erection abb ion

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Jl.t ••,.,....ABB Transmission and Distribution Management LtdSA THS / BU Transmission Systems and SubstationsP. O. Box 8131CH - 8050 ZOrichSwitzerland

BU TS I Global LEe BUill''''.C/o ABS SwitctllJ"lli 1\,\SE - 721 58 Vi,,;llJltlflSweden

Book No. 14Version 0

Erection

,.Suggestions for improvement of this bookas well as questions shall be addressed to:

SU TS / Global LEC Support ProgrammeC/o ASS Switchgear ASSE-721 58 VasterasSweden

J.SitemanErection

TelephoneTelefaxTelex

+ 46 21 328000+ 46 21 3280 1340490 abbsub s

,.Welcome to the preliminary Siteman Erec-tion handbook in the series of bookletswithin the LEC Support programme of BUTransmission Systems and Substations ofBATHS.

It is the intention of the BU to update thishandbook to reflect the philosophy of thewhole BU. We hope that you will find thebooklets 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 mayhave to improve the quality of this bookletas well as the other ones.'i.

CONTENTSCheck on arrival - mobilization page 5

Welding rules page 25

Brazing - Thermic welding process page 31

Cables u •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• page 51

Laying, termination and jointing ofhigh voltage cables <80 kV page 87

Cubicles in electrical rooms - Touch-uppainti ng page 113

Earth ing page 131

Air insulated switchgear page 157

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SITEMAN 01 - 941WAT 910033-1Edition January 1994

Check on arrival- mobilization

3. Site mobilization 73.1 Establishing of site routines 73.2 Site layout 73.3 Temporary power supply ·..· 83.4 Offices and indoor store 93.5 Outdoor stores 113.6 Personnel compartments - canteens 123.7 Site toilets (WC) 123.8 Waste container 123.9 Protection 12

:~~:~~:~~::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::: ~~

This document and parts thereof must not bereproduced or copied without written permis-sion, and the contents thereof must not beimparted to a third party nor be used for anyunauthorized purpose. Contravention will beprosecuted.

Addtional copies of this document may beobtained from ASS at its then current rate

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1. GeneralThis 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 eachcountry and site is unique, even if most of the actions to be taken are universal.

2. Checklist - arrival to the country - siteThe checklist, see Appendix 1, has a general character and summarizes questionsrepeated from site to site and may act as a reminder.

3. Site mobilization3.1 Establishing of site routines

For every project it is of utmust importance that the site procedures and routinesare agreed upon by all parties involved. The earlier ABB brings these questionsforward, 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 areworking in accordance with very strict protocol and are especially sensitive todirect contacts between customer and contractors.

- 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 withinwhich such claims must be submitted and how to measure the work. Note thatan agreement between the customer and the local project manager shall be(issued) signed before any extra work is undertaken. Do not forget to note allclaims 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 togetherwith the consultant, customer, subcontractor, etc.

3.2 Site layoutA site layout showing the service areas shall be done at an early stage and prior tothe start of the site activities. The layout shall show the following: (See Fig. 1 and2.)- Areas allocated to ABB for offices, stores, outdoor storage area, workshop.- Supply points for electricity, telephone, telefax. .- Supply points for water (incl. drinking water) and sewage.- Bench marks for checking of foundations.- The site layout shall also state the areas for the consultants, customer and

others.

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3.3 Temporary power supplyThe necessary temporary power demands have to be investigated and planned forat an early stage prior to erection start. Make a sketch indicating number of supplypoints starting type of outlet amp and volt for each. The following can act as aguide:_ 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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3.4 Offices and indoor storeThe requirements have to be checked for each project. The following informationcan only act as an indication and show some typical solutions.

A typical ASS site office and indoor store for a larger project may be housed inone 20 foot container or more, and can be equipped as shown in figures 3-5.

Example of equipment in the office-container as follows:- desks with lockable drawers- desk chairs- visitor's chairs- book shelves- rack for drawings incl. hangers- desk lamp- air-conditioner, when required- heater, when required- kitchenette- telephone- telex- telefax- typewriter- copying machine- electronic calculator with printer- safeThe kitchenette may be equipped with:- refrigerator- cooker- coffee machine- crockery

20'180- External Internal Internalstandard without with

insulation insulation

Lenght, mm 6058 5862 5802Width, mm 2438 2329 2209Height, mm 2591 2400 2340Weight, kg 2400 2400 3450

Figure 5.Typical indoor store.

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3.5 Outdoor storeThe storage area can vary between 100 - 4000 m2, as a guideline ca 60% ofcomplete switchyard. It can be located either inside or outside the switchyard. Ithas to be fenced in, which can be done either by the customer, by ASS or by thesubcontractor.

The ground shall be level and, if possible, covered with gravel.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 - canteensThe size is planned according to the man-power at peak. Various portablebuildings, container or tents can be used if no stationary facilities are available. Thecompartments shall include lockable rooms for changing of clothes.

If warm meals have to be served at site, a special organization has to beappointed to handle this separately.

3.7 Site toilets (We)The site toilets have to be arranged according to local standards and regulationsand 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.

3.8 Waste containerThe necessary equipment for the waste and arrangement for the emptying isneeded to be arranged either by the customer, by ABB or by the subcontractor asset out in the contract.

Adjacent should sand and water be available in case of fire.

3.9 Protection- First Aid-person- First Aid-kit- Stretcher, blankets- Safety belts- Helmets- Ropes, Sign plates- Fire extinguisher- Fire-plug (hydrant)- Ambulance transport- Telephone to:

- Hospital- Police- Fire-station/brigade-Ambulance

Note. The requirements can vary between countries. The arrangements have to beaccording to local standards and regulations.

4. Checklist for civil workPrior to "access to site" and start of erection, the civil work must be checked. Thechecklist, see Appendix 2, is detailing the most frequent points to be checked.

IJ_J1••...... r\JJIJ" ..·oIIUI" •

CHECKLIST Period

Arrival to the country - siteProject Site designation Order no Page

1

IDealt with by Dale Cont

2I

This checklist is supposed to be filled in with a few words answering following questions.Return one copy soonest to your company. The whole list does not necessarily have to be

icompleted at one time, it can be returned part by part.

1. TRAVEL

1.1 - Travel time?- Routine?- Alternative routines?

1.2 - Custom procedure?- Problems?- Need of visa, etc.?- Health check, compulsary

vaccinations?- Problems to get spare parts

etc. through customs aspersonal luggage?

1.3 - Transportation from airport?- Approx. cost?- Need of contact person at the

airport?

1.4 - Landing card. How to befilled in?

- How to declare money incustom?

1.5 - Other comments regardingthe travel?

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Arrival to the country - siteSite designation

~.1 - Hotel?- Rental of house / flat?- Approx. cost?- Cost?- Laundry?- Standard?

'.2 - Cost of living?- Shortage of important

commodities?- Shortage of foodstuffs?- Possibilities to import

Eu ropean food?- Canteens, restaurants?- Distance to site?

'.3 - Drinking water,need of boiling?

~.4 - Electricity supply?- Voltage?- Frequency?- Reliability?_. Adapter?

~.5 - Climate?- Recommendable clothes?- Insects?

~.6 - Laws/Regulations/Customsuseful to know?

- Religion?- Other languages spoken?- Authorities?

~.7 -- Personal belongings prefer-able to be brought from homecountry?

-~.-

~.8 - Customs regulations forpersonal belongings?

- Transport?

~.9 - Currency restrictions?- Travellers cheques, cash?- Preferable currency?- Accepted credit cards?

..-

SITEMAN 01-94A d' 1

.-

\ppen IXCHECKLIST Arrival to the country - site Period

l'IIlI"1.1Site designation Order no

Page

3Deallwith by Date Cont

42. LIVING CONDITIONS (cont.)

;>.10 Schools?- Swedish / International?- School fees?- Starting date / terms?

211 Address, residence?- Address, private mail?

2.12 Telephone, residence?- Preferable time for telephone

calls (Swedish time)?

2.13 Possibilities for recreation?- Clubs / club fees?- Waiting list?

214 Contact Swedish embassy,consulate?

- Contact man?- Program for evacuation in

case of emergency?

2.15 Other comments regardingliving conditions?

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SITEMAN 01-94 jllUIAppendix 1~.r"I'I'


1.1 - Hospital available?- Standard?- Address?

1.2 - Private doctors available?- Standard?- Address / Phone number?

1.3 - Dentist available?- Standard?- Address / Phone number?

1.4 - Medicine, antibiotica, serum,etc., available?

1.5 - Necessary arrangements incase of emergency sick-transportation to homecountry?

1.6 - Risk of deseases like malaria,dysenteri, etc.?

1.7 - Other comments regardingmedical facilities?

1.8 - Address to SOS internationallocal branch?

...

Appendix 1CHECKLIST Arrival to the country - sitePeriod

IJwjoct_.

Site designation Order no Page

----- 5Dealt with by Date Cont

------._. 64. WORKING CONDITIONS

4.1 - Address for company mail?

4.2 Telephone number duringworking hours?

- Preferable time for calls fromSweden (Swedish time)?

- Time difference - summer,winter?

4.3 Telex number?- Telefax number?

4.4 Working hours?- Local holidays?

4.5 Work permit / permit to stay?

4.6 Visit local ABB, contact man?- Available assistance from

local ABB?

4.7 Visit customer, contact man?

4.8 - Visit consultant, contact man.

4.9 - Visit subcontractor, contactman?

- Needed tools and equipmentfor erection available?

- Standard of supervisors andskilled man-power?

4.10 Visit transport company, con-tact man?

- Needed equipment for safeoff-loading available?

- Control of lifting devices?

4.11 Visit civil contractor, contactman?

- Any hinderance on site forstart of erection?

4.12 Local purchasing of erectionmaterial possible?

- Approx. cost level?

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·.13 - Local purchasing of erectiontools possible?

- Approx. cost level?

·.14 - Workshop for minor repairsand manufacturing available?

·.15 - Plant for hot dip galvanizingavailable?

·.16 - Bank opening accountprocedures for transfer?

·.17 - Customs procedures forhardware?

- Ocean freight / air-freight?- Possibilities for smoothening

customs procedures?

·18 - Location of site, travellingtime?

- Road description?

.19 - Electricity supply, worksite?- Voltage?- Frequency?.- Reliability?

·.20 - Other comments regardingworking conditions?

1.21 - Telephone number to police,ambulance, fire department?

1.22 - Trafficability to site, summer,winter, raining seasons?

CHECKLISTAooendix 1

Arrival to the country - sitePeriod

IJrojllcf--Site designation Ordarno Page

7Dealtwilh by Dale Cont

-5. TRANSPORTATION

5.1 Local public transports?

5.2 Rental of cars?- Approx. cost?

5.3 Purchasing of cars?- Approx. cost?

54 Fuel availability?- Approx. cost?

5.5 Driving license international /local?

5.6 Car insurance and regula-tions?

5.7 Workshop and spare partsavailable?

5.8 Heavy trucks?- Road conditions?

5.9 Import license?

510 Other comments regardingtransportation?

iJ.iJ-

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This checklist is supposed to be filled in with a few words answering following questionli.The main purpose however, is to remind the Site Construction Manager of all Civil Workto be checked before the erection shall start.

1. OUTDOOR

1.1 Roads- to the site- inside the site

1.2 Trafficability- trafficabillty large / heavy

equipment such as trans-formers

- trafficability building - anderection cranes limitations,which?

1.3 Laying of ground network- is expensive clearing required.- is re-filling required beforehand.- earth resistance?

1.4 Cable excavation- operating space available?- excavation for fencing?

1.5 Material unloading- in store- switchgear room- battery room- control room

is it possible / convenient?

1.6 Outdoor storing-steelwork- cable drums- free and levelled area size?- sleepers / beams protection?- fencing?

1.7 Fencing- foundations- connection ground network- gates function / locks- corrosion protection

1.8 Snow clearing

CHECKLIST Periodppendix

Arrival to the country - site1""''''1 Site designation Order no.

Page

Dealt with by2

Dale Cont

32. FOUNDATIONS

;>.1 f-oundations (general)correct location

?;> Individual foundations- correct placing- correct construction- foundation bolts

.size

• placing• clean and undamaged

threads• nuts and washers fitted

2.3 Large foundations(transformer / reactor)- dimensions- rails- embedded steelplates for

jacks / eyelets- foundation bolts

2.4 Oil pit- capacity- filling- cover- oil outlet

2.5 Cable routes

2.6 Ground network

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SITEMAN 01-94 n.,.,Aonendlx;' ;1'."····


CHECKLISTAppendix 2

Arrival to the country - sitePeriod

I~roloct Site designation Order no Page

4Dealtwilh by Dale ConI.

5

4. STATION BUILDING

4.1 Station building- function- quality- trafficability- painting-water- heating

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- water, showers, WC ready

for use- drainage correct inclination- lifting devices available- cleaning

ll.J.••

JI.II-

SITE MAN 01-94

Appen~ix ?II:.Arrival to the country - site

Site designation

).1 Security- fence and gates ready?- lockable stores?- site guarded?

5.2 Battery room- design- ventilation- holes- explosive-proof light fittings-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

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1. General 27

2. Standard marking 27

~:~g~~~em:~~~~~g.::::·.::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::~~~:1 ~:~~t~~~b~~~·:::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::~:3.2 Core numbers 28

Accessories and tools 28~~ ~

~~hx~~~~a~d~';d~':::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::: ~:Open type markers 29



II.

'III

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1. GeneralI ~lCre are a great variety of cable marking systems available on the market. ASShave chosen to work with the two following suppliers:- Partex.- Fleximark.

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 a computerized printer. The technicaldata are taken directly from the cable and core lists.

2. Standard markingAll 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.- Cable number.

~Core no. Cable no.

Core no. Cable no.T T

1033 -12342 -1234102 1 -1234 1234

101PE-1234-b

Fig. 2 Marking of a cable end consisting of 3cores and protective earth conductor

2.1 Cable markingYellow markings with black characters shall be used .

Holder for cable markings typePartex, which are used when extramany characters are required

2.2 Core markingWhite markings with black characters shall be used.

3. Mounting3.1 Cable numbersThe marking sleeves are to be fixed on the sheath of the cable close to thestripped end, see figure 6. When cables are terminated in a connection box, themarkings are to be fixed to the cables outside the box. The markers are threadedonto a plastic strap, which is fastened around the cable (figure 3).

3.2 Core numbersThe 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 theright or from bottom to the top:- Core number.- Cable number. See figure 6.

4. Accessories and tools4.1 PartexPlease contact Partex Fabriksaktiebolag for further information.

Address: Box 80S-547 01 Gullspang, SwedenTelephone +46 0551 20560

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4.2 FlexipartPlease ccontact Miltronic AB for further information.

Address: Box 1022S-611 29 Nyk6ping, SwedenTelephone +46 0155 87000

4.3 Other standardsOut~ide S~ed~n various customers may require special marking system. Thedesign office will then order the material needed and issue the necessary installa-tion instructions.

4.4 Open type markersPartex can also deliver an open marker, with which already terminated wires canbe marked. See figure 7.

I For diameter2.4-6.2 mm~---

·.,~

SITEMAN 11 - 941WAT 910033-11

Edition January 1994

Brazing

Thermic weldingprocess

A1.2.3.4.5.6.6.16.26.37.7.17.27.37.4

7.57.68.9.10.10.110.210.310.410.511.12.

BRAZINGGeneral 33Brazing equipment 33Setting the torch pressure for acetylene and oxygen 33Definitions, clarification of words 34Units of measure 34Flame brazing 34Wedling torches ...34Types of flame... .. 34Bunsen burner... . 35Different types of solder, their characteristics and use 35Silver solder . 35Brass solder .. 35Phosphor-copper solder... .. 35Copper solder .. 35Heat-resistant solder .. 36Aluminium solder .. 36International standard solders; preferred standard 36Flux 36Description of methods 37General...... .. 37Brazing, joining of copper bars (75 x 6) . . .. 37Brazing of copper bars (50 x 10) with prelocated solder..... 38Brazing of earthing conductorsfT-joints (branch-joints) 39Brazing of aluminium T-joints . .. 40Different types of solder and their working temperature 42Effective temperature ranges of different fluxes 43

THERMIC WELDING PROCESS 44Personal protection at welding 44Storing/keeping of weld metal 44Preparation and handling of welding moulds 44Preparation of conductors 44Thermic welding process 45Final treatment of connections 45



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1. GeneralBrazing is a method used for joining materials in cases when a joint of greater strength, than that obtainedby soldering, is required. The strength of the joint can be the same as that of the materials to be joined.

In this instruction brazing solder will be called solder only.The working temperature of the solder and the materials to be joined is, however, to be least 450 ·C.Copper and copper alloys can be easily brazed, but tin, lead and aluminium additives make brazing more

difficult.Carbon stells and alloyed steels can be easily brazed, but the brazeability will be reduced when the

carbon content and the alloy content, respectively, are increased.In the case of cast iron, the graphite opposes the wetting ot the solder.Aluminium and aluminium alloys can also be brazed.The strength of the joint varies, depending on the metals and the type of solder. As a guiding value for

steel, copper and brass, an initial tensile strength of 200 N/mm2 can be reckoned with. Adequate safety istherefore ensured.

REGULATORBLUE HOSE

FLASHBACK ARRESTER-RED HOSE

3. Setting the torch pressure for acetylene andoxygen.

- Screw in the diaphragm screw 1.- Turn clockwise- Read off the intermediate pressure on the low-pressure

gauge 2- Adjust to approx. 5 kgf/cm2 for oxygen and to approx.

1 .5 kgf/cm2 for acetylene.

4. Definitions, clarification of wordsBrazing solder - bonding material used in brazing - of metal or metal alloy. The solder must have thecapability 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 themateiral 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

flow-out and binding of the solder.

Maximum brazing temperature is the highest temperature that can be allowed without causing damage 10

the solder, flux or the parent material.

Bonding strength of a solder is the tensile strength between the solder and the parent material, measuredat 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 gaswelding. The solder is often referred to as brazing solder (example: joint brazing).

Gap brazing - The surfaces which are to be joined are parallel and placed at a certain distance from eachother (brazing gap), which ·ISnormally less than 0.5 mm. The solder flows out in the gap due to capillaryaction - 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 aV, 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 byhand and melts when it comes into contact with the heated parent material.

Brazing with prelocated solder - Before heat is applied, the solder is placed in the gap between the two

surfaces.

Wetting _ The ability of a molten drop of solder to spread itself out on a binding surface. Wetting can onlyoccur above a certain temperature and on clean surfaces.

5. Units of measurePressure:1 Pa ~ 1 N/m21 bar ~ 100 kPa1 Ibf/m2 6.98 kPa1 psi 6.98 kPa1 kp/cm2 98.1 kPa

6. Flame brazingThe material is heated with a burner - welding torch or bunsen burner.

I---~!outer flamed Sh:;a:CC!lame

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outer flame-~-- dark zone==s core flame_.------~--- -===~~~~-outer flameI. core fl ame~ __==--=-:±:r=

6.3 Bunsen burnerAn Lp-gas burner which consumes oxygen from the surrounding air through injector action in the burnernorzzle.

r7. Different types of solder, their characteristics and useThe 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., areto a great extent dependent upon the composition of the solder.

The solder is divided into different groups, such as;- silver solders- brass solders- phosphor-bronze solders- copper solders- heat resistant solders- aluminium solders

7.1 Silver soldersThese have good soldering properties. The working temperature lies between 600 and 800 'C. They arerelatively 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 arenot recommended for this purpose.

7.2 Brass soldersThese 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 forother metals except aluminium.

7.3 Phosphor-copper soldersThese 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).

7.4 Copper soldersThese 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.

N.B! They are not suitable for brazing copper or copper alloys.

7.5 Heat-resistant solderThis solder is relatively expensive and its working temperature is also high, 960 ·c, which increases thecost still further. It is only suitable for brazing of stainless steel, heat-resistant steel, nickel and nickel alloys

7.6 Aluminium solderThis is relatively inexpensive and its working temperature is low, 500 'C. It is used for brazing aluminiumand aluminium alloys which have a long magnesium content.

8. International standard solders; preferred standardSolders conforming to ASEA standard and equivalent German (DIN), British (BS) and American (AWS)types:

0) No DIN BS1845: AWS ASEA ABB8513 1977 A5.8.81 article no article no

1 L-AISiI2 AL2 BAISi4 24261 11241001-32 L-Cu CU2 BCu-1 250103 LCuZn40 cn RBCuZn-A 252514 L-Ag2P CP2 BCuP-6 25909 11221110-1045 L-AG15P CP1 BCuP-5 25983 11221131-106 •• )

11221131-111 "0)6 25990 11221171-2877 L-Ag55Sn AG14 BAg7 26829 11251040-1

*) No.1. Aluminium solder for brazing of aluminium and aluminum alloys

(Flux ASEA 1233 0012-207)2. Copper solder for brazing of steel. (Furnace brazing - no flux required)3. Brass solder for brazing of steel, copper and copper alloys but not stainless steel

(Flux ASEA 1233 0012-201).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.***) Flat bar 2.5 x 6.

6. Silver solder brazing in general; steel, stainless steel, copper and copperailoys. (Flux ASEA 1233 0012-201).

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, highlycorrosion resistant. (Flux ASEA 1233 0012-201).

9. FluxThe purpose at the flux is to dissolve the oxides on the binding surfaces and to prevent the formation of newoxides 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 onthe fact that it must be adapted to the working temperature required by the solder and, furthermore, that inthe molten state it must be so light flUid that it can be drawn into the gap between the pieces of parentmetal. 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 thebest 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.Note! The flux consists to a great extent of borax and boric acid but it also contains

additives which can be dangerous or poisonous. The precautionary noticeshould, therefore, be read carefUlly.

Note! The flux does not remove rust, oil, grease, paint or otherimpurities. Brazing flux is normally supplied in powderform. Mix the flux with distilled water to form apaste and then apply it with a brush. I.

10.1 GeneralPreparations: Select a suitable burner.

Welding burner[3unsen burner (acetylene or L.P gas)

rhe size of the burner depends on the dimensions of the item to be joined.Select solder and flux as mentioned in clause 8.

Cleaning: Wipe off grease and other impurities.If the oxide layer is excessive, brush or grind it away.

Assembly: Assemble the items in the correct position.-- Apply flux to the appropriate surface.- The width of the gap must be correct.- Secure the items so that they are not displaced during the brazing and cooling-off periods.

Brazing: Ignite the burner and adjust to obtain a suitable flame.Warn the parent metal first.- Apply more heat to the heaviest part or that part which dissipates heat quickest.

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.

Apply solder- Place the solder against the pieces to be joined.- Do not point the flame directly against solder.- Heat only so much that the solder melts uniformly and is drawn into the gap.- Apply solder until the gap is completely closed.- Cool the joint.

10.2Brazing, joining of copper bars (75 x 6)Preparations: Select a torch nozzle of suitable size, e.g. 700 I.Choose phosphor-copper solder L-Ag 15P CP1, 6 x 2,5 mm, page 7 no. 5.

Pre-cleaning: Wipe off grease and other impurities.Clean the joint surfaces with an abrasive tool or a brush.

Place the bars on a heat-insulating base, e.g. bricks and secure them in position with 30 mm overlap and agap width of 0.2 mm.

Brazing: Ignite the burner and adjust to obtain a suitable flame.Neutral flame

- Warn the bars first, alternatively until they obtain a dark-red colour; both barsshould reach the working temperature, approx. 700 'c, simUltaneously.

Apply the solder.

10.3 Brazing of Cu-bars (50 x 10) = with prelocated solder

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 isrecommended:

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.

Fig.10.Place the solder on the binding surface of one of the details.

bd==

Fig.11Relocate the details to their correct positions and secure them without altering the position of thewelding clamp.

Brazing: Ignite the burner and adjust to obtain a neutral flame.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.

--,---

II.

Inspection: Ensure that the solder har penetrated through and had adhered along all the edges of theIJlmj"JI) surfaces.

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 tothe table). Flux is not necessary.

Procure approximately 1 m Cu-wire of diameter 1.5 - 2 mm, for lashing the joint and strips or insulatingtape.

Assembly: Place the branch line against the trunk line,approx. 50 mm, and thereafter with approx. 50 mmradius as shown in the figure.

Using plastic straps or insulating tape, fix the lines to eachother. The distance between the fiXing points should beapproximately 40 mm in order to provide space for thelashing wire.

Wrap on the copper lashing wire, hard and tight, approx. 25 mm between the fixing points.Twine the two ends of the wire to secure the joint.

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 theflame.

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 thebranch line.

Do not point the flame directly against the solder.Heat only so much that the solder melts and flows in between the wires.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.Select a suitable solder, aluminium solder e.g. ASEA 11241001-3; refer to pages 17 and 7 (no. 1.).

Select a suitable flux; see group A on page 18, e.g. ASEA 1233 0012-207, page 7.Use flux in powder form on the joint; it is then most active on aluminium.

Assembly: Secure the details in the desired position with the aid of a welding clamp or other fixture.Ensure that the gap is as small as possible, preferably less than 0.5 mm.

Check the dimensions.

Brazing: Ignite the burner and adjust to a suitable flame.- Weak carburizing flame.

Heat the end of the solder careully and immerse it in the flux.- The flux will adhere to the solder

Preheat the joint- Enough to enable the flux to fasten.

Add flux with the aid of the soider.

----I-----,I-------I.

Maintain a small angle to the point of the jointMove 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 details (melting temp. of AI is 660 'C).

Continue heatingHeat 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).- Heat until all flux has melted to a clear fluid.

Apply the solderApply the flame with a sweeping movement

- Appiy the solder.- Heat in the vicinity of but not directily on the solder.- Heat until the solder begins to melt.

- Apply the solder at an even rate along the length of the joint- Heat only so much that the solder melts evenly and flows into the gap.- Adapt the amount of solder so that a fillet is formed on each side of the joint.

Post-cleaningRemove all residual flux.- Use a wire brush and water.

InspectionEnsure that a fillet is obtained on each side.

580550

Solders alloysfigures states

Ag85 Mn15

Cu48 Zn41, 8 Ni1 0 SiO.2

Designation Remarks

Ag32 Cu33 Zn35 Silver solder ') Asea 1122 1171-28Ag44 Cu30 Zn26 Silver solderAg5 Cu 88.8 P6.2 Phosphor Copper solderAg2 Cu91.5 P6.5 Phosphor Copper sOlder'l Asea 1122 1110-1O~Ag15 Cu80 P5 Phosphor Copper solder' Asea 11221131-106Ag49 Cu16 Zn23 Mg7.5 Ni45 Silver solder -10S

Ag55 Cu21 Zn22 Sn2 Silver solder ') Asea 11251040-1Ag34 Cu22 Zn24 Cd20 Silver solder

Ag40 Cu19 Zn21 Cd20 Silver solder

A18? Si13 Aluminium solder') Asea 11241001-3

AI86 Si10 Cu4 Aluminium solder

1111111111111111I-till,1111!IIII

Jill 500

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Group C

1. Personal protectionWelding smoke is developed during the welding operation. Precautions must be taken to minimize inhala-tion of the welding smoke, especially in narrow and poorly ventilated rooms. Arrange for efficient generalventilation as well as local evacuation of the smoke. If, for one reason or another, general protectiveequipment is impossible to use, then individual personal protections have to be used.

The welding smoke contains thin dispersed metallic oxides from zinc, copper, magnesium, etc. and mightat casting and welding operations cause acute poisoning with fever and symptoms similar to those ofinfluenza. Special treatment is usually not required. The symptoms on otherwise healthy persons. Whendoing the final treatment (for example removing the slag) of the weld joint there is a risk that hot slag will flyaround. Furthermore, handling the hot welding mould must be done with care to avoid burning damages.

Always use protective goggles and gloves.Suitable protective gloves against heat ant thermal radiation is for example gloves made at Namexfilt (do

not contain asbestos).

2. Storing/keeping of weld metalWeld metal shall be stored in a dry and fire secure room. Stored in a dry place the storage time is practicallyunlimited.

Weld metal boxes must not be subject to chocks during transport and handling as the ignition powder -being pressed together in the bottom of the container, might mix with the welding powder, and therebycausing porous welding joints when being used.

3. Preparation and handling of welding mouldsPrior to start of the welding the mould must be heated to min. 100 ·C.

Use gasol fire (preferably gasol stove) for heating. The welding mould must be kept absolutely dry duringthe welding operation. A damp mould may give a porous welding joint. If it is difficult to keep the mould dryfor example during rain, it is preferable to postpone the welding until better weather conditions appear.

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, usea 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 thatspare moulds are ordered in sufficient numbers.

Welding moulds must be modified to fit other wire dimensions than originally specified

4. Preparation of conductors (wires and bars)Oxide, dirt, etc. must be removed. Use wire-brush or file-brush. Oily/greasy conductors must be cleanedwith 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.

~-~ ~right

Fig. 22

Wet or damp conductors must first be dried out through heating with a gasol flame or by placing themimmediately 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.

II-

--II.11111

5. Thermic weldingInsert the conductors into the mould according to the applicable instruction (for each type 01 "11<11" 'III' '.

Damaged/cracked or worn-out moulds must not be used! Scrap them.When a sealing tightening kit is used, it must only be applied in the outer edge of the conduclor elI<IIIII"I,

nol inside the weld cavity.Check that the right size of the welding metal container is chosen. Compare with the number of 1110 w"I,1

mould type plate.Insert accompanying steel disc into the mould with the cone down. Pour the welding powder carefully HII"

the mould in order not to move the position of the steel disc.Knock the ignition powder out - it is pressed together in the bottom of the container - and spread it evenly

on top of the welding powder and on the mould lip at the cover opening. The latter in order to facilitate theignition.

Check that the mould is correctly closed around the conductors and standing in vertical positionbefore ignition.Close the mould cover and fire the ignition powder with a flint gun or other means without risk for burninginjuries.

When fire use protective gloves and goggles. Don't stand in front of the cover opening.When welding in narrow compartments or where it is an obvious risk that the mould will be affected by wetand damp conditions it is recommended that firing is made through a firing tape. Cut an approx. 10 em longfiring tape and insert it into the mould in such a way that the cover will keep it in position.

After welding, wait until the melted metal is solidified before opening the mould as described under item 3.

Should the melted metal have been leaking out in spite of the fact that sealing kits have been usedthe mould is probably worn out and should be scraped.Notel Material flown out from the mould means decreased mould quality.

Should the welding for some reason have been unsuccessful, it is recommended that the branched-offwire is cut and a new weld is made beside. Alternatively, the bad connection may be shunted according tothe figure below:

6. Final Treatment of connectionsRemove solified slag remains on the connection. No other final treatment is required.

Note! When welding copper wire to galvanized rods or wires, the connection shall after having cooleddown to below 100 'c be covered with cable compound, treated with insulating varnish or zinc-rich paint tomake it resistant against galvanic corrosion.

Ignitionpowder

Regarding personal protection equipment, see item 1.1) Preparation of welding mould according to item 3.2) Preparation of wires according to item 4.3) Insert wires in the mould according to above figure.

Note: If the run wire is 240 mm2 or above and the tap wire 120 mm2 or above the run wireshall be cut and with a 3 mm gap be positioned under the cast cavity centre.

Always place the tap wire in contact with the run wire.4) Close the cover well. Make sure that the wires have not moved out of position.5) Carry out the thermic welding operation as described under item 5.6) Make the finai treatment of the joint according to item 6.

-.-.-.-. Fig.25-.-III-:11-IIl

--.--

--

1) Preparation of welding mouid according to item 3.2) Preparation of wires according to item 4.3) Insert wires in the mould according to above figure.

Note: Always place the tap wire in contact with the run wire.

4) Close the cover well. Make sure that the wires have not moved out of position.5) Carry out the thermic welding operation as described under item 5.6) Make the final treatment of the joint according to item 6.

Ignitionpowder

Fig.26 1) Preparation of welding mould according to item 3.2) Preparation of wires according to item 4.3) Insert wires in the mould according to the above figure.4) Close the cover well.5) Carry out the thermic welding operation as described in item 5.6) Make the final treatment of the joint according to item 6.

_c. JOint Type: GR

----_ ..-_.---lI.-

Fig27 1) Preparation of welding mould according to item 3.

lIi_

2) Preparation of wire and rod according to item 4.3) Position the wire on top of earthing rod under the cast cavity centre.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, toguarantee that the mould will not slide down during welding.

I. 5) Carry out the thermic welding operation as described under item 5.6) Make the final treatment of the joint according to item 6.

I.,.I.1111II.

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.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, toguarantee that the mould will not slide down during welding.

5) Carry out the thermic welding operation as described under item 5.6) Make the final treatment of the joint according to item 6.

I-,---II-

--

SITEMAN 12 - 941WAT 910033-12Edition May 1996

List of Contents1. General 531.1 Classification of cables . 531.2 Stretch force .. ..531.3 Temperature .. 531.4 Bending radius .. 531.5 Distance between cable planes .. 531.6 Interrelations and location of different classes of cables 541.7 Distance between cables and rated data... .. 541.8 Cable drums .. 541.9 Handling of cable drums at site 541.10 Rotation of cabie drums .. 551.11 Braking of cable drums .. 552. Method of laying 562.1 Laying by hand ..562.2 Laying by motor-driven equipment, general......................... .. 572.3 Crossing of roads.. .. 582.4 Laying cables indoors 582.5 Cable channel....... .. 582.6 Cable ladder....... . 602.7 Section trays ..612.8 Conduits............ . 622.9 Cable table 633. Fixing of cables ...............................................................•................ 643.1 Supporting bar. .. 643.2 Profiled bars ...653.3 Suspension wire..................... ..663.4 Free suspension .. .. 673.5 Clamps for cables and conduits .. 683.6 Clips and cable straps.. .. .. 683.7 Cable straps .. 693.8 Lashing wire .... 703.9 Expansion bolts and plugs .. 704. Marking of cables 714.1 Standard marking .. .. 714.2 Cable marking .. 714.3 Core marking .. 724.4 Cable numbers................................... .. 724.5 Core numbers .. 724.6 Partex .. 724.7 Flexipart .. 734.8 Other standards. .. 734.9 Open type markers .. 735. Term inations 735.1 Length of cable ends 735.2 Termination sheet 746. Sensitive cables 757. Fireproof cables 76000. Examples of typical installations 77



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--J.

1. GeneralThis instruction describes standard method for laying and installation of cables. It does not cover cable-laying in special environments, such as in high temperature areas.

1.1 Classification of cablesThe following ABB cable standard and classification shall be applied on each installation:

KO POWER CABLES. LESS THAN 1000VK1 POWER CABLES. MORE THAN 1000 V

The high current in these cables may induce parasitic currents in screens and conductors of cables whichare laid in their vicinity. Well screened power cables can be laid in the same cable trench with other cables,but control and measuring cables require a minimum distance fa 300 mm from any power cable.

K2 CONTROL and SIGNALThe relay and signal cables shall be laid at least 300 mm from both power and measuring cables.

K3 CURRENT and VOLTAGE MEASURINGThe cables shall be laid at least 300 mm from other types of cables.

K4 SENSITIVE MEASUREMENTSThese cables shall be laid in separated and completely screened channels of copper or galvanised steelpipes.

K5 OPTICAL CABLESThese cables are not effected electrically by adjacent cables, however, these cables shall be considered ashigh risk of mechanical damage and shall be treated accordingly. For more details please refer toSITEMAN 13-94.

K6 PREFABRICATED CABLESThese are cables that carry control and communication signals between differenct control panels, mainly inthe same room. The cables have been prefabricated and tested with their intended end connection, thecables therefore have to be installed as per the manufacturer's instructions.

1.2 Stretch forceThe maximum stretch force when laying cables shall not exceed:- copper conductors . 70N/mm2 (7 kg/mm2)

- aluminium conductors .. 40N/mm2 (4 kg/mm2)

1.3 TemperatureIf the ambient temperature is below -10'C the cable must be heated before laying. Otherwise it will be toorigid to handle and the insulation could be damaged during bending.

Preheat the cable indoors at a minimum of 15 ·c for 24 hours. Temperature fluctucation results in lengthvariations in the cables and they must therefore be laid in gentle curves when the cables are long.

1.4 Bending radiiThe bending radii of the cables shall not exceed the following:Type of cable For laying When installed

Multi-core 15 x diameter 10 x diameterThree-core 15 x diameter 10 x diameterSingle-core 15 x diameter 10 x diameterPEX 20 x diameter 15 x diameterFibre optic cables 100 mm *) 200 mm *)

1.5 Distance between cable planesThe 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 cablesThe different classes of cables are grouped separately on racks.- KO, High voltage cable- K1, Low voltage power- K2, Control and signal- K3, Current and voltage measuring- K4, Sensitive measurements.- K5, Optical cables- K6, Prefabricated cables

'1.7 Distance between cables at rated dataCables shall be laid as shown in the installation documentation, and as described in section 1.1 of thisreport (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.

1.8 Cable drumsCable 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 siteA ramp, crane or forklift may be used for unloading cable drums. If neither of these are available, aprovisional ramp of square timbers or steel beams should be erected. The angle of inclination should notexceed 1 in 4. The timber and beams must be strong enough to support the weight of the drum.

Cable drums and coils, even if they are small and not heavy, should never be thrown onto the groundwhen 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 sitearea. The drums should never be rolled over longer distances.

I.I.I.II.I.

1.10 Rotation of cable drums

Standard cable drums have an arrow marked on the side. This arrow is showing the direction for rolling thedrum on the ground dUring short transits in order not to loosen 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 theOpposite direction to the pull.

(CJABB cab\eS

1.11 Braking of drums

When pulling off the cable, drum stands with hydraulic jacks and mechanical brakes are preferred to beused. The cable shall be pulled from the cable drum at a controlable and easy stopable rate. If the stand isnot 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 theground, not pulling.

2. Methods of layingBefore installing any type of cable, the entire cable route shall be thoroughly inspected to ensure that thereare no obstacles or hazards that may cause damage to the cables that shall be installed. This inspectionshall be made regularly during the cable installation period.

The following methods may be employed for allying of cables:- Laying by hand- Laying by motor-driven equipment.

,.2.1 Laying by handRollers placed at distances of 3 to 4 m will facilitate laying. Corner rollers or similar devices should beprovided where there are bends in the route, the minimum bending radii of the cables shall be maintained atall times, see fig. 4 and 5.The cables are to be carried by hand, if not supported by rollers, with the men standing 4 to 6 m apart alongthe cable route.

,.

Fig. 4 Layingby hand by theuse of cablerollers

,.

~.Fig. 5 Cornerrollers

2.2 Laying by motor-driven equipmentMlliordnven equipment is normally used where there are a large number of cables to be installed in longlUllS where the routing is not too sophisticated. This system is not normally used in HV switchtyard areas.

I he laying with motor-driven equipment is here divided into two groups:1.'lYing by motor-driven rollerslaying by winches and cable-pushers.

When motor-driven equipment is considered to be used, the following simplified conditions can act as aquide:

The cable volume, i.e. the volume of cables, has to be of such a proportion that the time gained by usingthe equipment is not lost in the transporting and handling of the motor-driven equipment.The cable diameter should not be less than 30 mm, more than one cable can be pulled simultaneously.

- The length of the cables should in average be more than 150 m.The cable routes shall be designed in a manner making it possible to postion the cables directly on theirfinal 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 isused, care shall be taken to ensure that all conductor strands are evenly stressed, see fig. 9 and 10.

2.3 Crossing of roadsIt is always advisable to provide spare pipes in order to avoid having to dig up the road if further cables areto be laid. Ducts which are not used at once should be plugged. The cables should not rest on the sharpedges 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 openingshall be removed prior to pulling in the pulling in the cable in order to prevent stones or coarse soil from

getting into the duct.

2.4 Laying cables indoorCables 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.

2.5 Cable channelThe 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.The cables can either be placed directly at the bottom of the channel or on cable support ladders.The main advantage of using cable channels is that cables may easily be replaced, added or inspected.

--J.

J.,.J.

Fig. 9 Cablechannels outdoor

Fig.10 Cable channel in outdoor switchboardplant.

2.6 Cable ladderDefinition of cable ladders specifies that the distance between the rungs may be a maximum of 300 mm. Ifthe rungs have a flat top surface they should be at least15 mm wide and round rungs should have a diame-ter of at least 19 mm.

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.

Fig. 12 Cable laddersfitted on ceiling pendant

Fig. 13 Wrapping a1-phase cable

At bends or where a cable leaves the cable ladder, the cable should be secured with plastic straps orlashing wire. In the case of vertical assembly, the cable is asia fixed to every second rung. Cable over40 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 particularlysuitable due to their great mechanical strength and good cooling properties.

J.

J.

,.,.,.,.

2.7 Section traysVarious sections are available. Most frequently used are Land U perforated sections.

Trays (U section) are available up to 600 mm.If used outdoor, all sections must be hot dipped galvanized, indoor electro-plated with zinc.

2.8 ConduitsConduits are protective pipes which may be of plastic or metal, rigid or flexible.

The conduits have to be secured to structures, machinery, building or equivalent.In harsh environments when the cable sheath gives insufficient protection, conduits should be used to

protect the cable. Steel pipes also offer an excellent protection against electrical disturbances.Flexible conduits may be used to mechanically protect flexible cables connecting electrical units.

111--

:>.9 Cable tableII", cable table constitutes a list of the cables in the cable network. The following are specified for eachcablc:

Iype of cablenumber of conductors and their sizescable lengthcable numbercable classification K1, K2 etc.destination point Adestination point A

I ~~~~,~~~~"'~~1'L356.RO 6~:::.~~:~:..t;:;I~·.::~~':"~,\r~1i'~'"ABB/•...OWlUOVIKA tAt<163 L.HELLSTRtlM

i·:-''-Kr,nu :KANSlUTNINGSPUNKTA :lEANSLUTNINOSPUNKT B :ll:ANMi'iRKNIHG)~rN~I",,;ifikntion lEt *Nr *In~d: XPostbetecknin<;l ll"Postbet•••ekning l(

-,,--:_.. ------------ -- ----oE----.IE - ---JIl--- --!If- ---------- - - lo:--- ----------- ---:lE-----

r'KK,1 (1)(50/25 75 90001 Kl +SA.l =P3-WT. TtrKKJ 4)(50/25 51 90002 Kl +5""'.1 =P3-HT. T2

r'liiJ 4)(185/50 4590003 Kl +SA.1 +5B.lfKKJ 4)(6/6 17 90004 Kl +5A,' =AL-WBT1.U12

[KKJ 4)(6/6 17 90005 1<1 +5""'.1 =Al-HDU1.Ul1

"K~KJ";II24_0/5_01 11090\°061KL--' +:~A" ~---.T~osl,,,at'oo Pc:,t_____________ Du1•• .J"'L,."~,,lo••.. YO"l'\t A'

____ ::JSepato.t"ofl c..'lo.ss

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

~ ----,-::,\,i,,- '14o~t\,

'- -l.<Cobi. "'0"-

, 1", -~-\k t'j1"-

3. Various fastening materialThe following selection of material Is only indicative. When ordering fastening material it is of utmostimportance to choose stainless material of the right quality for the purpose:

- 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 barThe ASEA standard supporting bar is hot dipped galvanzied and form pressed in order to provide space forthe cable straps between the iron and the base on which it is installed.

SUPPORTING BARMaterial: Steel, hot dipped galvanized 80 ~.

The bar is intended for installation of cables and tubes.A A

The bar should be mounted on the concrete with screws and plastic plugs or nailplug.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.

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Pl astic-straps '-;Z';l:>>~~!~~d!<?~'lj~4~~~;';':

Fig. 22 Cable draWing on strip iron in transformerassembly

Fig. 23 Cable drawing on strip iron along concretewall

3.2 Profiled bars

The section of the profiled bar is designed to act as a holder for special types of cable clamps. The barshould be hot dipped-galvanized or of other stainless material.

26 x 48 For embedmentr 1

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 forembedment in concrete .

. The distance between bars used to support cables shoUld be approximately 500 mm. Cables may befixed 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 cableInsulation.

3.3 Suspension wireThe 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. 26 Illuminationassembly with suspensionwire. The cable is fastenedto the wire with plastic straps

Fig. 27 Suspension wirewith turnbuckle

3.4 Free suspension

When parts of machinery are moving in relation to each other one method to solve the interconnection is touse freely suspended flexible cables.

The cables should be fastened in their ends by means of special supporting clamps releasing the strainfrom the conductors.

A multi cable loop may be kept together by brackets or terylene string where mechanical forces can occurdue to short-circuit.

Fig. 28 Freely suspended cables in a furnace

assembly

3.5 Clamps for cable and conduitsThere are a lot of both metal and plastic clamps for cables available on the market. The cable is mostlyscrewed 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).

3.6 Clips and strapsClips 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.

-•---.--.,...---••i

•--

I[J) Stainless steel

~

~l----------------------------; c:>

@1~---------------->[jgJ1------------------

f.JD----------I III :15 Cable straps (must be of plastic resistant to UV-radiation or stainless steel)

UV = Ultra violet (light). See also SITEMAN 84-011

3.8 Lashing wireThe lashing wire consists of a plastic coated galvanized steel wire. The wire is basically used to secure thecables to cable ladder rungs in bends and when the cable is leaving the ladder.Diameter Braking load Weight/100 m

Lashing wire white PVC 1.5 mm 25 kp 1.8 kgLashing wire black PVC 1.5 mm 25 kp 1.8 kg

3.9 Expansion bolts and plugsThe following figures show some samples of bolts and plugs used in concrete.

1;~;'iI_;iiiiiiii,iiii:a::l't10

4. Marking of CablesThere are a great variety of cable marking systems available on the market. ABB have choosen to work withthe two following suppliers:- Partex- Fleximark.

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 fromthe cable and core lists.

4.1 Standard markingAll 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.

~3-123LCore no Cable no

3 -12342 -12341 -1234

PE-1234

4.2 Cable markingYellow 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 markingWhite markings with black characters shall be used,

€:J3-1234q

~ I 3-1234

4.4 Cable numbersThe marking sleeves are to be fixed on the steath of the cable close to the stripped end, see fig, 45, Whencables are terminated in a connection box, the markings are to be fixed to the cables outside the box, Themarkers are threaded onto a piastic strap, which is fastened around the cabie (fig, 42),

4.5 Core numbersThe 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 thetop:- Core number- Cable number

See fig, 45,

4.6 PartexPlease contact Partex Fabriksaktiebolag for further information,

Address: Box 80S-547 02 Gullspang, SWEDEN

Telephone +46-551-20560

4.7 FlexipartPlease contact Miltronic AB for further information,Address: Box 1022

S-611 29 Nyk6ping, SWEDENTelephone +46-155-87000

4.8 Other standardsOutside Sweden various customers may require special marking system The design office will thencoordinate the material needed and issue the necessary installation instructions,

4.9 Open type markersPartex can also deliver an open marker, with which already terminated wires can be marked, See fig. 46,

I Fo, d;ameter2.4-6.2 mm

5.1 Length of cable endsIt is of utmost importance that both cable ends are measured to the correct length before cutting the cable,Enough is sufficient

Fig, 47 Cable ends to various equipmentThe 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 thefurthest terminal in the main terminal group,

5.2 Cable termination sheetThe sheet has the following information

cable typecable sizecable numberend destination "A"terminal pointend destination "B"instructionsschematic diagram sheet number

I~;~t.":i~~~m~:.,~~~t1.."I'~1~~r~.'KFT. L356.R01 168 167~:7;:':'~~'::'~':..t,n~,~·::,~:~;~%."':6'Wrl"d AB8/ PO~ LUDVIKA LAK

T62 l •HEllSTRtlMR ll:lEDNING ~ANSlUTNINGSPUNKT A 3EANSlUnl1HGSPUNKTB lEANWIN5TRUKTION *Schama-NrxSpeci fikaHon :lI:Nummer *Postbeteekning ,uttag *Ref :lEPostbeteckning , *blad--ll.----------------:lE-----------J!E-----------------------:!E------)(--------lE-----------------------lE------- -------------*---- -- ------

FKFR7ll:1.5 94106 +ETA.l L-AK.A2.1 DCU 4010.1 'X3 1111.2 'X3 ,110.3 ,ISOL.4 ,150l

.5 ,IS01

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£~~~'nhc..J)~cu.-'=:>hll\ 1'\.0.

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L- caIh "",,,\'Q'i)d.~\,~rf,.lA'

L.cabl~ "~o---eJd ••f:li'~

ollAS BUILT IJ.. 93 431 PARTTABElL I I"'T'"I'llnd Revision ApP<' Ye~rW •• r. L R.Vlnl'h .. ,lconl

UIQllchec •.• dny lu~~wn9 CheCked y I ~".,"' I ~~~m I"'" .. ;; o';IXNl 660 L~6-SAC 1B.UNDEN ;Bl LUNDBERG /UL LH LAK ,

--- ~~;~r.o~~~,~m~:t,:~~~'ki':zt';.,t'::;'~KFT • ~ ,56 . R0 1 245 244

I::~':';~ t:~:::.,~~%"n'::II~·.:':,~:~~:tid"A~~o"I.d AB B/ POW lUDVIKA LAK

T6Z L. HElLSTR!jMR KLEDtHNO .lfANSUJTNINGSPUNKT A oltANSL UTNINGSPUNKT B XANM/INSTRUKTION XSchema-tlrll$pf'lcifikation )(Nulllmer XPostbeteekni ng luttag XRef )(Postbeteckning . *blad- -)( --- ------ -------)(------- .---------------- - ---lE------}{--------)€-----------------------lOi---------------------3(------------

-CD'oI"'Yj?Q._. ---- ...-

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r-s",~o: N,f:

FKFR HEl.5 94106 -AL-AK.A21 lETA_lT

DCU 2166.1 -Q50,9.Xl ,'u.Z -Q50.9,Xl ,IU.5 ,ISOL., ,ISOL.5 ,!SOL

.6 ,HOl

.7 IISOL_5C ,PE

PARTTARELl I 1'""'"1'''''mnd RIVI.IO~ Appd Y"3rW ••• k IR~V lnrh~~u~r".gnc,c. , I' "WOO''' ,,", I~','wo" I Ultlt II'~~~O~P' ;~ ;;'jXNL 660 136-SACn, LINDEN ;Bl LUNDBERG /UL LH 1"100

6. Sensitive CablesCables that are designed to provide a high level of interference immunity are considered to be sensitivecables.

The most common interfaces are;

low frequency magnetic fields (from large currents in power cables)electrical radiation (overvoltages caused by short circuit in power cables)cross talk between cores/cores and between twisted pairs/twisted pairs.

These cables can be constructed as follows;twisted pairsscreen of aluminium foilscreened by steel, aluminium or copper tapescreened 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 signalsthyristor firing pulses

7. Fireproof CablesThe fire behaviour of cables is assessed and classified in terms of:

- Flame propagation flame protected cables- Smoke generation low smoke cables- Function during a fire fire resistant cables

When cables are buried in the ground, fire behaviour has no significance.Where cables are terminated indoors, there is a need for flame protection.Where cables are laid openly indoors, flame protected cables must be used.

Flame protected cablesResulting from test as recommended in IEC 332-1. Cat. A, B, C. (Tests on electrical cables under fireconditions). Cables are classified as foilows;

_ Cable propagates flame, this type of cable shall only be used in buried installations.- Self extinguisher after ignition with a small flame- Difficult to ignite and low flame propagation- Very difficult to ignite and very low flame propagation.

Low smoke cablesLow smoke cables give off less smoke than conventional plastic and rubber cables. Low smoke cables arealso difficult to ignite and show little flame propagation during testing. There are two kinds of low smokecables. 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

pass through smoke from an ignited cable sample in a sealed chamber.Places where low smoke cables should be used.

- Mass transit vehicles and equipment- Hospitals, hotels, restaurants and offices- Industrial premises and power plant control buildings- Offshore installations and ships

Fire resistant cablesFire resistant cables fulfil severai important demands. Besides being operationally dependable in fires, theyare also difficult to ignite, and limit the spread of fire. The fire resistant cables have good eiectrical andmechanical strength properties, load capacity and flexibility.

Fire resistant cables meet the demands of fire test class B30, in which the cables must retain its electricalfunction while being heated in an oven for 30 minutes from room temperature to 821 ·C. During this time thecable must be connected to the supply, and the fuses shall not interrupt the current.

In addition the fire resistant cables shall fufil the demands of the IEC test, where the cable is exposed toan open gas flame for 3 hours at 750 'C, during which time the cable must retain its electrical function. Thecable shall withstand its rated voltage for 12 hours after the fire.

--

000. Examples of Typical Installations001 Table for selection of material

~

Terylene Wooden KSV- lnstal- Plastic Lash Stain- Clamp No meanscord bracket bracket lation straps wire less bracket of

bracket steel securingMethod of laying straps

Laying inCable channel ~ - - - - - - - - •

'. .'~

Laying in E1Cable duct - - - - • 0 - - 0

Laying on FfCable ladder 0 - 0 - • 0 - - 0

Section rails/trays~ ~installation 6~~ ~~ - - - 0 • 0 - - 0

Conduits t - - - - - - - - •Supporting 61bar - - - - • 0 - - -

Profile bar

5Installation - - • - .*) 0*) - - -

Suspension lineInstallation - - - - - • - 0 - -

FreeSuspension - - 0 - - - - - - •Bracket FEJInstallation - 0 - • • - - 0 -

__ ') Cablestrapsupport mustbe used,see page29, Fig.49,

Cable channel

--.-:- ~, • ,I"~ ~r--• " • I

. I'',' : ~ I'.. • . \

\0" (I· .1 , " - ".. . ', :;. . -'

SWITCHGEAR and DISTRIBUTION" ~OA~~ ,-':',

LadderO!0f:1~ooooaQO -..

LadderOQOooOD 4D

Section beam •

":" ~able channel~

lOOooooool>': ••.••.. . . ,. -, ....

.... Cable channel I~.. ~7?': O,Qo()?~,,1;t .'"

• Strip iron

Plastic str ~

~QP. rt

-Ii-,--M_ BATHS/BU

Control cable4> 4>

Note: Power and controlcables are run on thesome ladder 5-10 m asshown

~-(j)

.& . ~ ~ •..:\ .

....•. _ 6 .6.' 4 . .~ 6'.(:) 'n' .<J . . J) .l.

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High tension

30mm

••----------•••

\ Tervlene strin9-

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Plastic straas

~"'-

F=

= ~

F=

= 1=

~II

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PHigh tension

Plastic strap~\

IPlastic strap.LlnIbends only.

\

Verticallaying control cables

Horizontallaying general

- Fig. 58 Typical installation

~

-,.,.,.,.,. Fig. 59 Typical installation

--,.,.II1II

- BATHSI

1------••.-----•mme-

SITE MAN 14 - 941WAT 910033-14

Edition January 1994

Laying, termination andjointing of high voltagecables <80 kV

List of contents1. General 892. Laying of high voltage cables <80 kV 892.1 Cable drums 892.2 Handling of cable drums at site 892.3 Rotation of cable drums 902.4 Braking of cable drums 903. Methods of laying 913.1 General rules when laying of cables 913.1.1 Stretch force 913.1.2 Bending radius 913.1.3 Distance between cable planes 913.1.4 Interrelations and location of different classes of cables 913.1.5 Distance between cables at rated data 913.1.6 Cable table 923.1.7 Cable laying card 923.2 Laying from a trailer 923.3 Laying by hand .. 923.4 Laying by motor-driven equipment, general 943.4.1 Laying by motor-driven rollers 953.4.2 Laying by winches and cable pushers 963.5 Laying in ground 993.6 Crossing of roads 993.7 Laying indoors 993.8 Temporary marking 993.9 Length of cable ends 1004. Description of cable ways 1004.1 Cable channel 1004.2 Cable duct 1014.3 Cable ladder 1034.4 Section rails/trays 1065. Termination and jointing of high voltage cables <80 kV 1075.1 Termination and jointing 1075.2 Crimping of conductors 1075.2.1 General 1075.2.2 Points to bear in mind when crimping 1075.2.3 Cu-terminals 1085.2.4 AI and AI/Cu-terminals 1095.2.5 Marking of terminals 1105.2.6 Dimension checking 1115.3 Tools 112



1. GeneralTho intention with this document is to give site personnel a guide-line regarding methods when handlingand laying of high voltage cables from 1 kV up to 80 kY.

Regarding termination and jointing it is impossible to give universal information because it is a differencebetween the different suppliers. Consequently, it is of utmost importance to follow the manufacturer'sinstruction when terminating and jointing of high voltage cables

2. Laying of high voltage cables2.1 Cable drumsCables are normally supplied on wooden drums. Short lengths may be supplied in rings or on other types ofdrums.

The drum required depends on the length, the weight and the outer diameter of the cable.

2.2 Handling of cable drums at siteCable drums are transported overland on railway, trucks or lorries. They are wedged tightly in order toprevent them from moving during transport. The drums must be inspected for damage before unloading andany complaints should be covered by a factual statement from the carrier in order to be able to claim dama-ges.

A ramp, crane or forklift may be used for unloading cable drums. If neither of these is available aprovisional ramp of square timbers of beams should be erected. The angle of inclination should not exceed1 in 4. The timber and beams must be strong enough to support the weight of the drum. While rolling downthe ramp the drum must be guided by ropes with the aid of winches or block and tackle. It is advisable topile sand approximately 20 em high at the end of the run to act as a stop.

Note: Neither coils nor drums, even if they are small and not heavy, should be thrown onto the groundwhen unloading them, as the cable is likely to be damaged.

A suitable trailer or tractor with forks should be used for transporting the cable drums within the site area.The drums should never be rolled over longer distances.

After removing the planking from the drum the cable should be inspected for visible damage which mayhave been caused by improper rolling of the drum. The labour who are going to carry out the cable layingshould be clearly informed that they are about to handle valuable and very easily damaged material. Thecable should not be pulled over hard and pointed obstacles, which could damage the insulation, nor shouldit be bent too sharply.

At site a record on all cable drums should be kept stating type and length of cable for each drum arrivingor leaving the storage area. This in order to always know the quantities in stock and quantities beinginstalled.

_ BATHSI

2.3 Rotation of cable drumsSome cable drums have a painted arrow on the side. This arrow is showing the direction for rolling the drumon 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 theopposite direction to the pull.

2.4 Braking the cable drumWhen pulling off the cable, drum stands with hydraulic jacks and mechanical brakes are preferabiy used. Ifthe stand is not equipped with a brake, a plank can be used for braking.

It must be possible to brake the drum at any time if there is a sudden stop in order to prevent furtherunrolling and consequent kinking of the cable, especially the latter must be prevented by all means.

Fig.4 Braking of drums. Please note:The arrow shows direction of rollingon the ground, not pulling.

3 Methods of layingIt is of utmost importance to follow instructions regarding bending radius, ambient temperature, stretchforce, 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

3.1.1 Stretch forceIn general, the maximum stretch force when laying cable may be:- with copper cables 5 Kp/mm2 (50 N) lead area- with aluminium cables 3 Kp/mm2 (30 N) lead area

3.1.2 TemperatureIf the ambient temperature is below -10°C the cable must be heated before laying. Otherwise it will be toostiff 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 radiusThe bending radius of the cable shall be minimum:

Type of cable For laying When installed

Three-coreSingle-corePEX

15 x diameter15 x diameter20 x diameter

10 x diameter10 x diameter15 x diameter

3.1.4 Distance between cable planesThe 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 dataPower cables shall be laid as stated in the installation drawings. In general spacing between cables shouldbe 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 30mm.

3.1.6 Cable tableThe cable table constitutes a list of the cables in the cable network. The following are specified for eachcable- type of cablenumber 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 cardThe 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 trailerCables may be laid out directly from a trailer if there are no obstacles in the trench or in its vicinity. Care hasto be taken that the drum is rotated carefully and braked, if necessary, in order to prevent excessive tensilestresses or kinking of the cable.

3.3 Laying by handRollers placed at distances of 3 to 4 m will facilitate laying. Corner rollers or similar devices should beprovided 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 alongthe route.

If there is not sufficient labour to lay long lengths in one sequence, the drum may be jacked up in thecentre 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 cableis lifted sideways over the drum towards the trench and the remaining cable pulled off from the bottom ofthe drum in a loop. The twist in the cable has to be spread over a length of 4 to 6 m.

Cable trench

%~"'iil!i,"1'!'!!i~ih:iM"~Pli1'Bji"

~

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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 bepulled off again in the direction from which it was first looped.

3.4 Laying by motor-driven equipment, generalThe 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 aguide:- 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 thecable and for simplifying the pull. The permissible pull is much higher with a pulling eye provided that allconductor 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 ropeholding 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 isexceeded, 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 begreased with a special lubricant and plastic pipes with boiled-down soap of low alkali content.

All cables and especially single-sore cables should not be straightened completely after laying, but leftslightly meandering, in order to allow for the longitUdinal expansion caused by changes in the temperature.

------••-----

3.4.1 Laying by motor-driven rollersI ho cable is pulled off the jacked-up drum by electrically driven rollers set up in the trench 20 to 30 m apart.

II heavy cables are to be pulled around a sharp bend, it may be necessary to set up one motor drivenroller before and one after the bend. All rollers are connected to the main switch box via smaller distributionIloxos and are switched on and off jointly. At the head of the cable 3 to 4 men or an auxiliary winch, whichmust run synchronously with the rollers, will be sufficient for gUiding it.

3.4.2 Laying by winches and cable pushersElectrical or petrol engine operated cable pulling machines - both pUlling and pushing are mostly operatedin groups and synchronized by the use of walkie-talkies, see fig. 13.

nFig. 13 Laying by winches andcable pushers.

1. Motor-driven drum stands with dynamometer2-3 Cable pushers4. Cable laying machine with winch

Accessories:1 pc1 pc50 pes12 pes

Cable stockingRoller for pUlling cables in pipesCable rollersCorner rollers

The wire is pulled out from machine 4 with the winch and is then run through machines 2 and 3 on a routeprepared with rollers. The wire is fixed to the cable end by means of a cable stocking. Each machine is thenmanned and communication is established with walkie-talkies. Machine 4 pulls the cable and machines 2and 3 assist by pushing the cable around corners and difficult passages.

---------------

Fig.14Cable winch.

f-lg.16 Cable .MUk'·~4Q,·~;·4lw·Wfo¥;&;slocking.

Glass fibre rod for drawing guide linesand cables through piping.

Fig. 21 Roller for pulling cablesinto concrete pipes.

•

3.5 Laying in groundFarth cables shall be laid directly in the ground in according to the installation drawings applicable to eachproject.

Note: If a cable channel is used, cheaper and simpler cables may be used. It is also much easier to addand replace cables.

3.6 Crossing of roadsFor 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 cablesare to be laid. Ducts which are not used at once should be plugged. The cables should not rest on the sharpodges 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 immediatelybefore the opening prior to pulling in the cable in order to prevent stones or coarse soil from getting into theduct and clogging it up, the pulled-in cable should be cushioned so that it is nearly in contact with the top ofthe 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 than10, Il,orl Ihe cables may be strapped to a strip iron. When support of the cable way or mechanical protectionI" IIocllssary, section beams can be used.

1 :1cHblos may be clamped directly onto walls, foundations and structures in building if the distance is11111II1llrll than 10~20 m.

:I." Tomporary markingWI,orl 11111cable is laid and cut off, both ends shall be temporarily marked in order to enable theItlllllllllclliion of the cable prior to termination and final marking. This is best done by the use of a suitableIIII'll 1I11e111water-proof marking pen with a point of approximately 2 mm's thickness.

3.9 Length of cable endsIt is of utmost importance that both cable ends are adjusted to the right length. Too long cables create wasloand 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 waysThe following section describes the cable ways recommended by ASS.

4.1 Cable channel

Descri ptionThe cable channels in outdoor switchyards are mostly made of concrete and covered with concrete slaps orwooden covers.

Indoor the channels are often integrated in the floors of the building and covered with channelled plates.

InstallationThe cables can either be placed directly in the bottom of the channel or on racks.

No means of securing the cables are necessary.

ApplicationThe main advantage of using cable channels is that cables may easily be replaced, added or inspected.

Cable channels make it possible to use not reinforced cables, since the channel itself offers the sufficientmechanical protection.

Fig.26 Cable channelsoutdoors.

-

---------

Fig.27 Cable channel in outdoor switchboardplant.

4.2 Cable duct

DescriptionDifferent types of ducts areused. One type of ducts is ina building embedded pipemade of galvanized steel or plastic. Another type is channel with one side detachable, such as a lid, madeof metal (generally galvanized sheet metal) or plastic. The duct may be entirely enclosed or perforated. Acovered cable ladder should be considered as a duct.

InstallationThe cable should lie loosely except in the case of vertical assembly. in this case the distance between theattachment 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.

ApplicationDucts may be used when special protection for mechanical or electrical disturbance is required.

Stool ducts may also be used as a thermal protection.Duels of plastic or stainless steel should be used in strong corrosive condition.Small channels of piastic are being used in cubicles for protecting and supporting a bundle of single

loadors.

4.3 Coble ladderDOBcrl ptlonI 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 shouldIIIIVO 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 orIIIHhing wire. In the case of vertical assembly, the cables are also fixed to every second rung. Cables over40 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.

ApplicationIn most cases the cable ladder offers the best solution when building cable ways. In cases of greatlIIochanical load, high short-circuiting currents and high ambient temperature cable ladders are particularlyHuiluble due to their great mechanical strength and good cooling properties.

I IlJ :1:' Cnill" laddersIIlIlIIi 1111 CIlilillg pandant.

diam. or max. 30 mm25-240mm

Metal screen

-.~~ --,-.~~ -.-,.

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\. ~

=

l= i=

t= 1=

!3 - hose Isin Ie h

~-

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~ =

~ =

~ =-

PHigh tension

4.4 Section rails/trays

DescriptionVarious sections are available. Most frequently used are Land U perforated sections.

Trays (U section) are available up to 600 mm.If used outdoor, all sections must be hot dipped galvanized. Indoor they may be painted or electro-plated

with zinc.See fig 31and 37.

InstallationSection rails/trays may be installed directiy onto foundations and walls in order to provide mounting holes forstraps and as protection for cables. They can also be mounted between two points providing a support forthe 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.

•••

A,mm

4987

124162236311461

•Fig. 35 Cable •protection.

.-.-JIIJII

----

5. Termination and jointing of high voltage cables < 80 kV.5.1 Termination and jointing.Since the design of termination and jointing components varies a lot between the different manufacturers, itis important to follow the manufacturer's instructions in order to safeguard a correct cable work. Redoing thetermination 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 GeneralThe 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 mm2C-sleeves up to 300 mm2

However, this instruction describes the most frequently used components covering the following areas:Cu-terminations up to 400 mm2

AI-terminations up to 630 mm2C-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 crimpingTerminals and connectors- The terminals (cable lug, splice, etc) must suit the cross-sectional area and construction of the conductor

(number of strands, degree of compression, shape, hardness).

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.

Icd _~, ••d~,,,

••

Markings ._ In order to avoid mistakes, both tools and terminations must carry unique and permanent markings,

which must also appear on the packaging. On crimping, the identification mark of the tool must beimpressed automatically on the termination.

Dimension checking_ The quality of the crimped connection and the condition (wear) of the crimping tool is checked by

measuring the dimensions of the termnation at the completed crimp._ A supplier of terminations and crimping tools shouid be able to provide details of nominal dimens'lons and

tolerances for the terminations before and after crimping, and to supply special measuring equipment for

this, where needed.

Cu-terminations_ Take great care not to damage any of the strands when stripping the copper cable. .._ Strip about 5 mm more of the insulation than the depth of the barrel of the cable lug or splice (I.e. up to

the inspection hole or cable stop). ._ Check carefully that the type number of the die corresponds to the marking of the cable lug or splice._ Normally one crimp is needed up to 400 mm2. For round compressed conductors 185 mm2 and above,

two adjacent crimps are needed.

AI-terminations_ 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._ The barrel of the aluminium terminations is serrated internally and protected against corrosion by a thin

layer of vaseline. . .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

Copper type terminals type KRlKRF:_ Used mainly to terminate cables at copper busbars and equipment terminals._ The same terminal is used for both flexible and stranded or sector-shaped

conductors.

Spliced type KS/KSF:_ Used primarily to splice copper conductors in underground cable systems._ 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

Branch connectors type C(C-sleeves):- This pattern up to 120 mm2.

--

••

5.2.4 AI and AI/Cu terminals

Spllco sleeve type AS:I JsocJmainly for jointing aluminium conductors in undergroundcullio systems, but also at the transition between overhead lines[Jilt) underground cables.

Coblo lug type AK:Usod to terminate aluminium conductors at busbars anduluminium terminals on apparatuses.

Alum Inium/Copper Terminals:I he AI/Cu terminals are manufactured by friction-welding the two component parts together, a method in

which the aluminium and copper are bonded together by the heat produced as one metal rotates againstltm other under pressure. The result is a totally hermetic joint, immune to corrosion and galvanic actionovon under outdoor conditions.

AI/Cu splice sleeve type AKS:For jointing AI to Cu conductors.

AI/Cu pin sleeve type AKP:To connect AI conductors to

equipment and junction boxes.

AI/Cu cable lug type AKK:Used to terminate an AI

conductor at a Cu busbar.

l()rminals for AI cables are made of solid pure aluminium.The system may be used for both stranded and solid aluminium conductors.Note that there is a difference of one area step between stranded and solid conductors.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 andmatrix also coincides with the outside diameter of the barrel.

5.2.5 Marking of terminalsAs well as showing cable area, the marking system indicates which tools should be used.

Cu conductor ~I (0Area In mm2 IN

Type No. ofhexagonal die

Cu conductor Cu conductor120-150 mm2 ~ 70-95 mm2

nDie identification

number

~Max. diameterof conductors

Aluminium terminalsNumber for circular Number for compressionpreforming punch ~ / punch and matrix

and matrix 4 £_;t~'20 - .,-;-:;;,."

150 SOLID

~Stranded AI Solid AI Bolt sizeconductor conductor M12in mm2 in mm2

••••

5.2.6 Dimension checking

Aluminium terminals:.- 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 tocheck that the correct tool has been used.~w

~ tMeasuring points

AI conductor, mm2 Tool T

Stranded Solid Matrix Punch mm

16 25 P13M P13D 6.825 35 P13M P13D 6.835 50 P20M P20D 10.8

50 70 P20M P20D 10.870 95 P20M P20D 10.895 120 P25M P25D 13.5

120 150 P25M P25D 13.5150 185 P25M P25D 13.5185 240 P32M P32D 18.4

240 P32M P32D 18.4300 P36M P36D 21.0400 P40M P40D 22.8500 P40M P40D 22.8

D = 52 500 A P52M P52D 31.0D = 52 630 A P52M P52D 31.0

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

6.47.68.8

10.312.113.9

16.516.320.3

20.623.424.627.4

C-sleeves- For C-sleeves, the dimension h is checked, preferably with a calliper, on maximum height of the crimped

oval.

C4C5C6C8-6, C8, C9-8 and C9C11-8, C11-9 and C11C13.8, C13-9, C13-11 and C13

C15-8, C15-9, C15-13 and C15C16-9, C16-13and C16

10.613.715.8

22.023.227.034.538.5

5.3 ToolsIn 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 forcrimped connections, the tools must be checked periodically according to ASS Quality System Guide-lineschapters 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.

---

--•••••----


Cubicles inelectrical rooms

Touch-up painting

List of contentsA. Cubicles in electrical rooms1. General 32. Handling of cubicles 32.1 Packing 32.2 Unloading 42.3 Checking 52.4 Lifting and indoor transport of cubicles 52.5 Storage 62.6 Temporary marking 73. Control 73.1 Access roads 73.2 Floors 73.3 Suspended floors 83.4 Depending points 94. Installation 104.1 Cubicles 104.2 Busbars 134.3 Clearance to walls and ceilings 154.4 Cleaning 15

-

B. Touch-up painting 175. General 175.1 Definitions 175.2 Cleaning prior to grinding 175.3 Grinding of damaged surfaces 185.4 Application of filler 185.5 Grinding after stopping up 185.6 Primer coating 185.7 Cleaning and masking prior areosol spray painting 185.8 Finishing coat 195.9 Finishing coating with areosol paint 195.10 Finishing coating - brush painting 195.11 Choice of fillers and paints 195.12 Tools, accessories, etc 196. Touch-up painting of galvanized steel with zinc-rich paint 206.1 General 206.2 Work steps - general 206.3 Choice of galvanopaste 20


-


1. GeneralTho intention with this instruction is to give a brief introduction of the methods used byAI3S when installing relay, control and distribution boards in electrical rooms.

II is of utmost importance, however, to penetrate all layout and installation drawingstogether with installation manuals for the delivered cubicles and equipment prior to startof installation.

2. Handling of cubicles

2.1 PackingThe cubicles may be delivered in the follOWingmanner:

Individual cubicles fitted with apparatus.Several cubicles mounted together as one unit.Accessories.

I he cubicles are normally delivered standing on a transport pallet covered with a plasticGover and firmly attached to the pallet.

Loose accessories are delivered in wooden boxes.When the cubicles are shipped overseas, a more durable packing is needed, such as:Cases of wood.Cases of plywood.Sleel containers with open roof.

Nolo that ASS-deliveries normally are covered with sealed air tight plastic bags beforeItloy are packed into the cases. Sags with moisture absorbing material are placed insideItlo cubicles to keep them dry.

Packing list is packed together with the cubicles.

IIII

iIIII I

I

II I I L II I I I

2.2 UnloadingHandle 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 forkliftmust be equipped with wheels big enough to make the handling of cases safe andsteady. The roads at site are often of poor quality during the erection period.

If possible, unload and transport the cubicles directly to their final position in theirpackings, see figure 2.~v~';;~ a

9rJj~F 4!1=== E:- l/fl)~. ~\ jlJ

----~ '$~~

To unload the cubicle from the pallet, move it forward or backwards on the pallet until thecubicle can be tilted. While holding the cubicle in a tilted position, pull away the pallet andset the cubicle down on the floor carefully, see figure 3.

~.

2.3 CheckingCheck the consignment against the accompanying packing list to ensure that the correctitems have been delivered. Any complaints are to be remitted as soon as possible to ASSin order to avoid delay in the installation work. Do not forget to make a check-up onseparately packed apparatus.

---------------

2.4 Lifting and indoor transport of cubiclesCubicles are normally provided with lifting devices. However, the method of lifting variesfrom type to type. It is therefore important to follow the lifting instruction given i theenclosed information in order not to damage the cubicles by applying the lifting slingswrongly. Figure 5 shows some typical lifting arrangements.

Indoor transport of Safesix switchgear. The cubicle should be lifted from the pallet withthe use of a fork lift. The cubicle can be transported indoors with a pallet lifter. Two liftingtackle are placed in the cubicle as shown in figure 4.

The lower door of the cubicle must be removed and put somewhere safe, before thefork lift is used to lift the cubicle, and kept safely during assembly period.

If the cubicle cannot be transported in the upright position because of for example lowdoors, it can be laid on its back on a pallet and moved with the use of a fork lift to itserection position.

To remove the connecting apparatus choose the selector to door position. Theconnecting apparatus can now be pulled out on the door extension rail. This can be donewith 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.Check that parts specified in the enclosed packing list are present. Any parts missing ordamaged must be claimed as soon as possible.

2.5 StorageSometimes the cubicles, due to various reasons, cannot be installed immediately upontheir arrival to site, but have to be stored.

The cubicles delivered on transport pallets covered with plastic wrapping are to bestored in clean, dry and dust-free premises. When the cubicles are equipped with heatingelements, these should be temporarily connected during storage in order to avoidcorrosion.

The cubicles delivered in wooden cases with sealed air tight plastic bags and moistureabsorbing material should be stored indoor or under cover. Do not open these cases ifthey are stored oudoor. The check of the content should then be carried out when thecubicles 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

storing periods should occur, the manufacturer should be contacted for advice.

2.6 Temporary markingTemporary marking of the cubicles can be necessary sometimes. Se careful when usinglabels or tapes on painted surfaces. A special marking tape can be ordered from yourASS-supplier.

3. Control

3.1 Access roads It is always very important to check the transport ways in order toensure that no obstacles can cause hinderance. The following check points can act as aguide:- Can the road be used by our transport vehicle?- Are there any electrical wires or pipes crossing the road?- Is it necessary to build temporary unloading platforms?- Are door openings large enough?- Hoisting wells?- Staircases?

3.2 FloorsThe cubicles are designed to be erected on an even and thoroughly levelled base toenable the interjoining of cubicles without any extra measures. See figure 6.

Experience proves that above tolerances are hard to obtain. ASS therefore recommendthat 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 andto 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 withdrawable circuit breaker may be more sensitive. Here the contact function betweenbreaker and the fixed contact can be jeopardized.

Check that the floor is even and in level, and that iron profiles are correctly embeddedas stated in the civil drawings. Holes for cable entries in the floor have to be carefullychecked regarding size and location.

•----•-••-••--::

Allows deviation (declivity)E(mm)

Description Measured Allowediength (m) deviation (mm)

Class 2

Warpage 2.0 ±34.0 ±5

Declivity L E

6.0 18.0 21+.0 1+8.0

3.3 Suspended floorSuspended floors are used mainly for the following reasons:- Flexible installation of cubicles. The final layout can be decided at a late stage.-- Open space under cubicles means no problem to install cables.- Easy to adjust the floor to correct level.- Easy to extend and re-position the panels.

The floor should be fire resistant and can be of electrically insulating or semiconductingdesign.

The insulating floor is used mostly in switchgear rooms or similar.The semiconducting floor is intended for computer rooms and other areas where static

electricity may cause damage, injury or inconvenience.The floors are built up of floor scaffold and fire resistant slabs. It can be completed with

stairs and banisters and can also be reinforced for higher loadings, see figure 9.

Fig. 8 Typical foundationfor cubicles.

The floor is built up from tubular legs,beams and fire-resistant slabs.

The legs are adjustable vertically.The shape of the base-plate ensuresthat the leg stands securely even onrough surfaces.

Fig. 9

The beams are tensioned betweenthe walls with the aid of a specialtensioning device.

-------------

3.4 Depending pointsWhen 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.

Air conditioner installed, ready.

4. Installation

4.1 CubiclesNote that a cubicle having a number of apparatus fitted on the door or on the hingedframe, will fall forward if the door or frame is accidentally opened before the cubicle hasbeen 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.

~

ii. ------------~Leg I enbuu----- -n un _

1) Note that the loose floor slabs under the cubicles have to be securedto the beams as well as the cubicles.

Fig. 10 Fastening of cubicles to suspended floors.

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.0 ~ P

~ . <1 q q

-0 "q " <1<J q

'1<1 .., .q

..</ A <J ... <1 <J "" <1

Fig. 11 Cubicles fastened with expansion-shell bolt in concrete.

Fig. 12 Cubicle fastened with clamp andexpansion-shell bolt.

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q 1 q

"<1

q • ~ <1 Concrete~" q q ~

q

", " q~

Fig. 13 Cubicle welded to embeddedL-profile.

Fig. 14 Cubicle fastened with clampeither with expansion-shell bolt inconcrete or welded T-bolt to steel beam.

.;;os ~,..c;:.~17;:)j)~y~~~ ..-IfA' .....:l" "\~ •·..:: •. >c.~A("b~.:7Lf...,..v

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flooring. -

Fig. 17 Cubicle fastened to pre-aligned profilebar with T-bolt and clamp.

Fig. 16 Attachment of Safesixcubicle on frame

4.2 BusbarsI or series-manufactured switchgear, apparatus, etc., special assembly instructions arenormally provided and these apply to the complete installation including the bolted jointsIn Ill() busbars.

I or joints in other equipment, where special measures must be taken, e.g. control ofIIllhloning torque, special locking facilities etc., instructions are either given on theIlHsornbly drawing or are supplied separately for the joints in question.

" modifications are necessary during the on-site installation, it is of utmost importancelillil 1110 joints are made in accordance with the applicable standard to ensure satisfactoryporlormance. See figures 18 and 19.

(I ('1Mr~~r) I

\\ II,

Joining is carried out from the front of thecubicle. The same method applies for bothhorizontal busbars, Nand PE busbars.

1. Dismantle the protective cover in front ofthe busbars so the joints are accessible.

2. Loosen the bolts to the joint pieces.

3. Slide the joint pieces towards the rightcubicle.

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 frontside!

Extreme nght

cub,cteExtreme leffcubicle

For busbarcann.bars

For busbarcann.bar

For busbarcann.bar

For busbarconn.bor

A-A A-A A-A A-A

~~~~2000, 1600 A

2000, 1600 A

2000, 1600 A

1250 A

2000, 1600 A

800 A

1250 A

1250 A

B-B B-B B-B B-B

~~~~2000, 1600 A

800 A

1250 A

1250 A

1250 A

800 A

800 A

800 A

2000. 1600 A

2000. 1600 A

2000. 1600 A

1250 A

B-B B-B

~~1250 A

800 A

800 A

800 A

-,.,.------------------

4.3 Clearance to walls and ceilingsMinimum clearance to ceilings and walls varies a lot between different types of cubiclesdopunding 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 theminimum clearance according to the manufacturer's installation manuals are kept.

Suo figures 20 - 21.

4.4 ClearingIlomove cable waste and other litter. Clean off grease and dirt, especially from theinsulators. Finally, vacuum-clean the cubicles. See figure 21.

I•..•,"'<,()

r-.-==""l---.L

jLftrn}--i I .1, ..,.,., Checking free space around cubicles,,'j

-I -I~"~'·,,,." AboveThere must be at least 150 mm free space abovethe cubicle. Where cables run in from above, thedistance also depends on the cable type and theway in which it is laid.I 11,;>0 Space required for switchgear

typo Conlor.Against wallsThe minimum distance between the rear of thecubicle and the wall behind, as well as between theend panels and wall at the side, should be at least40mm.

Cubicles with handles in the doors should have atleast 150 mm between the left end panel and thewall to allow the doors to open more than 90°.

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r-22 22.-no 1N..m,n 150 m,n 150

b. Goneral111111document is a guide-line for touch-up painting of products delivered to sites. It isIIl1flod on ABB:s quality requirements of today and the painting methods used by thenlllJlIllncturers.

In 1\1313 we have both normal wet painted products and powder painted products. SinceIHlwdor spraying cannot be used on site, a one-component, alkyd based paint system isIJllli/ou lor touch-up painting. As far as possible, however, touch-up painting shouldlll:l1iovo the same quality and finish as the original and adjacent surface.

SlJrlnces with no particular requirements regarding finish may be brush painted. InIlimo oxacting cases repair painting should be done by arerosol spraying. Examples ofIlIH: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-1I10nl,should be engaged. Do not forget to ask for a fixed price and check wether itIlIHlIJld be cheaper to order a spare part.

II louching up the paint yourself, do so in a room suitable for this, well ventilated andIroo 01dust.

Iiolore applying the filler and painting, carefully straighten the damaged steel sheet soIl1nl Iho layer of filler can be kept as thin as possible.

6.1 Definitions

Alkyd paint - has a binding agent composed of an acid and alcohol (synthetic resin),1I!r1llcalled alkyd.

fwo-component filler - a filler containing hardener. The advantage of this type of filler is111111II is stronger and more elastic and hardens more rapidly than a one-component filler.II doos not crackle so readily, is easy to rub down and gives a good finish.Whlto spirit - has various commercial names, e.g. petroleum spirits or mineral spirits. ItIII IIHI most common and least toxic medium for degreasing, diluting and cleaning.Xylono or dimethylbenzene is an extremely flammable solvent, mainly used as a paintIIlilHlnl.

Dlluont reducer - a general term for white spirits, xylene, etc.

b.2 Cloaning prior to grinding1\0111Iho damaged and the adjacent surfaces must be cleaned so that all grease, dust111111olhor dirt are removed. Otherwise impurities can be trapped in the abrasive paper111111IIJbbed into the surface.

(;Iolln with an organic solvent such as xylene or white spirit, using a non-fluffing ragIIII'pod in the solvent.

11.:1 Grinding of damaged surfacesI 111110dllmaged areas, which are to be stopped up, should preferably be machine grinded(11111111111machine 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 rubbing1"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 towards1110Ildjlll:enl surface.

5.4 Application of fillerDamage 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 rightproportions. Too much hardener speeds up hardening and too less slows it down. Followthe 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 evenlyas possible in order to obtain a flat and even surface. When dry, check with a straightedge that there is no unevenness. If the surface is uneven, stop up such areas again.There should be sufficient filler to allow it to be grinded down.

Note 1: Use as little filler as possible. Too much entails unnecessary grinding.Note 2: Careful preparation is essential if a good surface is to be obtained.

5.5 Grinding after stopping upThe stopped up area must be grinded to be even with the adjacent surfaces.

Start with abrasive paper No. 100. As the area becomes even change to a finer grade,e.g. No. 150, and finish with No. 180 to ensure that there are no visible scores. Check thesurface with the straight edge from time to time.

5.6 Primer coatingIf the original coating has been damaged or grinded through to the metal, a primer mustbe applied and rubbed down to an even surface.

Primer coating can be obtained as areosol spray or other types of cans.After primer coating, finish smoothly with abrasive paper No. 180.

5.7 Cleaning and masking prior areosol spray paintingProperly grinded surfaces should be cleaned with a non-fluffing rag dipped in white spirit.Before spraying, the area to be painted must be masked off from adjacent areas, whichmust be well covered. Use masking tape and paper. Remove the tape as soon as thepainting has been completed, otherwise it may stick and damage the paint.

5.8 Finishing coatBefore applying the finishing coat, all surfaces must be either primed or smoothly grinded,in some cases both. Choose the colour according to the manufacturers information.

5.9 Finishing coating with areosol paintBefore starting painting cheCk that the room is well ventilated and free of dust.

Read carefully the instructions on the areosol spray can.Shake the areosol spray can well. Hold the can about 20 cm (8 ins) from the surface to

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.

5.11 Chioce of fillers and paintsProject delivery contains products from many manufacturers. Consequently it isimpossible 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 originaladjacent surface. Choose the filler and paint according to the manufacturers instructions(or product pamphlets) to avoid mistakes during the touch-up painting work.

5.12 Tools, accessories, etc.1. Drilling machine with a wire brush.2. Drilling machine with rubber disc and abrasive paper.3. Oscillating grinder with abrasive paper (alternative to No.2).4. Abrasive paper, medium, grain size 1005. Abrasive paper, fine, grain size 1506. Abrasive paper, extra fine, grain size 1807. Abrasive paper for machine8. Spatulas.

6. Touch-up painting of galvanized steel with zinc-rich paint

6.1 GeneralThis information is intended for the repair of the corrosion protection on galvanized steel.

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 %). Thepaint is applied with a brush or areosol spray. Brush painting is preferable since the areo-sol gas contains toxic products

6.2 Work steps - generalHemove all burr, welding slag and rust. Use a wire brush, file and countersink bit orolher suitable tool.Cloan all surfaces from grease, old paint, etc.SUr repeatedly so that the zinc powder keeps well mixed in the can.Allow to dry for four hours before applying a second coat.

6.3 Choice of galvanopasteII IS important to have a zinc content of 93-95 % in the paint you have planned to use.

II II is impossible to purchase it locally, please contact your homeoffice for delivery tonllo III order to reach the right quality.

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List of Contents

General ..•................................................................................................... 133

~r~~!~i~~~~~~~.::.:::·::::::.·":·.·.:··::::::>::::···:.::::.::::..::.:.:.::.:::....::.::..::> i~~Earthing outdoor ............•......................................................................... 134Earth grid, earthing rods, pits etc 134Steel structure 135Transformers and high voltage apparatus 135

i~~i:::~e~~::~.~~r~~~:..::.'.::::::.:::::.::.::::.:..::.':.::.::':::'.::.:'.:.::::.':..: ::."~~~~:7~:~~~~~~.~.~.::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::~~~~:t~~i~i.o.n.S. ~~~. ~l~~~i~~.:::::::::::::::::::::::::::::::::::: :::::::: :::::::::::::::::::::::::::::: ~:~Installation 149Th~ 1~Tempoprary earthing , 149Principal arrangement for earthing of structures and apparatus 140

--------This document and parts thereof must not bereproduced or copied without written permis-sion, and the contents thereof must not beimparted to a third party nor be used for anyunauthorized purpose. Contravention will beprosecuted.

--Addtional copies of this document may beobtained from ASS at its then current rate -•

1. Generaln ordor 10 promote the understanding of earthing it is usual to divide the term under two general headings,rlllmoly system earthing and protective earthing.

1.1 System earthingPrimarily systems earthing is considered as the permanent connection of a system or part of a systemw[lleh would normally be under tension to earth. Normally it is the system or part of the system's zero pointwilieh Is connected to earth, direct or via a neutral earthing equipment.

1[10 lact that a point in the system is earthed, means that any part of system which is galvanicallyClHHloclod is also earthed. A system earthing does not effect parts of the system which are magnetically(;(Jupl(J(j, o.g. via a transformer to an earthed net.

In a power network there can be found several system earth's e.g. each voitage ievel can have its ownoHrllling.

J110 primary reasons for bonding the network potential to earth are to protect people and equipment.

1.2 Protective earthingJlio lovol 01 protection from high voltage for personnel that can be achieved by the selection of goodInsulation and thought/ul plant design is inadequate. The require-ments of high current instructions are thatoxposed details shall be protective earthed in a way that ensures complete safety.

An ox posed detail is understood to be one which can be touched, accessed or is of a prominent nature,hul which under normal conditions is not under tension. However due to its material nature or coating couldurllJor insulation failure conditions come under tension.

Examples of exposed details could be frames, covers and supports for machinery, transformer andoqulpmenl, 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 faultconditions 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 preventedil) 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 staysuro moonted sufficiently iong from the insulator pins or they are fastened to the pole via a stay insulator.

1.3 Eloctrlcal hazardAn 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 toII/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 currentPllttl rosislance. The bodies resistance drops normally to some value under 5000 ohms with the onset ofpomplration. 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 overloadnil sllllo during an earth fault.

• BATHS/6UTran$mj$$i()~

2. Earthing outdoor2.1 Earth grid, earthing rods, pits etc.The earth grid normally consists of some form of symmetrical grid net in order to achieve an evendissipation of voltage across the net.

The number of squares in an earth network for a station which is to have a direct earthed high voltagenet should be in the order of 25, for a small station 16 squares should be sufficient. An increase in thenumber of squares gives at best a marginal reduction in the station earth resistance.

Even a short vertically placed earth rod provides excellent earthing capability ~

I I II-------------------------l--------------------r----------

The above drawing gives anexample of an earth grid forsmall switchyards_ The griditself - in this case - is made of120 mm2 copper wires, buriedto a depth of 0.5 m. If the earthresistance has to be fu rthe rdecreased the earth grid maybe connected to a number ofrods forming earthing pits. Fig.3 gives an example of suchdesign. See also fig. 24.

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111I11l11l1/llnlJpils are usually composed of 1-4 earthing rods connected together via test link to the mainIllllill Wid I ho rods are copper clad steel rods of 1-2 meter length, which may be extended with other rodsI,y IIl1clIlIllld jllinls.

1/11'IOllllinks can be utilized for resistance measurement both of the earth grid and of the earthing pit.I .1111111111plls Garl be added, if needed.

~.~ 81001 structures

(Iw.lry uloolwork and high voltage equipment supports are earthed by connecting at least one of the legsIII Illo Wid. Siruciures standing on more than one foundation have an earth connection at each foundation if1I11ll1nrllllflull current path through the steel is >10 m.

:1.3 Transformer and high voltage apparatus1'lIwm Imnsformer neutral are directly connected to the earth grid by duplicate conductors eachdllllonllionod for the max fault current.

1111'ourlh wire from the transformer tank shall be connected directly to the grid.111111.voltago equipment normally earthed via the steel structures. Exceptions to this rule are items of

'"l1lll1l11onl wilh a neutral outlet e.g. surge arresters and potential transformers, which are earthed'"'lIllIlIloly, Also separately earthed are earthing switches and separately mounted operating mechanism asWlllilitl lorminal boxes for control cable, for example on current and potential transformers and marshalling1"""11 1m lIIulli-core cables.

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.

2.4 Overhead earth screenThe 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 primaryfunction is to protect against an overvoltage across the insulator elements tracking and carbonising theelements, see fig. 7. A radical alternative to protect against lightning strike would be to install the highvoltage cables in the ground. Unfortunately this is not economically practical, as underground cable is

appreciably more expensive than overhead cable.

Overhead earth lines

,~- - ~ - :~hing rod

a:: Protection angle

1) This wire is only included if required by the project specification. Normally theoverhead wire is terminated directly to the mast. To be installed if shown on theerection drawings for the project.

2.5 surge arrestersFor 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.

"" Earth grid

:',1I1I" mrostors can be designed with a counter that registers the number of times the arrester strikes Thellllllllllr 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:". ," II1I1rornillimetre. a minimum a

:In F-llneosI '1111:1111,of rnolallic material shall be earthed by connecting a number of the fence posts - at about 50 m11I1",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 connectedIII 111111c:ollductor.

3.1 GeneralThe basic objectives of an equipment-grounding system are the following:- To reduce the risk of electric shock to personnel.- To provide adequate current carrying capability, both in magnitude and duration, to accept the ground

fault current permitted by the overcurrent protection system without creating a fire or expiosive hazard tobUildings or contents.

- To provide a iow impedance return path for ground fault current necessary for the timely operation of theovercurrent 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 Istructure foundations.

Grounding conductor around the building shall be buried in the ground at a minimum distance of1500 mm from the outer boundary of the building. If high temperature is encountered at any location, thegrounding 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 twogrounding leads. Electrical continuity shall be ensured by bonding the different sections of hand-rails andmetallic stairs.

Metallic pipes, conduits and cable tray sections for cable installation shall be bonded to ensure electricalcontinuity and connected to grounding conductor at not more than 10m intervals. Apart from intermediateconnections, 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.

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4.1 I'rocnutlons and planning111111III,IIIIIIIIIon 01 the earth grid is one of the jobs which needs planning, not to come into conflict with the111111111"1111,1.0.oroction of steel structures, cable ducts, etc.

1111'mud, oxcavation at the same time may make the area too rough for achieving an efficient workflow.II III ,,111111convonient to excavate for laying the earth grid after erecting the steel structures and before

1Il1ll1l1l1l1l1ll1Hulators, busbars and other conductors.

4") Mnlorlnl1111111,1111,Wid is usually made of copper wires clamped, brazed or thermic-welded together. See fig. 36-38.

11111r: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.lnllnllonIII" IImlh !lrIll wilh its numerous connection must be installed with utmost care. The following points are'""IIIIII!lI/IIII:

111111I111IIH 01 vllal importance for personal safety111111I1111oriaiisburied and not available for inspection and repair after installation"111111111corrosion may take place,,111111r:irr:ull and earth-fault currents usually increase with time which means increased stress on the1111111111111jlllll~l 01 tho earth grid above ground must be made safe. Follow carefUlly the instructions given by11111t1IlHllIlIlllilco for:11.111111111101 stoel structure"'" II i11111III lowers (masts) with earth wires1IIIIIhlllll III apparatus and boxes1111111111111Hwllcllest11"r:III1I1II1:llrliJearthing switches1I111111111111111COoarlhingIlIllIlIllIlITlor Iflnks"'1111"dlvorlors and countersLlllll0 tll:roOr!S

11•• ,IIlUW"IrIlIlIl'lIld 11I1I1Iingoquipment of right capacity. High quality of right grade of brazing material shall beIIVIIIIIIIIIII 11111III Slioman 94-11.

C:"lIIl'r •••• lonIly"","I1" ""llljlrllssion tools of sufficient capacity - fitting the actual compression clamps. Ref. to Site man

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I "bllllle: woldlngWI!IrIlIIl"llllllrh; lJisc-grinder. Ref. to Siteman 94-11.

1.I ••• lllllU1\ 11"1,,1111,1,":11111101 steel brushes, separate ones for each type of metal.

4 n Ibllll'or ••ry oarthlngIII 11111Y 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 onnlll W\lll\ nido

I IIII! 111'""f11/1HIIIII oarth-fault currents and higher demand on portable earthing equipment, the111111"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.

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IIIJ :111I .111111nll f",IH Hrn used to reach deep earth levels where invariable low earth resistance can be obtained.! i"" 1I1"urllrtl IIbove.

601 Earthing device JSLK-F 185/11604 Insulating tube MGF 300605 Insulating tube MGF 301607 Operating socket JGS 16608 Phase clamp with rope JFKL609 Oistance piece MJL610 Contact device JBA 120612 Earthing terminal JVF 11

Tackle lineInsulatedoperatersp

SITE MAN 20 - 941WAT 910033-20I dillon .January 1994

Air insulatedsWitchgear

List of Contents1. General 1591.1 Design characteristics 1591.2 The single-line diagram 1591.3 Modifications, extensions 1601.4 Insulation 1601.5 Pollution 1602. Civil Work ...•..........•.................•..•...................................•...............1602.1 Drawings 1602.2 Foundations 1603. Heavy loads, such as transformers, reactors, etc 1623.1 Transport, roads, access roads and surveys 1624. Insulators 1624.1 Types of insulators 1624.2 Pollution 1645. Busbars and wires 1655.1 Types of busbars 1655.2 Materials 1655.3 Rigid and flexible conductors 1665.4 Mechanical strength 1665.5 Corona 1676. Clamps 1676.1 Types of clamps 1676.2 Design 1696.3 Material 1707. Erection .............•............................................................................1707.1 Access and work start 1707.2 Steel structure 1707.3 Outdoor earthing 1727.4 Insulators 1727.5 Busbars and wires 1737.6 Clamps 1767.7 High voltage apparatus 1798. Inspection, quality control 1819. Testing and commissioning .....................................•........•.....•....181



UIUIIl1nI

1111"""1'111"""' will, III prillciplo, ho a guideline for the installation of Air Insulated Switchgear and shall be'"",,w,," II rl" "1I1,,r '"forr"lliloo Is given on the drawings.

I I 1I•• luo "lIarnolnrl.UcBWI"'II pl"I"l'!loll II IIwlldlymd Iho main points to consider are:

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1I'''","r" Iwo IJIIlJor Iypos of high voltage switchyards:I III" "wllelllllll sllliionsIrnllhlorrflill Slflliofls

WIII'f1 ""l1ll1f1lrlll slool structures and foundations, the stress calculations are based on the maximum forcewilli II lilly pml ollho oquipment can be expected to withstand in its lifetime.

III" rfllll:II/,"icflllorcos acting on the electrical equipment and supporting structures are:11"",lwollllltNllrllll,I11J111Jsfrom conductors11"111111111WIII""l/lI'11111111elrclJlllorcesModl/Hllcll1 oporation forcesI IIr 1I111IJIlkolorcos

WI,,," clllIllllfliflll Ihe busbar the following main factors have to be considered:MlIXlrfllllfl 10fld currentMIIKlrllillo withstand impUlse voltageM,,,,ll/llIlcfll slrength to withstand dynamic forcesAlrllollpllfJrlc contamination

I 'J 11111 .Ingie-line diagramIII" 110111111101 fin outdoor substation is1"",,"1011 1110single-line diagram. This1111111111111IIllould show the connectionIIrill/lll0tll/lJlts of all electrical equipment,I" Ilil/lllllm, ovorhead lines, power111111,,",cIIlJlloclion points, power trans-I",,"orll, hi!lll voltage apparatuses, AC/III. C'"lvorlors, reactive power"IIIIp"rlllllllon equipment etc.

WIIIIII dosigning the single-line diagram1111'111111"wllching arrangements and the""w"" "I sorvice flexibility and reliability'"11'11110(;ollsidered.

11," III1Jsllrequent bus arrangements""' "IIIlwlI in Appendix 1.

A2308230

I III I: OI"olo-line Diagram,olliff;" I,V switchyard

1.3 Modifications, extensionsAlmost every switchyard will sooner or later be subject to modifications and/or extensions. Clarity andflexibility therefore have high priority in the design. Furthermore, access roads with safety clearances formoving equipment must be considered.

1.4 InsulationElectrical clearances are fundamental for the design. For safety and reliability it is essential that adequateclearances are provided to live parts.

1.5 PollutionsIn recent years contamination has been a growing problem in transmission sys-tems. The contamination ismainly of two kinds; coastal and industrial. See clause 4.2.

2.1 DrawingsFor outdoor switchyards the civil engineering design represents a iarge portion of the total design work.Drawing for levelling of the ground, dimensioning of the foundations, layout of cable ducts etc., have to beproduced.

The foundation drawings from an ABB design office shall show the foundation tops on which towers,apparatus structures etc. shall be fixed.

2.2 FoundationsIt is important that our site construction manager works in close cooperation with the site civil contractor inorder to guarantee a successful foundation work.

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.Note that approved expansion concrete must be used.

TemplatesTemplates are used for fixing the foundation bolts. For small foundations up to 0.5 x 0.5 m and in largequantities, steel tempiates as shown In fig. 2 are suitabie.

For larger foundations steei templates will be too heavy. A suitable material, which is usually easilyobtainable, is plywood (1/2 to 3/4" thick). The plywood tempiate design can be similar to that of the steelversion. For really large foundations, the wooden tempiate may be split into two parts as shown in fig. 3.

• "" •• ,kIItUIII. "'it,,, II,,, It'hl",,,,,'lIlIlly 01 AI3B, as the switchgear contractor, to check the location and the allignment of1111'""l1llnlllll 111,11••, 1,1I10poJl(jontly of who has done the civil works. When measuring the distance between1••,1111Will "" 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.

I1ll1uolll"lI ,,,••1"111101111,,fIlquired lor levelling of the foundations. A transparent plastic hose filled with'''''''111 '" " .f'111I IlIvlllcllli Hiso be used for shorter distances.

11111,,11'"11.III,III1II1ICfllo H bonch mark, i.e. a fix point to which all our measurements shall refer, when1·llfll,I'llllJ lIul flllHHllllilHlS

I'J"',, 1111"IIllcII,ll:rllltl 1m" 10 cure 2-3 weeks before load can be applied."I " ••'1111'JlOII I•• 10 till lukon to check that the foundation bolts are reliably fixed at the bottom end so that

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

1I1I1111I,"I111'H11Ililmdiny the foundations must be entered into the drawings in red and sent to the design"lIil" I", "IIIIIIIIIIU

I .11,,01,III, II11WllJdamage and that sufficent threads are over the top of the foundation.

",ollllnu (uptlon)11111•• 11111••11101HlrlJl:lurDS have been erected, the distance between the steel and the concrete may be filled"I' willi ""I1l:1olo ( nrouting). .

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3. Heavy loads, such as transformers, reactors, etc.3.1 Transports, roads, access roads and surveysThe transport of transformers has to be carefully planned. The roads from the harbour or the railway stationwhere 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 widetransport.

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 caseof 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.

4.1 Types of insulatorsInsulators in outdoor sWitchyards are used for supporting conductors and for providing Insulation betweenphases and to earth. Sheds on the insulators provide the necessary creepage distance.

Insulators used are basically of two types:- support insulators for static arrangements- chain insulators for flexible buswires.

In addition to electrical requirements insulators must withstand the mechanical forces caused by shortcircuit and earthquakes. This is especially important for support insulators.

Also environmental conditions, such as pollution and salt have to be considered.

Support insulatorsThere are two types of support insulators, "solid core" and "pin and cap".

For the lower voltage range the support insulators are made as one unit. For higher voltage ranges,however, the insulators (inSUlator stacks) are made up of several units bolted together.

Chain InsulatorsThe strings are composed of insulator elements with non-rigid connecting details.

III ""I", I" proloet tho insulators against damage due to flash-over the insulator string is fitted with arcing'"11111111111111111

1,1II11I1H:lllllllillings must be able to carry the rated short time current without serious damage. When the"'" II I 1:111:1111curronl is higher than the fittings can withstand, these must be by-passed by flexible conductors1111111111,,1,IIIIIII lor tho rated value.

1"""1111", "Irlnns in outdoor switchyards are used for stringing flexible conductors between gantries.111111/111,IllIpllclllo or oven triplicate strings may be used depending on conductor tensions etc.

AI I '''"Hllllhly witt! more than two insulator strings must satisfy the following conditions:I '111111IIIIHllon sharing between insulator strings.II ""11 III Iho Ilisulalor strings is broken the remaining ones must be undamaged.

'1111""111dllllip" of oither bolted or compression type hold the wire to the insulator. A turnbuckle is alsopl"vllll111 Ill, IllljlJHting the sag.

A",",h~.~._._._._._._

'L ~.·E\L.l·7-·_·-·-·-·~·~ / ... _. -. Insulator string Tension clamp

Turnbuckle,( i.lIl1y

III/ I:' ""IIIIIHI insulalor string

~~G,"'"

.L._.JI Ii ii i

~~~/w",m".

V III I1111/11CI1I11m usod to reduce the swing of the buswlres due to11111wll1d

nl"'I"III"111I1 strings are used on gantry beams to guide and""IIIII,IIIIIIIIIroppors.

4.2 PollutionPollution is, in some installations, a major maintenance problem. One basically distinguish betweenindustrial 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 isalready 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 byfollowing design and maintenance precautions, i.e.:1) Increasing the creepage distances2) Washing the insulators3) Applying silicone grease as a protective coating4) Using a suitabie insulator shape.

h I Typo. of busbars1111II lit I"", IIwlld'yards the two most commonly used types of busbars are strain bus bar of stranded wires~1Ii111111IIllpporlo(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 theseIWI' 111,,1/1111,mppor has the better. The conductivity of aluminium is about 60% of that of copper. This means1I1l11lIllllI,llIllJIII conductors require 60% larger area to achieve the same conductivity as copper. Comparinglilt, w"III'''" of tllo two metals, the main technical advantage of aluminium will appear. It is namely only 1/3,,11111111,1c"ppor. Aluminium can be operated at a somewhat higher temperature than copper which givesfill IIxl'/IIlIlv/lnluf]O.

I III 11111II/I/no cllrrent conducting capacity, the weight of the aluminium conductor will in general be"'"IHld""'lJly IOHH.

5.3 Rigid and flexible conductorsFor more moderate short-circuit currents and normal rated currents stranded wires are the most economicalalternative.

Tubes are used for high short-circuit currents and high rated currents.Bars are mostly used only for shorter connections, especially for current ratings on power transformer

secondaries.Aluminium iron-wires are used as overhead earth wires.More and more switchyards are built with aluminium tubes because of the increasing rated and short-

circuit currents. TUbe diameter and thickness are determined by mechanical strength rather than servicecurrents.

F = flexibie L = Bay iengthR = rigid W = Bay width

5.4 Mechanical strengthThe mechanical forces acting on electrical equipment and supporting structures are: dead weight, normalloads from conductors, ice load, wind load, short-circuit loading, mechanical operation and forces due toearthquake. The worst case for the electrical equipment and the supporting structures results from acombination of these factors.

Snatch forcesThe bundle conductor arrangement of strung (wires) type busbars constitute a special calculation andevaluation problem due to the snatch forces caused by short-circuit currents (parallel conductors forciblypulled together by magnetic attraction forces. These are causing high axial forces in the conductors).See fig. 19.

Q------9. ~. ~. ~({

Q----Q••0.---0

VIlllllllon.

A HI"'''11111'101'1,0111with lubular conductors is their sensitivity to vibrations. Vibrations often occur at mode-'"111 wlllli VII!cIl,III[lH, when the wind Initiates a frequency which coincides with the system's own freque1'"111111'''III1IV I :111/. ncy,

VII IIl1lh IIHI elllJI(j possibly cause the following defects:I "IIIJIIIl """Jlo ollho busbarI MIIIJIlII (01 IlIIpHCI) failure of the end fixings11II'lIl1l1c1ltlilellonlng of pantograph isolators11/'"11111"III IIllpporl insulators

111111111111111/111lollowing melhods for damping of tubular conductors are used.I III1HII wlro Ilisido Ihe tube[,1111111'''with (jnmping effectsAII"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 toII,IIIIIVII II low valuo of electric stress on the conductor surface.

II Clnmps

n I Iypo. of clamps11111111,""I'rinclpally two types of clamps

M,":llIllIll:II1 prossurel:llfllJHlHiH(I(j

111,11[111WIII,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 connectiont1IIlIVIl UIIHIIUJ

Bolted clamps . . .There are fundamentally four different groups of bolted clamps depending on the pnnclple of connection to

the conductor Le.:Fixed clamps

- Sliding clampsFlexible clampsSupport clamps(as conductor support only) See fig. 22

See fig. 21See fig. 22See fig. 23

~r@§)-o~

--~--

Welded clamps . . . .Welded clamps are sometimes used in large switchyards having aluminium type conductors of high current

rating. . r t dWelding gives very good contact properties but has the disadvantage of being. more comp Ica e ,

requiring high dimension accuracy and being less flexible when it comes to modifications etc.

WuhtUlt llIolhods11111WllhlllllJ "lllim must be protected by an inert shielding gas flow such as argon (MIG orTIG-welding).

I III ;'fi

Wllid IVI'" fl1mll}lll coupler. Cham-1IIIIId 111111"lor lJHHy insertion. Center01111'"II IlCCllrHllJ contering of coupler.

Fig. 27Streamlined, weld type T-connector.Tap element socket deep enough toallow for error in cut-off

WII IIIIVII olliV montioned the welding methods here. In case it will be applied, see SITE MAN 08-94 (WeldingII rill II) 111111SI J I MAN t7-94 (Aluminium welding).

1;","prOBBlon clamps111111111001comprossion clamps is most common when connecting the earth wires both under and aboveIlIflllllll

I '" 1111110lIollIlls soo SITEMAN 12-94. However, other frequent methods are brazing using bronz-alloy and111001111:wlIllIlIIIJ process described in SITEMAN 11-94.

WIIIIII 1I11:llIlIlJular earth bars are used they are mostly brazed together.

n'J I)"BIII"I IIIIlllclI1 cOllllllclions must be made so that maintenance never will be required. This is indeed a stringent111'11111111110111

1.11'''11"1IJHIHllor connection of conductors in outdoor switchyards must be designed and dimensioned to1l"ltllllllllllltllllltorrupted current supply and also not yield to mechanical forces between conductors due to11111II I IIICIJillIr olher severe stresses.

CIIIIIIICI roslatance1111111lXlilltlIIIlV important characteristic is the contact resistance which is responsible for the temperature111111111111wliidl must be kept as low as possible. The resistance must not increase significantly during theIIwlI<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 anotherIII 11111"" Jill oxort the required pressure11111CIIHI Hoclion must have sufficiently large cross1I11c11011III I!o able to conduct the rated current.

High voltage and current clampsSpecial attention must be paid to the clamp design when used for very high voltages (corona) and highcurrents. Such information is available in the manufacturer's catalogues and from the design office.

6.3 Material

Clamps for copper conductorsConnection clamps for copper conductors are manufactured exclusively of copper or of corrosion resistantbronze. 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 moreeasily removed.

Clamps for aluminium conductorsConnection 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 whichdevelop on its surface. These oxides are electrically insulating and must therefore be removed as effectivelyas possible from the contact surfaces.

BoltsGenerally, three types of material are used.- high alloyed, high strength aluminium (sensitive to corrosion). Used by EDF, France- hot dipped galvanized steel. Used in Germany- high alloyed Swedish stainless steel (expensive). Used by the Swedish State Power Board.

7.1 Access and work startWhen 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 theerection material such as steelwork, support and string insulators, conductors etc., have been erected andthe ground refilled and levelled. This applies also to the concrete cable ducts, which shall be ready at thesame time.

7.2 Steel structures

High towersIn order to facilitate more than one team to work with steel structures, it is recommended to start with thetowers. If the crane does not have sufficient height lifting capacity, the tower may be erected in two parts.The lower part is hoisted with a crane. The upper part is then erected manually, piece by piece, asillustrated in fig. 31. It is not necessary to fasten the hook of the crane at the top of the tower. If it is fastenedabove the center of gravity, it is safe enough.

'IUh'ol1lng 01 boltsWI,1I1111111tllWorS, the cross-beams or apparatus structures are assembled, the bolts must not be""llpllllllly Ilnhlaned. The final tightening shall be done after adjustment in straight position.

Adlu.lmonl11111/lllllJlilllllll1l 10 straight position is most conveniently controlled with a teodolite. The measurements are1111"",1111111two direclions at 90' angle as Shown in figure 32. The levelling could be done by shims orIlIvlIllllIlJ 1I1111i.IIlavelling nuts are used grouting may be required.

L1111 :1;'I", '"":Wlly millions should the towers be grounded immediatly after erected.

Cross beams .'Cross beams are to be erected on the ground and hoisted up by means of a dernck or, more convenient, a

mobile crane.

Apparatus structures ., .,Before the erection of Apparatus structures the Overhead lines and the Overhead Ilgtnlng protection wiresshould be installed for security reasons and the convenience of having more space. The erecMn ofApparatus structures will usually not involve any lifting problems.

7.3 Outdoor earthingFor the erection of the outdoor earthing refer to SITEMAN 18-94.

7.4 Insulators

Handling, checking and storing . .Of all the components going into the material handling process of a project the Insulators are the mosteasily damaged. Only in case of minor damages on the surface there IS a chance of acceptance. Thedesign office must be contacted for further instructions. .., .

Furthermore insulators are expensive items and they are also expensive to air freight due to their heavyweight. 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) ..Checking must be done immediately upon arrival, especially if the packing IS damaged or there IS the

slightest suspicion of careless handling.

InstallationAssemblyArrange a protected and controllable assembly area in the sWitchyard. . .

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.

111111111MII"I ,,,,"11111111"Ilroorocled at high levels. The lowest part of a support ',nsulator is normally 2.5 metres11111'VII UIIJlJlIlI ~;'J!lponBion insulators may be more than 10 metres above ground and of considerablew1I1U111

111'11""11'111,II lIlohllo crane with suitable soft slings should be used.

"""", ",,,llIlonnnco quostionsIIIIIIIIU 1I11111111111l11IClJwork 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 beIHmd

tuulll11111111111"Inlfl,'rollluni is modest, except for the lifting devices. Good soft slinging devices and a torqueWlfH 11'1I HIli FUHUjod.

, tI 11I1I.lIorll nnd Wires

11011111111111.chocking and storing1"'11""1:1111"'lIlorlnl, such as wire drums and tubes, will usually be stored outdoor because of size andw1I1U111/I ill IlIlporlanl that they do not come into contact with earth and sand Which may jeopardize contact1"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 waterIlIvIII 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,lIon1\11111IIll1dllltl 01 Blnol slructures and insulators follow the installation of conductors, which must be donewilli 0:11111iloilo "amage the insulator.

/I III 11"1'",111111/lial the material is kept clean. Parts to be connected together by means of clamps shall be"'1111,"111111111111111'"carelul cleaning and protection as described for the clamps. See Clause 7.6.

WAiININOI Novor use the some steel brush for copper and aluminium as it will accelerate corrosion.

WI,,, 1I""b,,rl"IIIIIU'lIlJ III Willi" must be done according to the sag and tension chart.

( 11111111:111""lIllllld lJn taken to avoid caging i.e. bending the wire so the strands go apart.WI "'" 1'1111111111110wlro always remember to tape the ends or use a special tool before cutting in order to

''''''1,111'' ""111111,,111place.I I"IIIW 1IIIIllW !Hlllln melhods to measure the length of buswire including the sag, both on the ground and

Illllw.HIII U/llllilcul

III 11,,, 1I1"llIr,,:n hnlweon the gantries is measured as illustrated in fig. 34. To thisI""ull, '" 1II1t!nd n ligure for the sag as stated in the sag and tension chart. Note thatIIllt. 11\111111III IIHllporature dependent. If compression clamps are used, their exten-"""I 1111111I Itit! 10 bo added.

III" 1:lllllplnln buswire including string insulators with hardware are assembled on theIJIIIIIIIII

NII".I AlwlIVII 11110covor and wood as protection against earth and sand.

1'1 II,,, '"",wl,,, Il1llssombled with a string insulator in one end on the ground. This endIII 1'111111111'1' A wiro puller is fitled in the other end and connected to a rope, see"u :11, IWI' 1I11111BIJringboards are fitled so that the sag can be measured. The""'"1101 "lid I" plllind up to the right sag and a tape marking is applied to the rope.1111,I,,",WII" It! tnkoll down and the total length is recorded and the second string'''"111111",III Iii Ind. 1t1O complete buswire is then finally installed as shown in fig. 36.

A = Distance between gantriesB = Sag plus compression clamp extensionC = Total length of buswire including insulator arrangements

'I /111,,111111'"I1I111){jIs to use a rope as a measurement and position it so that sag is correctly recorded,t1l111 flU :Ih

1IIhll hll l:onduclors1IIIIIIh C/lli 111111111lJo orocted in straight pieces or formed to different shapes by bending or by using various1""'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 thoroughly1"'"11II1II11d1'"111CIISl) 10 case.

11,,'.lInU1I,,, ',"11111"11"111,"huswiros/bars can be done manually or with various motor drive hoisting gears. Be sureIII 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 sure111111II IllY I"" Illlnimeod tomporarily.,

Fig. 37 Welding oftubular connectors

ToolsThe following list of tools is only indicative:Pulley blockSoft slingsRopeWire pUllerMeasuring boardTheodoliteWire drum standsDifferent types of hoisting gears:Winch for wire rope (type Tirfor)Motor winchWinch mounted on carMobile craneTorque 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 theouter surface can create corona.

Connections must be placed on a clean surface. Sand or other contaminants would cause damage to thethreads of the bolts and nuts. In case the connectors are delivered coated with contact paste the wrappingshould 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 dellvenesmay cause delays and extra costs at the end.

InstallationTreatmentThe 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 steelbrush, 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.

CI1I1 ••..,1 JI" •• I"Iillllllllll"IIIly (wlillirl !, fTlIJI.) afler cleaning, the contact surface shall be coated with the delivered contact1'''.111wl,I"', 11111111110IIrlJshod through with a steel brush all over the surface. For cable conductors, ensure111111111111'"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. Ample111",,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 •••• '11111101101 rigid connections

M"kll IIl/mlll/lllllo conductor completely fills the groove. At the end of the groove there is cavity to keep111111111111111:1111OJld 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 sidesI '" IWllllri CliP HIlll body of the connector, see fig. 40.

II 1-

111•• 11111"11 on 01 oxponsion connectors

WIII'" III1l/fTl1IJlIlIlJl oxpansion connector the positioning of the bus relative to the connector must take"rlilltlllli !ofTIpnrllllJro into account.

MIIt""HO 1110tolaltravel (L) of the bus. The distance (P) from the minimum temperature end position can111'1111\1'"1IIIIrlitio (Jiagram in fig. 51 by following the vertical line from L to the curve for actual ambientIIIrlll""lIlI/Il111lId IlIOn read P horizontally from the point of intersection. The meanings of Land Pare in-1111:1111111Irl IllllJro ~1 43.

I KllfTlpllI Arnhlonl temperature 40 'CMllxlmlJm travel (L): 80 mmP ~)6mm

(/[ r·'·,,·.1 I'

Connections to apparatus pad terminalsThe terminal is to be cleaned according to clause 8.6. The jointing shall be carried out with stainless steelbolts with double springwashers and washers as shown in fig. 44.

Tightening torqueEvery 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 aluminiumThis 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 theconnection 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 theconnection so that the aluminium is above the copper and thereby covers it so that rain water runs from thealuminium to the copper and not vice versa. See fig. 47-50 .

.-----AIo

J-o ofAluminium cold flowThe penetration of the oxide layer is partly a result of pressure applied. The higher the pressure, the moreeffective penetration. The difficulty, however, is that aluminium is cold floating, i.e. it becomes deformedunder 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 correctpressure will guarantee long and problemfree contact life.

IIluh.

1111'lolloWllIlllollln lIrO roquirod: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 important1111.11111'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.

",'11 }o 3D 40 50 60 70lu1.n 1 pO~f.ible travel L (1II1l)

, , IlIuh voltage apparatus

I"'PlJllulI .oquence

111111111nit In Hllould be erected and adjusted before connection of the primary conductors. If place isnvnllnlll", 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 busbars1111 , "10 cnrrlod nuL I

II",IIIIU

I I" 1I111111l1llno01 bolts and checking of steel structures etc. should be finalized before carrying out the°11ll/nllllIHlllosls on the equipment. The tests are performed first as local tests on the equipment itself andIIHI/1l1I1I1l1ImJII Ihe control room (remote) for checking of signals, interlocking etc.

Circuit breakersErection of circuit breakers is a comprehensive work and must be carried out according to the erectioninstructions.

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 coveredand the anti-condensation heaters be connected.

Lifting devices with sufficient capacity (check with dimension print) must be available.The flexible connectors between the breaker and the current transformers are included in the delivery.

Disconnecting switchesThe comments underitem "circuit-breakers"above are in manyrespects valid also fordisconnecting switches.Regarding switches withbuild-on earthingswitches it should berealized that there are alot of variations whenerecting the operatingmechanism.

Fig. 53 Erected discon-necting switches andvoltage transformers

t," IhlllU .wlh:ho.

1.111111",111111111"""11/111111Hwliches shall be made with shortest possible route to the earth grid.

/I In.paellon, quality control111111IIIIII1II1hllllll'",IIlIIClllo carry out an erection that comply with standards stated in the contract between111\1\'"11111111I,will 11IIor Hlld belween ABB and subcontractor. Make sure that the contract is understoodnVfllllllllllflllltlJlfH:1

1IIIIIIIlJ 1111111111111111111111olOclion a "Remaining list" has to be kept updated. The list shall state all work that11I1f1 III I't! ro flOrin or In uncloar.

1\11111111"IIIklllll IIvor" 1110list has to be finalized.NIIIII 1111111111<lIIIWIrIIlH IlHVO10 be up-dated "as built" in red and one copy submitted to the design office.

U In.llng ftnd CommissioningI Villi 1111"'1111111IIIIlCllJllJllIHsioning are usually not the ultimate responsibility of the erection engineer, he isltllll1U11nly Involve II!

I 11111111111111<1clIIIlIlllsHlolling goes hand in hand and require close cooperation.

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