Erection Abb Ion

Book No.
14
Version 0
~rec;~ion
.. ~ ~:
j :
.
Erection
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Jl.t ••
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ABB Transmission and Distribution Management
SA THS / BU Transmission Systems and Substations
Ltd BU TS I Global LEe BUill''''.
C/o ABS SwitctllJ"lli 1\,\
P. O. Box 8131 SE - 721 58 Vi,,;llJltlfl
CH - 8050 ZOrich Sweden
Switzerland
,.
Suggestions for improvement of this book
as well as questions shall be addressed to:
Siteman
J.
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SU TS / Global LEC Support Programme
C/o ASS Switchgear AS
SE-721 58 Vasteras
Sweden
Erection
Telephone + 46 21 328000
Telefax + 46 21 3280 13
Telex 40490 abbsub s Welcome to the preliminary Siteman Erec-
tion handbook in the series of booklets
within the LEC Support programme of BU
Transmission Systems and Substations of
BATHS.
It is the intention of the BU to update this
handbook to reflect the philosophy of the
whole BU. We hope that you will find the
booklets useful in your work.
This booklet is dedicated to the erection.
It includes internal ABB Substations, Swe-
den instructions to for example:
- Mobilize at a site
- Welding rules
- Cables
- Earthing
- Air Insulated Switchgear.
The authors welcome any idea you may
have to improve the quality of this booklet
'i. as well as the other ones.

I,. SITEMAN 01 - 94 Check on arrival
I. 1WAT 910033-1
Edition January 1994
- mobilization
Check on arrival - mobilization

CONTENTS
page 5
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Welding rules
Brazing - Thermic welding process
page 25
page 31
I.
Cables u ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••
Laying, termination and jointing of

high voltage cables <80 kV
Cubicles in electrical rooms - Touch-up
painti ng
page 51
page 87
page 113
I.
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Earth ing page 131
Air insulated switchgear page 157

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"i,..• 1. General
This document will, in principle, describe the following main subjects:
- check on arrival
- site mobilization
,'.
- check of civil works
It has to be emphasized that this instruction only can act as a guide, since each
country and site is unique, even if most of the actions to be taken are universal.
3. Site mobilization
3.1 Establishing of site routines
3.2 Site layout
3.3 Temporary power supply ·..· 8
7
7
7
,.• 2. Checklist - arrival to the country - site
The checklist, see Appendix 1 , has a general character and summarizes questions
,.
3.4 Offices and indoor store 9 repeated from site to site and may act as a reminder.
3.5 Outdoor stores 11
3.6 Personnel compartments - canteens 12
3. Site mobilization
,.•
3.7 Site toilets (WC) 12
3.8 Waste container 12 3.1 Establishing of site routines
3.9 Protection 12 For every project it is of utmust importance that the site procedures and routines
are agreed upon by all parties involved. The earlier ABB brings these questions
,.,
forward, the greater chance to introduce our routines.
:~~:~~:~
Below follow examples of points and routines to be negotiated and agreed upon.
- Routines for inspection, approval, progress reports, etc.
:::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::
~ ~~
- Routines for communication between customer, consultant, etc. and ABB site
representatives have to be agreed on. Remember that most consultants are
working in accordance with very strict protocol and are especially sensitive to
direct contacts between customer and contractors.
J;. - Routines for access to buildings and switchyard.

- Routines for planning and recording of staff and man-power.
- Rules for extra work. The contract normally specifies in detail how claims for
extra work and extension of time shall be handled. It also gives time limits within
which such claims must be submitted and how to measure the work. Note that
an agreement between the customer and the local project manager shall be
(issued) signed before any extra work is undertaken. Do not forget to note all
This document and parts thereof must not be

Jill claims in all directions in the SITE-DIARY.
- It does not matter how much information given in the contract documents earlier,
the practical application of these routines have to be established at site together
reproduced or copied without written permis-
with the consultant, customer, subcontractor, etc.
sion, and the contents thereof must not be
imparted to a third party nor be used for any
unauthorized purpose. Contravention will be
prosecuted.
"I 3.2 Site layout
A site layout showing the service areas shall be done at an early stage and prior to
the start of the site activities. The layout shall show the following: (See Fig. 1 and
2.)
Addtional copies of this document may be - Areas allocated to ABB for offices, stores, outdoor storage area, workshop.
obtained from ASS at its then current rate - Supply points for electricity, telephone, telefax. .
- Supply points for water (incl. drinking water) and sewage.
JI - Bench marks for checking of foundations.

- The site layout shall also state the areas for the consultants, customer and
others.
Support {'IOU""I/II/" JII

3.4 Offices and indoor store
The requirements have to be checked for each project. The following information
I~ J'
can
A
one
only act as an indication and show some typical solutions.
typical ASS site office and indoor store for a larger project may be housed in
20 foot container or more, and can be equipped as shown in figures 3-5.
c=, ABB mlllPMI t·ll

-
-
-
-
Example of equipment in the office-container
desks with lockable drawers
desk chairs
visitor's chairs
book shelves
as follows:
I~ -
-
rack for drawings incl. hangers
desk lamp
- air-conditioner, when required
i----1J ~ CUSTOMER I, - heater, when required
n I \ - kitchenette
"J'
AREA
SWITCH YARD
- telephone
I I ~~~~
~--l
lL ASS AREA '
OUSWllil "
EARll! WIIU
PII'I "
-
-
telex
telefax
I I \
,:g'-1
tIr
- typewriter
- copying machine
L __ ~ , (o-CONTRACTOR I - electronic calculator with printer
AREA
I - safe
The kitchenette may be equipped with:
I
- refrigerator
- cooker
- coffee machine
- crockery
3.3 Temporary power supply

The necessary temporary power demands have to be investigated and planned for
,.
at an early stage prior to erection start. Make a sketch indicating number of supply
points starting type of outlet amp and volt for each. The following can act as a
guide:
_ Office: 3-phase, 380 V, 25 A
_ Air-condition: 3-phase, 380 V, 16 A
_ Workshop/lighting: 3-phase, 380 V, 25 A
- Extra supply points in switchyards for
hand tools and electrical welding set: 3-phase, 380 V, 16 A
_ High-Vacuum transformer filter: 3-phase, 380 V, 200 A
(Approx. 130 kVA)
_ Gas-high voltage test:: 2-phase, 380 V, 320 A
(Approx. 210 kVA)
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20'180- External Internal Internal

standard without with
insulation insulation
Lenght, mm 6058 5862 5802
Width, mm 2438 2329 2209
Height, mm 2591 2400 2340
Weight, kg 2400 2400 3450
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I If. 3.5 Outdoor store
The storage area can vary between 100 - 4000 m2, as a guideline ca 60% of
Figure 5. complete switchyard. It can be located either inside or outside the switchyard. It
Typical indoor store. has to be fenced in, which can be done either by the customer, by ASS or by the
subcontractor.
The ground shall be level and, if possible, covered with gravel.
IJ_ ......
J1
CHECKLIST
••
Arrival to the country - site
Period
r\JJIJ" ..·oIIUI" •
Timber and sleepers shall be available and used to space all stored equipment
from the ground in order to protect it from water.
Tarpaulins, covers have to be available in order to protect broken or damaged
cases or to cover other sensitive equipment.
If required, do not forget to employ watchmen, if necessary on 24 hours basis.
3.6 Personnel compartments - canteens
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Project
This checklist is supposed

Site designation
Dealt with by
Order no
Dale
to be filled in with a few words answering

Return one copy soonest to your company.
completed
following
The whole list does not necessarily
at one time, it can be returned part by part.
questions.
have to be
Page
1
Cont
~:.
The size is planned according to the man-power at peak. Various portable
buildings, container or tents can be used if no stationary facilities are available. The 1. TRAVEL
compartments shall include lockable rooms for changing of clothes. 1.1 - Travel time?
If warm meals have to be served at site, a special organization has to be - Routine?
- Alternative routines?
appointed to handle this separately.
3.7 Site toilets (We)
The site toilets have to be arranged according to local standards and regulations
and prior to start of site works. If chemical or dry types of toilets have to be used,
do not forget to organize for emptying and service of these.
~. 1.2 -
-
-
-
Custom procedure?
Problems?
Need of visa, etc.?
Health check, compulsary
vaccinations?
3.8 Waste container
t'. - Problems to get spare parts
,.
etc. through customs as
The necessary equipment for the waste and arrangement for the emptying is
personal luggage?
needed to be arranged either by the customer, by ABB or by the subcontractor as
set out in the contract.
Adjacent should sand and water be available in case of fire. 1.3 - Transportation from airport?
- Approx. cost?
- Need of contact person at the
3.9 Protection
airport?
- First Aid-person
- First Aid-kit Ii_
- Stretcher, blankets
- Safety belts
- Helmets
- Ropes, Sign plates f. 1.4 - Landing card. How to be
filled in?
- How to declare money in
custom?
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- Fire extinguisher
- Fire-plug (hydrant) 1.5 - Other comments regarding
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- Ambulance transport the travel?
- Telephone to:
- Hospital
- Police
,.
- Fire-station/brigade
-Ambulance
Note. The requirements can vary between countries. The arrangements have to be
according to local standards and regulations.
4. Checklist for civil work

Prior to "access to site" and start of erection, the civil work must be checked. The
checklist, see Appendix 2, is detailing the most frequent points to be checked.
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SITEMAN 01-94
A\ppen d'IX 1
Site designation
CHECKLIST
l'IIlI"1.1
Period
Site designation
Order no
Page
I-
Deallwith by
Date
Cont
4
2. LIVING CONDITIONS (cont.)
~.1 - Hotel? ;>.10 Schools?
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- Rental of house / flat? - Swedish / International?
- Approx. cost? - School fees?
- Cost? - Starting date / terms?
- Laundry?
- Standard?
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211 Address, residence?
- Address, private mail?
'.2 - Cost of living?
- Shortage of important
commodities? 2.12 Telephone, residence?
- Shortage of foodstuffs?
- Preferable time for telephone
- Possibilities to import
calls (Swedish time)?
Eu ropean food?
- Canteens, restaurants?
- Distance to site?
2.13 Possibilities for recreation?
- Clubs / club fees?
- Waiting list?
'.3 - Drinking water,
need of boiling?
214 Contact Swedish embassy,
~.4 - Electricity supply? consulate?
- Contact man?
- Voltage?
- Frequency? - Program for evacuation in
- Reliability? case of emergency?
_. Adapter?
2.15 Other comments regarding

living conditions?
~.5 - Climate?
- Recommendable clothes?
- Insects?
~.6 - Laws/Regulations/Customs
useful to know?
- Religion?
- Other languages spoken?
- Authorities?
~.7 -- Personal belongings prefer-

able to be brought from home
country?
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~.8 - Customs regulations for

personal belongings?
- Transport?
~.9 - Currency restrictions?

- Travellers cheques, cash?
- Preferable currency?
- Accepted credit cards?
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SITEMAN 01-94 jllUI
Appendix 1 ~.r"I'I' Appendix 1
Arrival to the country - site CHECKLIST
IJwjoct
_. Arrival to the country - site
Period
Site designation Site designation Order no Page
----- 5
Dealt with by Date Cont
------._.
6
4. WORKING CONDITIONS
1.1 - Hospital available? 4.1 - Address for company mail?

- Standard?
- Address?
4.2 Telephone number during
working hours?
- Preferable time for calls from
1.2 - Private doctors available?
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Sweden (Swedish time)?
- Standard?
- Time difference - summer,
- Address / Phone number? winter?
1.3 - Dentist available?
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4.3 Telex number?
- Standard? - Telefax number?
- Address / Phone number?
4.4 Working hours?

1.4 - Medicine, antibiotica, serum, - Local holidays?
etc., available?
4.5 Work permit / permit to stay?

1.5 - Necessary arrangements in
case of emergency sick-
4.6 Visit local ABB, contact man?
transportation to home
- Available assistance from
country?
local ABB?
1.6 - Risk of deseases like malaria, 4.7 Visit customer, contact man?
dysenteri, etc.?
4.8 - Visit consultant, contact man.

1.7 - Other comments regarding
medical facilities?
4.9 - Visit subcontractor, contact
man?
1.8 - Address to SOS international - Needed tools and equipment
local branch? for erection available?
- Standard of supervisors and
...
,~ skilled man-power?
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4.10 Visit transport company, con-
tact man?
- Needed equipment for safe
off-loading available?
- Control of lifting devices?
4.11 Visit civil contractor, contact

man?
- Any hinderance on site for
,.
start of erection?
4.12 Local purchasing of erection

material possible?
- Approx. cost level?
Aooendix 1
CHECKLIST
IJrojllcf--
Period
Site designation Ordarno Page
7
Dealtwilh by Dale Cont
-
5. TRANSPORTATION
·.13 - Local purchasing of erection 5.1 Local public transports?

tools possible?
- Approx. cost level?
5.2 Rental of cars?
- Approx. cost?
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·.14 - Workshop for minor repairs
and manufacturing available?
5.3 Purchasing of cars?
- Approx. cost?
·.15 - Plant for hot dip galvanizing
iJ-
available?
54 Fuel availability?
- Approx. cost?
·.16 - Bank opening account
procedures for transfer?
5.5 Driving license international /
local?
·.17 - Customs procedures for
hardware?
- Ocean freight / air-freight? 5.6 Car insurance and regula-
- Possibilities for smoothening tions?
customs procedures?
5.7 Workshop and spare parts

·18 - Location of site, travelling available?
time?
- Road description?
5.8 Heavy trucks?
- Road conditions?
.19 - Electricity supply, worksite?
- Voltage?
- Frequency? 5.9 Import license?
.- Reliability?
510 Other comments regarding

·.20 - Other comments regarding transportation?
working conditions?
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1.21 - Telephone number to police,
ambulance, fire department?
1.22 - Trafficability to site, summer,

winter, raining seasons?
t-
ppendix
Arrival to the country - site CHECKLIST
1""''''1
Period
Site designation Site designation Order no.

Page
Dealt with by
2
Dale
Cont
3
This checklist is supposed to be filled in with a few words answering following questionli. 2. FOUNDATIONS
The main purpose however, is to remind the Site Construction Manager of all Civil Work
;>.1 f-oundations (general)
to be checked before the erection shall start.
correct location
1. OUTDOOR
?;> Individual foundations
1.1 Roads - correct placing
- to the site - correct construction
- inside the site
J.
- foundation bolts
.size
1.2 • placing
Trafficability
• clean and undamaged
- trafficabillty large / heavy threads
equipment such as trans-
• nuts and washers fitted
formers
- trafficability building - and
erection cranes limitations, 2.3 Large foundations
which? (transformer / reactor)
- dimensions
- rails
1.3 Laying of ground network
- embedded steelplates for
- is expensive clearing required. jacks / eyelets
- is re-filling required beforehand.
- foundation bolts
- earth resistance?
2.4 Oil pit

1.4 Cable excavation
- capacity
- operating space available?
- filling
- excavation for fencing?
- cover
- oil outlet
1.5 Material unloading

- in store
2.5 Cable routes
- switchgear room
- battery room
- control room
is it possible / convenient?
1'.• 2.6 Ground network
1.6 Outdoor storing

-steelwork
- cable drums
- free and levelled area size?
- sleepers / beams protection?
- fencing?
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1.7 Fencing
- foundations
- connection ground network
- gates function / locks
- corrosion protection
1.8 Snow clearing

Site designation
SITEMAN 01-94
Aonendlx;' ;1'."····
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CHECKLIST
I~roloct
Site designation
Period
Order no
Appendix 2
Page
4
Dealtwilh by Dale ConI.
5
4. STATION BUILDING
4.1 Station building

- function
- quality
- trafficability
- painting
-water
ll. - heating
J. 4.2 Floor
- basement for panels
- quality, finish
- measures
••
-fixing for
• cables
• panels
• cable ducts in floor
• indoor switchgear
• foundation bolts
-level
- making of holes
4.3 Cable routes

- placing
- measures
- fixings
- brackets
-ladders
- intakes
4.4 Others
- availability lockable rooms
JI. - water, showers, WC ready

for use
- drainage correct inclination
- lifting devices available
- cleaning
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SITE MAN 01-94
Appen~ix ? II:. SITEMAN 08 - 94
Site designation 1WAT 910033-8
Edition January 1994
IJ.
).1 Security
- fence and gates ready?
- lockable stores?
- site guarded?
5.2 Battery room

- design
- ventilation
- holes
- explosive-proof light fittings
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-water
- painting
5.3 Air treatment (whole building)

- air condition
- ventilation
- heating
-water
5.4 Electricity
- fittings
- outlets
- panel
5.5 Access
(estimated in % of full access)
- completed
-- started but not completed
- not yet started
- estimated start date
- estimated completed date
- documentation by photos
--
I.
1. General
I ~lCre are a great variety of cable marking systems available on the market. ASS
1. General 27 II. have chosen to work with the two following suppliers:
- Partex.
2. Standard marking 27 - Fleximark.
~:~g~~~e
m:~~~~~g.::::·.:::
:::::::::::::::::::::::::::::::::::::::::::::::::::::::::
~~ Each of these two systems is divided into two different marking systems:
- Preprinted cable markings.
- Computerized cable markings.
~:1 ~:~~t~~~b~~~·:::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::
~: 'III These markings are produced by the use of a computerized
data are taken directly from the cable and core lists.
printer. The technical
3.2 Core numbers 28
Accessories and tools 28

~~ ~ 2. Standard marking
All cables shall be provided with durable markers at both ends.
~~hx~~~~a~d~';d~':::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::: ~:
- Each cable shall be marked with cable number.
Open type markers 29
- Each core shall be marked with:
- Core number.
- Cable number.
Core no. ~ Cable no.
Core no. Cable no.

T T
3 -1234
103 2 -1234
102 1 -1234 1234
101
-b PE-1234
Fig. 2 Marking of a cable end consisting of 3

cores and protective earth conductor
••
reproduced or copied without written permis- 2.1 Cable marking
sion, and the contents thereof must not be Yellow markings with black characters shall be used .
prosecuted.
Addtional copies of this document may be

obtained from ASS at its then current rate
II.
I.
Holder for cable markings type
fl.
Partex, which are used when extra
many characters are required
:1.
2.2 Core marking
White markings with black characters shall be used.
I.
3. Mounting
II.
Fig. 6
r
u
3.1 Cable numbers 4.2 Flexipart
The marking sleeves are to be fixed on the sheath of the cable close to the Please ccontact Miltronic AB for further information.
Address: Box 1022
--
stripped end, see figure 6. When cables are terminated in a connection box, the
markings are to be fixed to the cables outside the box. The markers are threaded S-611 29 Nyk6ping, Sweden
onto a plastic strap, which is fastened around the cable (figure 3). Telephone +46 0155 87000
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3.2 Core numbers 4.3 Other standards
The markings are to be placed near to the points of connections. Out~ide S~ed~n various customers may require special marking system. The
The cable core marking should state in the following order from the left to the design office will then order the material needed and issue the necessary installa-
tion instructions.
right or from bottom to the top:
--
- Core number. 4.4 Open type markers
- Cable number. See figure 6. Partex can also deliver an open marker, with which already terminated wires can
be marked. See figure 7.
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4. Accessories and tools
For diameter
4.1 Partex
Please contact Partex Fabriksaktiebolag for further information.
~---I 2.4-6.2 mm
I.
Address: Box 80
S-547 01 Gullspang, Sweden
Telephone +46 0551 20560
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SITEMAN 11 - 94 Brazing
1WAT 910033-11
Edition January 1994 Thermic welding
process
·., ~
--
A BRAZING 1. General
1. General 33 Brazing is a method used for joining materials in cases when a joint of greater strength, than that obtained
2. Brazing equipment 33 by soldering, is required. The strength of the joint can be the same as that of the materials to be joined.
3. Setting the torch pressure for acetylene and oxygen 33 In this instruction brazing solder will be called solder only.
4. Definitions, clarification of words 34 The working temperature of the solder and the materials to be joined is, however, to be least 450 ·C.
5. Units of measure 34 Copper and copper alloys can be easily brazed, but tin, lead and aluminium additives make brazing more
6. Flame brazing 34 difficult.
6.1 Wedling torches ...34 Carbon stells and alloyed steels can be easily brazed, but the brazeability will be reduced when the
6.2 Types of flame... .. 34 carbon content and the alloy content, respectively, are increased.
6.3 Bunsen burner... . 35 In the case of cast iron, the graphite opposes the wetting ot the solder.
7. Different types of solder, their characteristics and use 35 Aluminium and aluminium alloys can also be brazed.
7.1 Silver solder . 35 The strength of the joint varies, depending on the metals and the type of solder. As a guiding value for
7.2 Brass solder .. 35 steel, copper and brass, an initial tensile strength of 200 N/mm2 can be reckoned with. Adequate safety is
7.3 Phosphor-copper solder... .. 35 therefore ensured.
7.4 Copper solder .. 35
7.5 Heat-resistant solder .. 36
7.6 Aluminium solder .. 36
8. International standard solders; preferred standard 36
REGULATOR
9. Flux 36
BLUE HOSE
10. Description of methods 37
10.1 General...... .. 37
10.2 Brazing, joining of copper bars (75 x 6) . . .. 37
10.3 Brazing of copper bars (50 x 10) with prelocated solder..... 38
10.4 Brazing of earthing conductorsfT-joints (branch-joints) 39
10.5 Brazing of aluminium T-joints . .. 40
11. Different types of solder and their working temperature 42
FLASHBACK ARRESTER
12. Effective temperature
THERMIC WELDING PROCESS

ranges of different fluxes 43
44
II. -RED HOSE
Personal protection at welding 44

Storing/keeping of weld metal 44
Preparation and handling of welding moulds 44
Preparation of conductors 44
Thermic welding process 45
Final treatment of connections 45

II-
imparted to a third party nor be used for any 3. Setting the torch pressure for acetylene and
oxygen.
prosecuted. - Screw in the diaphragm screw 1.
- Turn clockwise
Addtional copies of this document may be - Read off the intermediate pressure on the low-pressure
obtained from ASS at its then current rate gauge 2
- Adjust to approx. 5 kgf/cm2 for oxygen and to approx.
1 .5 kgf/cm2 for acetylene.
--
,
4. Definitions, clarification of words
outer flame
-~--
==s core flame
dark zone
Brazing solder - bonding material used in brazing - of metal or metal alloy. The solder must have the
_.------~--- -===~~~~-
••
capability of wetting the bonding surface of the material to ensure the creation of an alloy.
Flux is a facility in the form of a powder, paste or fluid which is applied to the bin-ding surface of the
_.
mateiral in order to reduce any oxides and to protect against oxidation while the material is being heated.
Working temperature is the lowest temperature of the contact point in the binding surface to ensure the outer flame
flow-out and binding of the solder.
Maximum brazing temperature
the solder, flux or the parent material.
is the highest temperature that can be allowed without causing damage 10 ~ __==--=-:±:r=
I. core fl ame
Bonding strength of a solder is the tensile strength between the solder and the parent material, measured
at right angles to the binding surface (example: joint brazing).
Brazing at a working temperature above 450 'c and a brazing procedure similar to that used in gas 6.3 Bunsen burner
welding. The solder is often referred to as brazing solder (example: joint brazing). An Lp-gas burner which consumes oxygen from the surrounding air through injector action in the burner
norzzle.
Gap brazing - The surfaces which are to be joined are parallel and placed at a certain distance from each
r
other (brazing gap), which ·ISnormally less than 0.5 mm. The solder flows out in the gap due to capillary
action - capillary brazing (refer to "Wetting").
Joint brazing - The surfaces to be joined are parallel and lie at a distance of more than 0,5 mm or form a
V, X or fillet joint. The gap is filled with solder.
Brazing with solder in direct contact - In this case, the solder ·In the form of a wire or strip is applied by
hand and melts when it comes into contact with the heated parent material.
Brazing
surfaces.
with prelocated solder - Before heat is applied, the solder is placed in the gap between the two II- 7. Different types of solder, their characteristics and use
Wetting _ The ability of a molten drop of solder to spread itself out on a binding surface. Wetting can only The solder usually consists of an alloy formed between two or more metals.
The cost of brazing, the strength of the joint, the anti-corrosive properties, the similarity in colour, etc., are
occur above a certain temperature and on clean surfaces.
II- to a great extent dependent upon the composition of the solder.

The solder is divided into different groups, such as;
- silver solders
5. Units of measure - brass solders
Pressure: - phosphor-bronze solders
1 Pa ~ 1 N/m2 - copper solders
1 bar ~ 100 kPa - heat resistant solders
1 Ibf/m2 6.98 kPa - aluminium solders
1 psi 6.98 kPa
1 kp/cm2 98.1 kPa
7.1 Silver solders

6. Flame brazing These have good soldering properties. The working temperature lies between 600 and 800 'C. They are
The material is heated with a burner - welding torch or bunsen burner. relatively expensive but this is partly outwe·lghed by the short heating time. With the exception of aluminium,
they are suitable for the majority of metals. They can be used for soldering heat-resistant stells but they are
not recommended for this purpose.
I---~! --
7.2 Brass solders
These are inexpensive but their working temperature is high, 900 'C. The cost of heating is relatively high.
They are best suited for carbon steels, cast iron, malleable iron and low-alloyed steels. They can be used for
other metals except aluminium.
7.3 Phosphor-copper solders

These have been specially produced for copper and copper alloys (bronze, red brass, brass). That with 5 %
Ag and a working temperature of 715 'c is intended directly for copper (copper piping).
d Sh:;a:
outer flame 7.4 Copper solders
CC!lame These are inexpensive but they have a high (1000 'C) working temperature. The cost of heating is high.
They are suitable for brazing details of steel and for securing carbide tips on tools.
: I N.B! They are not suitable for brazing copper or copper alloys.
--
7.5 Heat-resistant solder
This solder is relatively expensive and its working temperature is also high, 960 ·c, which increases the
cost still further. It is only suitable for brazing of stainless steel, heat-resistant steel, nickel and nickel alloys
10.1 General
Preparations: Select a suitable burner.
7.6 Aluminium solder
Welding burner
This is relatively inexpensive and its working temperature is low, 500 'C. It is used for brazing aluminium
[3unsen burner (acetylene or L.P gas)
and aluminium alloys which have a long magnesium content.
rhe size of the burner depends on the dimensions of the item to be joined.
8. International standard solders; preferred standard Select solder and flux as mentioned in clause 8.
Solders conforming to ASEA standard and equivalent German (DIN), British (BS) and American (AWS)
types: Cleaning: Wipe off grease and other impurities.
0) No DIN BS1845: AWS ASEA ABB If the oxide layer is excessive, brush or grind it away.
8513 1977 A5.8.81 article no article no
Assembly: Assemble the items in the correct position.
1 L-AISiI2 AL2 BAISi4 24261 11241001-3 -- Apply flux to the appropriate surface.
2 L-Cu CU2 BCu-1 25010 - The width of the gap must be correct.
3 LCuZn40 cn RBCuZn-A 25251 - Secure the items so that they are not displaced during the brazing and cooling-off periods.
4 L-Ag2P CP2 BCuP-6 25909 11221110-104
5 L-AG15P CP1 BCuP-5 25983 11221131-106 •• ) Brazing: Ignite the burner and adjust to obtain a suitable flame.
11221131-111 "0) Warn the parent metal first.
6 25990 11221171-287 - Apply more heat to the heaviest part or that part which dissipates heat quickest.
7 L-Ag55Sn AG14 BAg7 26829 11251040-1 Heat until the flux has melted and has penetrated in under the gap.
- Heat With a sweeping motion until the working temperature of the solder has been reached.
*) No.
1. Aluminium solder for brazing of aluminium and aluminum alloys Apply solder
(Flux ASEA 1233 0012-207) - Place the solder against the pieces to be joined.
2. Copper solder for brazing of steel. (Furnace brazing - no flux required) - Do not point the flame directly against solder.
3. Brass solder for brazing of steel, copper and copper alloys but not stainless steel - Heat only so much that the solder melts uniformly and is drawn into the gap.
(Flux ASEA 1233 0012-201). - Apply solder until the gap is completely closed.
- Cool the joint.
4. Phosphor-copper solder for copper and copper alloys in primarily statically loaded joints;
max. 300 'C. (Not suitable in atmosphere with high sulphur content).
5. Phosphor-copper solder for copper and copper alloys where the joint is subject to
fatigue forces; max. 300 'C. (Not suitable in atmosphere With high sulphur content).
*0) Flat bar 0.5 x 6. 10.2
***) Flat bar 2.5 x 6. Brazing, joining of copper bars (75 x 6)
6. Silver solder brazing in general; steel, stainless steel, copper and copper Preparations: Select a torch nozzle of suitable size, e.g. 700 I.
ailoys. (Flux ASEA 1233 0012-201). Choose phosphor-copper solder L-Ag 15P CP1, 6 x 2,5 mm, page 7 no. 5.
7. Silver solder for brazing in general; steel, stainless steel, copper and copper alloys,
silver and silver alloys. Low working temperature (650 'C), high tenacity solder, highly Pre-cleaning: Wipe off grease and other impurities.
corrosion resistant. (Flux ASEA 1233 0012-201). Clean the joint surfaces with an abrasive tool or a brush.
9. Flux
The purpose at the flux is to dissolve the oxides on the binding surfaces and to prevent the formation of new
oxides during the preheating stage. The flux is applied before heating.
The composition of the flux is partiy dependent on the metal oxides, which it is to dissolve, and partly on
the fact that it must be adapted to the working temperature required by the solder and, furthermore, that in
the molten state it must be so light flUid that it can be drawn into the gap between the pieces of parent
metal. It must also be possible to remove it. The flux is fUlly active for a few minutes after it has melted.
The figure on page 16 shows examples of the active working ranges, of different fluxes, within which the
best results will be obtained. The relationship between the solder and a suitable flux is given in clause 8.
Note! Pure copper can be brazed with advantage without the use of flux.
Place the bars on a heat-insulating base, e.g. bricks and secure them in position with 30 mm overlap and a
Note! The flux consists to a great extent of borax and boric acid but it also contains
gap width of 0.2 mm.
additives which can be dangerous or poisonous. The precautionary notice
should, therefore, be read carefUlly.
Brazing: Ignite the burner and adjust to obtain a suitable flame.
Note! The flux does not remove rust, oil, grease, paint or other
Neutral flame
impurities. Brazing flux is normally supplied in powder
- Warn the bars first, alternatively until they obtain a dark-red colour; both bars
form. Mix the flux with distilled water to form a
should reach the working temperature, approx. 700 'c, simUltaneously.
paste and then apply it with a brush.
I.
Apply the solder.
10.3 Brazing of Cu-bars (50 x 10) = with prelocated solder Inspection: Ensure that the solder har penetrated through and had adhered along all the edges of the
IJlmj"JI) surfaces.
Pre-cleaning: Clean the details and remove the oxides layer from the binding surfaces.
Preparations: Select a suitable burner; 100 I.

Select suitable solder, phosphor-copper solder, e.g. 6 x 0.5 mm; see page 7 no. 5.
Cut the solder into small pieces.
--
- Adapt the length to the appearance of the joint surface (L = 50) .
.. Adapt the amount of solder so that it covers the entire surface (6 pes.).
Assembly: To secure the details in the required position during the melting sequence, the following is
,-
recommended:
Secure the pieces in the desired position with a welding clamp and without the pieces of solder.
Retain the setting of the welding clamp and loosen the joint anew.
10.4 Brazing of earthing conductorsrr-joints (branch-joints)
Pre-cleaning: Wipe off grease, oil and other impurities.

Remove the oxides layer with at steel-wire brush or steel wool.
Preparations: Select a burner nozzle of suitable size, e.g. 300 I.

Select suitable solder, phosphor-copper solder which has a working temperature of 710 - 715 'C (refer to
--
the table). Flux is not necessary.
Procure approximately 1 m Cu-wire of diameter 1.5 - 2 mm, for lashing the joint and strips or insulating
tape.
Fig.10.
Place the solder on the binding surface of one of the details. Assembly: Place the branch line against the trunk line,
approx. 50 mm, and thereafter with approx. 50 mm
radius as shown in the figure.
bd
=
=
Fig.11
Relocate the details to their correct positions and secure them without altering the position of the
welding clamp.
Using plastic straps or insulating tape, fix the lines to each
other. The distance between the fiXing points should be
approximately 40 mm in order to provide space for the
II. lashing wire.
Wrap on the copper lashing wire, hard and tight, approx. 25 mm between the fixing points.
Brazing: Ignite the burner and adjust to obtain a neutral flame. Twine the two ends of the wire to secure the joint.
Alternatively heat the copper bars.
- use a sweaping movement when applying the flame
- the copper bars should simulaneously reach working temperature, approx. 750 DC.
-- heat until the solder melts, flows out and wets the binding surfaces.
--
--
I-
Brazing: Ignite the burner and adjust to obtain a neutral flame.
Heat the trunk line first, 50 - 100 mm adjacent to the joint; use a sweeping movement when applying the
flame.
Heat the area for the joint - alternatively oniy line, then the other. Heat until the material obtains a dark-
red colour, approx. 700 'C.
Apply the solder, commencing at the end of the
branch line.
-- Maintain a small angle to the point of the joint
Move the solder, with the flux, back and forth along the joint.
Heat so that the flux leaves the solder and transfers to the joint.
Do not disperse the powder with the pressure from the flame.
Flux must adhere to the entire length of the joint.
Do not melt the solder.
- Do not melt the aluminium
Continue heating
details (melting temp. of AI is 660 'C).
--
Heat a 50 - 100 mm zone on all sides of the joint.
Apply the flame with a sweeping movement.
- The details should simultaneously reach a working temperature (580 'C).
,I-
- Heat until all flux has melted to a clear fluid.
Apply the solder

Apply the flame with a sweeping movement
- Appiy the solder.
Do not point the flame directly against the solder. - Heat in the vicinity of but not directily on the solder.
Heat only so much that the solder melts and flows in between the wires. - Heat until the solder begins to melt.
Apply solder to the lashing wire until it is completely covered.
Repeat the procedure on the other side.
--
--
10.5 Brazing of aluminium T-joints
Pre-cleaning: Clean the details and remove the oxide layer.
Preparations: Select a suitable burner, e.g. 700 I. - Apply the solder at an even rate along the length of the joint
Select a suitable solder, aluminium solder e.g. ASEA 11241001-3; refer to pages 17 and 7 (no. 1.). - Heat only so much that the solder melts evenly and flows into the gap.
Select a suitable flux; see group A on page 18, e.g. ASEA 1233 0012-207, page 7. - Adapt the amount of solder so that a fillet is formed on each side of the joint.
Use flux in powder form on the joint; it is then most active on aluminium.
Post-cleaning
Assembly: Secure the details in the desired position with the aid of a welding clamp or other fixture. Remove all residual flux.
Ensure that the gap is as small as possible, preferably less than 0.5 mm. - Use a wire brush and water.
Check the dimensions.
Inspection
Brazing: Ignite the burner and adjust to a suitable flame. Ensure that a fillet is obtained on each side.
- Weak carburizing flame.
--
Heat the end of the solder careully and immerse it in the flux.
- The flux will adhere to the solder
I.
Preheat the joint
- Enough to enable the flux to fasten.
Add flux with the aid of the soider.

Solders alloys Designation Remarks
figures states
Z
:J
1111 o
«««~<3
(9(9(9«-1
«««Ow
1111 -E
:J
-1.~
«E
1I:J
Ag85 Mn15
1111 wCii
z .
WO
(9~
Cu48 Zn41, 8 Ni1 0 SiO.2
1111
Ag32 Cu33 Zn35

Ag44 Cu30 Zn26
Ag5 Cu 88.8 P6.2
Silver solder ')
Silver solder
Phosphor Copper solder
Asea 1122 1171-28
I-
till zz
::i::i
00
Ag2 Cu91.5 P6.5 Phosphor Copper sOlder'l Asea 1122 1110-1O~
Ag15 Cu80 P5 Phosphor Copper solder' Asea 11221131-106 ««~~«
CH~ «« g
Ag49 Cu16 Zn23 Mg7.5 Ni45 Silver solder -10S ««OOw
Ag55 Cu21 Zn22 Sn2
Ag34 Cu22 Zn24 Cd20
Silver solder ')
Silver solder
Asea 1125 1040-1 ,1111
Ag40 Cu19 Zn21 Cd20 Silver solder
580
550
A18? Si13
AI86 Si10 Cu4
Aluminium solder')
Aluminium solder
Asea 11241001-3
!IIII
Jill 500
Group A Group B Group C
_II
Jill
'rll
5. Thermic welding
Insert the conductors into the mould according to the applicable instruction (for each type 01 "11<11" 'III' '.
1. Personal protection Damaged/cracked or worn-out moulds must not be used! Scrap them.
Welding smoke is developed during the welding operation. Precautions must be taken to minimize inhala- When a sealing tightening kit is used, it must only be applied in the outer edge of the conduclor elI<IIIII"I,
tion of the welding smoke, especially in narrow and poorly ventilated rooms. Arrange for efficient general nol inside the weld cavity.
ventilation as well as local evacuation of the smoke. If, for one reason or another, general protective Check that the right size of the welding metal container is chosen. Compare with the number of 1110 w"I,1
equipment is impossible to use, then individual personal protections have to be used. mould type plate.
The welding smoke contains thin dispersed metallic oxides from zinc, copper, magnesium, etc. and might Insert accompanying steel disc into the mould with the cone down. Pour the welding powder carefully HII"
at casting and welding operations cause acute poisoning with fever and symptoms similar to those of the mould in order not to move the position of the steel disc.
influenza. Special treatment is usually not required. The symptoms on otherwise healthy persons. When Knock the ignition powder out - it is pressed together in the bottom of the container - and spread it evenly
doing the final treatment (for example removing the slag) of the weld joint there is a risk that hot slag will fly on top of the welding powder and on the mould lip at the cover opening. The latter in order to facilitate the
around. Furthermore, handling the hot welding mould must be done with care to avoid burning damages. ignition.
Always use protective goggles and gloves. Check that the mould is correctly closed around the conductors and standing in vertical position
Suitable protective gloves against heat ant thermal radiation is for example gloves made at Namexfilt (do before ignition.
not contain asbestos). Close the mould cover and fire the ignition powder with a flint gun or other means without risk for burning
injuries.
2. Storing/keeping of weld metal When fire use protective gloves and goggles. Don't stand in front of the cover opening.
Weld metal shall be stored in a dry and fire secure room. Stored in a dry place the storage time is practically
II-
When welding in narrow compartments or where it is an obvious risk that the mould will be affected by wet
unlimited.
and damp conditions it is recommended that firing is made through a firing tape. Cut an approx. 10 em long
Weld metal boxes must not be subject to chocks during transport and handling as the ignition powder -
firing tape and insert it into the mould in such a way that the cover will keep it in position.
being pressed together in the bottom of the container, might mix with the welding powder, and thereby
After welding, wait until the melted metal is solidified before opening the mould as described under item 3.
causing porous welding joints when being used.
Should the melted metal have been leaking out in spite of the fact that sealing kits have been used
3. Preparation and handling of welding moulds the mould is probably worn out and should be scraped.
Prior to start of the welding the mould must be heated to min. 100 ·C. Notel Material flown out from the mould means decreased mould quality.
--
Use gasol fire (preferably gasol stove) for heating. The welding mould must be kept absolutely dry during Should the welding for some reason have been unsuccessful, it is recommended that the branched-off
the welding operation. A damp mould may give a porous welding joint. If it is difficult to keep the mould dry wire is cut and a new weld is made beside. Alternatively, the bad connection may be shunted according to
for example during rain, it is preferable to postpone the welding until better weather conditions appear. the figure below:
A damp welding mould can also cause ejection of welding material (melt) from the mould.
The welding must be cleaned from slag, soot and possible remains of tightening cement. For cleaning, use
a melting pot scraper, file-brush and radiator-brush.
Screwdrivers, knives or other sharp tools must no be used!
Remaining hot slag (badly cleaned mould) might cause self-ignition of next "charge".
The life-cycle of the mould is estimated to be 70-100 joints. Thereafter it is usually scrapped. Make sure that
6. Final Treatment of connections
spare moulds are ordered in sufficient numbers.
Remove solified slag remains on the connection. No other final treatment is required.
Welding moulds must be modified to fit other wire dimensions
4. Preparation of conductors (wires and bars)

than originally specified
II. Note! When welding copper wire to galvanized rods or wires, the connection shall after having cooled
down to below 100 'c be covered with cable compound, treated with insulating varnish or zinc-rich paint to
make it resistant against galvanic corrosion.
Oxide, dirt, etc. must be removed. Use wire-brush or file-brush. Oily/greasy conductors must be cleaned
with a suitable solvent, for example varnolene or percloretylene.
Wires shall be cut with cable cutter or scissors and in right angle. Do not nut through a tape bandage. 11111
~-~ ~
right
Fig. 22
Wet or damp conductors must first be dried out through heating with a gasol flame or by placing them
immediately in the heated mould where they remain until completely dried.
In the meantime preparations for next welding can be made.
It is possible to weld a copper wire using a welding mould designed for a bigger area. In that case wrap on
a copper foil to the copper wire as a filling.
Ignition
powder
--
-.
-.
-.
-.
-.
Regarding personal protection equipment, see item 1. Fig.25 1) Preparation of welding mouid according to item 3.
1) Preparation of welding mould according to item 3. 2) Preparation of wires according to item 4.
2) Preparation of wires according to item 4. 3) Insert wires in the mould according to above figure.
3) Insert wires in the mould according to above figure. Note: Always place the tap wire in contact with the run wire.
Note: If the run wire is 240 mm2 or above and the tap wire 120 mm2 or above the run wire
4) Close the cover well. Make sure that the wires have not moved out of position.
shall be cut and with a 3 mm gap be positioned under the cast cavity centre.
5) Carry out the thermic welding operation as described under item 5.
-III
Always place the tap wire in contact with the run wire. 6) Make the final treatment of the joint according to item 6.
6) Make the finai treatment of the joint according to item 6.
-:11
-II
l
--.
--
Ignition
_c. JOint Type: GR
--
powder
--
_ .-
_.-
.
Fig.26 1)
2)
Preparation of welding mould according to item 3.
Preparation of wires according to item 4.
--
lI.-
3) Insert wires in the mould according to the above figure. Fig27 1) Preparation of welding mould according to item 3.
lI
4) Close the cover well. 2) Preparation of wire and rod according to item 4.
5) Carry out the thermic welding operation as described in item 5. 3) Position the wire on top of earthing rod under the cast cavity centre.
i_
6) Make the final treatment of the joint according to item 6. 4) Close the cover well. Make sure that the wires have not moved out of position.
Note: Hold the mould, with for example a self-locking plier applied around the rod, to
guarantee that the mould will not slide down during welding.
I. 5)
6)
Carry out the thermic welding operation as described under item 5.
Make the final treatment of the joint according to item 6.
I.
,.
I.
1111
II.
SITEMAN 12 - 94
I-
1WAT 910033-12
Edition May 1996
,-
--
II-
Fig.28 1) Preparation of the welding mould according to item 5.
2) Preparation of wire and rod according to item 4.
3) Position the wires on top of the earthing rod with a 3 mm gap under the cast cavity
centre.
--
Note: Hold the mould, with for example a self-locking plier applied around the rod, to
guarantee that the mould will not slide down during welding.

6) Make the final treatment of the joint according to item 6.
List of Contents
1.
1.1
1.2
1.3
1.4
1.5
1.6
General
Classification of cables
Stretch force
Temperature
Bending radius
Distance between cable planes
Interrelations and location of different classes of cables
..
..
..
.
53
53
.. .. 53
53
53
53
54
-- 1. General
This instruction describes standard method for laying and installation
laying in special environments, such as in high temperature areas.
1.1 Classification of cables

The following ABB cable standard
KO POWER CABLES. LESS THAN 1000V
and classification shall be applied
of cables. It does not cover cable-
on each installation:
1.7 Distance between cables and rated data... .. 54 K1 POWER CABLES. MORE THAN 1000 V
1.8 Cable drums .. 54
1.9 Handling of cable drums at site 54 The high current in these cables may induce parasitic currents in screens and conductors of cables which
1.10 Rotation of cabie drums .. 55 are laid in their vicinity. Well screened power cables can be laid in the same cable trench with other cables,
1.11 Braking of cable drums .. 55 but control and measuring cables require a minimum distance fa 300 mm from any power cable.
2. Method of laying 56
K2 CONTROL and SIGNAL
2.1 Laying by hand ..56
2.2 Laying by motor-driven equipment, general......................... .. 57 The relay and signal cables shall be laid at least 300 mm from both power and measuring cables.
2.3 Crossing of roads.. .. 58 K3 CURRENT and VOLTAGE MEASURING
2.4 Laying cables indoors 58
The cables shall be laid at least 300 mm from other types of cables.
2.5 Cable channel....... .. 58
2.6 Cable ladder....... . 60 K4 SENSITIVE MEASUREMENTS
2.7 Section trays ..61 These cables shall be laid in separated and completely screened channels of copper or galvanised steel
2.8 Conduits............ . 62 pipes.
2.9 Cable table 63
3. Fixing of cables ...............................................................•................ 64 K5 OPTICAL CABLES
3.1 Supporting bar. .. 64 These cables are not effected electrically by adjacent cables, however, these cables shall be considered as
3.2 Profiled bars ...65 high risk of mechanical damage and shall be treated accordingly. For more details please refer to
3.3 Suspension wire..................... ..66 SITEMAN 13-94.
3.4 Free suspension .. .. 67
3.5 Clamps for cables and conduits .. 68 K6 PREFABRICATED CABLES
3.6 Clips and cable straps.. .. .. 68 These are cables that carry control and communication signals between differenct control panels, mainly in
3.7 Cable straps .. 69 the same room. The cables have been prefabricated and tested with their intended end connection, the
3.8 Lashing wire .... 70 cables therefore have to be installed as per the manufacturer's instructions.
3.9 Expansion bolts and plugs .. 70
4. Marking of cables 71
1.2 Stretch force
4.1 Standard marking .. .. 71
The maximum stretch force when laying cables shall not exceed:
4.2 Cable marking .. 71
4.3 Core marking .. 72 - copper conductors . 70N/mm2 (7 kg/mm2)
4.4 Cable numbers................................... .. 72 - aluminium conductors .. 40N/mm2 (4 kg/mm2)
4.5 Core numbers .. 72
4.6 Partex .. 72 1.3 Temperature
4.7 Flexipart .. 73
--
If the ambient temperature is below -10'C the cable must be heated before laying. Otherwise it will be too
4.8 Other standards. .. 73
rigid to handle and the insulation could be damaged during bending.
4.9 Open type markers .. 73
5. Term inations 73 Preheat the cable indoors at a minimum of 15 ·cfor 24 hours. Temperature fluctucation results in length
5.1 Length of cable ends 73 variations in the cables and they must therefore be laid in gentle curves when the cables are long.
5.2 Termination sheet 74
6. Sensitive cables 75 1.4 Bending radii
7. Fireproof cables 76 The bending radii of the cables shall not exceed the following:
000. Examples of typical installations 77
J. Type of cable
Multi-core
Three-core
For laying
15 x diameter
15 x diameter
When installed
10 x diameter
10 x diameter
Single-core 15 x diameter 10 x diameter
This document and parts thereof must not be PEX 20 x diameter 15 x diameter
reproduced or copied without written permis- Fibre optic cables 100 mm *) 200 mm *)
unauthorized purpose. Contravention will be 1.5 Distance between cable planes
prosecuted. The vertical distance between cable planes and the distance to the ceiling should not be less than 300 mm.

1.6 Interrelations and location of different "K" classes of cables
I. 1.10 Rotation of cable drums
I.
The different classes of cables are grouped separately on racks. Standard cable drums have an arrow marked on the side. This arrow is showing the direction for rolling the
- KO, High voltage cable drum on the ground dUring short transits in order not to loosen the cable wound on the drum.
- K1, Low voltage power The cable should be pulled off from the top of the drum in such a way that the arrow shows in the
- K2, Control and signal Opposite direction to the pull.
- K3, Current and voltage measuring
I.
- K4, Sensitive measurements
.- K5, Optical cables
- K6, Prefabricated cables (CJ
'1.7 Distance between cables at rated data ABB cab\eS
Cables shall be laid as shown in the installation documentation, and as described in section 1.1 of this
report (Classification of cables). In general, spacing between power cables should be one cable diameter,
but not more than 30 mm. More space will not improve the cooling of the cables. Sufficient cooling of single·
core cables in a trefoil configuration is obtained with a spacing not less than 30 mm.
II.
1.8 Cable drums
Cable drums are made to 16 standard sizes and weight.
K4 K6 K7 K8 Kg K11 K12 K14 K16 K18 K20 K22 K24 K26 K28 K30.
The drum required depends on the length, the weight and the outer diameter of the cable.
1.9 Handling of cable drums at site

A ramp, crane or forklift may be used for unloading cable drums. If neither of these are available, a
provisional ramp of square timbers or steel beams should be erected. The angle of inclination should not
exceed 1 in 4. The timber and beams must be strong enough to support the weight of the drum.
I.
Cable drums and coils, even if they are small and not heavy, should never be thrown onto the ground
when unloading, the cable is likely to be damaged.
A suitable tractor trailor or forklift truck should be used for transporting the cable drums within the site
area. The drums should never be rolled over longer distances.
1.11 Braking of drums

When pulling off the cable, drum stands with hydraulic jacks and mechanical brakes are preferred to be
used. The cable shall be pulled from the cable drum at a controlable and easy stopable rate. If the stand is
not equipped With a mechanical brake, a wooden plank or suitable impliment can be used for braking.
It must be made pOSSible to easily stop the rotation of the cable drum at any given time.
Fig.3 Braking of drums. Please note: The arrow shows direction of rolling on the
ground, not pulling.
2. Methods of laying 2.2 Laying by motor-driven equipment
,.
Before installing any type of cable, the entire cable route shall be thoroughly inspected to ensure that there Mlliordnven equipment is normally used where there are a large number of cables to be installed in long
are no obstacles or hazards that may cause damage to the cables that shall be installed. This inspection lUllS where the routing is not too sophisticated. This system is not normally used in HV switchtyard areas.
shall be made regularly during the cable installation period. I he laying with motor-driven equipment is here divided into two groups:
The following methods may be employed for allying of cables: 1.'lYing by motor-driven rollers
,.
- Laying by hand laying by winches and cable-pushers.
- Laying by motor-driven equipment.
When motor-driven equipment is considered to be used, the following simplified conditions can act as a
quide:
2.1 Laying by hand
The cable volume, i.e. the volume of cables, has to be of such a proportion that the time gained by using
Rollers placed at distances of 3 to 4 m will facilitate laying. Corner rollers or similar devices should be
the equipment is not lost in the transporting and handling of the motor-driven equipment.
provided where there are bends in the route, the minimum bending radii of the cables shall be maintained at
The cable diameter should not be less than 30 mm, more than one cable can be pulled simultaneously.
all times, see fig. 4 and 5.
- The length of the cables should in average be more than 150 m.
The cables are to be carried by hand, if not supported by rollers, with the men standing 4 to 6 m apart along
The cable routes shall be designed in a manner making it possible to postion the cables directly on their
the cable route.
final place when pulling.
Experienced personnel has to be available.
The following should be observed when pulling With machinery:

When a heavy cable is laid, a cable stocking or a pulling eye should be used. The cable stocking shall be
placed over the outer sheath of the cable to the total length of the cable stocking. When a pulling eye is
used, care shall be taken to ensure that all conductor strands are evenly stressed, see fig. 9 and 10.
Fig. 4 Laying
by hand by the
use of cable
rollers
,.
Fig. 5 Corner
rollers
~.
Fig. 9 Cable
channels outdoor
2.3 Crossing of roads

It is always advisable to provide spare pipes in order to avoid having to dig up the road if further cables are
to be laid. Ducts which are not used at once should be plugged. The cables should not rest on the sharp
edges at the ends of the ducts. Steel pipes should have funnel-shaped ends, if possible.
If the end of a pipe or duct is levelled with the trench bed, the surface soil immediately before the opening
--
shall be removed prior to pulling in the pulling in the cable in order to prevent stones or coarse soil from
getting into the duct.
J.
2.4 Laying cables indoor
Cables which must be protected mechanically or against electrical disturbances should be laid in steel
ducts, trays or pipes.
1-3 cables may be clamped directly onto walls, foundations and structures in the building, if the distance
is not more than 10-20 mm.
J.
,.
2.5 Cable channel
The cable channels in outdoor switchyards are mostly made of concrete and covered with concrete slaps.
Indoor the channels are often integrated in the floors of the building and covered with metal plates. Fig.10 Cable channel in outdoor switchboard
The cables can either be placed directly at the bottom of the channel or on cable support ladders. plant.
The main advantage of using cable channels is that cables may easily be replaced, added or inspected.
J.
2.6 Cable ladder 2.7 Section trays
Definition of cable ladders specifies that the distance between the rungs may be a maximum of 300 mm. If Various sections are available. Most frequently used are Land U perforated sections.
the rungs have a flat top surface they should be at least15 mm wide and round rungs should have a diame- Trays (U section) are available up to 600 mm.
ter of at least 19 mm. If used outdoor, all sections must be hot dipped galvanized, indoor electro-plated with zinc.
Ladders are available in widths of 200, 300, 400, 500, 600 and 1000 mm.
All cables shall be secured at bends when laying in order to obtain a neat installation. No further means
of securing are necessary when the cables are laid horizontally, apart from high tension single core cables.
These cables should be laid in threefoil and fixed with terylene cord according to SITEMAN 14-94.
J.
Fig. 12 Cable ladders

fitted on ceiling pendant J.
,.
Fig. 13 Wrapping
1-phase cable
a
,.
At bends or where a cable leaves the cable ladder, the cable should be secured with plastic straps or
lashing wire. In the case of vertical assembly, the cable is asia fixed to every second rung. Cable over
40 mm should however, be secured with brackets type KSV, if the vertical run is more than 10m.
A maximum of five cables may be located under the same attachment device.
,.
,.
In most cases the cable ladder offers the best solution when building cable ways. In case of great
mechanical load, high short-circuiting currents and high ambient temperature cable ladders are particularly
suitable due to their great mechanical strength and good cooling properties.
:>.9 Cable table
2.8 Conduits
Conduits are protective pipes which may be of plastic or metal, rigid or flexible. II", cable table constitutes a list of the cables in the cable network. The following are specified for each
The conduits have to be secured to structures, machinery, building or equivalent. cablc:
In harsh environments when the cable sheath gives insufficient protection, conduits should be used to Iype of cable
protect the cable. Steel pipes also offer an excellent protection against electrical disturbances. number of conductors and their sizes
Flexible conduits may be used to mechanically protect flexible cables connecting electrical units. cable length
cable number
cable classification K1, K2 etc.
destination point A
destination point A
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3. Various fastening material
The following selection of material Is only indicative. When ordering fastening material it is of utmost
Fig. 22 Cable draWing on strip iron in transformer
importance to choose stainless material of the right quality for the purpose:
assembly
- outdoor, use hot dipped galvanized, brass, stainless steel or UV-resistant plastic material
- indoor, use the same material as for outdoor or at least zinc electro-plated steel.
3.1 Supporting bar

The ASEA standard supporting bar is hot dipped galvanzied and form pressed in order to provide space for
the cable straps between the iron and the base on which it is installed.
SUPPORTING BAR
Material: Steel, hot dipped galvanized 80 ~.
The bar is intended for installation of cables and tubes.
A A
Fig. 23 Cable drawing on strip iron along concrete

wall
3.2 Profiled bars

The section of the profiled bar is designed to act as a holder for special types of cable clamps. The bar
should be hot dipped-galvanized or of other stainless material.
The bar should be mounted on the concrete with screws and plastic plugs or nailplug.
r 1
26 x 48 For embedment
When it is mounted on steel, self-tapping screws or standard screws can be used. The bar may even be
tack-welded.
The bar is used for supporting a small number of cables (1-5) running to separately placed units.
II~~{I,
,'t4il.~
Pl astic-straps
~I
$2If~
>~~!~~
'-;Z';l:>
d!<?~'lj
~4~~~;';':
Fig. 24 Profile Bars and Clamps
Aable strap support Cable clamp

. . type KSV
Normally the profiled bar IS screwed permanently to walls or structures. A special bar is available for
embedment in concrete .
. The distance between bars used to support cables shoUld be approximately 500 mm. Cables may be
fixed with clamps or with cable straps together with a special support.
. The eable clamps shall not be re-tightened, since this can cause cold floating damaging the cable
Insulation.
3.3 Suspension wire
The suspension wire is a wire either galvanized or of stainless steel used to support the cable, see fig. 25,
26 and 27.
The cable may be fixed to the wire by means of plastic or stainless steel straps.
Fig. 27 Suspension wire

with turnbuckle
3.4 Free suspension

When parts of machinery are moving in relation to each other one method to solve the interconnection is to
use freely suspended flexible cables.
The cables should be fastened in their ends by means of special supporting clamps releasing the strain
from the conductors.
A multi cable loop may be kept together by brackets or terylene string where mechanical forces can occur
due to short-circuit.
Fig. 28 Freely suspended cables in a furnace

assembly
Fig. 26 Illumination
assembly with suspension
wire. The cable is fastened
to the wire with plastic straps
3.5 Clamps for cable and conduits
There are a lot of both metal and plastic clamps for cables available on the market. The cable is mostly
screwed onto the base. but it may also be pressed or hooked to various flanges and profiled bars. Some-
-
times also wooden clamps are used.
The distance between the clamps should be maximum 500 mm.
Clamps may be used to secure a small number of cables (1-5).
•
I[J) Stainless steel
--
-.
3.6 Clips and straps
--
.,..
.-
Clips may be of stainless steel, hot dipped galvanized steel or plastic.
Cable straps are made of plastic (resistant to UV-radiation) or stainless steel.
Clips and straps are used to fix cables directly to walls or structures when installing cables for separately
placed apparatuses. The distances between fixing point vary but should maximum be 500 mm.
--
• ~l----------------------------; c:>
• f.JD----------
@1~---------------->
•
i
[jgJ1------------------
- I III :15 Cable straps (must be of plastic resistant to UV-radiation

UV = Ultra violet (light). See also SITEMAN 84-011
or stainless steel)
3.8 Lashing wire 4. Marking of Cables
The lashing wire consists of a plastic coated galvanized steel wire. The wire is basically used to secure the There are a great variety of cable marking systems available on the market. ABB have choosen to work with
cables to cable ladder rungs in bends and when the cable is leaving the ladder. the two following suppliers:
Diameter Braking load Weight/100 m - Partex
- Fleximark.
Lashing wire white PVC 1.5 mm 25 kp 1.8 kg
Lashing wire black PVC 1.5 mm 25 kp 1.8 kg Each of these two systems is divided into two different marking systems:
- Preprinted cable markings
- Computerized cable markings
These markings are produced by the use of computerized printer. The technical data are taken directly from
the cable and core lists.
4.1 Standard marking

All cables shall be provided with durable markers at both ends.
- Each cable shall be marked with cable number
- Each core shall be marked with: Core number and Cable number.
3.9 Expansion bolts and plugs

The following figures show some samples of bolts and plugs used in concrete.
~3-123L
1;~;'iI_;iiiiiiii,iiii:a::l't10 Core no Cable no
3 -1234
2 -1234
1 -1234
PE-1234
4.2 Cable marking

Yellow markings with black characters shall be used.
~ :;: eo)®®
[~ )1)213H5HJ)1~
Fig. 43 Holder for cable markings type Partex, which are used when extra many characters are required
JIll BA THS/a
4.3 Core marking 4.7 Flexipart
White markings with black characters shall be used, Please contact Miltronic AB for further information,
Address: Box 1022
S-611 29 Nyk6ping, SWEDEN
€:J3-1234q Telephone +46-155-87000
4.8 Other standards
~ I 3-1234
Outside Sweden various customers may require special marking system The design office will then
coordinate the material needed and issue the necessary installation instructions,
4.9 Open type markers

Partex can also deliver an open marker, with which already terminated wires can be marked, See fig. 46,
4.4 Cable numbers
The marking sleeves are to be fixed on the steath of the cable close to the stripped end, see fig, 45, When
cables are terminated in a connection box, the markings are to be fixed to the cables outside the box, The I Fo, d;ameter
2.4-6.2 mm
markers are threaded onto a piastic strap, which is fastened around the cabie (fig, 42),
4.5 Core numbers

The markings are to be placed near to the points of connections.
The cable core marking should state in the following order from the left to the right or from bottom to the
top:
- Core number
- Cable number
See fig, 45,
4.6 Partex
Please contact Partex Fabriksaktiebolag for further information,
Address: Box 80 5.1 Length of cable ends

S-547 02 Gullspang, SWEDEN
It is of utmost importance that both cable ends are measured to the correct length before cutting the cable,
Telephone +46-551-20560 Enough is sufficient
Fig, 47 Cable ends to various equipment

The termination of the cable screens shall be done according to the information on the termination sheet
The cable cores shall be terminated at the assigned terminal point with sufficient length to reach the
furthest terminal in the main terminal group,
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The sheet has the following information
cable type
cable size
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instructions
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:\Q.(~'<'\<ll~"t~ 6. Sensitive Cables
i)d.~\,~rf,.lA' Cables that are designed to provide a high level of interference immunity are considered to be sensitive
L- caIh "",,,\'Q' cables.
L.cabl~ "~o The most common interfaces are;
---eJd ••f:li'~ low frequency magnetic fields (from large currents in power cables)
electrical radiation (overvoltages caused by short circuit in power cables)
IJ..
ollAS
I
BUILT 93 431 PARTTABElL
I I"'T'" cross talk between cores/cores and between twisted pairs/twisted pairs.
'llnd Revision ApP<' Ye~rW •• r. L R.Vlnl'h .. ,lconl
UIQllchec
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These cables can be constructed as follows;
twisted pairs
screen of aluminium foil
screened by steel, aluminium or copper tape
screened by copper wire braid (90 %)
individual screened pairs
By combining different kinds of screens one can achieve a desired protection level.
Sensitive signals;
analog signals (0-10V)
digital signals
thyristor firing pulses
7. Fireproof Cables
The fire behaviour
-
-
-
Flame propagation
Smoke generation
of cables is assessed
Function during a fire

and classified
flame protected cables
low smoke cables
fire resistant cables
in terms of:
When cables are buried in the ground, fire behaviour has no significance.
- ~
000. Examples of Typical Installations
001 Table for selection
Method of laying
of material
Terylene Wooden
cord bracket
KSV-
bracket
lnstal-
lation
bracket
Plastic
straps
Lash
wire
Stain-
less
steel
straps
Clamp
bracket
No means
of
securing
-
Where cables are terminated indoors, there is a need for flame protection.
Laying in
Where cables are laid openly indoors, flame protected cables must be used.
Cable channel
~ '. .'~
- - - - - - - - •
Flame protected cables
Resulting from test as recommended in IEC 332-1. Cat. A, B, C. (Tests on electrical cables under fire Laying in
conditions). Cables are classified
_ Cable propagates
as foilows;
flame, this type of cable shall only be used in buried installations.
Cable duct
E1 - - - - • 0 - - 0
- Self extinguisher after ignition with a small flame Laying on

- Difficult to ignite and low flame propagation Cable ladder Ff 0 - 0 - • 0 - - 0
- Very difficult to ignite and very low flame propagation.
Section rails/trays~ ~
Low smoke cables
Low smoke cables give off less smoke than conventional plastic and rubber cables. Low smoke cables are
installation 6~~ ~~ - - - 0
• 0 - - 0
also difficult to ignite and show little flame propagation during testing. There are two kinds of low smoke
cables. Zero-halogen (LSZH) cables and low-halogen (LSLH) cables.
LSZH cables shall be used where people are present every day and where evacuation could take time.
The test method used for classification of low smoke cables involves determining how much light can
Conduits
t - - - - - - - - •
pass through smoke from an ignited cable sample in a sealed chamber. Supporting
Places where low smoke cables should be used.
- Mass transit vehicles and equipment
bar
61 - - - - • 0 - - -
- Hospitals, hotels, restaurants and offices
Profile bar
- Industrial premises and power plant control buildings
- Offshore installations and ships
Installation
5 - - • - .*) 0*) - - -
Fire resistant cables Suspension line

Fire resistant cables fulfil severai important demands. Besides being operationally dependable in fires, they
are also difficult to ignite, and limit the spread of fire. The fire resistant cables have good eiectrical and
Installation - - - - - • - 0 - -
mechanical strength properties, load capacity and flexibility. Free
Fire resistant cables meet the demands of fire test class B30, in which the cables must retain its electrical
function while being heated in an oven for 30 minutes from room temperature to 821 ·C. During this time the
Suspension - - 0 - - - - - - •
cable must be connected to the supply, and the fuses shall not interrupt the current.
Bracket
In addition the fire resistant cables shall fufil the demands of the IEC test, where the cable is exposed to
an open gas flame for 3 hours at 750 'C, during which time the cable must retain its electrical function. The
Installation FEJ - 0 - • • - - 0 -
cable shall withstand its rated voltage for 12 hours after the fire.
__ ') Cablestrap support must be used, see page 29, Fig. 49,
Cable channel
--.-:- ~
, • ,I"~
• " ~r--
• I
. I'
',' : ~ I'.. • .\
\0"
1
.,
(I·
, "
:;. . -'
.
- ".
'
.
Plastic str ~
~QP. rt
SWITCHGEAR and DISTRIBUTION" ~OA~~ ,-':',
Ladder
":" ~able channel~
O!0f:1
~ooooaQO -..
lOOooooool>':
. . -, ....
•.. ,.
••.•
Ladder .... Cable channel I

OQOooOD 4D
~..
': O,Qo()?~,,1;t~7?
.'"
Section beam
• • Strip iron
-
i-,
I
--
M
_ BATHS/BU
Control cable
4> 4>
~-
(j)
Note: Power and control

cables are run on the
some ladder 5-10 m as
shown
.& . ~ ~ •..:\ .
....•
._ 6 .6.' 4 . .~ 6'.(:) 'n' .<J . . J) .l.
...• . e:,.' ',0 <). , -4- • .u
. 4 .• "" d :. ~. . . ~ -".:.' .1l'A ..6 . D . v .

'0'" - _" " ~ " d •. '.•P.. - />'- • ~ ~
•• \ Tervlene strin9- Plastic straas
High tension
- ~
~
"'-
F=
-
30mm
I:::
= ~
- F=
- = 1=
-
~II
F=
- 1=
- /3 - P hase Isin Ie h
--
High tension
-
•
•
IPlasticstrap.Lln
Ibends only.
-
~
Fig. 58 Typical installation
-
Plastic strap~
\
\
,.
,.
,.
,.
,. Fig. 59 Typical installation
Vertical Horizontal
-
-
laying control cables laying general
,.
,.
II1II
BATHSI
1- SITE MAN 14 - 94
1WAT 910033-14
Laying, termination and
jointing of high voltage
- Edition January 1994 cables <80 kV
-
-
-
-
••
.-
-
-
-
-
•
mme-
List of contents 1. General
1. General 89 Tho intention with this document is to give site personnel a guide-line regarding methods when handling
2. Laying of high voltage cables <80 kV 89 and laying of high voltage cables from 1 kV up to 80 kY.
2.1 Cable drums 89 Regarding termination and jointing it is impossible to give universal information because it is a difference
2.2 Handling of cable drums at site 89 between the different suppliers. Consequently, it is of utmost importance to follow the manufacturer's
2.3 Rotation of cable drums 90 instruction when terminating and jointing of high voltage cables
2.4 Braking of cable drums 90
3. Methods of laying 91 2. Laying of high voltage cables
3.1 General rules when laying of cables 91
3.1.1 Stretch force 91 2.1 Cable drums
3.1.2 Bending radius 91 Cables are normally supplied on wooden drums. Short lengths may be supplied in rings or on other types of
3.1.3 Distance between cable planes 91 drums.
3.1.4 Interrelations and location of different classes of cables 91 The drum required depends on the length, the weight and the outer diameter of the cable.
3.1.5 Distance between cables at rated data 91
3.1.6 Cable table 92 2.2 Handling of cable drums at site
3.1.7 Cable laying card 92 Cable drums are transported overland on railway, trucks or lorries. They are wedged tightly in order to
3.2 Laying from a trailer 92 prevent them from moving during transport. The drums must be inspected for damage before unloading and
3.3 Laying by hand .. 92 any complaints should be covered by a factual statement from the carrier in order to be able to claim dama-
3.4 Laying by motor-driven equipment, general 94 ges.
3.4.1 Laying by motor-driven rollers 95 A ramp, crane or forklift may be used for unloading cable drums. If neither of these is available a
3.4.2 Laying by winches and cable pushers 96 provisional ramp of square timbers of beams should be erected. The angle of inclination should not exceed
3.5 Laying in ground 99 1 in 4. The timber and beams must be strong enough to support the weight of the drum. While rolling down
3.6 Crossing of roads 99 the ramp the drum must be guided by ropes with the aid of winches or block and tackle. It is advisable to
3.7 Laying indoors 99 pile sand approximately 20 em high at the end of the run to act as a stop.
3.8 Temporary marking 99 Note: Neither coils nor drums, even if they are small and not heavy, should be thrown onto the ground
3.9 Length of cable ends 100 when unloading them, as the cable is likely to be damaged.
4. Description of cable ways 100 A suitable trailer or tractor with forks should be used for transporting the cable drums within the site area.
4.1 Cable channel 100 The drums should never be rolled over longer distances.
4.2 Cable duct 101 After removing the planking from the drum the cable should be inspected for visible damage which may
4.3 Cable ladder 103 have been caused by improper rolling of the drum. The labour who are going to carry out the cable laying
4.4 Section rails/trays 106 should be clearly informed that they are about to handle valuable and very easily damaged material. The
5. Termination and jointing of high voltage cables <80 kV 107 cable should not be pulled over hard and pointed obstacles, which could damage the insulation, nor should
5.1 Termination and jointing 107 it be bent too sharply.
5.2 Crimping of conductors 107 At site a record on all cable drums should be kept stating type and length of cable for each drum arriving
5.2.1 General 107 or leaving the storage area. This in order to always know the quantities in stock and quantities being
5.2.2 Points to bear in mind when crimping 107 installed.
5.2.3 Cu-terminals 108
5.2.4 AI and AI/Cu-terminals 109
5.2.5 Marking of terminals 110
5.2.6 Dimension checking 111
5.3 Tools 112

prosecuted.

_ BATHSI
2.3 Rotation of cable drums
Some cable drums have a painted arrow on the side. This arrow is showing the direction for rolling the drum
on the ground during transportation in order not to loose the cable wound on the drum.
The cable should be pulled off from the top of the drum in such a way that the arrow shows in the
opposite direction to the pull.
Fig.4 Braking of drums. Please note:

The arrow shows direction of rolling
on the ground, not pulling.
3 Methods of laying
It is of utmost importance to follow instructions regarding bending radius, ambient temperature, stretch
force, etc. given by the manufacturer when laying of power cables.
The following methods and recommendations may be a guide-line for laying of high voltage cables.
3.1 General rules when laying of cable
2.4 Braking the cable drum 3.1.1 Stretch force

When pulling off the cable, drum stands with hydraulic jacks and mechanical brakes are preferabiy used. If In general, the maximum stretch force when laying cable may be:
the stand is not equipped with a brake, a plank can be used for braking. - with copper cables 5 Kp/mm2 (50 N) lead area
It must be possible to brake the drum at any time if there is a sudden stop in order to prevent further - with aluminium cables 3 Kp/mm2 (30 N) lead area
unrolling and consequent kinking of the cable, especially the latter must be prevented by all means.
3.1.2 Temperature
If the ambient temperature is below -10°C the cable must be heated before laying. Otherwise it will be too
stiff to handle and the insulation could be damaged during bending.
Preheat the cable in a store at a minimum of 15°C for 24 hours.
Temperature fluctuation result in length variations in the cables and they must therefore be laid in gentle
curves if the cables are long.
3.1.3 Bending radius

The bending radius of the cable shall be minimum:
Type of cable For laying When installed
Three-core 15 x diameter 10 x diameter

Single-core 15 x diameter 10 x diameter
PEX 20 x diameter 15 x diameter
3.1.4 Distance between cable planes

The vertical distance between cable planes and the distance to the ceiling should not be less than 300 mm.
3.1.5 Distance between cables at rated data

Power cables shall be laid as stated in the installation drawings. In general spacing between cables should
be one cable diameter, but not more than 30 mm. More space will not improve the cooling of the cables.
Sufficient cooling of single-core cables in a trefoil configuration is obtained with a spacing not less than 30
mm.
3.1.6 Cable table
The cable table constitutes a list of the cables in the cable network. The following are specified for each
cable
- type of cable
- number of core and their areas
- an individual cable number
- the plant parts to be connected by the cable
- routing of cables (option)
3.1.7 Cable laying card

The card has the following functions:
- to specify the information given in the cable table, one card for each cable
- to act as a work order to the cable laying team
- to record work progress. By using one cardbox for unlaid cables and one box for laid, the progress of
work can easily be measured at any time
3.2 Laying from a trailer

Cables may be laid out directly from a trailer if there are no obstacles in the trench or in its vicinity. Care has
to be taken that the drum is rotated carefully and braked, if necessary, in order to prevent excessive tensile
stresses or kinking of the cable.
3.3 Laying by hand

Rollers placed at distances of 3 to 4 m will facilitate laying. Corner rollers or similar devices should be
provided where there are bends in the route, always maintaining the minimum bending radius of the cables,
see fig. 6 and 7.
The cable is to be carried in hand, if not supported by rollers, with the men standing 4 to 6 m apart along
the route.
If there is not sufficient labour to lay long lengths in one sequence, the drum may be jacked up in the
centre of the section and the required length pulled off from the top of the drum in the direction "A" (see fig.
5). The drum is then further rotated and a vertical loop 3 to 4 m long pulled off in the direction "B". The cable
is lifted sideways over the drum towards the trench and the remaining cable pulled off from the bottom of ~
the drum in a loop. The twist in the cable has to be spread over a length of 4 to 6 m.
Cable trench
'III
%~"'iil!i,"1'!'!!i~ih:iM"~Pli1'Bji"
'III
~
IJIIIII
III'
I11III
I11III BATHS/BU
If obstacles in the trench prevent laying of the second half of the cable, it should be laid out in a con-
figuration of 8 on the side of the drum towards direction "A". It should be noted that the cable can only be
pulled off again in the direction from which it was first looped.
-
-
-
3.4 Laying by motor-driven equipment, general
The laying with motor-driven equipment is here divided into two groups:
- Laying by motor-driven rollers
-
-
- Laying by winches and cable-pushers
When motor-driven equipment is considered to be used, the following simplified conditions can act as a
guide:
- The cable volume, i.e. the number and volume of cables, has to be of such a proportion that the time
gained by using the equipment is not lost in transport and handling of the same.
-
- The cable diameter should not be less than 30 mm, if not more than one cable can simUltaneously be
pulled.
- The length of the cables should In average be over 50 m, since manual handling of both ends is
inevitable.
••
- The cable routes shall be designed in a manner making it possible to position the cables directly on their
final place when pUlling.
- Experienced personnel has to be available.
The following should be observed when pulling with machinery:

When a heavy cable is laid, a cable stocking or a pulling eye should be used In order not to damage the
-
cable and for simplifying the pull. The permissible pull is much higher with a pulling eye provided that all
conductor strands are evenly stressed, see fig. 9 and 10.
A continuous check on the stretch force by means of strain gauge or a dynamometer attached to the rope
holding the winch, with the latter resting on rollers.
-
A shearing pin or a friction coupling, which will interrupt the pulling if the maximum stretch force is
exceeded, must be prOVided at the winch.
Cable and pulling rope should be guided by rollers, especially at the bends, see fig. 19-21.
The stretch force may be still higher if the cable is pulled into a steel or plastic pipe, even if the pipes are
greased. They may reach 100 % of the weight of the cable if the bends total about 300°. Steel pipes may be 3.4.1 Laying by motor-driven rollers
-
greased with a special lubricant and plastic pipes with boiled-down soap of low alkali content. I ho cable is pulled off the jacked-up drum by electrically driven rollers set up in the trench 20 to 30 m apart.
All cables and especially single-sore cables should not be straightened completely after laying, but left II heavy cables are to be pulled around a sharp bend, it may be necessary to set up one motor driven
slightly meandering, in order to allow for the longitUdinal expansion caused by changes in the temperature. roller before and one after the bend. All rollers are connected to the main switch box via smaller distribution
Iloxos and are switched on and off jointly. At the head of the cable 3 to 4 men or an auxiliary winch, which
must run synchronously with the rollers, will be sufficient for gUiding it.
-
-
-
-- Fig.14
Cable winch.
-
3.4.2 Laying by winches and cable pushers
Electrical or petrol engine operated cable pulling machines - both pUlling and pushing are mostly operated
in groups and synchronized by the use of walkie-talkies, see fig. 13.
-
Fig. 13 Laying by winches and
n -
-
cable pushers.
-
1. Motor-driven drum stands with dynamometer
2-3 Cable pushers
4. Cable laying machine with winch
Accessories:
-
1 pc Cable stocking
1 pc Roller for pUlling cables in pipes
50 pes Cable rollers
12 pes Corner rollers
f-lg.16 Cable .MUk'·~4Q,·~;·4lw·Wfo¥;&;
-
slocking.
The wire is pulled out from machine 4 with the winch and is then run through machines 2 and 3 on a route
prepared with rollers. The wire is fixed to the cable end by means of a cable stocking. Each machine is then
manned and communication is established with walkie-talkies. Machine 4 pulls the cable and machines 2
-
and 3 assist by pushing the cable around corners and difficult passages.
--
-
3.5 Laying in ground
Farth cables shall be laid directly in the ground in according to the installation drawings applicable to each
project.
Note: If a cable channel is used, cheaper and simpler cables may be used. It is also much easier to add
Glass fibre rod for drawing guide lines and replace cables.
and cables through piping.
3.6 Crossing of roads
For the crossing of roads the cables must be drawn into pipes.
It is always advisable to provide spare pipes in order to avoid having to dig up the road if further cables
are to be laid. Ducts which are not used at once should be plugged. The cables should not rest on the sharp
odges at the ends of the ducts. Steel pipes should have funnel-shaped ends, if possible.
If the end of a pipe or duct is levelled with the trench bed, a deepening should be made immediately
•
before the opening prior to pulling in the cable in order to prevent stones or coarse soil from getting into the
duct and clogging it up, the pulled-in cable should be cushioned so that it is nearly in contact with the top of
the duct at both ends, fig 23.
The inner diameter of the duct shall be at least 1.5 times the outer diameter of the cable.
'I I ;i\-I-j -~--'=:::

...;:';:;~~
..~;Ll.jf;;~~:;.~;.:-:;;~-,
------- =~~nel-shaped
:1.1 Laying cables indoors

(;lIlJlo which must be protected mechanically or against electrical disturbances should be laid in steel ducts,
III'y" llr pipos.
II 1110 disturbances do not effect more than 10m of the cable run and if the number of cables is less than
10, Il,orl Ihe cables may be strapped to a strip iron. When support of the cable way or mechanical protection
I" IIocllssary, section beams can be used.
1 :1 cHblos may be clamped directly onto walls, foundations and structures in building if the distance is
11111 II1llrll than 10~20 m.
:I." Tomporary marking

WI,orl 11111 cable is laid and cut off, both ends shall be temporarily marked in order to enable the
Fig. 21 Roller for pulling cables Itlllllllllclliion of the cable prior to termination and final marking. This is best done by the use of a suitable
into concrete pipes. IIII'll 1I11e111 water-proof marking pen with a point of approximately 2 mm's thickness.
3.9 Length of cable ends
It is of utmost importance that both cable ends are adjusted to the right length. Too long cables create waslo
and too short ones mostly mean that a new cable has to be pulled, since jointing often is not allowed.
The following calculations may act as a guide, see fig 25.
Connection box a
-
-
-
:/
Fig.25 Cable ends to various equipment.
4. Description of cable ways
-
The following section describes the cable ways recommended by ASS.
4.1 Cable channel

Descri ption
The cable channels in outdoor switchyards are mostly made of concrete and covered with concrete slaps or
wooden covers.
Indoor the channels are often integrated in the floors of the building and covered with channelled plates. Fig.27 Cable channel in outdoor switchboard
plant.
Installation
-
The cables can either be placed directly in the bottom of the channel or on racks.
No means of securing the cables are necessary. 4.2 Cable duct
Description
Application
Different types of ducts are
The main advantage of using cable channels is that cables may easily be replaced, added or inspected.
used. One type of ducts is in
-
Cable channels make it possible to use not reinforced cables, since the channel itself offers the sufficient
a building embedded pipe
mechanical protection.
made of galvanized steel or plastic. Another type is channel with one side detachable, such as a lid, made
of metal (generally galvanized sheet metal) or plastic. The duct may be entirely enclosed or perforated. A
covered cable ladder should be considered as a duct.
-
Installation
The cable should lie loosely except in the case of vertical assembly. in this case the distance between the
attachment points should be max. 500 mm.
No means of securing are necessary in horizontal ducts.
Plastic straps or lashing wire are used to fasten the cable to vertical perforated ducts.
-
Application
Ducts may be used when special protection for mechanical or electrical disturbance is required.
Stool ducts may also be used as a thermal protection.
Fig.26 Cable channels Duels of plastic or stainless steel should be used in strong corrosive condition.
-
outdoors. Small channels of piastic are being used in cubicles for protecting and supporting a bundle of single
loadors.
4.3 Coble ladder
DOBcrl ptlon
I lAMA's *) definition of cable ladders specifies that the distance between the rungs may be a maximum of
:100 111m.If the rungs have a flat top surlace they should be at least 15 mm wide and round rungs should
IIIIVO a diameter of at least 19 mm.
I adders are available in widths of 200,300,400, 500, 600 and 1000 mm.
') f-1-AMA Rules for Swedish design on electrical equipment.
AI bonds or where a cable leaves the cable ladder, the cable should be secured with plastic straps or
IIIHhing wire. In the case of vertical assembly, the cables are also fixed to every second rung. Cables over
40 mm should, however, be secured with brackets type KSV, if the vertical run is more than 10m.
A maximum of five cables may be located under the same attachment device.
Application
In most cases the cable ladder offers the best solution when building cable ways. In cases of great
lIIochanical load, high short-circuiting currents and high ambient temperature cable ladders are particularly
Huiluble due to their great mechanical strength and good cooling properties.
I IlJ :1:' Cnill" ladders

IIlIlIIi 1111 CIlilillg pandant.
- \ Jgalene strin!L -
--
~
\. ~ 1\1
~
.~~
,- = ~ =
-
diam. or max. 30 mm
.~~
25-240mm
Metal screen
.-
,. l= i= ~
=
--
-- t= 1= ~
=
- -
-- !P
3 - hose
High tension
Isin Ie h
••
••
l1li
l1li
4.4 Section rails/trays A,mm
Description 49
Various sections are available. Most frequently used are Land U perforated sections. 87
Trays (U section) are available up to 600 mm. 124
If used outdoor, all sections must be hot dipped galvanized. Indoor they may be painted or electro-plated 162
with zinc. 236
See fig 31 and 37. 311
•
Installation 461
Section rails/trays may be installed directiy onto foundations and walls in order to provide mounting holes for
straps and as protection for cables. They can also be mounted between two points providing a support for
the cables.
When the cable is secured to the rails/trays, the fixing points should not be spaced more than 500 mm.
The cables should be secured with plastic straps or lashing wire.
Section rails may be used for a small number of cables (1-20 depending on the size) to separate units as
a protection and support for the cables.
Trays can be used as above, but can carry more cables depending on the width of the tray.
•
•
• 5. Termination
5.1 Termination
and jointing
and jointing.
of high voltage cables < 80 kV.
Since the design of termination and jointing components varies a lot between the different manufacturers, it
•
Fig. 35 Cable is important to follow the manufacturer's instructions in order to safeguard a correct cable work. Redoing the
protection. termination or jointing is always very costful and time consuming.
Note:
.-
• Read carefUlly through the instruction before commencing work.
• Cross out those sections which do not apply for the work in question .
5.2 Crimping of conductors
5.2.1 General
.-
The Elpress system is the most common system used by ASS and covers the following areas:
Cu-terminations up to 1000 mm2
AI-terminations up to 1200 mm2
C-sleeves up to 300 mm2
However, this instruction describes the most frequently used components covering the following areas:
Cu-terminations up to 400 mm2
JII
AI-terminations up to 630 mm2
C-sleeves up to 150 mm2
Full information on material and tools shall always be submitted to site prior to erection start.
5.2.2 Points to bear in mind when crimping
JII Terminals
-
and connectors
The terminals (cable lug, splice, etc) must suit the cross-sectional
(number of strands, degree of compression, shape, hardness).
area and construction of the conductor
--
Crimping tool
- The crimping tool must be correct for termination and must be designed so that the crimping operation
cannot be interrupted until the crimping cycle is complete, except by performing a special operation.
5.2.4 AI and AI/Cu terminals
Markings .
_ In order to avoid mistakes, both tools and terminations must carry unique and permanent markings, Spllco sleeve type AS:
which must also appear on the packaging. On crimping, the identification mark of the tool must be I JsocJmainly for jointing aluminium conductors in underground
impressed automatically on the termination. cullio systems, but also at the transition between overhead lines
[Jilt) underground cables.
Dimension checking
_ The quality of the crimped connection and the condition (wear) of the crimping tool is checked by
Coblo lug type AK:
measuring the dimensions of the termnation at the completed crimp. Usod to terminate aluminium conductors at busbars and
_ A supplier of terminations and crimping tools shouid be able to provide details of nominal dimens'lons and
uluminium terminals on apparatuses.
tolerances for the terminations before and after crimping, and to supply special measuring equipment for
this, where needed.
Cu-terminations Alum Inium/Copper Terminals:

_ Take great care not to damage any of the strands when stripping the copper cable. .. I he AI/Cu terminals are manufactured by friction-welding the two component parts together, a method in
_ Strip about 5 mm more of the insulation than the depth of the barrel of the cable lug or splice (I.e. up to which the aluminium and copper are bonded together by the heat produced as one metal rotates against
the inspection hole or cable stop). . ltm other under pressure. The result is a totally hermetic joint, immune to corrosion and galvanic action
_ Check carefully that the type number of the die corresponds to the marking of the cable lug or splice. ovon under outdoor conditions.
_ Normally one crimp is needed up to 400 mm2. For round compressed conductors 185 mm2 and above,
two adjacent crimps are needed.
AI/Cu splice sleeve type AKS:
AI-terminations For jointing AI to Cu conductors.
_ Take great care not to damage any of the strands when stripping the aluminium cable.
_ The stripped iength must be 5 mm more than the depth of the socket in the termination. .
_ Circular performing with the appropriate tool may be necessary if stranded or sector-shaped cable IS
used.
_ Two crimps with a punch are always made in the aluminium termination barrel.
AI/Cu pin sleeve type AKP:
_ The barrel of the aluminium terminations is serrated internally and protected against corrosion by a thin
To connect AI conductors to
layer of vaseline. . . equipment and junction boxes.
No preparation such as cleaning or application of compound is needed. There IS no need to wire-brush
the stripped cable end.
5.2.3 Cu-terminals
-
AI/Cu cable lug type AKK:
Copper type terminals type KRlKRF: Used to terminate an AI
_ Used mainly to terminate cables at copper busbars and equipment terminals. conductor at a Cu busbar.
_ The same terminal is used for both flexible and stranded or sector-shaped
conductors.
-
l()rminals for AI cables are made of solid pure aluminium.
Spliced type KS/KSF: The system may be used for both stranded and solid aluminium conductors.
_ Used primarily to splice copper conductors in underground cable systems. Note that there is a difference of one area step between stranded and solid conductors.
_ The same splice is used for both flexible and stranded or sector-shaped
conductors. These splices can also be used for straight jointing of earthing I Example: Barrels for 120 mm2 stranded wire, fit 150 mm2 solid conductors.
The punch identification number is automatically imprinted on the terminal. Comparison of the imprints
with the barrel marking provides a check that the correct tool has been used. The number of the punch and
cd _ matrix also coincides with the outside diameter of the barrel.
Branch connectors type C

(C-sleeves):
- This pattern up to 120 mm2.
~, ••
~,,,
d
••
••
5.2.5 Marking of terminals 5.2.6 Dimension checking
As well as showing cable area, the marking system indicates which tools should be used.
Aluminium terminals:
Cu conductor
Area In mm2
~I
IN
(0 .- The result of crimping can be measured after a period of use.
- If dimension T is exceeded, the tools must be adjusted or replaced.
- The number of the punch is imprinted at the bottom of the crimp. This number is the same as the outside
diameter of the terminal barrel. The number also appears in the marking of the barrel, making it easy to
~w
check that the correct tool has been used.
Type No. of
hexagonal die
~
t
Cu conductor Cu conductor Die identification
Measuring points
number
120-150 mm2 ~ 70-95 mm2
n ~
AI conductor,
Stranded
16
25
mm2
Solid
25
35
Tool
Matrix
P13M
P13M
Punch
P13D
P13D
T
mm
6.8
6.8
Max. diameter
of conductors 35 50 P20M P20D 10.8
50 70 P20M P20D 10.8
70 95 P20M P20D 10.8
Aluminium terminals
Number for circular Number for compression 95 120 P25M P25D 13.5
preforming punch ~
4 £_/ punch and matrix 120

150
150
185
P25M
P25M
P25D
P25D
13.5
13.5
~
and matrix
185 240 P32M P32D 18.4
;t
240 P32M P32D 18.4
'20 - .,-;-:;;,." 300 P36M P36D 21.0
150 SOLID 400 P40M P40D 22.8
500 P40M P40D 22.8
~ D = 52 500 A P52M P52D 31.0
Stranded AI Solid AI Bolt size D = 52 630 A P52M P52D 31.0
conductor conductor M12
in mm2 in mm2
Copper terminalS:
- The dimension N is checked on the hexagon faces that have the impression of the dies. Measure with a
calliper on one or both sides of the impression.
Types KR and KS
Area mm2 N mm
6.4
••
7.6
8.8
10.3
12.1
13.9
••
16.5
16.3
20.3
20.6
23.4
24.6
27.4
C-sleeves
- For C-sleeves,
oval.
the dimension h is checked, preferably with a calliper, on maximum height of the crimped
- SITEMAN 16 - 94
1WAT 910033-16
Cubicles in
electrical rooms
C4
C5
C6
10.6
13.7
15.8
- Edition January 1994
Touch-up painting
-
C8-6, C8, C9-8 and C9 22.0
C11-8, C11-9 and C11 23.2
C13.8, C13-9, C13-11 and C13 27.0
C15-8, C15-9, C15-13 and C15 34.5
C16-9, C16-13and C16 38.5
5.3 Tools
In order to guarantee a good quality of cable work it is important to follow the general information or guide-
lines from the actual supplier.
It is also very important to point out that some tools must be checked periodically. Regarding tools for
crimped connections, the tools must be checked periodically according to ASS Quality System Guide-lines
-
chapters No. 4.11 and 4.12 respectively.
Note: It is the responsibility of the user to ensure this is done.
Regarding tools for crimping connectors, see ASS Corporate Standard book C8.
-
••
••
•
--
--
List of contents
A.
1.
2.
2.1
2.2
2.3
Cubicles in electrical rooms
General
Handling of cubicles
Packing
Unloading
Checking
3
3
3
4
5
- 1. General
Tho intention with this instruction is to give a brief introduction of the methods used by
AI3S when installing relay, control and distribution boards in electrical rooms.
II is of utmost importance, however, to penetrate all layout and installation drawings
together with installation manuals for the delivered cubicles and equipment prior to start
2.4 Lifting and indoor transport of cubicles 5 of installation.
2.5 Storage 6
2.6 Temporary marking 7
2. Handling of cubicles
3. Control 7
3.1 Access roads 7 2.1 Packing
3.2 Floors 7 The cubicles may be delivered in the follOWing manner:
3.3 Suspended floors 8 Individual cubicles fitted with apparatus.
3.4 Depending points 9 Several cubicles mounted together as one unit.
4. Installation 10
Accessories.
4.1 Cubicles 10
4.2 Busbars 13 I he cubicles are normally delivered standing on a transport pallet covered with a plastic
4.3 Clearance to walls and ceilings 15 Gover and firmly attached to the pallet.
4.4 Cleaning 15 Loose accessories are delivered in wooden boxes.
-
When the cubicles are shipped overseas, a more durable packing is needed, such as:
B. Touch-up painting 17 Cases of wood.
5. General 17
Cases of plywood.
5.1 Definitions 17
Sleel containers with open roof.
5.2 Cleaning prior to grinding 17
5.3 Grinding of damaged surfaces 18 Nolo that ASS-deliveries normally are covered with sealed air tight plastic bags before
5.4 Application of filler 18 Itloy are packed into the cases. Sags with moisture absorbing material are placed inside
5.5 Grinding after stopping up 18 Itlo cubicles to keep them dry.
5.6 Primer coating 18 Packing list is packed together with the cubicles.
5.7 Cleaning and masking prior areosol spray painting 18
5.8 Finishing coat 19
5.9 Finishing coating with areosol paint 19 I
5.10 Finishing coating - brush painting 19 I
5.11 Choice of fillers and paints 19 I
5.12 Tools, accessories, etc 19
I
6. Touch-up painting of galvanized steel with zinc-rich paint 20
6.1 General 20
6.2 Work steps - general 20
6.3 Choice of galvanopaste 20 i
II
I
sion, and the contents thereof must not be I I
imparted to a third party nor be used for any I
prosecuted.
I
I I L II I I I
I

2.2 Unloading
Handle the cubicle carefully when unloading or moving them.
The easiest way to unload from a truck is to use a forklift truck. Note that the forklift - 2.4 Lifting and indoor transport of cubicles
Cubicles are normally provided with lifting devices. However, the method of lifting varies
from type to type. It is therefore important to follow the lifting instruction given i the
--
must be equipped with wheels big enough to make the handling of cases safe and enclosed information in order not to damage the cubicles by applying the lifting slings
steady. The roads at site are often of poor quality during the erection period. wrongly. Figure 5 shows some typical lifting arrangements.
If possible, unload and transport the cubicles directly to their final position in their Indoor transport of Safesix switchgear. The cubicle should be lifted from the pallet with
~v~'
the use of a fork lift. The cubicle can be transported indoors with a pallet lifter. Two lifting
-
packings, see figure 2.
tackle are placed in the cubicle as shown in figure 4.
The lower door of the cubicle must be removed and put somewhere safe, before the
fork lift is used to lift the cubicle, and kept safely during assembly period.
;;~ a If the cubicle cannot be transported in the upright position because of for example low
-
doors, it can be laid on its back on a pallet and moved with the use of a fork lift to its
9rJj erection position.
~F 4!1
To remove the connecting apparatus choose the selector to door position. The
connecting apparatus can now be pulled out on the door extension rail. This can be done
-
with the cubicle mounted on the pallet. The trolley moves most safely on a low position.
The busbar and the roofing plate are delivered separately packed in each cubicle.
=== E:- l/fl) Check that parts specified in the enclosed packing list are present. Any parts missing or
damaged must be claimed as soon as possible.
~.----
~
~\ jlJ
'$
-
-
~~
To unload the cubicle from the pallet, move it forward or backwards on the pallet until the
-
cubicle can be tilted. While holding the cubicle in a tilted position, pull away the pallet and
set the cubicle down on the floor carefully, see figure 3.
-
~.
-
-
-
2.3 Checking
Check the consignment against the accompanying packing list to ensure that the correct
items have been delivered. Any complaints are to be remitted as soon as possible to ASS
in order to avoid delay in the installation work. Do not forget to make a check-up on
separately packed apparatus.
2.5 Storage
Sometimes the cubicles, due to various reasons, cannot be installed immediately upon
their arrival to site, but have to be stored.
• Allows deviation (declivity)
E(mm)
-
The cubicles delivered on transport pallets covered with plastic wrapping are to be
stored in clean, dry and dust-free premises. When the cubicles are equipped with heating
elements, these should be temporarily connected during storage in order to avoid Description Measured Allowed
corrosion. deviation (mm)
--
iength (m)
The cubicles delivered in wooden cases with sealed air tight plastic bags and moisture Class 2
absorbing material should be stored indoor or under cover. Do not open these cases if Warpage 2.0 ±3
they are stored oudoor. The check of the content should then be carried out when the 4.0 ±5
Declivity L E
cubicles are installed.
-
Always use timber to space the cases from the ground.
The equipment may be stored for a couple of months in unopened cases. If longer 6.0 18.0 21+.0 1+8.0
storing periods should occur, the manufacturer should be contacted for advice.
•
2.6 Temporary marking
Temporary marking of the cubicles can be necessary sometimes. Se careful when using
3.3 Suspended floor
labels or tapes on painted surfaces. A special marking tape can be ordered from your
Suspended floors are used mainly for the following reasons:
ASS-supplier.
-
- Flexible installation of cubicles. The final layout can be decided at a late stage.
-- Open space under cubicles means no problem to install cables.
3. Control
- Easy to adjust the floor to correct level.
3.1 Access roads It is always very important to check the transport ways in order to - Easy to extend and re-position the panels.
•
ensure that no obstacles can cause hinderance. The following check points can act as a
The floor should be fire resistant and can be of electrically insulating or semiconducting
guide:
design.
- Can the road be used by our transport vehicle?
The insulating floor is used mostly in switchgear rooms or similar.
- Are there any electrical wires or pipes crossing the road?
The semiconducting floor is intended for computer rooms and other areas where static
•
- Is it necessary to build temporary unloading platforms?
electricity may cause damage, injury or inconvenience.
- Are door openings large enough?
The floors are built up of floor scaffold and fire resistant slabs. It can be completed with
- Hoisting wells?
stairs and banisters and can also be reinforced for higher loadings, see figure 9.
- Staircases?
3.2 Floors
The cubicles are designed to be erected on an even and thoroughly levelled base to
enable the interjoining of cubicles without any extra measures. See figure 6.
-
••
Experience proves that above tolerances are hard to obtain. ASS therefore recommend
that steel profiles are embedded in the concrete in a manner as shown in figures 7 and 8.
The civil work drawings have to show in detail the foundation design for all cubicles and
to specify the tolerances required for each project.
-
If the floor is not in level, it will be difficult to open and close the doors. Cubicles with
drawable circuit breaker may be more sensitive. Here the contact function between
breaker and the fixed contact can be jeopardized.
Check that the floor is even and in level, and that iron profiles are correctly embedded
-
as stated in the civil drawings. Holes for cable entries in the floor have to be carefully
checked regarding size and location.
::
- 3.4 Depending points
When ASS is given access to electrical rooms, the depending points stated in our
contract and erection plans shall be completed. The following list may act as an example:
-
Access roads ready.
All civil work ready.
- Doors and windows installed.
Room painted, cleaned.
-
Lighting installed, ready.
Power outlets ready.
_. Room lockable.
- Roof sealed, ready.
-
Fig. 8 Typical foundation Air conditioner installed, ready.
for cubicles.
4. Installation
-
4.1 Cubicles
Note that a cubicle having a number of apparatus fitted on the door or on the hinged
frame, will fall forward if the door or frame is accidentally opened before the cubicle has
been secured to a nearby cubicle or to the floor, alternatively the wall.
-
The erection of cubicles starts preferrably at the highest point of the floor.
Cubicles with adjustable screws must not rest on these after alignment. Shims have to
be inserted to take up the load.
The cubicles are bolted or welded to the base, see figures 10 -17.
-
Note! No welding is allowed on cubicles with electronic equipment.
When drilling in concrete floors, remember always to take measures preventing dust to
enter into the apparatus of the cubicles.
For further information do always read the installation manual for the actual equipment
-
carefully before the start of installation.
The floor is built up from tubular legs,
-
beams and fire-resistant slabs.
The legs are adjustable vertically.

The shape of the base-plate ensures
The beams are tensioned between
the walls with the aid of a special
- en
-
that the leg stands securely even on tensioning device.
ii
rough surfaces.
. ------------~Leg Ibuu----- -n un _
Fig. 9 ~
-
1) Note that the loose floor slabs under the cubicles have to be secured
to the beams as well as the cubicles.
Fig. 10 Fastening of cubicles to suspended floors.
- <l .;;os ~,..c;:.~17 ;:)j)~y~~~ ..-If
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Fig. 16 Attachment of Safesix
A' .....:l" "\~
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'7 j.:--::O
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<J q
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<1 cubicle on frame -"'~-s:::"~I\~""'?
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... <1
.q flooring. -
A <J <J
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Fig. 17 Cubicle fastened to pre-aligned profile

Fig. 11 Cubicles fastened with expansion- Fig. 12 Cubicle fastened with clamp and bar with T-bolt and clamp.
shell bolt in concrete. expansion-shell bolt.
4.2 Busbars
I or series-manufactured switchgear, apparatus, etc., special assembly instructions are
normally provided and these apply to the complete installation including the bolted joints
In Ill() busbars.
I or joints in other equipment, where special measures must be taken, e.g. control of
IIllhloning torque, special locking facilities etc., instructions are either given on the
IlHsornbly drawing or are supplied separately for the joints in question.
" modifications are necessary during the on-site installation, it is of utmost importance
lillil 1110 joints are made in accordance with the applicable standard to ensure satisfactory
.<J
q
1 q
porlormance. See figures 18 and 19.
q
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q <1 Concrete
~
q q
~
",
(I ('1 Mr~~r
q
q
~ "
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Fig. 14 Cubicle fastened with clamp
Joining is carried out from the front of the
cubicle. The same method applies for both
Fig. 13 Cubicle welded to embedded
either with expansion-shell bolt in horizontal busbars, Nand PE busbars.
L-profile.
concrete or welded T-bolt to steel beam. 1. Dismantle the protective cover in front of
the busbars so the joints are accessible.
) I 2. Loosen the bolts to the joint pieces.

3. Slide the joint pieces towards the right
\ cubicle.
\ II, 4. Tighten all bolts with a torque wrench,

20 Nm.
5. Replace the protective cover.
Note tn the case of double joint pieces,

both should be placed on the front
side!
Extreme
cub,cte
nght Extreme
cubicle
leff
- 4.3 Clearance to walls and ceilings

Minimum clearance to ceilings and walls varies a lot between different types of cubicles
dopunding on demands regarding cooling and required installation space for the bus-
bars, opening of doors, etc.
,.
Install the cubicle according to drawings from the design office and check that the
minimum clearance according to the manufacturer's installation manuals are kept.
Suo figures 20 - 21.
,.
4.4 Clearing
Ilomove cable waste and other litter. Clean off grease and dirt, especially from the
insulators. Finally, vacuum-clean the cubicles. See figure 21.
•..•
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,"'<,()
r-.-==""l---.L
A-A A-A A-A A-A
--
For busbar
cann.bars
~~~~
2000, 1600 A
2000, 1600 A
2000, 1600 A
1250 A
2000, 1600 A
800 A
1250 A
1250 A
-
-- jLftrn}
--
For busbar
1250 A 800 A
cann.bar
800 A 800 A
B-B B-B B-B B-B
For busbar
~~~~
2000. 1600 A 2000. 1600 A 2000, 1600 A 1250 A
- -I
,,'j
-I~"~'·,.",,
--i I .1, ..,.,., Checking free space around cubicles
--
cann.bar Above
2000. 1600 A 1250 A 800 A 1250 A There must be at least 150 mm free space above
the cubicle. Where cables run in from above, the
B-B B-B distance also depends on the cable type and the
I 11,;>0 Space required for switchgear way in which it is laid.
--
typo Conlor.
Against walls
For busbar
~~ The minimum distance between the rear of the
1250 A 800 A
conn.bor cubicle and the wall behind, as well as between the
800 A 800 A end panels and wall at the side, should be at least
--
40mm.
Cubicles with handles in the doors should have at
least 150 mm between the left end panel and the
wall to allow the doors to open more than 90°.
--
rs RJQbI side wall wlthouf eartt"Hnn sw,l
b. Goneral
D 111111 document is a guide-line for touch-up painting of products delivered to sites. It is

IIl1flod on ABB:s quality requirements of today and the painting methods used by the
nlllJlIllncturers.
D D In 1\1313 we have both normal wet painted products and powder painted products. Since
IHlwdor spraying cannot be used on site, a one-component, alkyd based paint system is
~ ~ ~ IJllli/ou lor touch-up painting. As far as possible, however, touch-up painting should
lll:l1iovo the same quality and finish as the original and adjacent surface.
SlJrlnces with no particular requirements regarding finish may be brush painted. In
Ilimo oxacting cases repair painting should be done by arerosol spraying. Examples of
OJ
0
- -- --
0 0
- IlIH:h surlaces are the outsides of control cabinets, desks, connection boxes, etc.
III Cflses where there are considerable damages, a local contractor, with suitable equip-
'"
0
OJ 1I10nl,should be engaged. Do not forget to ask for a fixed price and check wether it
U IlIHlIJld be cheaper to order a spare part.
<;
c
0
II louching up the paint yourself, do so in a room suitable for this, well ventilated and
iii
c
Iroo 01dust.
OJ
E Iiolore applying the filler and painting, carefully straighten the damaged steel sheet so
4"0
is
(; Il1nl Iho layer of filler can be kept as thin as possible.
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6.1 Definitions
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D V1 Alkyd paint - has a binding agent composed of an acid and alcohol (synthetic resin),
-
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~ 1I!r1llcalled alkyd.
C u
l!
0
u
o. fwo-component filler - a filler containing hardener. The advantage of this type of filler is
111111
II is stronger and more elastic and hardens more rapidly than a one-component filler.
....£2 r-22 22.- II doos not crackle so readily, is easy to rub down and gives a good finish.
400 ~
...1lQ 65
t--
no 1N..
~ m,n 150 m,n 150 Whlto spirit - has various commercial names, e.g. petroleum spirits or mineral spirits. It
--12Q c III IIHI most common and least toxic medium for degreasing, diluting and cleaning.
E
Xylono or dimethylbenzene is an extremely flammable solvent, mainly used as a paint
IIlilHlnl.
Dlluont reducer - a general term for white spirits, xylene, etc.
b.2 Cloaning prior to grinding

1\0111Iho damaged and the adjacent surfaces must be cleaned so that all grease, dust
111111 olhor dirt are removed. Otherwise impurities can be trapped in the abrasive paper
111111 IIJbbed into the surface.
(;Iolln with an organic solvent such as xylene or white spirit, using a non-fluffing rag
IIII'pod in the solvent.
11.:1 Grinding of damaged surfaces

I 111110 dllmaged areas, which are to be stopped up, should preferably be machine grinded
(11111111111 machine with a wire brush or rubbed disc or an oscillating grinder).
I )III1lHIJCSwhich are limited to the paint should carefully be grinded so that no marks
"'0 vl:ilml, Ihus avoiding the necessity of stopping. Start with a relatively coarse rubbing
1"11'0' No 100. Then rub the area around the damaged part with a finer paper, e.g. No.
I',ll III I HO.
1\11 !Ill1lding should be done so that the transition becomes less and less visible towards
1110Ildjlll:enl surface.
5.4 Application of filler
Damage should be stopped up with a generally accepted filler system.
If a two-component filler is used, it is important to mix filler and hardener in the right
proportions. Too much hardener speeds up hardening and too less slows it down. Follow
the instructions. Do not mix more than will be needed.
Use a spatula that is suitable in size for the damaged area. Spread the filler as evenly
as possible in order to obtain a flat and even surface. When dry, check with a straight
- 5.11 Chioce of fillers and paints
Project delivery contains products from many manufacturers. Consequently it is
impossible to write a list regarding colours, article numbers, etc.
The main goal for touch-up paint is to get the same quality and finish as the original
adjacent surface. Choose the filler and paint according to the manufacturers instructions
(or product pamphlets) to avoid mistakes during the touch-up painting work.
-
edge that there is no unevenness. If the surface is uneven, stop up such areas again. 5.12 Tools, accessories, etc.
There should be sufficient filler to allow it to be grinded down. 1. Drilling machine with a wire brush.
Note 1: Use as little filler as possible. Too much entails unnecessary grinding. 2. Drilling machine with rubber disc and abrasive paper.
Note 2: Careful preparation is essential if a good surface is to be obtained.
-
3. Oscillating grinder with abrasive paper (alternative to No.2).
4. Abrasive paper, medium, grain size 100
5.5 Grinding after stopping up 5. Abrasive paper, fine, grain size 150
The stopped up area must be grinded to be even with the adjacent surfaces. 6. Abrasive paper, extra fine, grain size 180
Start with abrasive paper No. 100. As the area becomes even change to a finer grade,
-
7. Abrasive paper for machine
e.g. No. 150, and finish with No. 180 to ensure that there are no visible scores. Check the 8. Spatulas.
surface with the straight edge from time to time.
-
5.6 Primer coating 6. Touch-up painting of galvanized steel with zinc-rich paint
If the original coating has been damaged or grinded through to the metal, a primer must
be applied and rubbed down to an even surface. 6.1 General
Primer coating can be obtained as areosol spray or other types of cans. This information is intended for the repair of the corrosion protection on galvanized steel.
After primer coating, finish smoothly with abrasive paper No. 180. Damages on galvanized parts, caused by, for example welding, drilling, cutting, etc.,
must be repaired with a zinc-rich paint (galvanopaste - zinc content 93 to 95 %). The
5.7 Cleaning and masking prior areosol spray painting paint is applied with a brush or areosol spray. Brush painting is preferable since the areo-
Properly grinded surfaces should be cleaned with a non-fluffing rag dipped in white spirit. sol gas contains toxic products
Before spraying, the area to be painted must be masked off from adjacent areas, which
must be well covered. Use masking tape and paper. Remove the tape as soon as the 6.2 Work steps - general
painting has been completed, otherwise it may stick and damage the paint. Hemove all burr, welding slag and rust. Use a wire brush, file and countersink bit or
olher suitable tool.
Cloan all surfaces from grease, old paint, etc.
-
5.8 Finishing coat
Before applying the finishing coat, all surfaces must be either primed or smoothly grinded, SUr repeatedly so that the zinc powder keeps well mixed in the can.
in some cases both. Choose the colour according to the manufacturers information. Allow to dry for four hours before applying a second coat.
5.9 Finishing coating with areosol paint 6.3 Choice of galvanopaste

Before starting painting cheCk that the room is well ventilated and free of dust. II IS important to have a zinc content of 93-95 % in the paint you have planned to use.
Read carefully the instructions on the areosol spray can. II II is impossible to purchase it locally, please contact your homeoffice for delivery to
Shake the areosol spray can well. Hold the can about 20 cm (8 ins) from the surface to nllo III order to reach the right quality.
•
be painted. Check first on a separate test piece.
When you have finished painting, turn the can upside down, push the button and empty
the nozzle in order to avoid that it is getting clogged with dried paint.
5.10 Finishing coating - brush painting

- Use a brush of good quality which does not loose hair.
- Stir the paint in the can to an even consistency. Regarding diluent, see the instruc-
tions for the paint being used.
- Brush the paint in four directions (vertically and horizontically) to obtain a good surface
finish.
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1. General
List of Contents
n ordor 10 promote the understanding of earthing it is usual to divide the term under two general headings,
rlllmoly system earthing and protective earthing.
-
General ..•................................................................................................... 133
....::.::..::> i~~
1.1 System earthing
~r~~!~i~~~~~~~.::.:::·::::::.·":·.·.:··::::::>::::···:.::::.::::
..::.:.:.::.::: Primarily systems earthing is considered as the permanent connection of a system or part of a system
w[lleh would normally be under tension to earth. Normally it is the system or part of the system's zero point
Earthing outdoor ............•......................................................................... 134
wilieh Is connected to earth, direct or via a neutral earthing equipment.
-
Earth grid, earthing rods, pits etc 134
1[10 lact that a point in the system is earthed, means that any part of system which is galvanically
Steel structure 135
ClHHloclod is also earthed. A system earthing does not effect parts of the system which are magnetically
Transformers and high voltage apparatus 135
(;(Jupl(J(j, o.g. via a transformer to an earthed net.
i~~i:::~e~~::~.
~~r~~~:
..::.'.::::::
.:::::
.::.:::
:.:
..::.':.::.::':::'
.::.:'.:.:
:::.':.:. ::."~~~ In a power network there can be found several system earth's e.g. each voitage ievel can have its own
-
oHrllling.
J 110 primary reasons for bonding the network potential to earth are to protect people and equipment.
~:7~:~~~~~~.~.~.::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::
~~~ 1.2 Protective earthing
~:t~~i~i.o.n.S. ~~~. ~l~~~i~~.:::::::::::::::::::::::::::::::::::: :::::::: :::::::::::::::::::::::::::::: ~:~ Jlio lovol 01 protection from high voltage for personnel that can be achieved by the selection of good
-
Insulation and thought/ul plant design is inadequate. The require-ments of high current instructions are that
Installation 149
oxposed details shall be protective earthed in a way that ensures complete safety.
Th~ 1~
An ox posed detail is understood to be one which can be touched, accessed or is of a prominent nature,
Tempoprary earthing , 149
hul which under normal conditions is not under tension. However due to its material nature or coating could
Principal arrangement for earthing of structures and apparatus 140
urllJor insulation failure conditions come under tension.
-
Examples of exposed details could be frames, covers and supports for machinery, transformer and
oqulpmenl, mountings lor insulators and bushings, lead sheating, reinforcement bar, screening and termi-
nation boxes lor cables, metal transformer housing, fencing and other such like piant details.
Jho purpose and requirement of protective earthing of exposed details is that during earth fault
conditions it wili direct the flow of current to earth in such a manner that voltage that:
-
11) could bo dangerous to personnel on the plant or for people in general are prevented
il) could create fire are prevented.
II Is parlicularly important that the protective earthing is effective against the onset of fire when the exposed
(jolnlls ara Ilammable, particularly wood. Metal poles with stays shouid normally be earthed, whereas stay-
-
od woodon poles are generally not earthed. The necessary protection is achieved via the fact that the stays
uro moonted sufficiently iong from the insulator pins or they are fastened to the pole via a stay insulator.
1.3 Eloctrlcal hazard

An oslimalo 01 level of danger from an electrical hazard can not be achieved solely by evaluating the voit-
-
11110 Iho porson will be exposed to, the magnitude and duration of the current the body couid be exposed to
II/IS lJfofll signilicance as well as the current path through the body.
1110 magnitude of the current flowing through a body is in part determined by the voltage and current
Pllttl rosislance. The bodies resistance drops normally to some value under 5000 ohms with the onset of
-
pomplration. This obviously means that the risk for electrocution is proportionally greater in humid and wet
/HOIIS liS opposed to dry areas.
I III 1 S[lOWS example of step and touch voltages in the vicinity of an earthing electrode in the overload
nil sllllo during an earth fault.
-
-
prosecuted.

•
• BATHS/6UTran$mj$$i()~
2. Earthing outdoor 111I11l11l1/llnlJpils are usually composed of 1-4 earthing rods connected together via test link to the main
Illllill Wid I ho rods are copper clad steel rods of 1-2 meter length, which may be extended with other rods
2.1 Earth grid, earthing rods, pits etc. I,y IIl1clIlIllld jllinls.
The earth grid normally consists of some form of symmetrical grid net in order to achieve an even
1/11'IOllllinks can be utilized for resistance measurement both of the earth grid and of the earthing pit.
dissipation of voltage across the net. I .1111111111
plls Garl be added, if needed.
The number of squares in an earth network for a station which is to have a direct earthed high voltage
net should be in the order of 25, for a small station 16 squares should be sufficient. An increase in the ~.~ 81001 structures
number of squares gives at best a marginal reduction in the station earth resistance.
(Iw.lry uloolwork and high voltage equipment supports are earthed by connecting at least one of the legs
Even a short vertically placed earth rod provides excellent earthing capability ~
III Illo Wid. Siruciures standing on more than one foundation have an earth connection at each foundation if
1I11ll1nrllllflull current path through the steel is >10 m.
I I
-------------------------l--------------------r----------
II
~
Yl~..Jlr-··
The above drawing gives an
I, '-.!llmi
example of an earth grid for
small switchyards_ The grid
itself - in this case - is made of
~Ir " l :1.3 Transformer and high voltage apparatus
1'lIwm Imnsformer neutral are directly connected to the earth grid by duplicate conductors each
120 mm2 copper wires, buried i!JlT"( (, 1 '-@ <9'"' dllllonllionod for the max fault current.
to a depth of 0.5 m. If the earth 1111'ourlh wire from the transformer tank shall be connected directly to the grid.
resistance has to be fu rthe r ~--~:~- - ~---\;--------- ---------k----- -----------, 111111. voltago equipment normally earthed via the steel structures. Exceptions to this rule are items of
decreased the earth grid may ,~ ,~ '"l1lll1l11onl wilh a neutral outlet e.g. surge arresters and potential transformers, which are earthed
be connected to a number of
'"'lIllIlIloly, Also separately earthed are earthing switches and separately mounted operating mechanism as
rods forming earthing pits. Fig. Wlllilitl lorminal boxes for control cable, for example on current and potential transformers and marshalling
3 gives an example of such 1"""11 1m lIIulli-core cables.
design. See also fig. 24. III "'"I1ll countries it is established practice to earth all equipment to the grid with separate earth wires,
111111111111/1pmallell path with the steel of the supporting structure.
Mn rod
L~" 'h-Z •.•3f)40 !
1
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=cr=:=tJ="., 2=]10J'lAINCiRID
CDPP'''',,,,"
(AflTMROD.
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Test link chamber

Fig.3
2.4 Overhead earth screen
The primary reason for erecting a protective overhead earth in a switchyard is to provide protection against
a direct lightning strike.
Protection against direct lightning strikes is achieved by erecting a lightning trap over the phase lines, see
fig. 6. Arcing horns on insulator chains are also considered as line protection, even though their primary
function is to protect against an overvoltage across the insulator elements tracking and carbonising the
elements, see fig. 7. A radical alternative to protect against lightning strike would be to install the high
voltage cables in the ground. Unfortunately this is not economically practical, as underground cable is
""
appreciably more expensive than overhead cable.
Overhead earth lines
Earth grid
:',1I1I" mrostors can be designed with a counter that registers the number of times the arrester strikes The
llllllllllr doos not need to be mounted above touch height protection level. The recommended mounti~
'"IIIJllllllllpprclXImately 1..8 metres above ground level. The connection between the counter and the s gr
'1111111"""1001should be Insulated for 3 kV (air insulated or cable). The cable shall have as ., u ge
:". ," II 1I1rornillimetre. a minimum a
:In F-llneos
of rnolallic material shall be earthed by connecting a number of the fence posts - at about 50 m
I '1111:1111,
11I1",vIIL, 10 the main earth grid. In some instances separate earthing of fences is specified.
II 1110~1Jl>stallon belongs to a solidly earthed high voltage system, an earthing conductor shall be buried
,,11I1I111I,I 0.5 m one metre outSide the fence. All gate posts and earthed fence posts must be connected
III 111111
c:ollductor.
,~- - ~ - :~hing rod
a:: Protection angle
1) This wire is only included if required by the project specification. Normally the
overhead wire is terminated directly to the mast. To be installed if shown on the
erection drawings for the project.
2.5 surge arresters

For overvoltage protection of high voltage equipment surge arresters are used.
Modern surge arresters have contributed towards better protection of transformer stations not to mention
substantial economic savings.
Connection of the surge arrester to the earth grid shall be as direct as possible.
WARNING! The surge arrester must never be separately earthed as it then may cancel the
protection of the transformer.
3.1 General
The basic objectives of an equipment-grounding system are the following:
- To reduce the risk of electric shock to personnel. I) W'PERsrt:£1
~) EMJIirC~
- To provide adequate current carrying capability, both in magnitude and duration, to accept the ground 3) BSmm:ClJIlItt:
fault current permitted by the overcurrent protection system without creating a fire or expiosive hazard to ~) a'ltrnl D..tIrIlf
bUildings or contents.
- To provide a iow impedance return path for ground fault current necessary for the timely operation of the
overcurrent protection system.
Wherever a grounding conductor crosses cable trenches, underground service ducts, pipes, tunnels,
railway tracks, etc., it shall be laid at least 300 mm below them and shall be rerouted around equipment I
structure foundations.
Grounding conductor around the building shall be buried in the ground at a minimum distance of
1500 mm from the outer boundary of the building. If high temperature is encountered at any location, the
grounding conductor shall be laid at least 1500 mm away from such location.
Grounding conductors embedded in concrete shall have approximately 50 mm concrete cover. If ground-
ing conductor is required to be embedded in major foundations, then it shall be laid in a sleeve.
All steel columns and metallic stairs shall be connected to the nearest grounding conductor by two
grounding leads. Electrical continuity shall be ensured by bonding the different sections of hand-rails and
metallic stairs.
Metallic pipes, conduits and cable tray sections for cable installation shall be bonded to ensure electrical
continuity and connected to grounding conductor at not more than 10m intervals. Apart from intermediate
connections, both ends shall also be connected to the grounding system.
Metal conduits and lattice structures shall not be used as ground continuity conductor.
A separated grounding conductor shall be provided for grounding lightning fixtures, receptacles, switches,
junction boxes, lightning conduits, etc.
Wherever grounding conductors cross or run along metallic structures such as gas, water or steam
conduit or pipes, steel reinforcement in concrete etc. it shall be bonded to the same.
SA.l SA.2 SU SA.' I SA.> SA.6 SA.?
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1\1). l'oWili
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4/0 AIOGOR
Tl2Omm'
SEMCE BUIlDING
OR VALVE HALL IN TIlE CASE, WHEN T11E CABLE ENTIRIOO IS fROM T11E
GWUNDiNG SrslEM TO' Df mE ClJBIa.E SfIALL THE ClJBIa.E Bl: PREPARED
l~mm' roR TIllS TYP 0, II/STALLAnON

Willi Tf.RMIHAnON ELOIJ<S AND CU-BAlII< THE TOP,
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SERVICE BUILDING
SEII'IICE BUILVIII] ... GWUNDING SI'SYEM
GRQUNDI~ SYS''-'i ON CABLE RACE~AYS
ON CABLE RACEWAYS 1 185mml
00"[[:
I) ," Ilil. CASE, *fEll T11E CABLE ENTERING IS fROM 'NE
I) I~ mE CASE, WHEN 1l1E GABLS f1'TERIIIG IS fROM 111£
1'111' O! nlE ClJ8Ia.E SHAlL T11[ CUBIa.E BE PREPMEO
TOP Of 11ft: CUBIG_E SHALL niE ClJEIa.E BE PREPAREO
1011 1II1S lIllE Cf tNSTA.uAm~J,
FOR THIS TiPE Of INSTALLATION,
WIl11 TIRMIIIATlDN BLOCKS A'lJ ClJ-BAR IN T11E TOP.
WlT11TERHlNA no~ BLOO<S AND CU-3AR I~ T11E TO!'.
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0 0
1) I
\/ I WATRPIPE
0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0
STRAJCHT PEDESTAL
'J I WI\111i l'II'I~) W111IINSULAmlG KAT£~
----.
1 ILllll! I'1l'1 .k.lINT ~JlAl.I. HAVE rLAT B4.R / 'EARTHTHERt1INAl~
0 0 0
1)
0 0 0
1)
0 0 0
I)
~ WII !'I (I ru till
II! I:tJtlU! LillI
I'll'! '; IN BOTH SIDES AND
IOfXntrR W1!"HnoUDU.(; JUMPER.
'I
',' ,
3)
(r~"
r
G2:X1tID iIIRE
~
\lbH
Fig 19 Computer Floor.
SECTION A - A .~~
SERV:CE BUILDING
GROUNDI"'G SYSTE~
on CABLE RACEWAYS
00'£;
1) OOOU"'G WATER PIPES FROM VAlVE fW.l

;w.u. BE conNECTED DIRECTlY AFTER
PASSI"'Gmltm THE WAll
SERVICE BUILDI"'G
GROlmDI"'G Sl;TEM
ON G<8l£ R~C€WAYS
""INlet: OUiLDII-G
(;ootJ~ING SYSTEM
ON C\!Il.E RACEWAYS
..
2) CABLE RACEWAYt{)R[ THEil ~O FEET LOt,\;

S_ BE COIIIIECTill TO ""'UNO EACH 150 FEET / 45 MmJl
(111- A.'Il OUTDOOR)
1) AlL JOIIITS SHALL BE OONE WiTH

OOi'RESSIOH CLAMP ( C- SLEEVE)
~ ~
._:.~.,-,
••
~VJEWA
SS:S:SSS:SS:S:SS" ~ . j2mm OR 1/2"
1) THEGRJUNDWIRE SHALL BE ':I~"D WITH

F1RE-RETlJilMNT HATERJAL OF STAINlESS
STEEL rrPE BANDIT -STRAF
2) THE MIIIIMUMD:STANCf BETNEnl CABLES

NlJ QIDUIID>IIR£ IS 12 mm OR 1/2"
-
GROONDlt.IG stST'E
4.1 I'rocnutlons and planning
35mm
11111 1III,IIIIIIIIIon 01 the earth grid is one of the jobs which needs planning, not to come into conflict with the
11111111 1"1111, 1.0.oroction of steel structures, cable ducts, etc.
120 mrr: lNOOOR 1111'mud, oxcavation at the same time may make the area too rough for achieving an efficient workflow.
II III ,,111111 convonient to excavate for laying the earth grid after erecting the steel structures and before
1Il1ll1l1l1l1l1ll1Hulators, busbars and other conductors.
PO\l£R lDlTNIiIG FIRE AlARM T~_E
')- 1)- 1)- 1)-

I 4") Mnlorlnl
1111111,1111, Wid is usually made of copper wires clamped, brazed or thermic-welded together. See fig. 36-38.
11111 r:1I'HJtJclor lor the earth grid should be supplied in sufficient lengths to minimize the number of joints.
II' 111IIIIIIId copper wires are softer to handle than standard wire and therefore recommended.
4.:1 In.lnllnllon
III" IImlh !lrIll wilh its numerous connection must be installed with utmost care. The following points are
'""IIIIII!lI/IIII:
11111 1I111I IH 01 vllal importance for personal safety
11111 1I1111oriaiisburied and not available for inspection and repair after installation
"111111111 corrosion may take place
,,111111 r:irr:ull and earth-fault currents usually increase with time which means increased stress on the
111111
OPERATION AND
CONNECTIONS BOXES
1111111 jlllll~l 01 tho earth grid above ground must be made safe. Follow carefUlly the instructions given by
@ 11111 t1IlHllIlIlllilco for:
I)
11.1111111111 01 stoel structure
1@-:'1 "'" II i1111 1III lowers (masts) with earth wires
101
\
\ -,
, 1IIIIIhlllll III apparatus and boxes
1111111111111 Hwllclles
'-_.--'
~-~
J r-. t11"r:III1I1II1:llrliJearthing switches
I I
1I111111111111111CO oarlhing
IlIllIlIllIlITlor Iflnks
"'1111" dlvorlors and counters
Llllll0 tll:roOr!S
11•• ,IIlU
W"IrIlIlIl'lIld 11I1I1Iingoquipment of right capacity. High quality of right grade of brazing material shall be
IIVIIIIIIIIIII 11111III Slioman 94-11.
n n
C:"lIIl'r •••• lon
Ily"","I1" ""llljlrllssion tools of sufficient capacity - fitting the actual compression clamps. Ref. to Site man
~
0 ,''' I;'
I "bllllle: woldlng
n n
WI!IrIlIIl"llllllrh; lJisc-grinder. Ref. to Siteman 94-11.
0 0
1.I ••• lllllU
1\ 11"1,,1111,1,":111111
01 steel brushes, separate ones for each type of metal.
n D
4 n Ibllll'or ••ry oarthlng
D 0
III 11111
Y lIul wmk In fl switchyard in service or with the system outside in service it is not sufficient to open
",,,11,111, 1I,11111!lr:IIIIIloclors in question. To be safe the phase conductors must be effectively grounded on
nlll W\lll\ nido
I IIII! 111'""f11/1HIIIII oarth-fault currents and higher demand on portable earthing equipment, the
111111"llll 111111III Ilxo(1 oarthing switches is becoming more and more frequent. However, portabie earthing is
,,1111II II! 11111'"
r:1I1l1lT1011Iyused method. See Appendix 1.
rOf
'~
-
-
II
I
(I
\1
j
-
'I v_ ~s- /
[--------
IIIJ :111
I .111111nll f",IH Hrn used to reach deep earth levels where invariable low earth resistance can be obtained.
! i"" 1I1"urllrtl IIbove.
SITE MAN 20 - 94 Air insulated
1WAT 910033-20 sWitchgear
I dillon .January 1994
601 Earthing device JSLK-F 185/11

604 Insulating tube MGF 300
605 Insulating tube MGF 301
607 Operating socket JGS 16
608 Phase clamp with rope JFKL
609 Oistance piece MJL
610 Contact device JBA 120
612 Earthing terminal JVF 11
Tackle line
Insulated
operaters
p
List of Contents UIUIIl1nI
1. General 159 1111"""1'111"""' will, III prillciplo, ho a guideline for the installation of Air Insulated Switchgear and shall be
1.1 Design characteristics 159 '"",,w,," II rl" "1I1,,r '"forr"lliloo Is given on the drawings.
1.2 The single-line diagram 159
1.3 Modifications, extensions 160 I I 1I•• luo "lIarnolnrl.UcB
1.4 Insulation 160 WI"'II pl"I"l'!loll II IIwlldlymd Iho main points to consider are:
1.5 Pollution 160 lIy"""11 "'":IlII'y
2. Civil Work ...•..........•.................•..•...................................•...............
160 I IJIiUt1 tHdlllltilOIlH
2.1 Drawings 160 1,llhlh
2.2 Foundations 160 I '",llllllIy lllopmllliofl

3. Heavy loads, such as transformers, reactors, etc 162 MnlrllflllltrH:n
3.1 Transport, roads, access roads and surveys 162 I IIVllllfl11l1l1ll
4. Insulators 162 AVIIIIIIIII" "1"11:0
4.1 Types of insulators 162
4.2 Pollution 164 1I'''","r" Iwo IJIIlJor Iypos of high voltage switchyards:
I III" "wllelllllll sllliions
5. Busbars and wires 165
Irnllhlorrflill Slflliofls
5.1 Types of busbars 165
5.2 Materials 165 WIII'f1 ""l1ll1f1lrlll slool structures and foundations, the stress calculations are based on the maximum force
5.3 Rigid and flexible conductors 166 willi II lilly pml ollho oquipment can be expected to withstand in its lifetime.
5.4 Mechanical strength 166 III" rfllll:II/,"icflllorcos acting on the electrical equipment and supporting structures are:
5.5 Corona 167 11"",lwolllllt
6. Clamps 167 Nllrllll,I11J111Jsfrom conductors
6.1 Types of clamps 167 11"111111111
6.2 Design 169 WIII""l/lI'
6.3 Material 170 11111111 elrclJlllorces
7. Erection .............•............................................................................
170 Modl/Hllcll1 oporation forces
7.1 Access and work start 170 I IIr 1I111IJIlkolorcos
7.2 Steel structure 170
WI,,," clllIllllfliflll Ihe busbar the following main factors have to be considered:
7.3 Outdoor earthing 172
MlIXlrfllllfl 10fld current
7.4 Insulators 172
MIIKlrllillo withstand impUlse voltage
7.5 Busbars and wires 173
M,,,,ll/llIlcfll slrength to withstand dynamic forces
7.6 Clamps 176
AlrllollpllfJrlc contamination
7.7 High voltage apparatus 179
8. Inspection, quality control 181
I 'J 11111 .Ingie-line diagram
9. Testing and commissioning .....................................•........•.....•.... 181
III" 1101111111 01 fin outdoor substation is
1"",,"1011 1110single-line diagram. This
1111111111111 IIllould show the connection
IIrill/lll0tll/lJlts of all electrical equipment,
I" Ilil/lllllm, ovorhead lines, power
111111,,", cIIlJlloclion points, power trans-
I",,"orll, hi!lll voltage apparatuses, AC/
III. C'"lvorlors, reactive power
"IIIIp"rlllllllon equipment etc.
A230
WIIIIII dosigning the single-line diagram
This document and parts thereof must not be 1111'111111 "wllching arrangements and the 8230
reproduced or copied without written permis- ""w"" "I sorvice flexibility and reliability
sion, and the contents thereof must not be '"11'11110(;ollsidered.
imparted to a third party nor be used for any 11," III1Jsllrequent bus arrangements
""' "IIIlwlI in Appendix 1.
prosecuted.

obtained from ASS at its then current rate I III I: OI"olo-line Diagram
,olliff;" I,V switchyard
1.3 Modifications, extensions • "" •• ,kIItU
Almost every switchyard will sooner or later be subject to modifications and/or extensions. Clarity and III. "'it,,, II,,, It'hl",,,,,'lIlIlly 01 AI3B, as the switchgear contractor, to check the location and the allignment of
flexibility therefore have high priority in the design. Furthermore, access roads with safety clearances for 1111'""l1llnlllll 111,11••, 1,1I10poJl(jontly of who has done the civil works. When measuring the distance between
moving equipment must be considered. 1••,1111 Will "" 111111" 1lIllIlllllllon, 11long steel tape-measure may be used. The same method can also be used
,,,' ""1""111111111I0lwooli IlllJrldHtlons when distances are not too long.
1.4 Insulation I1ll1uolll"lI ,,,••1"111101111,, fIlquired lor levelling of the foundations. A transparent plastic hose filled with
Electrical clearances are fundamental for the design. For safety and reliability it is essential that adequate '''''''111 '" " .f'111I IlIvlllcllli Hiso be used for shorter distances.
clearances are provided to live parts. 11111,,11'"11.III,III1II1ICfllo H bonch mark, i.e. a fix point to which all our measurements shall refer, when
1·llfll,I'llllJ lIul flllHHllllilHlS
1.5 Pollutions I'J"',, 1111"IIllcII,ll:rllltl 1m" 10 cure 2-3 weeks before load can be applied.
In recent years contamination has been a growing problem in transmission sys-tems. The contamination is "I " ••'1111
'JlOII I•• 10 till lukon to check that the foundation bolts are reliably fixed at the bottom end so that
mainly of two kinds; coastal and industrial. See clause 4.2. II IllY will II' IIII'"VO dlJrlllU Iho filling and vibration of the con-crete.
1111'""II. ,,""111'0 IIvHilable 2-3 weeks before they are embedded in the foundations.
N" '11110111111 ••111111110carried out on the foundation before a letter of access is issued by the civil
l'IIIIlIlUIlII
2.1 Drawings 1I1I1111I,"I111'H11Ililmdiny the foundations must be entered into the drawings in red and sent to the design
For outdoor switchyards the civil engineering design represents a iarge portion of the total design work. "lIil" I", "IIIIIIIIIIU
Drawing for levelling of the ground, dimensioning of the foundations, layout of cable ducts etc., have to be I .11,,01,III, II11WllJdamage and that sufficent threads are over the top of the foundation.
produced.
",ollllnu (uptlon)
The foundation drawings from an ABB design office shall show the foundation tops on which towers,
apparatus structures etc. shall be fixed. 11111
•• 11111••11101HlrlJl:lurDS have been erected, the distance between the steel and the concrete may be filled
"I' willi ""I1l:1olo ( nrouting). .
2.2 Foundations G~,"g
It is important that our site construction manager works in close cooperation with the site civil contractor in ~5X25 CHAMFER
order to guarantee a successful foundation work. Len~h of
bolt threads
Normally the foundation bolts are embedded in the foundations from the begin-ning.
However, pockets are sometimes left in the foundations and the bolts are casted in under our supervision.
~ -- FSL
Note that approved expansion concrete must be used.
Templates 50 thick layer of

Templates are used for fixing the foundation bolts. For small foundations up to 0.5 x 0.5 m and in large stone chi ppings
quantities, steel tempiates as shown In fig. 2 are suitabie.
For larger foundations steei templates will be too heavy. A suitable material, which is usually easily
obtainable, is plywood (1/2 to 3/4" thick). The plywood tempiate design can be similar to that of the steel
version. For really large foundations, the wooden tempiate may be split into two parts as shown in fig. 3.
IIIJ I,
1IIIIIulnilc l/I~i und
11111111 I hwln
3. Heavy loads, such as transformers, reactors, etc.
3.1 Transports, roads, access roads and surveys
The transport of transformers has to be carefully planned. The roads from the harbour or the railway station
where the transformers are landed up to site have to be investigated. Allowed loads for roads, bridges,
heights to viaducts and other hindrances have to be checked.
The local authorities have to be contacted so they can issue a permission for extra heavy, long and wide
transport.
A local transport company has to be engaged, insurance checked etc.
The above can all either be included in the total transport, ex works, or partly organized from site.
The location of the access roads in relation to power transformer foundations is an essential factor in the
switchyard layout. They have to be planned so that the transformer can easily be shifted or replaced in case
of emergency, preferably with a mobile crane.
Note! The safety clearance to live parts must be checked.
The installation of transformers is always carried out under supervision of an expert from the manufacturer.
III ""I", I" proloet tho insulators against damage due to flash-over the insulator string is fitted with arcing
'"11111111111111111
4.1 Types of insulators
1,1II11I1H:lllllllillings must be able to carry the rated short time current without serious damage. When the
Insulators in outdoor sWitchyards are used for supporting conductors and for providing Insulation between
"'" II I 1:111:1111curronl is higher than the fittings can withstand, these must be by-passed by flexible conductors
phases and to earth. Sheds on the insulators provide the necessary creepage distance. 1111111111,,1,
IIIIIII lor tho rated value.
Insulators used are basically of two types:
1"""1111", "Irlnns in outdoor switchyards are used for stringing flexible conductors between gantries.
- support insulators for static arrangements
111111/111,IllIpllclllo or oven triplicate strings may be used depending on conductor tensions etc.
- chain insulators for flexible buswires.
AI I '''"Hllllhly witt! more than two insulator strings must satisfy the following conditions:
In addition to electrical requirements insulators must withstand the mechanical forces caused by short I '111111 IIIIHllon sharing between insulator strings.
circuit and earthquakes. This is especially important for support insulators. II ""11 III Iho Ilisulalor strings is broken the remaining ones must be undamaged.
Also environmental conditions, such as pollution and salt have to be considered.
'1111""111 dllllip" of oither bolted or compression type hold the wire to the insulator. A turnbuckle is also
Support insulators pl"vllll111 Ill, IllljlJHting the sag.
There are two types of support insulators, "solid core" and "pin and cap".
A",",h~.~._._._._._._
·E\L.l·7-·_·-·-·-·~·
'L ~.
III/
,
( i.lIl1y
~
I:' ""IIIIIHI
/ ... _.
Turnbuckle
insulalor
-.
string
Insulator string Tension clamp
For the lower voltage range the support insulators are made as one unit. For higher voltage ranges, V III I 1111/11
CI1I11m usod to reduce the swing of the buswlres due to
however, the insulators (inSUlator stacks) are made up of several units bolted together. 11111wll1d
nl"'I"III"111I1 strings are used on gantry beams to guide and
Chain Insulators
""IIIII,IIIIIIIIIroppors.
The strings are composed of insulator elements with non-rigid connecting details. ~~G,"'"
.L._.J
I I
i i
i i
~/w",m".
~~
h I Typo. of busbars
1111II lit I"", IIwlld'yards the two most commonly used types of busbars are strain bus bar of stranded wires
~1Ii111111 IIllpporlo(j lubular busbar, see fig. 16 and 17.ln addition to these, two types of rods and other
",,,11""1' 1110l]Hod for special purposes.
n"J Malorlnl
, .111'1'''' IIIl1l/1llJrnlnlum are the metals which are used for busbars.
I .IIIIIIIIIICHI willi most other metals, both copper and aluminium have good electrical conductivity. Of these
IWI' 111,,1/1111, mppor has the better. The conductivity of aluminium is about 60% of that of copper. This means
1I1l11lIllllI,llIllJIII conductors require 60% larger area to achieve the same conductivity as copper. Comparing
lilt, w"III'''"
of tllo two metals, the main technical advantage of aluminium will appear. It is namely only 1/3
,,11111111,1
c"ppor. Aluminium can be operated at a somewhat higher temperature than copper which gives
fill IIxl'/IIlIlv/lnluf]O.
I I II 11111
II/I/no cllrrent conducting capacity, the weight of the aluminium conductor will in general be
"'"IHld""'lJly IOHH.
4.2 Pollution
Pollution is, in some installations, a major maintenance problem. One basically distinguish between
industrial pollution with deposited layers and salt pollution in coastal areas.
Experiments have verified that the individual effect of either contamination or humidity is not very severe,
but combined contamination and humidity severely affect insulation performance.
Flash-over in case of industrial pollution evolves slowly. Salt deposits are dissolved and dry band forma-
tion develops gradually. On the other hand flash-over in case of coastal salt evolves rapidly since the salt is
already dissolved and the whole surface suddenly starts conducting. . . . .
Tests and experiences gained in the field have shown that the effect of pollution can be minimized by
following design and maintenance precautions, i.e.:
1) Increasing the creepage distances
2) Washing the insulators
3) Applying silicone grease as a protective coating
4) Using a suitabie insulator shape.
VIlllllllon.
5.3 Rigid and flexible conductors
For more moderate short-circuit currents and normal rated currents stranded wires are the most economical A HI"'''11111'101'1,0111 with lubular conductors is their sensitivity to vibrations. Vibrations often occur at mode-
alternative. '"111 wlllli VII!cIl,III[lH, when the wind Initiates a frequency which coincides with the system's own freque
Tubes are used for high short-circuit currents and high rated currents. 1'"111111'''III1IV I :111/. ncy,
Bars are mostly used only for shorter connections, especially for current ratings on power transformer VII IIl1lh II HI elllJI(j possibly cause the following defects:
secondaries. I "IIIJIIIl """Jlo ollho busbar
Aluminium iron-wires are used as overhead earth wires. I MIIIJIlII (01 IlIIpHCI) failure of the end fixings
More and more switchyards are built with aluminium tubes because of the increasing rated and short- 11II'lIl1l1c1ltlilellonlng of pantograph isolators
circuit currents. TUbe diameter and thickness are determined by mechanical strength rather than service 11/'"11111"III IIllpporl insulators
currents. 11111111111111
1/111 lollowing melhods for damping of tubular conductors are used.
I III1HII wlro Ilisido Ihe tube
[,1111111'''
with (jnmping effects
AII"IIIIIV III II liS (jampers.
h n Cmonll
II',' IlKtlllllllllV 11I(]hvoltage installations corona rings and large radius bends are used and care is taken to
II,IIIIIVII II low valuo of electric stress on the conductor surface.
II Clnmps
n I Iypo. of clamps
11111111,""I'rinclpally two types of clamps
M,":llIllIll:II1 prossure
l:llfllJHlHiH(I(j
111,11[111
WIII,I,,(1
1IIl' "11I",:llIlIlle/l1 pressure clamps" (compressed or bolted) are the most commonly used in outdoor
"Wile IIVIlIIi" (losl~lrl(]d by ASS. Of the two types the bolted design is almost exclusively used for connection
t1IIlIVIl UIIHIIUJ
F = flexibie L = Bay iength

=
R rigid W = Bay width
5.4 Mechanical strength

The mechanical forces acting on electrical equipment and supporting structures are: dead weight, normal
loads from conductors, ice load, wind load, short-circuit loading, mechanical operation and forces due to
earthquake. The worst case for the electrical equipment and the supporting structures results from a
combination of these factors.
Snatch forces
The bundle conductor arrangement of strung (wires) type busbars constitute a special calculation and
evaluation problem due to the snatch forces caused by short-circuit currents (parallel conductors forcibly
pulled together by magnetic attraction forces. These are causing high axial forces in the conductors).
See fig. 19.
..
Q------9
~
~~
Q----Q
••
({ 0.---0
WuhtUlt llIolhods
Bolted clamps . . . 11111
WllhlllllJ "lllim must be protected by an inert shielding gas flow such as argon (MIG orTIG-welding).
There are fundamentally four different groups of bolted clamps depending on the pnnclple of connection to
the conductor Le.:
Fixed clamps See fig. 21
- Sliding clamps See fig. 22
Flexible clamps See fig. 23
Support clamps
(as conductor support only) See fig. 22
--~-- I III ;'fi Fig. 27

Wllid IVI'" fl1mll}lll coupler. Cham- Streamlined, weld type T-connector.
~r@§)-o 1IIIIId 111111"
lor lJHHy insertion. Center
01111'"II IlCCllrHllJ contering of coupler.
Tap element socket deep enough to
allow for error in cut-off
~ WII IIIIVII olliV montioned the welding methods here. In case it will be applied, see SITE MAN 08-94 (Welding
II rill II) 111111
SI J I MAN t7-94 (Aluminium welding).
1;","prOBBlon clamps
111111111001
comprossion clamps is most common when connecting the earth wires both under and above
IlIflllllll
I '" 1111110 lIollIlls soo SITEMAN 12-94. However, other frequent methods are brazing using bronz-alloy and
111001111: wlIllIlIIIJ process described in SITEMAN 11-94.
Welded clamps . . . . WIIIIII 1I11:llIlIlJular earth bars are used they are mostly brazed together.
Welded clamps are sometimes used in large switchyards having aluminium type conductors of high current
rating. . r t d n'J I)"BIII"

Welding gives very good contact properties but has the disadvantage of being. more comp Ica e , I IIIIlllclI1 cOllllllclions must be made so that maintenance never will be required. This is indeed a stringent
requiring high dimension accuracy and being less flexible when it comes to modifications etc. 111'11111111110111
1.11'''11"1IJHIHllor connection of conductors in outdoor switchyards must be designed and dimensioned to
1l"ltllllllllllltllllltorrupted current supply and also not yield to mechanical forces between conductors due to
11111II I IIICIJillIr olher severe stresses.
CIIIIIIICI roslatance
111111 1lXlilltlIIIlV important characteristic is the contact resistance which is responsible for the temperature
111111111111 wliidl must be kept as low as possible. The resistance must not increase significantly during the
IIwlI<IIVllllj'" llllllime.
nllllill 111II'lIr1llnl design characteristics are:
""I1I"oIlHllIn bolls placed as close as possible to the conductor
'"II1I"I1"HllIII bolls placed opposite to one another
III 11111 "" Jill oxort the required pressure
11111 CIIHI Hoclion must have sufficiently large cross
1I11c11011 III I!o able to conduct the rated current.
High voltage and current clamps
Special attention must be paid to the clamp design when used for very high voltages (corona) and high
currents. Such information is available in the manufacturer's catalogues and from the design office.
6.3 Material
Clamps for copper conductors

Connection clamps for copper conductors are manufactured exclusively of copper or of corrosion resistant
bronze. Bronze is the more common material. Brass must not be used due to risk of stress corrosion.
Copper and bronze connectings cause less problems than the aluminium ones, since the oxides are more
easily removed.
Clamps for aluminium conductors

Connection clamps for aluminium conductors are manufactured of corrosion resistant copper-free alumi-
nium alloy.
The corrosion resistance of aluminium depends to a large extent on the difficulty to reduce oxides which
develop on its surface. These oxides are electrically insulating and must therefore be removed as effectively
as possible from the contact surfaces. 'IUh'ol1lng 01 bolts
Bolts WI,1I1111111 tllWorS, the cross-beams or apparatus structures are assembled, the bolts must not be
Generally, three types of material are used. ""llpllllllly Ilnhlaned. The final tightening shall be done after adjustment in straight position.
- high alloyed, high strength aluminium (sensitive to corrosion). Used by EDF, France
- hot dipped galvanized steel. Used in Germany Adlu.lmonl
- high alloyed Swedish stainless steel (expensive). Used by the Swedish State Power Board. 11111 /lllllJlilllllll1l 10 straight position is most conveniently controlled with a teodolite. The measurements are
1111"",1111111 two direclions at 90' angle as Shown in figure 32. The levelling could be done by shims or
IlIvlIllllIlJ 1I1111i. IIlavelling nuts are used grouting may be required.
7.1 Access and work start

When a co-contractor is responsible for the civil work the engineer in charge (customer or representative)
shall grant access to site in writing and in due time.
If allowed by the time schedule, the erection of high-voltage apparatuses shall not commence until the
erection material such as steelwork, support and string insulators, conductors etc., have been erected and
the ground refilled and levelled. This applies also to the concrete cable ducts, which shall be ready at the
same time.
7.2 Steel structures
High towers
In order to facilitate more than one team to work with steel structures, it is recommended to start with the 1111 :1;'
L
towers. If the crane does not have sufficient height lifting capacity, the tower may be erected in two parts.
I", '"":Wlly millions should the towers be grounded immediatly after erected.
The lower part is hoisted with a crane. The upper part is then erected manually, piece by piece, as
illustrated in fig. 31. It is not necessary to fasten the hook of the crane at the top of the tower. If it is fastened
above the center of gravity, it is safe enough.
111111111
MII"I ,,,,"11111111" Ilroorocled at high levels. The lowest part of a support ',nsulator is normally 2.5 metres
'VII UIIJlJlIlI ~;'J!lponBion insulators may be more than 10 metres above ground and of considerable
11111
w1I1U111
111'11""11'111, II lIlohllo crane with suitable soft slings should be used.
"""", ",,,llIlonnnco quostions

IIIIIIIIU 1I11111111111l11IClJ work including transport in the sWitchyard care shall be taken to protect the insulators.
'lwlI,lly,,"1 "Iolliwork may have to be painted or re-painted after some years. If sand blasting of the
"llInlwlIll, Jr,I"IIPOHI)(j as part of the painting process, it should generally be refused due to the
''''lIllIlIllllllly ""llcullies in protecting insulator surfaces. For minor repair of scratches galvanization may be
IHmd
tuulll
11111
111111"
Inlfl,'rollluni is modest, except for the lifting devices. Good soft slinging devices and a torque
WlfH 11'1I HIli FUHUjod.
, tI 11I1I.lIorll nnd Wires
11011111111111. chocking and storing

1"'11""1:1111"'lIlorlnl, such as wire drums and tubes, will usually be stored outdoor because of size and
w1I1U111 /I ill IlIlporlanl that they do not come into contact with earth and sand Which may jeopardize contact
1"111'''' 110"1I11t!',,,:roase corona in case of surface scratches.
11111111""""11,IllIlay be necessary to build wooden platforms or similar to keep the material above water
IlIvIII I III" III pori laps also the best protection against earth and sand influences as above.
t!tlll/il dll,,:klnl] and handling routines shall apply.
11I1I'"IIo,lIon
1\11111 IIll1dllltl 01 Blnol slructures and insulators follow the installation of conductors, which must be done
willi 0:11111 iloilo "amage the insulator.
Cross beams .'
Cross beams are to be erected on the ground and hoisted up by means of a dernck or, more convenient, a /I III 11"1'",111111/lial the material is kept clean. Parts to be connected together by means of clamps shall be
"'1111,"1 11111111111111'" carelul cleaning and protection as described for the clamps. See Clause 7.6.
mobile crane.
WAiININOI Novor use the some steel brush for copper and aluminium as it will accelerate corrosion.
Apparatus structures ., .,
Before the erection of Apparatus structures the Overhead lines and the Overhead Ilgtnlng protection wires
should be installed for security reasons and the convenience of having more space. The erecMn of
WI,,, 1I""b,,rl
"IIIIIU'lIlJ III Willi" must be done according to the sag and tension chart.
Apparatus structures will usually not involve any lifting problems.
( 11111111:111""lIllllld lJn taken to avoid caging i.e. bending the wire so the strands go apart.
WI "'" 1'111111111 1110wlro always remember to tape the ends or use a special tool before cutting in order to
7.3 Outdoor earthing
For the erection of the outdoor earthing refer to SITEMAN 18-94. ''''''1,111'' ""111111,,111 place.
I I"IIIW 1IIIIllW !Hlllln melhods to measure the length of buswire including the sag, both on the ground and
Illllw.HIII U/llllilcul
7.4 Insulators
III 11,,, 1I1"llIr,,:n hnlweon the gantries is measured as illustrated in fig. 34. To this
Handling, checking and storing . . I""ull, '" 1II1t!nd n ligure for the sag as stated in the sag and tension chart. Note that
Of all the components going into the material handling process of a project the Insulators are the most IIllt. 11\111111III IIHllporature dependent. If compression clamps are used, their exten-
easily damaged. Only in case of minor damages on the surface there IS a chance of acceptance. The """I 1111111
I Itit! 10 bo added.
design office must be contacted for further instructions. .., . III" 1:lllllplnln buswire including string insulators with hardware are assembled on the
Furthermore insulators are expensive items and they are also expensive to air freight due to their heavy IJIIIIIIIII
weight. This called for keen precautions and care during the whole handling process. 0
When ordering it is always advisable to include some spare Insulators of each type (up to 5 Yo) .. NII".I AlwlIVII 11110covor and wood as protection against earth and sand.
Checking must be done immediately upon arrival, especially if the packing IS damaged or there IS the 1'1 II,,, '"",wl,,, Il1llssombled with a string insulator in one end on the ground. This end
slightest suspicion of careless handling. III 1'11111111
1'1' A wiro puller is fitled in the other end and connected to a rope, see
"u :11, IWI' 1I11111BIJring boards are fitled so that the sag can be measured. The
Installation ""'"1101 "lid I" plllind up to the right sag and a tape marking is applied to the rope.
Assembly 1111,I,,",WII" It! tnkoll down and the total length is recorded and the second string
Arrange a protected and controllable assembly area in the sWitchyard. . . '''"111111",III Iii Ind. 1t1O complete buswire is then finally installed as shown in fig. 36.
Assemble all the components, insulator elements and fittings, to composite Units at ground level.
Fit the insulator assembly into place.
Follow a sequential plan which will give good control.
Tighten the bolts to right torque. .
A torque wrench is recommended, manual or electnc.
Use tools with care not to knock off porcelain chips.
A = Distance between gantries 'I /111,,111111'"I1I111){jIs to use a rope as a measurement and position it so that sag is correctly recorded,
B = Sag plus compression clamp extension t1l111 flU :Ih
C = Total length of buswire including insulator arrangements
1IIhll hll l:onduclors
1IIIIIIh C/lli 111111111
lJo orocted in straight pieces or formed to different shapes by bending or by using various
1""'II'/lIIIIIIIJlllJlm oloments which are welded together to obtain the necessary shape. Bending and weiding
"'''/II" 1,"1111IpllcIIII problems regarding tools and special trained staff, which have to be thoroughly
1"'"11II1II11d1'"111CIISl) 10 case.
11,,'.lInU
1I,,, ',"11111"11"111,"huswiros/bars can be done manually or with various motor drive hoisting gears. Be sure
III IIIIV" ""lIlcllII,1 lifllng points in order not to bend the busbars.
II 11".11,111 <:lIfIIllll:lms (oxpansion joints) have been welded on the ground in between sections make sure
111111
,II IllY I"" Illlnimeod tomporarily.
Fig. 37 Welding of
tubular connectors
CI1I1 •• ..,1 JI" •• I"
Iillllllllll"IIIly (wlillirl !, fTlIJI.) afler cleaning, the contact surface shall be coated with the delivered contact
1'''.111 wl,I"', 11111111 110IIrlJshod through with a steel brush all over the surface. For cable conductors, ensure
11111111111 1'"11111l""lotrnlos as deeply as possible between the strands of the cable.
11111UrI""'" wllillflip In soal the sUrface from renewed oxidation, although not completely effective. Ample
111",,111will 111111'
'''''Ilofl contact surfaces from water penetration.
WAIININUI Novor UIIO tho same steel brush for copper and aluminium as it will accelerate corrosion.
111 •••• '111111011
01 rigid connections
M"kll IIl/mlll/lllllo conductor completely fills the groove. At the end of the groove there is cavity to keep
111111111111111:1111
OJld Iroo, a space shall be left between the conductor and the end of the conductor groove,
II11I1I1U:111
WllI'rI IrllIllIlllJlII 1110cap on the body make sure that approximately the same gap is left on both sides
I '" IWllllri CliP HIlll body of the connector, see fig. 40.
II 1-
Tools
The following list of tools is only indicative:
Pulley block 111•• 11111"11 on 01 oxponsion connectors
Soft slings WIII'" III1l/fTl1IJlIlIlJl oxpansion connector the positioning of the bus relative to the connector must take
Rope "rlilltlllli !ofTIpnrllllJro into account.
Wire pUller MIIt""HO 1110tolaltravel (L) of the bus. The distance (P) from the minimum temperature end position can
Measuring board 111'1111\1'" 1IIIIrlitio (Jiagram in fig. 51 by following the vertical line from L to the curve for actual ambient
Theodolite IIIrlll""lIlI/Il111lId IlIOn read P horizontally from the point of intersection. The meanings of Land Pare in-
Wire drum stands 1111:1111111 Irl IllllJro ~ 1 43.
Different types of hoisting gears: I KllfTlpllI Arnhlonl temperature 40 'C
Winch for wire rope (type Tirfor) MllxlmlJm travel (L): 80 mm
Motor winch P ~)6mm
Winch mounted on car
Mobile crane
Torque wrenches
7.6 Clamps
(/
Handling, checking and storing . .
The connection clamps must be handled with care. Scratches on the surface as even slight damaging of the
outer surface can create corona. [ r·'·,,· .1 I'
Connections must be placed on a clean surface. Sand or other contaminants would cause damage to the
threads of the bolts and nuts. In case the connectors are delivered coated with contact paste the wrapping
should not be opened until the connectors are installed. . .
It is highly recommended to check the number and type of the clamps against the shipping and the.
PLANA documents or similar. The clamps are installed rather late In the erection penod. Faulty dellvenes
may cause delays and extra costs at the end.
Installation
Treatment
The brushing is carried out in two steps. First dry and then with contact paste.
Cleaning .
The contact surface of the connector as well as the conductor shall be thoroughly cleaned With a steel
brush, in order to remove the oxide layer. Different brushes must be used for copper and aiumlnlum.
As already mentioned the oxides are electrically insulating and aluminium has the thickest layer.
Connections to apparatus pad terminals IIluh.
The terminal is to be cleaned according to clause 8.6. The jointing shall be carried out with stainless steel 1111'lolloWllIlllollln lIrO roquirod:
bolts with double springwashers and washers as shown in fig. 44. I", 1111 'V/,,,,, ,,(
t:lIIIIII'N
II,,,, ,,"11111110
"looIIJnlHllOS, separate ones for copper and aluminium respectively.
'1" 1IIIU'H/dIl111/m
/I '0"1"" wIIIIII:lllIlIllllllliing device for heavier clamps are required.
1111 1'f1'IIIJ1t1."iN/U" dtlmps:
I I, III, 11111HI llpllrlllod, hydruulic or electrical/hydraulic operated compression tools are used. It is important
1111.1 1111'looln lIrO lIpprovOlJ by the manufacturer of the clamps. See SITE MAN 12-94.
I ," 1/ "'//1111' WI/It fl//II process:
/I ""I 0' "l'oeil Ie mOIJlds is required. See SITEMAN 11-94.
Tightening torque
Every clamp manufacturer specifies a recommended tightening pressure i.e. the required torque for tight-
ening the bolts. It is of utmost importance that the correct torque is applied.
The tightening torque for M12 is 60--85 Nm for dry or slightly oiled screws.
Pre-tighten the bolts in the sequence shown in fig. 45 and 46 to 60 % of the recommended torque. Re-
tighten all bolts to their recommended torque following the same sequence.
It may be needed to check the torque before handing over to commissioning.
31135 31
UiJ.-42246
::~
24
Fig. 45 Fig. 46
Connection between copper and aluminium

This type of connection is tricky, since copper and aluminium are 1.8 V apart in the electrochemical series.
One method is to use bi-metallic spacers or to get the copper part tin plated. Another method is forming the
connection as a so-called Mass-Anode-System, which means that the volume and surface area of alumi-
nium dominate over copper, eliminating the need of bi-metal. In this case it is important to orientate the
connection so that the aluminium is above the copper and thereby covers it so that rain water runs from the
aluminium to the copper and not vice versa. See fig. 47-50 .
.-----AI
o
",'11 }o 3D 40 50 60 70
lu1.n 1 pO~f.ible travel L (1II1l)
J-o of , , IlIuh voltage apparatus
I"'PlJllulI .oquence
111111111nit In Hllould be erected and adjusted before connection of the primary conductors. If place is
nvnllnlll", Itlll apparatus may be erected indoors and later transported to the sWitchyard.
III pnlollol wllh the erection of apparatuses the laying of cabies, erection of support insulators busbars
1111 , "10 cnrrlod nuL
II",IIIIU
I
Aluminium cold flow

I I" 1I111111l1llno 01 bolts and checking of steel structures etc. should be finalized before carrying out the
The penetration of the oxide layer is partly a result of pressure applied. The higher the pressure, the more
°11ll/nllllIHlllosls on the equipment. The tests are performed first as local tests on the equipment itself and
effective penetration. The difficulty, however, is that aluminium is cold floating, i.e. it becomes deformed
IIHI/1l1I1I1l1ImJII Ihe control room (remote) for checking of signals, interlocking etc.
under pressure. The pressure therefore must be limited to about 20 N/mm2.
To summarize:
Thorough brushing, ample greasing followed by immediate installation and tightening with correct
pressure will guarantee long and problemfree contact life.
Circuit breakers t," IhlllU .wlh:ho.
Erection of circuit breakers is a comprehensive work and must be carried out according to the erection 1.111111",111111111"
""11/111111
Hwliches shall be made with shortest possible route to the earth grid.
instructions.
Precaution: If the equipment is stored outdoor, which often is the case, it must be positioned so that it,
during rainy periods, is not exposed to water. For longer storage periods the equipment must be covered /I In.paellon, quality control
and the anti-condensation heaters be connected. 11111
1IIIIII1II1hllllll'",IIlIIClllo carry out an erection that comply with standards stated in the contract between
Lifting devices with sufficient capacity (check with dimension print) must be available. 111\1\'"111 11111 I ,will 11 IIor Hlld belween ABB and subcontractor. Make sure that the contract is understood
The flexible connectors between the breaker and the current transformers are included in the delivery. nVfllllllllllflllltlJlfH:1
1IIIIIIIlJ 11111 11111111111111111

olOclion a "Remaining list" has to be kept updated. The list shall state all work that
11I1f1 III I't! ro flOrin or In uncloar.
1\11111111 "IIIklllll IIvor" 1110list has to be finalized.
NIIIII 111111
1111
<lIIIWIrIIlH IlHVO 10 be up-dated "as built" in red and one copy submitted to the design office.
U In.llng ftnd Commissioning

I Villi 1111"'1111111IIIIlCllJllJllIHsioning are usually not the ultimate responsibility of the erection engineer, he is
ltllll1U11nly Involve II!
I 1111
111111
1111<1
clIIIlIlllsHlolling goes hand in hand and require close cooperation.
Disconnecting switches
The comments under
item "circuit-breakers"
above are in many
respects valid also for
disconnecting switches.
Regarding switches with
build-on earthing
switches it should be
realized that there are a
lot of variations when
erecting the operating
mechanism.
Fig. 53 Erected discon-

necting switches and
voltage transformers
c c
c c: .::..
c:
0
I' "2-
c: "2-
0" 0" 0'
III
a; III
..•. ..•.
.::.. C1l
n C1l
::;" III 0"
n :I c
c: C. III
..•. 0"
~ ..• III
0" III
..•
..• III
C1l :I
III III -::-
~
..• ~
-
0"
-::- c:
III
0"
III
..•
III
s:
!!!.
S -=- :I
""'" ""'" 0" III
..• -=- :I
C1l C.
III
..•.
..•
C1l
••• III
:I
III
":" ~i III C1l
..•
'<
..•. ~
-
,C1l 0"
!..L! c:
3 III
0"
III
~ ..•
III
,
c ..
~, ,~, ,.-: 1 ~. -~
-
~
.= ~, r r II , [~:i Iln~.
..
~ IIU~:0
1 r , L~U 0
TRANSFORMER BAY A+B 145 kV

(7244 OOOO-F)
LL = line bay length
L = transformer bay length

T
W = bay width

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Book No.

'i. as well as the other ones.

Check on arrival - mobilization

Laying, termination and jointing of

Air insulated switchgear page 157

J;. - Routines for access to buildings and switchyard.

This document and parts thereof must not be

JI - Bench marks for checking of foundations.

Support {'IOU""I/II/" JII

c=, ABB mlllPMI t·ll

3.3 Temporary power supply

20'180- External Internal Internal

This checklist is supposed

to be filled in with a few words answering

4. Checklist for civil work

~.1 - Hotel? ;>.10 Schools?

2.15 Other comments regarding

~.7 -- Personal belongings prefer-

~.8 - Customs regulations for

~.9 - Currency restrictions?

Site designation Site designation Order no Page

1.1 - Hospital available? 4.1 - Address for company mail?

1.3 - Dentist available?

4.4 Working hours?

4.5 Work permit / permit to stay?

4.8 - Visit consultant, contact man.

4.11 Visit civil contractor, contact

4.12 Local purchasing of erection

Site designation Ordarno Page

·.13 - Local purchasing of erection 5.1 Local public transports?

5.7 Workshop and spare parts

510 Other comments regarding

1.22 - Trafficability to site, summer,

Site designation Site designation Order no.

2.4 Oil pit

1.5 Material unloading

1.6 Outdoor storing

1.8 Snow clearing

4.1 Station building

4.3 Cable routes

JI. - water, showers, WC ready

5.2 Battery room

5.3 Air treatment (whole building)

Accessories and tools 28

Core no. ~ Cable no.

Core no. Cable no.

Fig. 2 Marking of a cable end consisting of 3

This document and parts thereof must not be

Addtional copies of this document may be

THERMIC WELDING PROCESS

Personal protection at welding 44

This document and parts thereof must not be

II- to a great extent dependent upon the composition of the solder.

7.1 Silver solders

7.3 Phosphor-copper solders

Preparations: Select a suitable burner; 100 I.

10.4 Brazing of earthing conductorsrr-joints (branch-joints)

Pre-cleaning: Wipe off grease, oil and other impurities.

Preparations: Select a burner nozzle of suitable size, e.g. 300 I.

II. lashing wire.

Apply the solder

Pre-cleaning: Clean the details and remove the oxide layer.

)~rN~I",,;ifikntion lEt Nr In~d: XPostbetecknin<;l ll"Postbet •••

'-___________ .. _.-------IflI::.!.Q.. "''"''W\bQr