Page : 1 of 16

Doc. No.: LSC-IJ-1

Issued : Feb. 2014
Rev. : 0

BETTER FRIEND THROUGH BETTER PRODUCTS

Jointing Manual
Non-Straight through Joint
For 132kV XLPE Power Cable
 Page 2 of 16

CONTENTS

1. Cable cutting and offset

2. Removal of outer layers

3. Annealing for cable straightening

4. Removal of insulation screen and smoothing of cable insulation

5. Exposure of cable conductor

6. Positioning of the parts

7. Initial setting of pre-molded joint sleeve

8. Compression of ferrule

9. Grooving of cable insulation

10. Fitting of corona shield

11. Final setting of pre-molded joint sleeve

12. Supplementary treatment

13. Setting of protective casing and insulating plate

14. Waterproof procedure of protective casing

15. Earthing
 Page 3 of 16

※ All works should be done according to the dimension of installation drawing.

※ Unless otherwise noted, bolts used here are hexagonal bolts.

1. Cable cutting and offset

(1) Cut off the surplus length of the cable so that two cables overlap each other from

the jointing center as shown in Fig.

300mm
Jointing center
(End position of conductor)
300mm

(2) Straighten both cables at least 1.5m from the jointing center.

2. Removal of outer layers

(1) Remove the PE jacket.

Jointing center
PE Jacket (End position of conductor)
Metal sheath(Al)

300
 Page 4 of 16

(3) Removal of metal sheath

-Remove the metal sheath to expose extruded semi-conductive layer

- Remove asphalt coating on the remained metal sheath.

- Remove swellable tape except 30mm from the edge of metal sheath.

metal sheath Jointing center

Swellable tape

30

Extruded semi-conductive layer

3. Annealing for cable straightening

(1) Check the belt heater.

(2) Wrap two layers of PS tape with 50% overlap over cables.

(3) Wrap one layer of aluminum foil.

(4) Wrap the belt heater.

(5) Place the thermocouple underneath the belt heater.

Note :  Thermocouple must be underneath the belt heater.

 Do not wrap the belt heater too tightly.

(6) Wrap aluminum foil and slightly press it with hands.

(7) Set the temperature at 90°C for 6 hours depending on the cable insulation

thickness.

(8) Straighten both cables using steel or aluminum angle as soon as annealing process

is completed.

Note : At least 5 hours of cooling is required.

 Page 5 of 16

4. Removal of insulation screen and smoothing of cable insulation

(1) Place the marking tape on the cable.

(2) Remove insulation screen with glass to expose the cable insulation.

Marking tape Cable insulation

(3) Using glass, chamfer the edge of insulation screen in order to make smooth transition

from cable insulation to insulation screen according to assemble drawing..

Note : Be sure not to make the pit on the cable insulation with glass.

Chamfer

Less than 3mm

40~100(chamfer)
 Page 6 of 16

(4) Smooth the chamfered edge of insulation screen and cable insulation with emery cloth

# 400, #600 and #800 in order.

Caution : Do not smooth cable insulation with emery cloth used in insulation
screen

(5) Clean the cable insulation as well as insulation screen with ethanol.

Cleaning direction

Caution : Be sure not to contaminate cable insulation with semi-conductive particles

(6) To avoid contamination by semi-conductive particles while lubricating the cable insulation
with silicone grease, heat the area specified below with a thermo gun for about five
minutes.
Thermo gun

5. Exposure of cable conductor

(1) Place the marking tape on the edge of insulation screen in order to cut the surplus
length of 300mm for both side A and B.

Marking tape

300

(2) Mark the conductor exposure length from the cable end.
 Page 7 of 16

(3) Using the tool provided, make square cut until conductor is exposed.

Caution : After conductors are exposed, smooth the edge of cable insulation.

Cable
conductor

6. Positioning of the parts

Side A Side B

(1) Heat shrinkable tube

(2) Coffin Box(A) (1) Heat shrinkable tube
(3) Heat shrinkable tube (2) Coffin Box(B)
(4) Protective casing (A) (3) Heat shrinkable tube
(4) Protective casing (B)
(5) Heat shrinkable tube
(5) Heat shrinkable tube
(6) Insulating plate

Caution : Make sure that all necessary parts are in place with above order before
the initial setting of joint sleeve.
 Page 8 of 16

7. Initial setting of the pre-molded joint sleeve

(1) Clamp the side A cable tightly.

(2) Using marking tape, mark on the cable of side A and side B from the edge of
insulation screen, and mark center position on the joint sleeve outer surface.
(3) Visually check inside of joint sleeve for possible contaminants. If any, clean them with
ethanol.
(4) Clean the cable insulation with ethanol and completely volatilize the surface for at least
five minutes.
(5) Lubricate inside of the joint sleeve and the cable insulation with silicone grease.
(6) Place the joint sleeve in the installation tool.
(7) Insert the guiding cone into the cable conductor and operate the installation tool to move
the joint to the presetting position.

Center position Guide cone

Side A

Clamping unit Guide cone

Clamping the side A cable and Placing pre-molded joint sleeve in the installation tool
*Note : Installation tool can be changed according to the site condition
(8) Remove the guide cone.
 Page 9 of 16

(9) After presetting, the cable insulation must be exposed no less than 50mm in order to
groove cable insulation.
Caution : Do not leave the joint sleeve expanded for more than 4 hours after the

initial setting.

8. Compression of ferrule
(1) bolt tinned copper braid.

Tinned copper braid (supplied with corona shield)

(2) Compress the ferrule
(number of crimping : 1 at each side, Crimping pressure : 700kg/cm 2, Dies Model No : CW14)

compression
Marking tape

(3) Compress the ferrule and check the dimension.

 Page 10 of 16

9. Grooving of cable insulation

(1) Tape the tinned copper braid in order to fix them while grooving.

PVC tape

(2) Using the grooving tool, cut grooves in the cable insulation as shown below.

ΦA

(3) While grooving, keep checking the dimension (ΦA) specified in the installation drawing.
(4) Round the edge of cable insulation with glass.

10. Fitting of corona shield

(1) When grooving is completed, remove tape and temporarily fit the corona shield to ensure
that it fits correctly.

(2) Connect tinned copper braids to corona shield.

(3) Fit the corona shield in the grooved cable insulation.

Caution : Corona shield must not exceed 1mm and not below 3mm of the level
of cable insulation

Corona shield
 Page 11 of 16

11. Final setting of the pre-molded joint sleeve

(1) Clean and lubricate the cable insulation.
(2) Operate the installation tool and move the joint sleeve to the jointing center.
(3) After final setting with L3, remove the installation tool.

Side B

L3

L1 L2

Caution : Make sure that the installation tolerance of L3 must be within the
range of  3mm.

(4) Check the dimension (L1, L2) and remove marking tapes on both side A and B.
 Page 12 of 16

12. Supplementary treatment

(1) Wrap one layer of semi-conductive tape with 50% overlap on joint sleeve.

Semi-conductive tape

(2) Wrap one layer of copper mesh & insulating tape with 50% overlap e and bind copper
mesh with copper wires tightly. Solder copper mesh and copper wires together.

Caution : Do not wrap copper mesh with excessive tension

Copper mesh
Semi-conductive tape

Copper wire (Soldering)

(3) Wrap three layer of insulating tape with 50% overlap.

Insulating tape

(3) Apply the heat shrinkable tube.

 Page 13 of 16

13. Setting of protective casing and insulating plate

(1) Position the protective casing (A), (B) and insulating flange and connect them.

Protective casing (A)

Protective casing (B)

Spring washer

(2) Insert the lead spacer between protective casing and metallic sheath.
At side land cable, uniformly spread tinned copper braids over the entire surface of
metallic sheath and bind them tightly with soldering using the pb soldering material.
 Page 14 of 16

14. Waterproof procedure of protective casing

(1) Mix base resin and hardener of epoxy putty until the color of mixture becomes uniform.
(2) Apply mixed epoxy putty and glass tape at the ends of protective casing (A)(land cable).
And apply plumbing, mixed epoxy putty and glass tape at the ends of
protective casing(B)(submarine cable).

Epoxy putty + Glass tape Plumbing + Epoxy putty + Glass tape

(3) Preposition heat shrinkable tubes and wrap one layer of NF-500 tape as illustrated below.

NF-500 tape Heat shrinkable tube

(4) Apply heat shrinkable tubes and shrink it from center to both ends.
(5) Wrap three layers of Insulating tape, and two layers of PVC tape with 50% overlap at
both edges of heat shrinkable tubes.
 Page 15 of 16

(6) Mix base resin and hardener of waterproof compound together and pour them into the
protective casing.(If any)
Waterproof compound(If any)

Heat shrinkable tube Insulating tape + PVC tape

(7) Cover the caps on the protective casing and solder them.

Cap

(8) Preposition the heat shrinkable tube and wrap one layer of NF-500 tape.

(9) Apply the heat shrinkable tube over the region specified. Shrink
them from center to both ends.
(10) Wrap three layers of Insulating tape, and two layers of PVC tape with 50% overlap at
both edges of heat shrinkable tube.
 Page 16 of 16

15. Earthing
(1) Connect the earthing terminal to earthing terminal lug in the protective casing (A) and (B).

Earthing terminal

Flat washer
Spring washer
Earthing terminal lug

(2) Insert earthing lead into earthing terminal.

Earthing lead
(3) Preposition the heat shrinkable tube and wrap one layer of NF-500 tape. Compress the
earthing terminal.

(4) Place the heat shrinkable tube in the dotted position and shrink it from center to both ends.

Heat shrinkable tube NF-500 tape

(5) Wrap five layers of Insulating tape and two layers of PVC tape with 50% overlap over at
both edges of heat shrinkable tube and region specified in the picture below.

Insulating tape+ PVC tape

Heat shrinkable tube