape and copper woven fabric tape shall be applied over the insulation
screen.

2.7 Metallic Sheath

The water impervious sheath shall consist of a seamless and continuously extruded corrugated aluminum. The aluminum
used for the sheath shall be accordance with the clause 5 of IEC 60840.
The aluminum sheath shall be of best quality. It shall be tightly extruded over the water blocking layer. The metallic
sheath shall be impervious to moisture, tightly fitting and free from defects and impurities such as oxides that could
give rise to failure under working conditions.
The offered cable is capable to withstand 31.5kA for 3 seconds as earth fault current. Short circuit current shall be
calculated as per IEC 60949.

2.8 Outer Sheath

The outer sheath shall be of extruded MDPE with graphite coating and suitably prepared against cracking and
decomposition under the prevailing service conditions at site. Also chemical additive is used to protect cable from
termite.

The following letters shall be embossed and printed on the outer sheath:

132kV ELECTRIC CABLE TAIHAN 2008 PROPERTY OF OETC, Oman

3. Tests at works

3.1 Routine tests

The routine factory tests shall be carried out on all finished lengths of cable before or after final drumming in
accordance with IEC publication 60840
Page: 3 of 3

a) Partial discharge test


b) Voltage test
c) Electrical test on oversheath of the cable

3.2 Sample tests

The sample tests shall be carried out on samples in accordance with IEC publication 60840

a) Conductor examination
b) Measurement of electrical resistance of conductor and metallic sheath
c) Measurement of thickness of insulation and oversheath
d) Measurement of metallic sheath
e) Measurement of diameters
f) Hot set test for XLPE insulation
g) Measurement of capacitance
h) Water penetration test if applicable
Construction Data

No Description Unit Particular

1 Basic standard - - IEC 60840

2 Rated Voltage (U) KV - 132

3 Conductor Material - - Annealed Copper

Nom. Cross section sqmm Nominal 2500

Diameter mm Approx. 61.2

Shape - - 5-Segmental compacted

DC resistance at 20 /km Maximum 0.0072

4 Conductor Material - - Semi-Conductive Compound

Screen Thickness mm Nominal 1.5

5 Insulation Material - - XLPE

Thickness mm Nominal 20.0

mm Minimum 19.0

6 Insulation Material - - Semi-Conductive Compound

Screen Thickness mm Nominal 1.5

7 Water Material - - Semi-Conductive Swellable Tapes

Barrier Thickness mm Approx. 0.5

8 Metallic Material - - Corrugated Aluminium

Sheath Thickness mm Nominal 2.6

9 Outer Material - - MDPE (with GRAPHITE COATING)

Sheath Thickness mm Nominal 4.0


Anti-termite
10 Material - - Anti-termite Additive
Protection
11 Earth Fault Current kA 3sec 31.5

12 Diameter of complete cable mm Approx. 142.0

13 Weight of complete cable kg/m Approx. 35.5

14 A.C Voltage test KV/min - 190 / 30

15 Material of drum - - Steel


4. Drawings of Accessories

4. 1 Sealing End Termination


4. 2 Premolded Insulated Joint
4. 3 Premolded Normal Joint
4. 4 Cross Bonding Link Box with SVL
4. 5 Solid Bonding Link Box without SVL
4. 6 Sheath Voltage Limiter
4. 7 Concentric Bonding Cable 400SQmm
4. 8 Earthing Cable 400SQmm
SECTION

4. 1

Sealing End Termination


SECTION

4. 2

Premolded Insulated Joint


SECTION

4. 3

Premolded Normal Joint


SECTION

4. 4

Cross Bonding Link Box with SVL


SECTION

4. 5

Solid Bonding Link Box without SVL


SECTION

4. 6

Sheath Voltage Limiter


SECTION

4. 7

Concentric Bonding Cable 400SQmm


SECTION

4. 8

Earthing Cable 400SQmm


5. Testing and commissioning Test Report

5. 1 Cable Sheath Test Before Jointing


5. 2 Tests After Installation
5. 3 Test Procedure Report
SECTION

5. 1

Cable Sheath Test Before Jointing


SECTION

5. 2

Tests After Installation


SECTION

5. 3

Test Procedure Report


6. Operational Maintenance Instructions
of Power cable

6. 1 Cable Laying Work


6. 2 Jointing Work
6. 3 Maintenance
SECTION

6. 1

Cable Laying Work


Project Name : 132kV 400sqmm XLPE Cable Project
Cable Laying Methodology

TECHNICAL DATA

Cable Laying Methodology

1
Project Name : 132kV 400sqmm XLPE Cable Project
Cable Laying Methodology

1 CABLE LAYING

1.1 Pulling Tension Calculation

Since we have to secure that the pulling tensio n and the side pressure along the cable
would not exceed the maxi mum allowable values of th e cable, ca lculation shall be
performed before cable laying. With the Pulling Tension Calculation, t he use of cable
laying equipment and their locations could be defined to fit the actual site condition.

1.1.1 Permissible Pulling Tension and Side Pressure of Cables

The Permis sible Pulling Tension and Side pressure during cable pullin g shou ld
not exceed the following figures :

In case of the conductor is pulled by means of a pulling eye :

Tmax = 7 kg/mm2 x S

where : Tmax - Permissible Tension (kg)


S - Cross Sectional Area of conductor (mm2)

Pmax = T/R = 350 kg/m (recommended)

Where : Pmax- Permissible Side Pressure at the cable sheath


T - Pulling Tension at the curved cable
R - Radius of curve

1.1.2 Bond Pulling

In case of the Pulling Tension and Side Pressure become critical, Bond Pulling
could be applied to minimize the stress on the cable.

Bond wire shall be tied t o the cable by nylon stri ng at equal intervals (about 1 m)
and pulled by winches.

At each change of direction of th e route, the bond should be taken through a


snatch block anchored to the side of the trench.

The bond is also to be removed pri or to entering a duct so that the cable and
bond wire run in differe nt ducts. Th e bond wire should be r e-connected after t he
cable leaves the duct.

1.1.3 Caterpillar

In case the bond pulling method is not app ropriate, using Caterpillar is a n
alternative method.

2
Project Name : 132kV 400sqmm XLPE Cable Project
Cable Laying Methodology

1.2 Define of Cable Laying Devices and their Locations at Site

After the Pulling Tensio n Calculation, the Cable Pulling Devices and the ir locations at
site shall be defined. Th e Pulling Method and Cable Pulling Calculation shall be revised
subject to site conditions.

1.3 Cable Trench Inspection

The entire route shall b e checked before the laying work commences. Sharp edges of
gravel and any other object should not be left on trench.

1.4 Cleaning of Duct

The interior of the duct shall be thoroughly cleaned by wire brush or other proper devices.
The pilot wire must have been put into the duct before commencement of installation.

1.5 Setting of Cable Laying Equipment

1.5.1 Cable Bedding with stabilized sand

Before setting any of la ying equipment, at le ast 75 mm of stabilized sand sha ll


be filled into the cable trench as the bedding for cable to be laid.

1.5.2 Setting of Winch, Tension-Meter

A winch an d tension-meter suitable to measu re the pulling tension anticipate d


shall be set. The fixing of the winch base shall be carried o ut with spe cial car e
and shall withstand a tension of approximate 5 tons.

3
Project Name : 132kV 400sqmm XLPE Cable Project
Cable Laying Methodology

1.6 Passing Pilot Wire Along the Cable Route

The steel w ire rope for pulling the cable sho uld have saf ety factor of 2.0 3.0 for
calculated maximum value of the pulling tension. The wire shall be laid on the rollers
properly all the way along the trench. It is import ant that the wire rope is to be handled in
such a manner that the wire rope does not twist or kink.

W A L K WA Y

CABLE DRUM WINCH WIRE DRUM

STEEL PLATES

TOP VIEW
CABLE DRUM

UNDER ROLLER
FREE ROLLER

SECTION

FIGURE 6.1

( CABLE LAYING )

1.7 Checking of Communication System

Normally, walkie-talkies are to be used as the communication media during cable laying.
This communication system must be ch ecked along the entire cable route b efore
commencing the cable laying. In case of a walkie-talkie are not fully functioning alo ng the
entire cable route, cable telephone network shall be built before cable installation.

1.8 Transportation of Drum

The cable drum transported to the site is to be unloade d on the pr oposed positio n
preliminarily leveled. Generally, a cable drum shall not be moved more than 30 meters by
means of ro lling the drum itself. If it is n ecessary to roll a drum, be sure to turn it in the
direction of the arrow marked on the sideboa rd. When unloading th e drums fro m the
truck at inst allation site, care must be paid to confirm the direction of the arrow and
drums are put down in such a direction to facilitate out the cable.

4
Project Name : 132kV 400sqmm XLPE Cable Project
Cable Laying Methodology

1.9 Placing of Drums

Using a pair of jacks and shaft or a set of under-rollers, the drums is to be placed. In
case the cable route is inclined, the drum shall be placed on the higher side as a rule . In
case there is a curve on the route the drum shall be placed on the side near the curve as
a rule.

1.10 Removal of Battens

The battens of cable dr um are to be removed while rotating the dru m little by little.
Attention is to be paid to prevent the removed battens from falling int o the cab le trench
and damaging the cable. After removal of battens, a vinyl sheets or rubber sheets sh ould
be laid und er the cable drum to pr otect outer surface of t he cable fro m any object, like
nails, staples, etc.

1.11 Attaching then Pulling Eye

The pulling eye is fixed securely on to the end of the cable.

1.12 Pulling Out the Cable End

The end of the cable is pulled out slowly from the drum and the pulling eye is connected
to the wire rope with a swivel. Ea ch joint is connected completely a nd secured with
shackles of other suitable devices.

1.13 Pulling the Cables

1.13.1 Leading the Cable End into the Cable Trench

The cable pulled out of the drum sh all be led to the cable trench with great care
and suitable guides so as not to give the cables an excessive stress and surface
damage.

1.13.2 Braking of Cable Drum

The rotating speed of th e drum is to be corresp onding to th at of pulling speed.


However, t he rotating speed shall be also controlled with a brakin g system.
Usually, the under-roller has built-in braking system.

1.13.3 Arrangement of the Cable Pulling Staff

The cable p ulling staff shall be at the necessa ry positions. The te st of walkie-
talkie shall be performed among the staff b efore cable pulling. The walkie-talkie
shall be provided minimum at the cable drum-side, winch-side, cable head and
cable corners. This is essential to co ntrol cable pulling, espe cially when we need
to stop cable pulling in an emergency.
1.13.4 Arrangement of Cable Head

5
Project Name : 132kV 400sqmm XLPE Cable Project
Cable Laying Methodology

The cable head shall b e arranged as per figure. The rope shall be co nnected
around cable head. The two men shall follow th e cable hea d and hold t he rope in
order to help the smooth running of cable when the cable h ead goes through on
the cable ro llers. The t wo men, who follow the cable hea d, hall keep behind of
swivel for safety.

1.13.5 Cable Pulling to Cable Duct

The cable h ead shall b e stopped a t the entran ce of the ca ble duct. En sure the
bell-mouth is set properly at entrance of cable duct. And then cable pulling shall be
started into the cable duct.

1.13.6 Other Instructions during Cable Pulling

In any time, if sharp edges of gravel, stone and any other objects are found in the
trench, they shall be removed out of the trench.

The cable pulling shal l be stopped immediately in case of cable roller or curve
roller is pulled out or u nset. The cable shall b e touched directly to th e trench
bottom or wall.

1.13.7 Disposition of Cable End

When the leading end of the cable approach es to the jo inting po sition at th e
winch-side and the ta il end of the cable is abo ut to go off the drum, th e pullin g
work is to be stopped. Then the cable end on the drum is to be loosened and
removed from the drum gradually. The pulling work is to be again started and the
both ends of the cable are to be laid at the final position.

1.13.8 Cable Arrangement in the Trench

After cable pulling, the cable shall be formed the alignme nt accord ing to the
design drawing provided.

1.13.9 Protection on the Laid Cable

The laid cable shall be protected by sandbags or the like subject to site condition.

1.14 Cut & Cap if Surplus Cable remains (in case of XLPE cable)

1.14.1 The pulling work stopped.


1.14.2 The cable is cut and capped at the both ends.

1.15 After Treatment of Cable Ends

An appropriate way of protection must be applied to pre vent both ends of the cable
from sustaining external damage, submersion into the water, etc.

1.15.1 Positioning of Cable Ends

6
Project Name : 132kV 400sqmm XLPE Cable Project
Cable Laying Methodology

The cable e nds sha ll b e shifted closer to the wall instea d of pla cing t hem just
under the manhole or access, so that they may not be hit by an o bject falling
down from above.

The cable e nds sha ll be raised as high as po ssible so th at the water will not
penetrate into the cable.

1.15.2 Cable Identification

The identification phase of the cables shall be marked with color tape on both
ends of the laid cables

7
SECTION

6. 2

Jointing Work
FITTING INSTRUCTION
FOR PRE -MOLDED JOINT

OF 132 XLPE 1C CABLE

Signed by
J.S.NAM
Manager of
EHV Accessories Engineering Team

TAIHAN ELECTRIC WIRE CO.,LTD.


ENERGY CABLE BUSINESS UNIT
EHV POWER CABLE ACCESSORY PLANT

MOPMJ132 REV.0
132 XLPE PMJ

1. Preparation
1) Preparation note
Work area has to be dry, clean and dust free.
The jointing materials and tools shall be kept clean, and remove moisture and dust with alcohol
or the knife.

Note: All materials to be used for jointing must be checked against the assembly drawing.

2. Arrange the cable


1) Place cables at the right jointing position.
2) Take specified off-set.
3) Straighten two cables and laid to overlap each for approximately 600 length.

Fig. 1 Arrange the cable

Note: The minimum acceptable bending radius of the cable is 20 times of the outer diameter of the
cable.

4) Cable pre-cutting
Check the joint center and pre-cutting point.
Cut the cable at the right angle to the cable axis.

TAIHAN ELECTRIC WIRE CO.,LTD.


ENERGY CABLE BUSINESS UNIT
EHV POWER CABLE ACCESSORY PLANT
132 XLPE PMJ

3. Outer jacket removing


1) Remove the cable outer jacket according to the assembly drawing.
Cut the jacket in cylindrical direction, and pull up anti-corrosion jacket.

Fig. 2 Outer jacket removing

Cut the metallic sheath as shown in assembly drawing.


Semi-con. swellable tape shall be wrapped on cable, remained length of 1000..

Fig. 3 Fig. 3 Setting the Semi-con swellable tape & Annealed copper wire

4. Annealing
1) Preparation of annealing
Wrap the non-adhesive Teflon tape with 1/2 lap.
The thermo couple, as sensor for temperature-control, shall be set on the taped core.

Fig. 4 Application of Teflon tape and thermo couple

TAIHAN ELECTRIC WIRE CO.,LTD.


ENERGY CABLE BUSINESS UNIT
EHV POWER CABLE ACCESSORY PLANT
132 XLPE PMJ

The vulcanized rubber tape shall be wrapped over the Teflon tape without overlap and gap
between any turn and the next turn.
A pair of half split aluminum pipe shall be set onto the taped core.
Binding aluminum pipe tightly with band or wire
A band heater shall be wrapped onto the aluminum pipe, being covered with lagging materials.

Note: The vulcanized rubber tape shall be wrapped no added tension.

2) Annealing
The temperature controller shall be operated to get the temperature curve as shown Fig. 5.

Fig. 5 Operating of temperature controller

Lagging materials and band heater shall be removed at 65.

3) Check cable straightness


Straighten the cable less than 1/300 as shown in Fig. 6.

Fig. 6 Cable straightness

5. Cable cutting
1) Check the joint center and cutting point.
2) Cut the cable as shown in the assembly drawing.
Note: Be careful to cut the conductor perpendicularly.

TAIHAN ELECTRIC WIRE CO.,LTD.


ENERGY CABLE BUSINESS UNIT
EHV POWER CABLE ACCESSORY PLANT
132 XLPE PMJ

6. Removing semi-conductive layer


1) Mark the removing part of the outer semi-conducting screen with tape.
2) Removing the semi-conductive layer.
Remove the semi-conductive layer with special tool, according to dimension of assembly
drawing.
Using thin piece of glass, taper from the end of semi-conductive layer as shown in the assembly
drawing.

Note: XLPE insulation can be easily damaged if proper care is not taken while stripping cable.
Note: Boundary line between insulation and semi-conductive layer must be regulated as shown in Fig. 7.

Fig. 7 Boundary between insulation and semi-conductive layer

7. Exposing conductor
1) Using a removal tool, remove the XLPE insulation to expose the required length of the conductor as
shown in the assembly drawing.

Fig. 8 Exposing conductor

Note: Do not scrape/nick the conductor.

TAIHAN ELECTRIC WIRE CO.,LTD.


ENERGY CABLE BUSINESS UNIT
EHV POWER CABLE ACCESSORY PLANT
132 XLPE PMJ

8. Polishing XLPE insulation


1) Polish the insulation, starting with 240 grit and ending with 800 grit sandpapers.
#240#400#600#800
2) Check the diameter with a pair of venire calipers at every 100 interval. The entire diameter shall be
measured in two directions such as horizontal and vertical to verify the circular shape.
3) Wrap the non-adhesive Teflon tape with 1/2 lap on semi-conductive layer nearby polished insulation.
4) Apply heat on surface of Teflon tape with heater gun about 5minutes.
Note: Do not reuse the sandpapers which were used for sanding the semi-conducting screen.
Note: Do not sand particularly one side, sand the insulation roundly.
Note: Be careful to direction of cleaning to avoid attaching material of semi-conducting screen on the
XLPE insulation.

9. Preparing the assembling parts


1) The polished XLPE insulation shall be temporarily protected prior to putting all the assembling parts
through the cable.
2) All components shall be put through the cable in the correct order as follow and also assembly
drawing.
Long side: Heat shrinkable tubeOuter case(B)Insulator
Short side: Heat shrinkable tubeOuter case(A)
Note: XLPE insulation can be very easily damaged if proper care is not taken.

10. Mounting the pre-molded unit


1) Apply silicone grease onto inner surface of pre-molded unit, surface of cable (long side only).
2) Set a Sliding jig on cable (long side).
3) Apply silicone grease onto surface of sliding tool.
4) Load the pre-molded unit on mobile support, and move it to reach sliding tool
5) Hook the lever-block on mounting tool.
6) Operate the lever-block to insert the pre-molded unit completely.

Fig. 9 Expanding the pre-molded unit

7) And then pull out the sliding tool.

TAIHAN ELECTRIC WIRE CO.,LTD.


ENERGY CABLE BUSINESS UNIT
EHV POWER CABLE ACCESSORY PLANT
132 XLPE PMJ

Note: Check the surface of the unit during/after mounting operation.


Note: Be careful to inserting direction of pre-molded unit.

11. Compressing the conductor sleeve


1) Cover the insulation surface by clean cloth.
2) Strip off the conductor screen completely.
3) Insert the cable conductor into the conductor sleeve.
4) Compress the conductor sleeve with the hexagonal dies shown on the assembly drawing.

Fig. 10 Compressing the conductor sleeve

Note: After compressing, check the straightness and elongation of sleeve.

12. Groove the XLPE insulation


1) Setup the grooving guide onto conductor sleeve.
2) Setup the grooving tool onto grooving guide.
3) Turn the grooving tool to groove the XLPE insulation.

Fig. 11 Groove the XLPE insulation

4) Check whether corona shield fits in a groove.

Note: Dimension of outer insulation must check every step, when strip off the XLPE insulation.

TAIHAN ELECTRIC WIRE CO.,LTD.


ENERGY CABLE BUSINESS UNIT
EHV POWER CABLE ACCESSORY PLANT
132 XLPE PMJ

13. Assembling the corona shield


1) Wash and clean the conductor sleeve and exposed conductor.
2) Assemble the braided copper wire with corona shield.
3) Assemble the corona shield.

14. Setting the pre-molded unit


1) Wash and clean the cable insulation with alcohol.
2) Apply silicone grease onto the insulation surface and corona shield surface.
3) Set the mounting tool at side of pre-molded unit.
4) Operate the lever-block to move the pre-molded unit in joint center.

Fig. 12 Setting the pre-molded unit

5) Set the pre-molded unit in correct position as shown in Fig. 13.

Fig. 13 Setting the pre-molded unit in final position

15. Wrapping the tape


1) Wrap the self-bonding tape at both taper parts of pre-molded unit with strong tension.
2) Wrap the EPR tape at all area as shown in assembly drawing.
3) Wrap the shield mesh tape at all area as shown in assembly drawing.
4) Wrap the self bonding tape as shown in assembly drawing.
5) Wrap the PVC tape at all area as shown in assembly drawing.

TAIHAN ELECTRIC WIRE CO.,LTD.


ENERGY CABLE BUSINESS UNIT
EHV POWER CABLE ACCESSORY PLANT
132 XLPE PMJ

16. Treatment of the earthing sleeve


1) Both sides of cable metallic sheath shall be bonded with the braided copper wire of the earthing
sleeve as shown in assembly drawing.
2) Gather wires of copper sheath wire
3) Connecting the wires or bonding conductor to the earthing sleeve by compression.

17. Setting the protection tube


1) Connect both sides of FRP case as shown in assembly drawing.

18. Waterproof layer


1) Proceed according to the assembly drawing.
2) Pour the water proof compound on the protection tube. And then assemble the covers by bolting..

TAIHAN ELECTRIC WIRE CO.,LTD.


ENERGY CABLE BUSINESS UNIT
EHV POWER CABLE ACCESSORY PLANT
TAIHAN ELECTRIC WIRE CO., LTD.

REF. NO. : TECEHV-1325-A01


DATE: 2009. 02. 25.

TERMINATING INSTRUCTION
OF
OUTDOOR SEALING END
FOR
132kV 1C X 2500SQ
CROSS-LINKED POLYETHYLENE INSULATED
POWER CABLE

SIGNED BY

Team Manager,
Acc'y Engineering Section
EHV Factory
TAIHAN ELECTRIC WIRE CO., LTD.
TERMINATING INSTRUCTION
OF
OUTDOOR SEALING END
FOR
132kV SINGLE CORE CROSS-LINKED
POLYETHYLENE INSULATED POWER CABLE

1. Introduction

This instruction explains the terminating procedure of sealing end for 132kV single
core cross-linked polyethylene insulated metallic sheathed and PVC covered
power cable.
This jointing instruction is compiled for the authorized jointer and describe the
process of jointing work in accordance with the attached drawing.
During actual jointing, all dimensions should be independently checked on the
applicable drawing by two jointers.

In these process of terminating works, be careful of the following items.


(1) Dust
(2) Moisture
(3) The direct sunshine

2. Checking Materials

Check the name of part and quantity as shown attached drawing.

3. Terminating Procedure

3-1 Preparation

3-1-1 Raise the cable to the prescribed position, provisionally fix it to the
structure.

3-1-2 Straighten the cable less than 2mm/600mm as shown in Fig. 1.


If necessary, anneal cable core for straightening.

Fig.1

-1-
TAIHAN ELECTRIC WIRE CO., LTD.
3-1-3 Measure the actual length of the porcelain bushing "L1" and mark the
cable cutting point as shown in Fig. 2. "L1+K" from the upper surface
of the structure.

3-1-4 Cut the cable at the cutting point as shown in Fig. 2.

Fig.2

3-2 Cable termination

3-2-1 Remove the outer covering over the metallic sheath as shown in Fig. 3.

Fig.3

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TAIHAN ELECTRIC WIRE CO., LTD.
3-2-2 Wipe off the compound over the metallic sheath with gasoline.

3-2-3 Solder on the surface of the metallic sheath as soon as possible as shown in
Fig. 4. and Bond the braided copper wire on the solder.
(refer to attached drawing)

* Soldering method : Refer to attached Appendix 1

Fig.4

3-2-4 Cut off the metallic sheath at the cutting point using the saw for the metallic
sheath, as shown in Fig. 4. Be careful not to damage the metallic shielding and
the insulation.

3-2-5 Enlarge the end of the metallic sheath


not to damage the cable core and
straighten the cable once more.

3-2-6 Remove the metallic shielding over the


extruded insulation screen as shown in
Fig.4.

* If necessary, put the cable upward temporarily


to enable carrying out in subsequent operation
without being obstructed by the bottom plate.

Fig.4
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TAIHAN ELECTRIC WIRE CO., LTD.
3-2-7 Straightening of Cable
A tape Heater shall be wrapped onto the aluminum pipe, being covered with
heat insulating mat as shown in Fig.5.

Fig.5

* Check point
If necessary, to remove the winding form of cable white winding on the reel,
after wrapping vulcanized rubber tape or scrap cable sheath around cable, put
the cable between angle AL and binding tightly for at least 12 hours as
shown in Fig.6. (Usually above work was carried out right after cable laying)

If the winded form can not be removed, apply a beat for approx.2 to 3 hours
while straightening by above method.

Fig.6

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TAIHAN ELECTRIC WIRE CO., LTD.
3-2-8 Cutting of Cable
Cut the cable as shown in Fig.7.

Fig.7

3-2-9 Cleaning the Cable Core


Remove the dust on the insulation screen.

3-2-10 Removing Insulation


Remove the insulation of cable as shown in Fig. 8.

Fig.8

3-2-11 Compression of the connector


Insert the conductor into the connector and compress the connector with the
hexagonal dies with 1/3 over lapping of die width as shown in Fig. 9.
After compression, file the surface of connector and make it smooth.

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TAIHAN ELECTRIC WIRE CO., LTD.

Fig.9

3-2-12 Removing Insulation Screen.


After compressing the conductor sleeve, mark the removing & polishing point
of the insulation screen.
Remove the Insulation screen of cable and shave the insulation with the
stripping tool as shown in Fig. 10. If any of the insulation screen remains on the
cable, remove all of the remaining insulation screen using a thin piece of glass.

Fig.10

* In the above mentioned operation, special care must be taken not to damage
the insulation of cable, because a slight damage causes a electrical breakdown.
Practice this work using the surplus cable before commencement of actual
terminating work.

3-2-13 Polish the Insulation screen


Polish the Insulation screen using a thin piece of glass as shown in Fig.11.
Remain the Insulation screen by 0.5mm in thickness.
And then, Using a thin piece of glass, taper from the end of the each part as
shown in Fig.12.

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TAIHAN ELECTRIC WIRE CO., LTD.

Fig.11

Fig.12

3-2-14 Polishing the Insulation


Using sandpaper of #240m #400m #600 and #1,000 grade, form and polish
the tapered portion of the semi-conductive layer on the insulation as shown in
Fig. 13.
After polishing, check with the magnifying glass the surface of insulation is no
wound as shown in Fig. 13.

Fig.13

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TAIHAN ELECTRIC WIRE CO., LTD.
* Do not reuse the sandpapers which were used for polishing the insulation
screen.
* Use the sandpapers in the indicated order:
1. #240: #240 grade sandpaper should be used until the scores from the
stripping tool are removed completely.
2. #400 and more high grade: #400 grade sandpaper should be used
until the scores from the #240 grade sandpaper are removed.
And more grade sandpaper should be used the same manner
* Make sure the difference between the crosswise diameters less than 0.5mm
to confirm that the insulation is formed circular.

Using a wiping paper soaked in ethyl alcohol or other suitable solvent, clean
the cable

3-2-16 Cover the clean seat (ex.PE sheet) over the insulation and slide the parts onto
the cable according to following order.
.

Fig.15

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TAIHAN ELECTRIC WIRE CO., LTD.
3-2-17 Insert the pre-molded stress-relief cone.
Apply the silicone oil over the insulation inner surface of pre-molded stress
relief cone. Put the pre-molded stress relief cone on the insulation as shown in
Fig.16.

3-2-18 Wrap the tapes


Wrap the one layer(1/2lapped) of shield mesh tape over the Insulation screen
to Metallic sheath as shown in Fig.16. Then wrap the one layer (1/2lapped) of
Adhesive PVC tape over the Shield mesh tape as shown in Fig.16

Fig.16

3-2-19 Marking
Mark the setting point of the stress relief cone and measuring point after
terminating with PVC tape as shown in Fig.16.

3-2-20 Wrap self bonding tape from the tapered point to the lower part of connector
and then put on the heat shrinkable tube. Heat and shrink the tube as shown in
Fig.17

Fig.17

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TAIHAN ELECTRIC WIRE CO., LTD.
3-2-21 Setting of porcelain bushing.
1) Wipe cleanly the surface of porcelain bushing with gasoline or alcohol.
2) Fix the insulating supporter on the structure.
3) Set the epoxy insulator to the porcelain bushing with O ring gaskets and
fitting metal as shown attached drawing.
4) Apply the silicone oil on the stress cone and inner surface of the epoxy
insulator.
5) Lift the porcelain bushing and epoxy insulator on the connector, and carry
down them slowly to the insulating supporter.

* When carry down the porcelain bushing, be careful not to damage the inner
surface of epoxy insulator by the edge of connector.

6) Check and adjust the length of connector above the top surface of porcelain
bushing as shown in Fig.18.

Fig.18

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TAIHAN ELECTRIC WIRE CO., LTD.
3-2-22 Setting of the compression ring
1) Apply the silicone grease on the stress relief cone semi-conductive portion
and compression ring inner surface.
2) Screw the shaft of compression ring to the epoxy insulator as shown in
Fig.19.

Fig.19

3) Compress the springs of compression ringby screwing nuts onto the shaft
so that compressed length of spring becomes 10mm.

3-2-23 Arrangement the cable wire shield (according to attached drawing)

3-2-24 Filling silicone oil into the porcelain bushing

3-2-25 Fix the top plate, tightening metal and fixing plate.
(Note) Recomfirm the exposed connector length.

3-2-26 Set the rain shield.

3-2-27 Earthing

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TAIHAN ELECTRIC WIRE CO., LTD.
Appendix 1
Soldering
(1) Using a steel wire brush, polish the solder wiping area of the aluminum sheath
(see dimensions in drawing) until the oxide film is completely remover, creating
a lustrous surface.

CHECK POINT: To ensure correct plating, use a suitable wire brush.


The recommended brush has a width of approx. 30 to
50 and a length of approx. 30. Make sure the
brush is not rusty.

CHECK POINT: To avoid making oil flow-paths on the surface of the


sheath, do not polish along the cable axis.

CHECK POINT: To make the subsequent tinning procedure easier,


polish the surface at different angles.
(see figure below).

(2) Before making the solder wipe, it is necessary to perform a separate plating
operation using an aluminum-plating solder, which is formed by friction of the
steel wire brush during application. The recommended plating procedure is as
follows:

(a) Heat up the area to be plated to a temperature (approx. 120 to 130)at


which the stick-type plating solder just melts when rubbed on the aluminum
sheath surface.

* The plating solder is composed of 20% tin and 50% zinc and has a
melting point of 100 to 120

CHECK POINT: Wrap tape or other suitable material on the cut end of
the anti-corrosion layer to prevent it from melting or
burning during plating and pre-solder wiping.
TAIHAN ELECTRIC WIRE CO., LTD.
CHECK POINT: To avoid re-oxidation, the torch's flame should be blue.

CHECK POINT: The supplied plating solder is stamped "AL" on its


surface.

(b) Continue heating the aluminum sheath, and rub and coat the stick-type
(See figure below)

CHECK POINT: Do not melt the plating solder in the flame.

(c) After coating plating solder at intervals along the entire required surface
area heat the surface again until the applied solder is molten. Then use a
new steel wire brush to spread the plating solder to form a uniform layer
over the entire surface.

CHECK POINT: Do not reuse the wire brush which was used for polishing.

(d) Repeat steps (b) and (c) above.

CHECK POINT: Make sure that the surface appears bright after plating,
indicating that the plating solder has become alloyed.

CHECK POINT: Make sure that there are no dull or unplated areas,
especially on the bottom of the cable. If a dull of
unplated area remains, repeat the plating operation until
a satisfactory finish is obtained.
SECTION

6. 3

Maintenance
DOC. No. TH-EHV-E&I-M-R0

TECHNICAL DATA

OPEPERATION AND MAINTENANCE INSTRUCTION

Maintenance Manual Taihan Electric Wire Co., Ltd. 1/9


DOC. No. TH-EHV-E&I-M-R0

1. Handling and Storage of Materials

All packages with umbrella mark shall be kept in dry location and all jointing materials shall
be kept in well ventilated store.

2. Planning

The Important process of cable installation work shall be studied beforehand sufficiently so as
to p roceed t he i nstallation wo rk as p lanned. E specially t he d etailed d esigning wo rk r egarding
cable route, c able s ection l ength an d p ositioning o f jointing b ays and t erminations shall b e
finished o n p lanning s tage, an d ac tual i nstallation s chedule s hall b e p rogrammed p rior t o t he
commencement of work considering special crossings, removal methods of obstructions in the
route.

2.1 Maximum Section Length

When the maximum cable section is designed, following limitations shall be considered.

(a) Local restrictions on continuous trench length that can be opened


(b) Manufacturing facility of one continuous cable length
(c) Transportation facility
(d) Handling limitations at site
(e) Permissible induced voltage at cable metallic sheath/shield
(f) Balancing of Cross-bonding, Solid-Bonding and earth system
(g) Positioning of jointing bays or Termination
Existing services shall be avoided inside jointing bay or man-hole as much as possible to
keep enough space for jointing work.
The dimensions of jointing bay or man-hole shall be large enough to secure sufficient
space for offset arrangement and supporting structure.

Maintenance Manual Taihan Electric Wire Co., Ltd. 2/9


DOC. No. TH-EHV-E&I-M-R0

2.2 Minimum Bending Radius of Cable

Permissible mi nimum b ending r adius of c able, w hich d epends o n t ype o f c able, i s g iven a s
below :

230kV 1x2500mm2 XLPE Power Cable: 20d


d: Overall diameter of cable(mm)

Cables shall not be bent with the radii smaller than those shown in the above said in any case.
It is necessary to take larger radius than the minimum at offset portions or bending portions,
taking thermal expansion which may cause severer condition into account.

2.3 Direct Burial

Cable route shall be selected to avoid bending portions as few as possible. It is recommended
that at least several times the minimum bending radius, preferably more than 5m, shall be
taken at corners of the route, because larger radius provides lower side wall pressure.
Enough s pace s hall b e kept i nside t he c able trench an d i t shall b e c onfirmed wi th available
records of e xisting s ervices and sufficient number of trial holes that the t rench, especially at
jointing bays, has no obstructions to the installation work.
It is also shall be confirmed that no harmful chemical agents to the cable are contained in the
surrounding soil and water along the route.

2.4 Duct System

Larger bending radius is generally required in duct system than in direct burial. Since friction
coefficient of duct is larger than that of cable roller used in direct burial installation, which
results high pulling tension, the maximum section length between adjacent man-holes is limited
to shorter than that of direct burial.
Therefore e ach s ection l ength s hall b e d etermined aft er c areful c alculation o f t he p ulling
tension and the side wall pressure of corresponding section.
Cable protrusion from duct into man-hole by thermal expansion shall also be considered when
the d imensions o f the m an-hole ar e d ecided. A nd i t s hall be n oted that offset ar rangement i s
requested to absorb the thermal behavior of the cable during its service life.

Maintenance Manual Taihan Electric Wire Co., Ltd. 3/9


DOC. No. TH-EHV-E&I-M-R0

Size of duct shall be selected according to the following table.

Table 2.4 Internal diameter of duct


Case Internal diameter of duct(mm)
One cable in a duct D > 1.3d and D > d+30
D : internal diameter of duct
d : overall diameter of cable

Internal surface of duct including joint parts shall be smooth and without any harmful defects
against the cable such as projections, cracks, scratches. Any sharp edge shall be rounded off at
both ends of duct.
Every duct shall be provided with a d rawing wire inside and both ends shall be plugged with
proper manner to prevent ingress of soil, sand, concrete etc.

2.5 Cable Tunnel

Cable tunnel dimensions shall be so designed as to secure enough space both for setting of
cables on supporting structures and for installation and jointing work. And its bending corners
shall also be designed to give the permissible bending radii to cables with enough margin.
When cables are laid on cable racks or cable supports, they shall be fixed with cable cleats at
adequate intervals to absorb the thermal expansion and contraction with their lateral or vertical
movement within the length between adjacent cleats.
If cables are laid free without any binding, they may move according to the thermal behavior
and may drop from the racks or supports. And the metal sheath of cable may be subjected to
excessive strain at bent portions where the thermal movement of the cable is concentrated
partially.
Therefore SNAKE INSTALLATION, laying a cable in uniform wave-form, is usually applied
along the route on racks or supports to encourage the absorption of thermal movement of the
cable smoothly. But at the ends of the route, the cable shall be set straight and fixed with cable
cleats, then raised to the sealing ends.

2.6 Special Construction

There may include many types of special construction in cable routes, such as river crossings,
railway c rossings, r oad crossings, cable t unnel and c able b ridges. A s i ntroduced i n p revious
sections to some extent, special care must be taken to lay cables at such places.
It i s not possible to l ist u p all co untermeasures t o cope with a nd cover e very s pecial
construction, however, followings ar e generally recognized as basic key points which shall be

Maintenance Manual Taihan Electric Wire Co., Ltd. 4/9


DOC. No. TH-EHV-E&I-M-R0

taken account of the design and actual installation work.

(a) The thermal environment must be satisfactory


(b) Any thermo mechanical forces that could be experienced must be adequately constrained or
dissipated.
(c) Where c ables ar e e xposed i n ai r, c are mu st be d uly taken o f r isks d ue t o f ire, v andalism,
accidental damage by third party and solar radiation
(d) Exposure to vibration
(e) Specified installation radii must be observed

3. Cable Laying Work


Cable l aying wo rk an d civil w ork s hall b e c arried o ut i n accordance with the at tached
Technical Data TH-EHV-E&I-PC-R0.

4. Jointing Work

Jointing work shall be carried out in accordance with the instructions

. Earthing and Bonding Work


Earthing and bonding work shall be carried out in accordance with the attached SCHEMATIC
DIAGRAM.

. Electrical Test After Installation


After completion of installation work including miscellaneous work such as installation of
earthing /bonding equipments, the power cable, joints and sealing ends shall be tested with the

voltage being applied between each conductor and earth for the specified period in accordance
with IEC60840 or equivalent standard.
If the cable is terminated inside the cable end box of transformer or switchgear, this test
requires good coordination between the purchaser, the manufacturer of the transformer or
switchgear and the cable contractor.
It i s n ecessary t o c onfirm t hat a t ransformer o r s witchgear is d esigned t o wi thstand t he
required v oltage an d that t he me dium b etween t he e nclosure o f a t ransformer o r s witchgear
and the sealing end has sufficient electrical strength/insulation resistively for the test voltage.

Maintenance Manual Taihan Electric Wire Co., Ltd. 5/9


DOC. No. TH-EHV-E&I-M-R0

. Maintenance

Maintenance of the cable system is important to confirm the system in good operation.
Therefore t he s ystem shall b e i nspected a nd o bserved p eriodically for t he m aintenance.
Recommended items for maintenance work are introduced in Table1.

.1 Patrolling the Cable Route

Frequent patrol of the cable route is advisable, daily patrol is recommendable, in order to
avoid unexpected cable damages.
It is necessary to check whether other excavation works in the route are properly supervised
or not.
In c ase t hat an y e xcavations n oticed i n t he r oute, p rovide the e xact ca ble l ocation a nd the
suitable instruction to protect the cable from the outer damage.
Also, it is necessary to supervise the work until backfilling is finished.
When the cable has been installed in duct system or in tunnel, it is necessary to check that
the offset in a man-hole its correct from and the cable is placing at correct position.

.2 Checking Anti-corrosive Sheath

Most of cable faults come from external damage.


In case of XLPE insulated cable, the cable will be deteriorated in the following sequence, if anti-
corrosive sheath is damaged.
Therefore, it is very important to make sure that the anti-corrosive sheath has no fault.
DC 5kV i s t o b e a pplied b etween me tallic sheath/screen and e arth after confirming t hat
insulation resistance of the anti-corrosive sheath shows a reasonable value.

Maintenance Manual Taihan Electric Wire Co., Ltd. 6/9


DOC. No. TH-EHV-E&I-M-R0

Damage of anti-corrosive sheath

Water or moisture penetrates into cable

Migration of Moisture into Insulation Corrosion of metallic sheath

Chemical or electrical treeing Discontinuity of metallic screen

Discharge of charging current

Break Down

Links, insulators and earthing/bonding wires shall be cleaned up before measuring insulation
resistance of the sheath so as to minimize excess leakage current. In case that the element of a
surge diverter in a link box is gapless type (Zinc Oxide Element), the link bar between high
voltage part and the surge diverter shall be disconnected temporarily.

Maintenance Manual Taihan Electric Wire Co., Ltd. 7/9


DOC. No. TH-EHV-E&I-M-R0
Table 1. Recommended routine maintenance
Item Description Frequency

(1) Check the existing of execution of civil and Suitably


construction works near to the cable route.
1. Inspection of
cable (2) Observe the termination of the cable 1/month
i) Contamination of outdoor sealing ends
ii) Loose connection of earthing leads/earthing links
iii) Deformation of the exposed cable due to external
damage.

(1) Power Cable Sheath 1/year


i) Measuring of insulation resistance of anti-corrosive
2. Anti-corrosive sheath (by using 1000V megger)
sheath ii) D.C. Test 1/year
5kV D.C. is to be applied between metal sheath or
screen tape/wire and earth for a period of one minute.

(1) Visual inspection on a link box No water inside the link 1/year
3. Earthing box
(2) Check no loose connection of earthing/bonding leads 1/year
and earthing links

4. Surge Diverter (1) Measuring of insulating resistance by using 1000V 1/year


Megger

Maintenance Manual Taihan Electric Wire Co., Ltd. 8/9


DOC. No. TH-EHV-E&I-M-R0
8. Serious Cable Damage
If cable is damaged seriously, it is required to cut the damaged cable and to replace the
damaged length.
It should be confirmed that no water or no moisture is in the cable to be left before sealing
the cable ends according to the following procedure.

(1) Cut the cable at damaged portion

(2) Check whether water/moisture is in the cable or not. Visual inspection shall be carried out
on part by part, i.e. between strands of conductor, insulation, insulation screen tape/wire, fabric
tape, the gap between core and metal sheath. And check whether such parts are wet or not.

(3) If the cable has possibility of containing water/moisture in it, cut the cable at positions until
no water and no moisture in the cable.

(4) The same procedure mentioned in (1), (2), and (3) shall be carried out until confirming that
no water and no moisture in the cable.

(5) After confirming i t, put a p iece of insulation t ape/sliced thin XLPE i nsulation, fabric t ape,
segment insulating tape of conductor etc., which are suspected of containing moisture, into
insulation oil heated up between 125 and 165. If no bubble appears and no sound occurs,
the moisture contents is estimated lower per cents in that sample, when putting it into the oil.

(6) The same procedure mentioned in (1) to (5) shall be carried out until passing the test
described in (5).

(7) Further 3 meters of the cable shall be cut off and firmly seal the end of it not to allow
ingressing any moisture nor water.

(8) It is very important to estimate the cable length that has been affected by the damage at
initial stage in order to minimize the repair cost and time.
Engineer shall be required to make quick and proper decision considering the design of the total
cable s ystem aft er modification d ue t o the r epair, r equired re-commissioning d ate of t he
damaged circuit, necessary materials for repair in hand, site conditions for additional joint
positions, etc. in addition to such points.
It i s s ometime r equired t o r eplace t he wh ole l ength o f t he d amaged s ection d ue t o t he
conditions aforementioned.

Maintenance Manual Taihan Electric Wire Co., Ltd. 9/9