Ningbo Hyuan Power Industry Co., Ltd.  

Product Name: 66kv-110kv-145kv-245kv Cabel Joint with Silicon Rubber Model NO.: YJJJ Application: Substation Material: Silicon Rubber Type: Cable Joint Trademark: HEMG Transport Package: Carton with Wooden Specification: 66kv/110kv/145kv/245kv Origin: China Product Description 66KV/110/138kV XLPE Cable Pre-mould Rubber Insulation (Straight Through) JointI. Scope 1.1 The process is only suitable for the installation66 -110~138kV XLPE cable pre-mould rubber insulation (straight through) joint 2. Installation Procedure2.1 Preparation2.1.1 Study the installation instruction before installation carefully. Pay attention to cleaning and drying the cable pre-mould rubber insulation (straight) joint; check the accessory's surface after be cut and keep them smoothly. You must cut emerge power during installation.2.1.2 According to the packing list, check the amount of accessory. And check the product's type immediately. Prepare all the necessary installation tools and keep clean on site. 2.1.3 Put the high voltage out of electricity to assure the constructer's security on site.2.1.4 Before installation, please check the cable and 2.1.5 check the cable before installation, it shall meet the following requirement:A) cable phase correctB) the condition of insulation is good, no affected with damp, the insulation eccentricity meet requirement of relevant standardC) insulation property of outer sheath is good, do test according to relevant standard, the result is ok(test item: DC voltage 10kV, 1min or insulation resistance>2500MΩ).2.1.6 control the temperature, humidity and cleanliness strictly at worksite during installation, temperature shall be 0-35ºC, relative humidity be 70%, some proper measures shall be taken when temperature and humidity exceeds range, like built a work shed and clean the worksite.2.1.7 the waste like plastic wraps, plastic bags, foam and filling paste produced during the installation shouldn't be discarded anywhere, it shall be reclaimed by qualified party2.1.8 clean and dry the cable and insulation joint body before installation, check the surface of cable insulation to make sure it's smooth, check whether all parts are fixed, size is correct or not, marks made right or not.2.1.9 in the step of 2.4.3, it shall insert the side of insulation unit with insulation part to cable 1 first when install insulation joint, pay more attention to this procedure and make sure it doesn't turn over.2.1.10 it will don't cause any harm to human when use silicone oil, 8010 resin and 8016 resin during the installation. 2.2. Cable treatmentPut the cable on the position place and cut as shown in Fig.1Fig.1 2.3.Treat the cable metal screen, heat and alignment.2.3.1.Cable metal screen treatmentThere are three kinds of cable metal screen: A aluminium sheath, B copper wire screen, C copper wire screen plus lead sheath.Note: According to the requirement to treat the cable.A. Aluminium sheath cableA1. Remove L1 the outer sheath of cable1, L2 of cable2, bear the metal sheath; Remove graphite layer down 300mm to the outer sheath fracture of the two cables as shown in Fig.2A2. Remove 870mm metal sheath of cable 1, 510mm of cable 2, bare semi- conductor buffer layer, expand the end of metal sheath into horn-mouth and chamfer, bind one end of 35mm2 (14pcs) copper braid wire separately on the metal sheath of the two cables with binder and weld with tin sturdily (weld 7pcs for each cable)as show in Fig.2. Fig. 2B. Copper wire screen cableB.1 Remove 1000mm outer sheath of cable 1, 640mm of cable 2, and remove the graphite layer down 300mm to the outer sheath fracture of the two cables as shown in Fig.3.B.2 Measure130mm on the left from the outer sheath end of cable 1, and 130mm on the right of cable 2. Bind the copper screen wire with copper binder and weld with tin sturdily. Then bind back the copper screen wire on the binder place, remain 500mm copper screen wire, remove the rest as shown in Fig.3. Fig.3C. Copper wire screen/lead sheath cableC.1 Remove L1 outer sheath of cable 1, L2 of cable 2,and remove the graphite layer down 300mm to the outer sheath fracture of the two cables as shown in Fig.4 Fig.4C.2 Remain 50mm copper wire screen each from the fracture of two cables outer sheath, remove the rest. Measure 870mm from the cable 1 end as the lead sheath end, 510mm from the cable 2 end as the lead sheath end, remove the rest lead sheath of the two cables, and clean the remaining lead sheath surface, then bind 35mm2 copper braid wire (14pcs, each 7pcs) on the lead sheath and copper wire screen and weld with tin sturdily. 2.3.2 Wrap the heating tape around the cable buffer layer, heat and calibrate the cable end for 3h,the heating temperature is 70~80°C to remove the cable mechanical stress.Note: the temperature should not more than 80°C, and the heating time should not too long.2.3.3 Remove all semi-conductor buffer layer over the metal sheath end of the two cables after cooling.2.3.4 Remove 300-2+3mm semi-conductor layer of the cable1 and cable2 end, bare the insulation layer as shown in Fig.5. Note: Don't damage the insulation layer when you remove the semi-conductor.2.3.5 Remove 88-0+1mm cable core of the cable1 and cable2 as shown in Fig.5.Fig. 5 Fig.62.3.6 Make the semi-conductor end of two cables into a 20~30mm slope, and polish the slope with emery paper to make it transition smoothly with insulation layer. Then polish the cable insulation layer with emery paper #120,#240,#320 and #600 as shown in Fig.6Note: You should polish carefully and smoothly without any pit and step, and can only use with glass piece, do not use with semi-cond. knife or insulation stripping knife. 2.3.7 Clean the insulation layer and semi-cond. layer of the two cables with cleaning cloth, and wrap a layer of plastic film over the cable conductor.2.4 Assemble the components2.4.1 Measure and write down the outer diameter of main insulation and inner diameter of pre-mould insulation joint. The outer diameter of the cable main insulation is more than 6~14mm the inner diameter of pre-mould insulation joint2.4.2 Put the heat shrink tube, copper protective shell, sealing ring and epoxy insulation ring (only for insulation joint) into the cable separately as shown in Fig.7.Note: Put the copper shell with connector pin into the longer cable 1, and check the sealing groove of the copper shell must have the sealing ring.Fig.72.4.3 Install the fixing clamp on the suitable position of the cable1. Remove the plastic film, apply a layer of silicone grease over the insulation surface and semi-cond. layer surface of the cable1, and apply a layer of silicone grease into the surface of the cleaned pre-mould rubber insulation unit. Slide the insulation unit into the cable 1 by special tool, and remove the special tool till the cable conductor is bared completely and wrap a layer of plastic film temporarily as shown in Fig.8Note: clean the pre-mould rubber insulation unit only with cleaning cloth, not any others. (For insulation joint, slide the cable 1 first)Fig.82.5 Press the ferrule2.5.1 Remove the temporarily plastic film, bare the conductor of cable 1.2.5.2 Wrap a layer of plastic film first temporarily to prevent the copper scrap down to the cable insulation layer.2.5.3 Polish the surface of two cable conductors with #120 emery paper and clean, then slide the ferrule, press the ferrule according to the following dimension table; measure the L between the two insulation distance after pressing, the distance should not more than 216mm, remove the sharp edge and clean, then remove the temporarily plastic film and determine the pressing center 1/2 as shown in Fig.9Fig.9item1234456789Cable section240300400,500630700,8001000120014001600CuCorecableDΦ31Φ35Φ40Φ40Φ47Φ54Φ58Φ64Φ66Φ70Width of die29333737445256626468length40404040404242424242AlCorecableDΦ31Φ35Φ40Φ47Φ54Φ58Φ64Φ66Φ70Φ75Width of die29333744525662646877length404040404242424242502.6 Install the equipotent copper sleeve2.6.1 Connect the copper braid tape and equalization sleeve with bolt, and the copper braid tape should cover over the equalization sleeve completely, and put the two pieces of equipotent copper sleeve over the pressed ferrule, then wrap the constant force spring on the center of hollow, wrap 2 layers of PVC adhesive tape over the constant force spring, the PVC tape should be cover over the constant force spring completely.Note: The wrapped tape can not higher than the surface of equalization sleeve. Note: Wrapped layer should not higher than the surface of equipotent copper sleeve2.6.2 Make a mark: Measure the length K from the insulation unit of the cable 1, and make a mark on the cable 2 of pressing center K/2 as shown in Fig.9.2.6.3 Remove the temporarily plastic film, after cleaning the insulation layer surface of cable 2, apply a layer of silicone grease over the outer surface of equipotent copper sleeve and insulation layer surface of cable 2.2.7 Put the pre-mould insulation unit to the cable 2 according to the method of 2.4.3, the end should be at the same level of the mark as shown in Fig.10Fig.102.8 Treatment of the cable and joint outer screen2.8.1 Wrap two layers of waterproof tape over the two end of pre-mould insulation unit to seal, then wrap a layer of semi-cond. tape from the end of two cable metal screen to the stress cone of insulation unit ends, fill up the step of stress cone with semi-cond. tape as shown in Fig.11Fig.112.8.2 Wrap lead tape and copper meshA. For Insulation joint: Wrap a layer of lead tape to the pre-mould insulation unit from the metal sheath of cable 2 first, then wrap a layer of copper mesh to the metal sheath of cable 2 from the pre-mould insulation unit, then bind the lead tape and copper mesh with copper binder and weld with tin on the metal sheath of cable 2. Wrap a layer of lead tape to the place of pre-mould insulation unit stress cone from the metal sheath of the cable 1, then wrap a layer of copper mesh over the lead tape to the metal sheath of the cable 1 from the pre-mould insulation unit, then bind the lead tape and copper mesh with copper binder and weld with tin to the metal sheath of the cable 1.the metal tape is lapping about 30mm with the metal sheath, then wrap DJ-30 insulation tape on the insulation place of pre-mould insulation unit within the range of 110mm, then fill up the step between the insulation place of stress cone, and cover over the insulation unit not more than 200mm, the wrapping layer should not less than 8 as shown in Fig.12.Note: The metal tape should not wrap over the insulation unit of pre-mould insulation unit. B. For straight jointWrap a layer of lead tape on the metal sheath of cable 2 first, then wrap a layer of copper mesh on the lead tape till to the cable 1 metal sheath of pre-mould insulation unit another end, bind with copper binder and weld with tin on the crossing place and metal sheath. metal tape is lapping 30mm with metal sheath2.9 Install copper protective shellShrink the two heat shrink tube Φ200x800 at the place of the joint center, the two end is lapping 50mm with the metal sheath, the middle part is natural lapping, then wrap 2~3 layers of waterproof tape on the lapping place.Aluminium sheath and copper wire screen + lead sheath cable: Wrap rubber tape or filling tape away from the end 120mm of aluminium/lead sheath, the diameter of wrapped tape is clear with the inner diameter of the copper protective end.Copper wire screen cable: Wrap rubber tape or filling tape from two side to the end of outer sheath, the diameter of wrapped tape is clear with the inner diameter of the copper protective shell end.Apply a layer of RTV silicone paste on the sealing groove of copper shell, and put the sealing ring into the sealing groove, then apply a layer of conductor grease on the flange end surface of copper shell with the connector pin, and assemble the two copper shell, and fix the bolt as shown in Fig.14. adjust the copper shell position to make the two end of copper shell at the same distance from the fracture of cable outer sheath.A For insulation joint: Move the epoxy insulation ring to the place of the center, apply RTV silicone grease in the sealing ring groove of two copper protective shell flange and put the sealing ring in the groove, fix the two copper protective shell on the epoxy insulation ring by bolt as shown in Fig.14B For straight joint: Move the two copper protective shell to the place of center, apply RTV silicone grease in the sealing ring groove of two copper protective shell flange and put the sealing ring in the groove, fix the two copper protective shell by bolt. 2.10 Treatment of wiping sleeve2.10.1 Epoxy mud treatment2.10.1.1 Fold back 35mm2 copper braid tape or copper wire screen separately and bind them on the end of wiping sleeve with copper binder and weld with tin. Then apply epoxy mud between the copper shell and cable outer sheath evenly. The Max.OD after wrapping is not more than Φ165mm, and the epoxy mud and the cable lapping length is not more than 100mm the end of copper shell as shown in Fig.15.2.10.1.2 Wrap two layers of waterproof tape by half-lapping over the epoxy mud surface and cover 50mm over the epoxy mud.. 2.10.1.3 Put the small heat shrink tube over the binding place of the copper shell, heat and shrink, the heat shrink tube is lapping at least 50mm with cable heat, the other end with the insulation layer of the copper shell 2.10.2 Plumb sealing treatment2.10.2.1 Put the half-liner into the tail part of the copper shell, and bind the half-liner on the metal sheath with copper binder, then make plumb treatment from the tail part of copper shell to the circle of the cable metal sheath. The Max.OD after plumb is not more than Φ165mm, and the plumb part the cable lapping length is not more than 100mm the end of copper shell as shown in Fig.16.2.10.2.2 after cooling to the natural temperature at the plumbing part, wrap 2~3 layers of waterproof tape on the range from the cable outer sheath to the copper shell insulation layer(you should wrap more at the bare part of the cable metal sheath), lapping each 50mm with the waterproof tape,cable outer sheath and copper shell insulation layer .2.10.2.3 Put a small heat shrink tube into the binding place of the copper shell, heat and shrink the tube, and the tube is lapping at least 50mm with cable outer sheath, the other end is lapping with the insulation layer on the copper shell2.10.3 When casting paste into the copper shell, you should put the mixed resin(8016 insulation resin) into the copper shell, wrap 2~3 layers of waterproof tape around the casting port and seal (Note: if unnecessary to reinforce the protective, without this step).2.10.4 Apply a layer of epoxy mud on the connection of the two copper shell flange, and cover over the metal bare part completely, lapping 20mm with the two end insulation layer, and wrap 2~3 layers of waterproof tape on the epoxy mud by half-lapping, lapping 20mm with the insulation layer. Put a big heat shrink tube into the above wrapping place , heat and shrink, the two end of the tube is covered over the waterproof tape, then wrap 2~3 layers waterproof tape on the end of the tube, then wrap 1~2 layer PVC adhesive tape over the waterproof tape to seal.3. Connect the earth cable3.1 For straight joint: for general earth cable, peel off the cable end, bare cable conductor L/2+5mm(L=length of the earth ferrule), connect the cable conductor and the connector pin of the copper shell with the earth ferrule, and crimp, remove the sharp edge of the ferrule, and fill up the gap between the two end of the ferrule with waterproof tape, and lapping at least 30mm separately with earth cable end and the insulation layer of the connector pin, and wrap 3~4 layers waterproof tape, and 2~3 layers PVC tape outside the waterproof tape to seal.3.2 For insulation joint: for general earth cable, refer to the 3.1 treatment of the straight joint. Connected with coaxial cable. The treatment is as follow:3.2.1 Peel off the coaxial cable according to the size of Fig.17.(A is the distance between the two connector pin on the copper shell). Note: the size of 250 is only for reference, the actual size you can adjust according to the site. Bind the outer conductor of the coaxial cable, and wrap 4~5 layers waterproof tape at the crossing place away L/2+5mm (L=the length of the earth ferrule) from the outer conductor end.3.2.2 Put the breakout into the cable crossing place, heat and shrink from the root to the two end, then wrap 3~4 layers of waterproof tape over the end of the breakout after shrinked, then lapping at least 30mm with the cable and the tube part of the breakout, and wrap 2~3 layers of PVC tape outside the waterproof tape to seal. Put the two small heat shrink tube separately into the branch cable, and lapping at least 30mm with breakout, heat and shrink, the other end is at the same level with the cable insulation, cut the rest heat shrink tube, then wrap 3~4layers of waterproof tape at the lapping place of the heat shrink tube and breakout, then wrap 2~3 layers of PVC tape outside the waterproof tape to seal as shown in3.2.3 Connect the in/outer conductor of coaxial cable separately to two connector pin on the copper shell with the earth ferrule(in order to make the connection correctly, you should be carefully note the narrow make of the connector pin as shown in Fig.18), and crimp. Remove the sharp edge, and fill up the gap between the two end of the ferrule with waterproof tape, and lapping at least 30mm separately with earth cable end and the insulation layer of the connector pin, and wrap 3~4 layers waterproof tape, and 2~3 layers PVC tape outside the waterproof tape to seal. After wrapping, the Max. OD is not more than Φ40mm.Connect the earth cable to the earth equipment and earth net, That's all for the installation of 66-110~132KV insulation/straight joint without glass fiber steel outer shell.4 Install glass fiber steel outer shell4.1 Note: Before the treatment of the earth cable according to the installation instruction item 3.0, you should put the earth cable pass through the earth exit hole of the outer shell first, then make it connect.4.1.1 When connecting earth cable, it should avoid any large bending moment or torque to the connector pin which will cause deformation to connector pin and hurt to the cable insulation layer.4.2 Install Step:4.2.1 After installation the joint, You should protect the tail part wrapping place of the copper shell end, then put the joint into the bottom box of the outer shell, the ends of outer shell is lapping evenly with the cable, then fill up the filling tape between the outer shell end and the cable to avoid leakage, then cover the glass fiber steel outer shell and fasten each bolts.4.2.2 Apply a layer of epoxy mud evenly over the tail part of the outer shell end and the earth exit hole, the epoxy mud is separately lapping 60~100mm with the cable and outer shell, wrap 2~3 layers of waterproof tape over the epoxy mud surface and cover over the epoxy mud, then wrap 1~2 layers of black PVC tape outside the waterproof tape to seal.4.2.3 Pour the mixed insulating resin (8010 resin) into the box, and cover the lid. Then wrap 2~3 layers of the waterproof tape on the lid, wrap 1~2 layers of PVC tape outside the waterproof tape to seal. Clean the working site. That's all for the installation of 66-110~132KV insulation/straight joint with glass fiber steel outer shell.ANNEX A Installation Drawing of YJJJ(T)I-132KV XLPE Cable Pre-mould Rubber Insulation (Straight) Joint YJJTI-110~132KV XLPE Cable Pre-mould Rubber Straight Joint1-epoxy mud(or plumb) 2-waterproof tape,HS tube 3-insulation resin 4- earth cable 5-earth ferrule 6-connector pin 7-copper shell 8-HS tube,waterproof tape 9-PVC adhesive tape 10-ferrule 11- equalization sleeve 12-pre-mould insulation unitYJJJI-110~132KV XLPE Cable Pre-mould Rubber Insulation Joint1-epoxy mud(or plumb) 2-waterproof tape,HS tube 3- earth cable 4-earth ferrule 5-connector pin 6-copper shell 7-HS tube,waterproof tape 8-PVC adhesive tape 9-insulation resin 10-ferrule 11- equalization sleeve 12-pre-mould insulation unit