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Section 4 I Page 1UK POWER NETWORKS 33kV CABLE JOINTING MANUAL I 2012

4 INSTALLING HEATSHRINK MATERIALS AND COMPONENTS

4.1 Installing Stress Control and Insulation Materials

4.1.1 Single-Core Paper Insulated Cables in Transition Joints

Preparethecableasdescribedinsection3.2.Useachinagraphpenciltomark20mmontotheleadsheathand10mmontotheinsulationpapers.

Removethereleasepaperfromthemediumlengthofyellowstresscontroltape.Stretchthetapetoabouthalfitsoriginalwidthandwrapitaroundtheleadsheathfor20mm.Removethetwinebinderfromthescreenedgeandcontinuewiththetapeoverthescreenpapersandontotheinsulationfor10mm.

Useachinagraphpenciltomarktheleadsheath20mmbeyondtheyellowstresscontroltape.Positiontheclearbarriertubingoverthecoreendandovertheyellowstresscontroltape,overlappingontotheleadsheathby20mm.UN

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Shrinkthetubingdown,startingontheleadsheathandcontinuingtowardsthecoreend.Oncecompletedthetubingshouldbefullyshrunkandhaveasmoothfinishwithoutwrinklesorcreases.

Positiontheshortblackconductivesleeve220mmfromthecoreendandshrinkthetubingdownstartingattheopencableendbeforeworkingtowardstheleadsheath.

4.1.2 Single-Core Polymeric Pot Ends

Preparethecablesasdescribedinsection3.1uptoandincludingthescreenremovalpoint.Thedimensionforthescreenis80mm.

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Removetheinsulationfor30mmfromtheendofthecable.

Cleananddegreasetheinsulationwithanapprovedsolventwipetoremovealltracesofconductingmaterial.Alwayswipefromtheopencutendtowardsthescreenwirestoavoidcontaminatingtheinsulationwithcarbonfromthescreenlayer.

Wraptheconductivetapesuppliedinthejointingkitaroundthe30mmofexposedconductorstretchingittoabouthalfitsoriginalwidth.

Increasetheconductordiametersufficientlysothattheinsulatingrodisasnugfitovertheconductor.Pushtheinsulatingrodontotheconductorensuringthatitbuttsagainstthecableinsulation.

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Useashortstripofyellowstresscontrolmasticandremovethereleasepapersfromashortstripofyellowstresscontrolmastictape.Wrapitaroundtheedgeoftheinsulationscreenstarting20mmfromthescreenedge,beforecontinuingfor10mmontothecoreinsulation.Stretchthetapetoapproximatelyhalfitsoriginalwidthtoobtainafineedgeontotheinsulation.

Usingalongstripofyellowstresscontrolmasticandremovethereleasepapers.Wrapitaroundthecoreinsulationstarting10mmfromtheinsulationedge,beforecontinuingontotheinsulatingrodcoveringthe'paintedarea'and10mmbeyondontotherodinsulation.

Useonlyasmuchoftheyellowstresscontrolmastisasnecessarytofillinthestepbetweentheinsulationandtherod.

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Wraponelayerofredmasticaroundtheinsulatingrod60mmfromitsendandwithawidthof10mm.

Positiontheblackstresscontroltubingovertheinsulatingrodandbuttitupagainstthecableoversheathcut.Shrinkthetubingdownstartingattheoversheathendbeforeworkingtowardstheinsulatingrodend.

Useonelayerofredmasticaroundeachendoftheinstalledstresscontrolledtube60mminfromeachendandwithawidtehof10mm.

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Slidetheredinsulatingtubingoverthestresscontroltubebuttingitagainstthecableover-sheathandcoincidingwiththestresscontroltubingedge.

Shrinkthetubingdownstartingattheover-sheathendandworkingtowardstheinsulatingrodend.

Placetheblackandredscreenedinsulatingtubingovertheassemblyandpositionittocoincidewiththepreviouslyinstalledtubes.

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Shrinktheblackandredtubedownstartinginthecentre.Whenthissectionisfullyshrunkitshouldbesmoothwithoutridgesandshouldnotmovewhentwistingthetubeend.

Continuetheshrinkingprocess,workingtowardsoneendandstopping50mmfromtheend.Thenshrinktowardstheoppositeendstopping50mmfromtheend.Finallyshrinkdownthefirstremaining50mmoftubingfollowedbythesecond50mmoftubing.Thisprocessensuresthatnoairistrappedinsidethetube.

4.1.3 Resin Filled Three-Core Transition Straight Joints (Three-Core Paper to 3 x Single-Core Polymeric Cables)

Preparethecablesuptothepointasdescribedinsection3.3.

ProtecttheCopperWovenTape(CWT)withnylontape,startingfrom20mmontotheleadsheathextending30mmontothecores.Thenylontapeshouldbeappliedwithtension.

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Atthescreenterminationpositionwraponelayerofvoidfillingyellowstresscontrolmasticaroundeachcore,overlappingthescreenpapersby20mmandtheinsulationby10mm.Removethemetalbinderfromthescreenedgeduringthetapingprocess.

Slidetheclearbarriertubingovereachcoreandposition30mmfromtheendofthemetalsheath.Shrinkdownthetubingstartingatthecrutchpositionworkingtowardstheopencoreends.Checkthetubingisshrunkdownevenlyandfreefromcreasesorwrinkles.

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Slidetheblackconductingtubingoverthecoreendsandpositionthem50mmfromtheendofthemetalsheath.Shrinkthetubesdownatthispositionstartingatthecrutchbeforeworkingtowardsthecoreends.

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Slidethesmallyellowmasticwedgeintothecrutchusingtheinstallationtoolprovided.Takethelargerwedgeandinsertitintothecrutchbehindthesmallerwedgeusingthesametool.Removethenylontapeafterinsertionofbothwedges.

Degreasethecoresusingapprovedsolventwipes.Makeachinagraphpencilmarkontheconductivetubes70mmfromtheleadsheathcutandfor20mmontotheleadsheath.

Wrapstripsofyellowmasticaroundthecrutchbetweenthetwochinagraphpencilmarks.Applysufficienttensiontostretchthetapetohalfitsoriginalwidthuntila'cone'shapeisformed.

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Passtheconductivebreakoutoverthecoresandpushitwelldownintothecrutch,usingtheyellowwedgeinstallationtool.Holdthebreakoutinplaceandshrinkitdownstartingatthecentre,beforefirstlyworkingtowardstheleadsheathandthentowardsthebreakoutfingers.

4.1.4 Heatshrink Three-Core Transition Straight Joint (Three-Core Paper to 3 x Single-Core Polymeric Cables)

Preparethecablesuptothepointasdescribedinsection3.3.

ProtecttheCWTwithnylontape,starting20mmontotheleadsheathextending30mmontothecores.Thenylontapeshouldbeappliedwithtension.

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Atthescreenterminationpositionwraponelayerofvoidfillingyellowstresscontrolmasticaroundeachcoreoverlappingthescreenpapersby20mmandtheinsulationby10mm.Removethemetalbinderfromthescreenedgeduringthetapingprocess.

Slidetheclearbarriertubingovereachcoreandposition30mmfromtheendofthemetalsheath.Shrinkdownthetubingstartingatthecrutchpositionbeforeworkingtowardstheopencoreends.Checkthetubingisshrunkdownevenlyandisfreefromcreasesorwrinkles.

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Slidetheblackconductingtubingoverthecoreendsandpositionthem50mmfromtheendofthemetalsheath.Shrinkthetubesdownatthispositionstartingatthecrutchworkingtowardsthecoreends.

Slidethesmallersuppliedyellowmasticwedgeintothecrutchusingtheinstallationtoolprovided.Takethelargerwedgeandinsertitintothecrutchbehindthesmallerwedgeusingthesametool.Removethenylontapeafterinsertionofbothwedges.

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Degreasethecoresusingapprovedsolventwipes.Makeachinagraphpencilmarkontheconductivetubes70mmfromtheleadsheathcutandfor20mmontotheleadsheath.

Wrapthestripsofyellowstresscontrolmasticaroundthecrutchbetweenthetwochinagraphpencilmarks.Applysufficienttensiontostretchthetapetohalfitsoriginalwidthuntilaconeshapeisformed.

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Passtheconductivebreakoutoverthecoresandpushitwelldownintothecrutch,usingtheyellowwedgeinstallationtool.Holdthebreakoutinplaceandshrinkitdown,startingatthecentrebeforeworkingtowardstheleadsheathandthentowardsthebreakoutfingers.

Positiontheshortlengthofwrap-aroundheatshrinktubeoverthepapercablesothatitcoverstheleadsheathandthethreefingerbreakout.Leaveagapofatleast100mmbetweentheendofthewraparoundandthearmoursealingsleeve.

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Shrinkthewrap-aroundinplacestartinginthemiddle,untilthesurfacepaintonthetubeturnsfromgreentoblack.Thengraduallymovetoeachendusingthesameprocess.Extraheatshouldbeappliedtothemetalchanneluntilthewhitemarkerlinecanbeclearlyseenunderit.

Positiontheshortsealingheatshrinktubesovertheturretsoftheheatshrinkbreakout,ensuringtheyarepushedrightintothecrutchandshrinkinplace.

4.1.5 HSL Breakout Module

Preparethecablesuptothepointasdescribedinsection3.4.1to3.4.3.

Useachinagraphpenciltomarkeachleadsheath100mmfromthearmourcutedge.Foldashortlengthoftinnedcoppermeshinhalflengthways.

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Wrapthetinnedcoppermesharoundtheleadsheathscenteredonthe100mmmark.

Positiononeofthelengthsofbraidoverthemeshsothatthelooseendpointsawayfromthecrutchofthecable.

Securealengthofearthbraidtoeachleadoftheleadsheathsusingoneturnoftherollspringsdirectlyontothecoppermeshwrap.

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Bendthebraidsbackovertherollspringandthensecureinplacewiththeremainingturns.

CovereachoftherollspringswithtwolayersofPVCtape.

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Securethebraidendstothearmoursandthesupportringwitharolloftinnedcoppermeshsandwichingthebraidsbetweenthemeshwraps.

Finally,securethemeshandbraidstothesupportringandarmoursusingthewormdriveclipsprovided,withoneclipeithersideofthesupportringscentralridge.

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CoverthewormdriveclipswithPVCtapetotidyuptheirlooseends.

Slideasealingsleeveovereachleadsheathandrollspringconnectionuptowheretheearthbraidmeetsthesupportring.Shrinkthemdownstartingontheleadsheathsandcontinuingtowardsthearmourwiresarea.

Wrapastripofblackmasticbehindthesupportringoverthearmourwires,fillingthespacebetweentheringandtheoutersheath.

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Passthebreakoutovertheleadsealingsleevesandpulldownintothecrutch.Shrinkthebreakoutdownstartinginthecentrebeforemovingtowardstheover-sheathandthenshrinkthebreakoutfingers.

Positionthecrutchsealingsleevewithoneendlevelwiththeendofthefingersonthebreakoutandshrinkintoplace.

4.1.6 HSL Cable Core Preparation

Preparethecablesasdetailedinsection4.1.5andremovetheleadsheathsasdescribed insection3.4.4.

Useachinagraphpenciltomark20mmontotheleadsheath,and10mmontothe insulationpapers.

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Removethereleasepaperfromoneofthemediumlengthsyellowstresscontroltape.Stretchthetapetoabouthalfitsoriginalwidthandwrapitaroundtheleadsheathfor20mm.Removethetwinebinderfromthescreenedgeandcontinuewiththetapeoverthescreenpapersandontotheinsulationfor10mm.

Makeamarkontheleadsheathusingachinagraphpencil20mmbeyondtheyellowstresscontroltape.Positiontheclearbarriertubingoverthecoreendandtheyellowstresscontroltapeoverlappingontotheleadsheathby20mm.

Shrinkthetubingdown,startingontheleadsheathandcontinuingtowardsthecoreend.Oncecompletedthetubingshouldbefullyshrunkandhaveasmoothfinishwithoutwrinklesorcreases.

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Positiontheshortblackconductivesleeve220mmfromthecoreendandshrinkthetubingdown,startingattheopencableendbeforeworkingtowardstheleadsheath.

4.1.7 Paper Insulation 'Shim Kit' for Cable Cross Sections 70mm & 95mm

Forcablesbelowtheminimumsizerangespecifiedonthekitlabela'shimkit'mustbeused.

Thecableswillbeatthestageofpreparationdescribedinsections4.1.1,4.1.3,4.1.4or 4.1.6.

Applyapieceoftheyellowstresscontroltape20mmovertheendoftheconductivetubeandontothecleartubingby10mm.Usesomeoftheyellowtapeprovidedinthemainjointkit.

Positionashortlengthofthesmallerdiameterstresscontroltubing(42/16)overthecoreend,overlappingtheconductivetubesandtheyellowstresscontrolmasticby40mm.

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Shrinkthestresscontroltubingdown,startingfromtheyellowmastictapeandworkingtowardstheopencoreend.

Wraponeoftheredmasticstripsprovidedaroundtheendofthestresscontroltube30mmontothetubingand10mmontothecore.

Positionashortlengthofthelargerdiameterstresscontroltubing(54/24)directlyoverthepreviouslyappliedstresscontroltubeandshrinkdownfollowingthesameprocedureasbefore.

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Applyoneoftheredmasticstripsprovidedaroundtheendofthestresscontroltube30mmontothetubingand10mmontothepreviouslyappliedredmastic.

4.1.8 Paper Insulation 'Shim Kit' for Cable Cross Sections 120mm & 150mm

Forcablesbelowtheminimumsizerangespecifiedonthekitlabel,a'shimkit'mustbeused.

Thecableswillbeatthestageofpreparationdescribedinsections4.1.1,4.1.3,4.1.4or 4.1.6.

Applyashortlengthoftheyellowstresscontroltape20mmovertheendoftheconductivetubeandontothecleartubingby10mm.Usesomeoftheyellowtapesuppliedinthemainjointkit.

Positionashortlengthofthestresscontroltubing(54/24)overthecoreend,overlappingtheconductivetubesandtheyellowstresscontrolmasticby40mm.UN

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Shrinkthestresscontroltubingdown,startingfromtheyellowmastictapeandworkingtowardstheopencoreend.

Wraponeoftheredmasticstripsprovidedaroundeachendofthestresscontroltube30mmontothetubingand10mmontothecore.

4.1.9 Single-Core Polymeric Terminations (Indoor and Outdoor)

Followthecablepreparationproceduresforpolymericcablesasdescribedinsection3.1.

Useachinagraphpenciltomarktheoutersheath60mmbelowthesheathcutposition.

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Wraponelayerofredsealanttapeoverthecablesheathdowntothechinagraphpencilmark.

Bendbackthecopperscreenwirescarefullyandlaythemontothemastictapetakingcarenottocrossoveranyofthewires.Securethewireswithawirebinderatthe60mmmark.

Makeachinagraphpencilmarkontothecorescreen40mmfromthesheathcut.

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Removethecorescreendowntothe40mmmarkusingtheapprovedscreenstrippingtool.

Makeamarkwithachinagraphpencil20mmontothecorescreenand10mmontotheinsulation.

Removethereleasepaperandwraptheyellowstresscontrolmasticaroundthescreencutbetweenthetwopencilmarks.Stretchthetapetohalfitsoriginalwidthtoachieveafinethinedgeontotheinsulation.

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Positiontheblackstresscontroltubingoverthecoresothatitislevelwiththeoutersheathcut.Shrinkthetubingdown,startingatthesheathcutendandworkingupwards.Whenfullyshrunkthetubingshouldbesmoothandwrinklefree.

Removetheinsulationfromthecoreendaccordingtotheinnerdimensionofthecablelugbarrel.

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Fitthecablelugensuringthatthelugbuttsagainsttheinsulationedgeandhandtightenthesecuringbolts.

Shearofftheboltheadsusingtheapprovedtoolsandfillintheindentswiththegreyclayprovided.

Wraptheredsealanttapearoundthelugbarrel,overlappingontotheinsulation.Buildupthediameterdifferencewiththeredtapesothatasmoothandevenprofileisachieved.

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Removethereleasepaperfromtheredtubing.Placethetubingoverthecableend(withthesealantcoatedenddownwards),levelwiththewirebinder.

Shrinkthetubingdownstartingattheoutersheathend,beforeworkingtowardsthecable lug.

Cutthetubingbackontothecablelug,levelwiththetopofthemainbody,ifnecessary.

Post-heatthepalmofthecableluguntilabeadofthesealantappearsaroundthetopof thetubing.

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Useachinagraphpenciltomarkthepositionfortheshedsonthetubingatthedimensiongivenintheterminationinstruction.

Placetwoskirtsoverthecableendandpositiononthepreviouslymademarks.Shrinkeachshedinplace.

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Foroutdoorterminationstherearefourskirtstobefittedtoeachtermination.Theseshouldbeplacedandshrunkintopositionatthemeasurementsindicatedintherelevantjointinginstruction.

4.2 Installing Mechanical Connectors and Lugs

4.2.1 Single-Core Polymeric Straight Joints

Thecableswillhavebeenprepareduptothepointasdescribedinsection3.1.

Positionthecombinedstresscontrol,screenedinsulatingtubingandoutersealingsleeveoveroneofthecableends.

Removetheinsulationasdescribedinsection3.1.3.

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Theconnectorcomeswithmetalinsertstofitsmallconductors.Iftheconductorwillnotfittheconnector,discardtheinsertandusetheconnectorwithoutit.

Fittheconductorsintotheconnector.Theinsulationshouldbuttagainsttheendoftheconnector.

Usingtheapprovedinsulatedtooltoholdtheconnector,takeupthetensiononalltheboltsequallywithoutshearingthemoff.

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Continuetotightenandsheeroffalltheboltsstartingwiththeboltsateachendfollowedbythecentralbolts.

Filltheboltholesintheconnectorwiththegreyclaysuppliedinthejointkit.

4.2.2 Single-Core Transitional Straight Joints

Thecableswillhavebeenprepareduptothepointasdescribedinsections3.1and3.2.

Slidethefivepiecetubingsetoverthepolymericcableside.Nestingthetubesetontheplasticbagwrappingwillkeeptheinsideofthetubesclean.Thetubesetshouldbeplacedintheordershown.

Note :Itisimportantthatthefourthtube(thesecondlargest)isplacedwithinthetubeset sothattheuncoatedinneredgepointstowardsthejointcentre.

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Removetheinsulationfrombothcablesusingthemethodsdescribedinsections3.1.3and3.2.5.

Theconnectorisa'TwoPiece'designwiththetwohalvessecuredtogetherwithacentralshearbolt.Eachconnectorhalfhastwoconductorsecuringboltswhicharealsooftheshearofftype.

Fittheconductorsintotheconnector.Theinsulationshouldbuttagainsteachendoftheconnector.

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Usingtheapprovedinsulatedtooltoholdtheconnector,takeupthetensiononalltheboltsequallywithoutshearingthemoff.

Continuetotightenandsheeroffalltheboltsstartingwiththoseateachendfollowedbythecentralbolt.

Filltheboltholesintheconnectorwiththegreyclaysuppliedinthejointkit.

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4.2.3 Resin Filled Three-Core Trifurcating Joints (Three-Core Paper to 3 x Single-Core Polymeric Cables)

Thecableswillhavebeenprepareduptothepointasdescribedinsection3.1and4.1.3.

Slidetheplastictrifurcatingendoftheplasticjointboxoverthesingle-corecablesandpositionitawayfromthejointingarea.

Slidethethreepiecetubingsetsoverthepolymericcableside.Nestingthetubesetsontheplasticbagwrappingtokeeptheinsideofthetubesclean.Thetubesetsshouldbeplacedintheordershown.

Setthecoresintheirfinaljointingposition.Checkthattheconductorshavebeencuttoallowforanyconnectorcentralmoistureblock.Removetheinsulationfrombothconductors,sections3.1.3and3.3.7,totheconnectorinsertiondepth.

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Inserteachendofthecoreintoitsrespective'connectorhalf'andfinger-tightenthebolts.

Alignandpositionthetwoconnectorhalvessothatthecentralfixingboltcanbeinsertedintothecentralfixinghole.Theuseofforceforthisoperationshouldnotbenecessary.

Holdtheconnectorwiththeapprovedholdingtoolandtightenthetwoboltsononesideuntiltheysheeroff.

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Repeattheoperationontheothersideoftheconnector.Checkthatthecombinedtubesetislocatedoverthesingle-corecablesandsheeroffthecentralfixingbolt.

Cleananddegreasetheconnector.Filltheboltholeswiththesuppliedgreyclaytoobtainasmoothfinish.

4.2.4 Heatshrink Three-Core Transition Straight Joint (Three-Core Paper to 3 x Single-Core Polymeric Cables)

Thecableswillhavebeenprepareduptothepointasdescribedinsections3.1and4.1.4.

Slidetheouterjointheatshrinksealingbreakoutoverthesingle-corecablesandpositionitawayfromthejointingarea.

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Slidethefourpiecetubingsetoverthepolymericcableside.Nestingthetubesetontheplasticbagwrappingwillkeeptheinsideofthetubesclean.Thetubesetshouldbeplacedintheordershown.

Removetheinsulationfrombothcablesusingthemethodsdescribedinsections3.1.3and3.3.7.

Slidethemechanicalconnectorontotheconductoronthepapersideofthejoint.Theconnectorisfittedwithaninserttoaccommodatesmallersectioncables;ifthecableconductorfitsintotheconnectorwiththeinsertinplace,useit-ifnot,removetheinsertanduseitwithout.

Checkthattheconnectorbuttsupagainsttheinsulationandfinger-tightenthebolts.

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Insertthesingle-corepolymericcablesintotheconnectorensuringthattheconnector buttsupagainsttheinsulationandfinger-tightenthebolts.

Holdtheconnectorwiththeapprovedholdingtoolandtighteneachbolthalfaturnatatimewithasocketuntilitshearsoff.Startwiththeboltnearesttheinsulationateachendbeforemovingontotheothertwobolts,workingtowardsthemiddle.

Smoothoffanysharpedgesfromtheboltsandthencleananddegreasetheconnector.Filltheboltholeswiththesuppliedgreyclaytoobtainasmoothfinish.

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4.2.5 HSL Trifurcating Joints (Three-Core HSL to 3 x Single-Core Polymeric Cables)

ThecableswillhavebeenprepareduptothepointasdescribedinSection3.1and4.1.6.

Slidetheplastictrifurcatingendoftheplasticjointboxoverthesingle-corecablesandpositionitawayfromthejointingarea.

Positionacombinedtubeset(stresscontrol,insulatingtubeandscreenedinsulating)overeachofthesingle-corepolymericcables.

Setthecoresintheirfinaljointingposition.Checkthattheconductorshavebeencuttoallowforanyconnectorcentralmoistureblock.Removetheinsulationfrombothconductors(3.1.3and3.3.7)totheconnectorinsertiondepth.

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Inserteachendofthecoreintoitsrespective'connectorhalf'andfinger-tightenthebolts.

Alignandpositionthetwoconnectorhalvessothatthecentralfixingboltcanbeinsertedintothecentralfixinghole.Theuseofforceforthisoperationshouldnotbenecessary.

Holdtheconnectorwiththeapprovedholdingtoolandtightenthetwoboltsononesideuntiltheysheeroff.

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Repeattheoperationontheothersideoftheconnector.Checkthatthecombinedtubesetislocatedoverthesingle-corecablesandsheeroffthecentralfixingbolt.

Cleananddegreasetheconnector.Filltheboltholeswiththesuppliedgreyclaytoobtainasmoothfinish.

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4.2.6 Mechanical Lugs for Indoor and Outdoor Terminations

Followthecablepreparationproceduresforpolymericcablesinsections3.1.1to3.1.3beforeinstallinganymechanicallugs.

Eachkitcomeswiththecorrectsizeandtypeoflugforeachtermination.Removetheconductorinsulationtotheinsertiondepthofthelug.

Placethelugovertheconductorsothatthebottomofthebarrelbuttsupagainstthecoreinsulation.

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Tightentheboltsbyhandandcheckthatthepalmholeslineupwiththeirrespectiveconnectionpoint.

Tightentheboltsuntiltheboltheadsshearoff.

4.3 Installing Connector Stress Control and Heatshrink Insulation


Fittheconnectoruptothepointasdescribedinsection4.2.1.

Useachinagraphpenciltomarktheblackinsulationscreenofbothcables20mmfromthescreencut.

Makeasecondchinagraphpencilmarkontheinsulation10mmfromthescreencut.

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Stretchoneoftheshortyellowstresscontrolmasticsuppliedinthekittohalfitsoriginalwidth.Wrapitaroundthecorescreenandinsulationbetweenthetwochinagraphpencilmarks.Repeatfortheothercableside.

Usethelongstripofyellowstresscontrolmastictowrapthemasticaroundtheconnectorwitha50%overlap,stretchingthemastictoabouthalfitsoriginalwidth.Coveralltheconnectorareaandoverlaptotheinsulationoneachsideoftheconnectorby5mm.Makesurethereisasmoothtransitionfromtheconnectorontotheinsulation.

Positiontheblackstresscontroltubecentrallyovertheconnectorarea.Eachendofthetubeshouldextendbeyondthescreenterminationpointsofeachcable.Shrinkthestresscontroltubingdown,startinginthecentreandworkingtowardseachendinturn.

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Positionthescreenedinsulatingredandblacktubecentrallyoverthestresscontroltubeandstartshrinkingthesleeveatthecentrepositionusingequalheatoverthewholesurface.

Whenthetubingisproperlyshrunk,theridgesontheouterblacklayerofthetubeshouldnolongerbevisible.

Continuetoshrinkthetubefromthecentretowithin50mmofoneend.

Removetheheatfromthatendandstartshrinkingfromthemiddleagaintowardstheotherendofthetubing.Stopagain50mmfromtheend.Thisensuresthatairinsidethetubeisexpelledasthetubeshrinks.

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Returntoeachtubeendinturntocompletetheshrinkingprocesscompletely.

4.3.2 Single-Core Transition Straight Joints


Wrapashortpieceoftheyellowstresscontrolmasticaroundthepapercablecoreattheedgeoftheshortblackconductingsleeve.Start20mmontheconductingtube,continuingfor10mmontotheclearbarriertube.

Wrapashorterpieceoftheyellowstresscontrolmasticaroundthepolymericscreen,starting20mmfromthescreenedgeandcontinuingfor10mmontotheinsulation.Stretchthetapetohalfitsoriginalwidthduringthetapingprocess.

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Usethelongstripsofyellowstresscontrolmastictowrapthemasticaroundtheconnectorwitha50%overlap,stretchingittoabouthalfitsoriginalwidth.Covertheconnectorareaandoverlapontotheinsulationeachsideoftheconnectorby5mm.Makesureaminimumcoverageof2mmisachievedovertheconnectorarea.

Pulltheblackstresscontroltubingfrominsidethenestedtubesetandpositionitcentrallyovertheconnectorarea,leavinga20mmgapbetweentheoversheathandthetubingend.

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Shrinkthestresscontroltubingdownstartinginthecentre,beforeworkingtowardseachendinturn.Whenfinishedthetubingshouldbefullyshrunkandwrinklefree.

Wrapapieceofredsealantmasticaroundeachendofthestresscontroltubing.Startfrom10mmonthestresscontroltubingandextendfor10mmontothecorescreenatbothends.

Pulltheredinsulatingtubingfrominsidethenestedtubesetandpositionitcentrallyoverthestresscontroltube.Startshrinkinginthecentrebeforeworkingtowardseachendinturn.

Note:Continueontothenextstepwhiletheredinsulatingtubingisstillhot.

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Pulltheblackandredscreenedinsulatingtubingcentrallyovertheredinsulatingtubeandstartshrinkingthesleeveatthecentrepositionusingequalheatoverthewholesurface.Whenthetubingisproperlyshrunk,theridgesontheouterblacklayerofthetubeshouldnolongerbevisibleandthetubecannolongerbemoved.


Removetheheatfromthatendandstartshrinkingfromthemiddleagaintowardstheotherendofthetubing.Stopagain50mmfromtheend.Thisensuresairinsidethetubeisexpelledasthetubeshrinks.


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Pulltheblackcompressionsealingsleeveacrossthejointtothepapercablesideandplaceitsothatatleast50mmofleadsheathisstillvisible.

Shrinkthetubingdown,startingonthetubesetendandworkingtowardstheleadsheath.Oncecompletedthereshouldbeapproximately50mmofleadsheathstillexposed.

4.3.3 Resin Filled Three-Core Transition Straight Joints (Three-Core Paper to Single-Core Polymeric Cables)


Removethereleasepaperfromoneoftheshortyellowstresscontrolmasticstripsandwrapitaroundthepolymericcorescreen,starting20mmfromthescreenedgeandcontinueontotheinsulationfor10mm.Stretchthetapetohalfitsoriginalwidthtoachieveafinethinedgeontheinsulation.

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Repeattheexerciseonthepapercablecore,wrappingtheyellowstresscontrolmasticaroundtheedgeoftheconductivetubing.Cover20mmoftheconductivetubingandcontinueontothecleartubingfor10mm.

Ensurethattheboltholesarefilledwiththesuppliedgreyclaytoleaveasmoothprofile.Usealongpieceoftheyellowstresscontrolmastictofilltheendsoftheconnectorandtheinsulationcutbackcontinuing10mmontotheinsulation,and20mmontotheconnector.Ifthereisastepbetweenthebodyoftheconnectorandthecableinsulationapplyyellowstresscontrolmastictoformasmooththeprofile.

Removethereleasepaperfromtheyellowstresscontrolmasticpatchandwrapitcentrallyaroundtheconnector,takingcaretoexcludeanytrappedairasitisapplied.Whenfinishedthepatchshouldbesmoothandwrinklefree.

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Slidethestresscontroltubingfrominsidethenestedtubesetandpositionitcentrallyovertheconnectorarea.Makesurethattheoverlapovereachtapedscreenedgeisequal.Shrinkthetubingstartinginthecentreandworkingtowardseachendinturn.

Removethereleasepaperfromonelengthoftheredsealanttapeandwrapitaroundtheendofthestresscontroltube.Overlapthetapeontothetubeby20mmandby10mmontothecore.

Pulltheredinsulatingtubesfromthetubesetsandcentrallypositionthemoverthestresscontroltubes.Shrinkthetubingstartinginthecentrebeforeworkingtowardseachendinturn.Whencompletethetubeshouldbesmoothandwrinklefree.

Note:Continuewiththenextstepwhiletheredinsulatingtubingisstillhot.

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Positionthescreenedredandblackinsulatingtubescentrallyovertheredinsulatingtubes.Startshrinkingthesleevesatthecentrepositionusingequalheatoverthewholesurface.Whenthetubingisproperlyshrunk,theridgesontheouterblacklayerofeachtubeshouldnolongerbevisibleandthetubescannolongerbemoved.


Removetheheatfromthatendandstartshrinkingfromthemiddleagaintowardstheotherendofthetubing.Stopagain50mmfromtheend.Thisensuresairinsidethetubeisexpelledasthetubeshrinks.

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4.3.4 Heatshrink Three-Core Transition Straight Joints (Three-Core PILC to Single-Core Polymeric)



Repeattheexerciseonthepapercablecore,wrappingtheyellowmasticaroundtheedgeoftheconductivetubing.Cover20mmoftheconductivetubingandcontinueontothecleartubingfor10mm.

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Checkthattheboltholesarefilledwiththesuppliedclaytoleaveasmoothprofile.Using alongpieceoftheyellowstresscontrolmastic,filltheendsoftheconnectorsandthe insulationcutbacks,continuing10mmontotheinsulationand20mmontotheconnector. Ifthereisastepbetweenthebodyoftheconnectorandthecableinsulationapply yellowstresscontrolmastictoformaprofile.

Removethereleasepaperfromoneoftheyellowstresscontrolmasticpatchandwrapitcentrallyaroundtheconnector,takingcaretoexcludetheairasitiswrapped.Whenfinishedthepatchshouldbesmoothandwrinklefree.Repeattheprocesswithallthreeconnectors.

Slidethestresscontroltubesfrominsidethenestedtubesetsandpositionthemcentrallyovereachconnectorensuringthattheoverlapovereachtapedscreenedgeisequal.Shrinkthetubingstartinginthecentrebeforeworkingtowardseachendinturn.

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Removethereleasepaperfromonelengthoftheredsealantmastictapeandwrapitaroundtheendofthestresscontroltube.Overlapthetapeontothetubeby20mmandby10mmontothecore.

Pulltheredinsulatingtubesfromthetubesetsandcentrallypositionthemoverthestresscontroltubes.Shrinkthetubingstartinginthecentrebeforeworkingtowardseachendinturn.Whencompletethetubeshouldbesmoothandwrinklefree.

Note:Continuewiththenextstepwhiletheredinsulatingtubesarestillhot.

Pullthescreenedredandblackinsulatingtubescentrallyovertheredinsulatingtubesandstartshrinkingthesleevesatthecentrepositionusingequalheatoverthewholesurface.Whenthetubesareproperlyshrunk,theridgesontheouterblacklayerofthetubesshouldnolongerbevisibleandthetubescannolongerbemoved.

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Section4IPage61UK POWER NETWORKS 33kV CABLE JOINTING MANUAL I 2012

Continuetoshrinkthetubesfromthecentretowithin50mmofoneend.

Removetheheatfromthatendandstartshrinkingfromthemiddletowardstheotherendofthetubes.Stop50mmfromtheend.Thisensuresairinsidethetubeisexpelledasthetubeshrinks.


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Positionthethreecompressionsleevesoverthepaperendofthejoint,sothattheyequallyoverlaptheredandblackinsulationtubesandthecoretubes.Theuncoatedendofthecompressionsleeveshouldbepositionedtowardsthecentreofthejoint.Shrinkinplacestartingfromthecentreofthetubestowardsthecentreofthejointbeforefinallyshrinkingfromthecentretowardsthecrutch.


Fittheconnectoruptothepointasdescribedin4.2.5.


Repeatthisonthepapercablecore,wrappingtheyellowmasticaroundtheedgeoftheconductivetubing.Cover20mmoftheconductivetubingandcontinueontothecleartubingfor10mm.UN

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Checkthattheboltholesarefilledwiththesuppliedgreyclaytoleaveasmoothprofile. Usealongpieceoftheyellowstresscontrolmastictocoverbothendsoftheconnector, 20mmontheconnectorand10mmontotheinsulation.

Removethereleasepaperfromtheyellowstresscontrolmasticpatchandwrapitcentrallyaroundtheconnector,takingcaretoexcludeanytrappedairasitisapplied.Whenfinishedthepatchshouldbesmoothandwrinklefree.

Slidethestresscontroltubesfrominsidethenestedtubesetsandpositionthemcentrallyovertheconnectorsensuringthattheoverlapovereachtapedscreenedgeisequal.Shrinkthetubesstartinginthecentrebeforeworkingtowardseachendinturn.

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Removethereleasepaperfromonelengthoftheredsealantmastictapeandwrapitaroundbothendsofthestresscontroltube.Overlapthetapeontothetubeby20mmandby10mmontothecore.

Pulltheredinsulatingtubesfromthetubesetsandcentrallypositionthemoverthestresscontroltubes.Shrinkthetubesstartinginthecentrebeforeworkingtowardseachendinturn.Whencompletethetubesshouldbesmoothandwrinklefree.

Note:Continuewiththenextstepwhiletheredinsulatingtubesarestillhot.

Pullthescreenedblackandredinsulatingtubescentrallyovertheredinsulatingtubesandstartshrinkingatthecentrepositionusingequalheatoverthewholesurface.Whenthetubesareproperlyshrunk,theridgesontheouterblacklayerofthetubesshouldnolongerbevisibleandthetubescannolongerbemoved.

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Continuetoshrinkthetubesfromthecentretowithin50mmofoneend.

Removetheheatfromthatendandstartshrinkingfromthemiddleagaintowardstheotherendofthetubes.Stopagain50mmfromtheend.Thisensuresairinsidethetubeisexpelledasthetubeshrinks.


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4.4 Installing Mechanical Earth Bonds and Associated Components


Completetheproceduresforinsulatingtheconnectorasdescribedin4.3.1.

Wrapthejointwithonelayerofthetinnedcoppermeshensuringthereisa50mmoverlapontotheoversheathofthecablesidewiththeshortshieldwires.

Continueacrossthewholejointwiththetinnedcoppermeshata50%overlapandsecureontotheoppositejointside.

Onthecablesidewiththelongscreenwires,bendthescreenwiresbackacrossthejointandformthemintotwoseparateconductors.Onthecablesidewiththeshortscreenwires,repeatthesameexerciseandfoldthegatheredwiresbacktowardsthejointcentre.

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Gatherthewirestogetherandcutthemcentrallyabovethetinnedcoppermeshoverlappingthecablesheath.Installthecopperscreenwireconductorsintotheirrespectiveconnectorandtightentheboltsuntiltheheadsshearoff.

Wrapasecondlayerofthecoppermesharoundthejoint,asbefore,sothatthewholeareaiscompletelycoveredincludingthemechanicalscreenconnectors.

Cleananddegreasetheoutersheathsofbothcablesfor150mmfromthesheathcut.Slidethelargeoutersealingsleevecentrallyoverthejointarea.

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Startshrinkingthetubeatthecentrebeforeworkingtowardseachendinturn.Allowtocoolbeforemovingorbackfillingthejoint.

4.4.2 Single-Core Transition Joints

Completetheproceduresforinsulatingtheconnectorasdescribedin4.3.2.

Wraptwolayersoftinnedcoppermeshat50%overlapoverthejointfromtheleadsheathonthepapercabletotheover-sheathcutonthepolymericcable.

Foldbackthecopperscreenwiresoverthejointandformthemintoanearthleadexceptfortheareaovertheleadsheath.Atthispointopenupthewiresandplacethemdirectlyontothetinnedcoppermesh.Wraptherollspringoverthescreenwiresandtwistuptight.

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CompletelycovertherollspringwithtwolayersofPVCtape.

Clean,degreaseandabradetheoutersheathsfor150mmfromthesheathcuts.Slidethelargeoutersealingsleeveoverthejointareaandstartshrinkingthetubeatthecentrebeforeworkingtowardseachendinturn.

Allowthejointtocoolbeforemovingorbackfilling.UN

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4.4.3 Polymeric Pot Ends

Completethestepsinsection4.1.2.

Laythecopperscreenwiresbackoverontothescreenedblackandredinsulatingsleeveanddistributethemaroundthecircumferenceevenly.

Wrapthetinnedtinnedcoppermeshwitha50%overlaparoundthepotend,startingattheoutersheathandcontinuingupontothecopperscreenwires,beforecoveringtheinsulatingrod.

Note:Thestresscontroltubingandtherodendmustbeincontactwiththetinnedcoppermesh.

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Covertheendsofthecopperscreenwiresunderthetinnedcoppermeshwithtwolayers offabrictape.

Placetheheatshrinkendcapoverthepotendandshrinkitintoplace.Startattheclosedendbeforeworkingtowardsthecablesheath.Duringtheshrinkingprocesscarefullypushtheclosedendofthecapagainsttheinsulatingendwithanappropriatetool.

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Checkthattheover-sheathiscleananddegreased.Positiontheoutersealingsleeveover thepotendassemblysothatitlinesupwiththeendoftheendcap.

Shrinkthetubingdown,startingatthecentreworkingtowardseachendinturn.Donotmoveorbackfilluntilthepotendhascooled.

4.4.4 Resin Filled Three-Core Transition Straight Joints (Three-Core Paper to 3 x Single-Core Polymeric Cables)

Completetheproceduresforinstallingtheconnectorinsulationinsection4.3.3.

Pullthecorestogetherascloselyaspossibleandwraponelayeroftinnedcoppermesharoundthejointwitha50%overlap.Continueontotheleadsheathfor30mmanduptothescreenwiresontheoppositejointside.

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Laythecopperwirescreensbackacrossthejointandformthemintothreeseparateearthconductors.Connectthecopperscreenwirestoeachofthethreeearthbraidsusingthemechanicalconnectorsprovided.

Positionthethreeearthbraidsevenlyaroundtheleadsheathareaontopofthetinnedcoppermesh.Connectthethreeearthbraidstotheleadsheathusingalargerollspring.

Wraptherollspringoverthebraidsandtwistthespringuptightly.CovertherollspringwithtwolayersofPVCtape.

Wraptheremainingexposedleadsheathwiththestripsofredsealanttape.This is an important moisture seal. Do not leave out.

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4.4.5 Heatshrink Three-Core Transition Straight Joints (Three-Core Paper to Single-Core Polymeric)


Pullthecorestogetherascloselyaspossibleandwraponelayeroftinnedcoppermesharoundthejointwitha50%overlap.Continueontotheleadsheathfor30mmanduptothescreenwiresontheoppositejointside.

Laythescreenwiresbackacrossthejointandformthemintothreeseparateearthconductors.Connectthecopperwirescreenstothethreeearthbraidsusingthemechanicalconnectorsprovided.

Laythethreeearthleadsevenlyaroundtheleadsheathontopofthetinnedcoppermesh.Connectthethreeearthbraidstotheleadsheathusingalargerollspring.Wraptherollspringoverthebraidsandtwistthespringuptightly.CoverthespringwithtwolayersofPVCtape.UN

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Applyonehalflaplayerofwhitefabrictapeoverthesingle-corepolymericendofthejointforadistanceof150mmfromthecableoversheathtoprotectthetinnedcoppermeshtapefromtheheatgeneratedbyshrinkingtheThree-Corebreakout.

Pulltheheatshrinkbreakoutbackoverthejointasfarasitwillgoandshrinkinplace,startingwiththeturretsbeforemovingontothemainbody.

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Wraptheremainingexposedleadsheathwiththestripofblackmasticsealanttape.Thisisanimportantmoistureseal.Donotleaveout.

Positionthewraparoundheatshrinkjointsleevearoundthejointandconnectthetwoendstogetherusingthemaetalchannelandthemetaljoiningclip.

Shrinkthewraparoundsleeveinplace,startingatthemiddlebeforemovingtowardseachendinturn.Thegreenpaintonthesurfaceofthesleeveshoulddisappearwhenthetubeiscorrectlyshrunk.

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Extraheatshouldbeappliedtothemetalchanneluntilthewhitemarkerlinecanbe clearlyseenunderit.

Donotmoveorbackfilluntilthejointhascompletelycooled.



Wraponelayeroftinnedcoppermeshwitha50%overlapovereachinsulatedcorecontinuingacrossthejointedcoresfromthesheathcutonthepolymericcables.Finish50mmontotheleadsheaths.

Laythecopperscreenwiresbackacrossthejointandformthemintothreeseparateearthconductors.Connectthecopperscreenwirestoeachofthreeearthbraidsusingmechanicalconnectorsprovidedinthekit.UN

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Connecttheeachearthbraidstoeachoftheindividulleadsheathsusingatwoturnsoftherollsprings.

Turntheendoftheearthbraidsbackoverthetwoturnsoftherollspringensuringthattheyareflatandeven.Wraptheremainderofthespringlengthoverthebraidsandtwistthespringuptightly.

CovertherollspringswithtwolayersofPVCtape.

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Wraptheremainingexposedleadsheathswiththestripsofredsealanttape.This is an important moisture seal. Do not leave out.

4.4.7 Connection of Screen Wires on Indoor and Outdoor Terminations

Completetheproceduresforinstallingtheterminationsdescribedinsection4.1.8.

ConnectthescreenwirestotheEarthingstudorpositionprovided(outdoorterminations)asapplicableforthegeometryoftheapparatus.

4.4.8 Fitting Plastic Joint Boxes (Trifurcating Joints Only)

Trimofftheendsofthejointboxsuppliedwiththekit,sothatitwillfitoverthecablesenteringthebox.

Usingtheboxasaguide,offerituptothecableandmarkthestandoffpositionsofthemouldingswithachinagraphpencil.

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Removethebackingfromtherubberpatchessuppliedinthekitandapplycentrally(overthepreviouslymademarks)withthestickysideout.

Placethetwohalvesofthejointshelloverthejointandclipthetwohalvestogetherwiththeclipsprovided.Checkenoughclipsareusedtostoptheresinleakingoutwhenitispouredin.

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TapethejointboxtotheincomingcablewithPVCoranothersuitabletape.Iflargegapsareleftwhentheshellisfitteditmaybenecessarytopacktheendsofthejointshelloutwiththeclaypacksuppliedinsomekits.

Forextrasecurity,runalengthofPVCtapedowntheseamsofthejointshellandfittheplasticlid.

4.4.9 Mixing and Installation of Polyurethane Resin

All33kVjointsshouldbefilledwith3-partpolyurethaneresin.CheckthatthecorrectPersonalProtectiveEquipmentiswornatalltimesandtheresinisnotmixedinaconfinedspace.

Checkthelabelonthebuckettoensurethattheresinhasnotpassedtheusebydate.

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Emptythecontentsofthebucketandcheckforanydamagetothepackaging.

Pickupthefoilbagcontainingtheresinandhardenerandapplypressuretothelargeresinpouchsothattheresinbreaksthesealbetweenthetwosectionsandmixeswiththehardener.

Mixthecontentsofbagbykneadingthefoilbagforaminimumoftwominutes.

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Carefullycutoneofthecornersoffthefoilbagandpourallthecontentsintothesuppliedplasticbucket.

Pourapproximatelyhalfofthesandsuppliedintheplasticbagintothebucketandstiruntilitisthoroughlymixedintotheresin.

Pourtherestofthesandintothebucketandmixuntilnorawsandisvisibleandtheresinhasnolumpsinit.

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Pourthemixedresinintothejointshell.

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