hv cable joints and terminations

NS 0129Network Standards

Volume 1

Construction Standards for High VoltageCable Joints and Terminations

1 October 1997

Amendments included from CIA 1087, 21 Dec 1999; CIA 1094, 1 Mar 2000, CIA 1114, 15 June 2000,CIA 1170, 15 May 2001, CIA 1188, 25 July 2001, CIA 1226, 27 Mar 2002 and CIA 1242, 23 April 2002

SUMMARYNetwork Standard NS 0129 provides the requirements for making joints andterminations on high voltage cables.

GENERALThis Standard is subject to amendment by EnergyAustralia at any time.

Any proposed deviation from this Standard must be submitted to EnergyAustralia forapproval before it is implemented.

ISSUEEnergyAustralia staff: This Standard is for issue to all staff involved with highvoltage cable jointing work, and for general reference by technical and engineeringstaff.

Where this document is issued as a controlled document replacing an earlier edition;remove and destroy the superseded document.

Accredited Service Providers and Contractors: This document is issued on anuncontrolled basis. It is the user’s responsibility to ensure that the document beingused is current and includes any amendments issued since the date on the document.

EnergyAustralia offers a subscription service which provides for updates andamendments to standards on payment of an annual fee.

Current network standards are also available on EnergyAustralia’s Internet site atwww.energy.com.au.

DISCLAIMERThis Standard has been developed using information available from field and othersources and is suitable for most situations encountered in EnergyAustralia. Particularconditions, projects or localities may require special or different practices. It is theresponsibility of all persons involved to ensure that a safe system of work is employedand that statutory requirements are met.

EnergyAustralia will not accept any liability for work carried out to a supersededstandard. EnergyAustralia may not accept work carried out which is not in accordancewith current standard requirements.

EnergyAustralia’s standards are subject to ongoing review. It is possible that conflictmay exist between standard documents. In this event, the most recent standard is toprevail.

INTERPRETATIONIn the event that any user of this Standard considers that any of its provisions isuncertain, ambiguous or otherwise in need of interpretation, the user should requestEnergyAustralia to clarify the provision. EnergyAustralia’s interpretation shall thenapply as though it were included in the Standard, and is final and binding. Nocorrespondence will be entered into with any person disputing the meaning of theprovision published in the Standard or the accuracy of EnergyAustralia’sinterpretation.

Network Standard NS 0129

Construction Standards for High VoltageCable Joints and Terminations

1 October 1997CONTENTS

1. INTRODUCTION................................................................................... 12. RESPONSIBILITIES ............................................................................. 2

2.1 Clients ..................................................................................... 22.2 EnergyAustralia Representatives ............................................ 22.3 Electrical Safety Rules ............................................................ 22.4 Admittance to EnergyAustralia Premises ................................ 2

3. CONSTRUCTION OF UNDERGROUND TO OVERHEAD (UG/OH)PILC CABLE TERMINATIONS.............................................................. 4

4. CONNECTION OF UNDERGROUND MULTI-CORE CABLE TO HVABC....................................................................................................... 84.1 HV ABC to Underground Cable Construction........................ 10

5. Suburban Type Transformer Cable Termination (HV1-20)................. 116. INDOOR COLDSHRINK TERMINATION, PAPER INSULATED

CABLES .............................................................................................. 127. OUTDOOR COLDSHRINK TERMINATION, PAPER INSULATED

CABLES .............................................................................................. 168. (Deleted by CIA 1170, 15 May 2001) .................................................. 189. INDOOR AND OUTDOOR SINGLE-CORE HEATSHRINK

TERMINATIONS, XLPE-INSULATED CABLES (HV1-27) .................. 199.1 General ................................................................................. 199.2 Special Requirements ........................................................... 20

10. TRANSFORMER HEATSHRINK TERMINATION SINGLE-CORE,PAPER-INSULATED CABLES (HV1-28) ............................................ 26

11. POT END (LIVE END SEAL) HEATSHRINK TERMINATION SINGLE-CORE, PAPER-INSULATED CABLES (HV1-35) ................................ 29

12. POT END (LIVE END SEAL) HEATSHRINK TERMINATIONMULTICORE, PAPER-INSULATED CABLES (HV1-36) ..................... 31

13. STRAIGHT THROUGH HEATSHRINK JOINT SINGLE-CORE,PAPER-INSULATED CABLES (HV2-2) .............................................. 33

14. STRAIGHT THROUGH HEATSHRINK JOINT UP TO 300mm2

MULTICORE, PAPER-INSULATED CABLES (HV2-3) ....................... 3514.1 Approved Heatshrink Joint Kits ............................................. 3514.2 Core Connectors ................................................................... 3514.3 Earth Continuity..................................................................... 36

14.4 Stripping Dimensions ............................................................ 3714.5 Other Requirements .............................................................. 37

15. STRAIGHT THROUGH HEATSHRINK JOINT MULTICORE, PAPER-INSULATED CABLES 300 TO 500mm2 (HV2-4) ................................ 3915.1 Approved Heatshrink Joint Kits ............................................. 3915.2 Core Connectors ................................................................... 3915.3 Earth Continuity..................................................................... 4015.4 Stripping Dimensions ............................................................ 4015.5 Other Requirements .............................................................. 41

16. THREE-TO-ONE HEATSHRINK TRANSITION JOINT PAPER-INSULATED CABLES (HV2-5)............................................................ 4216.1 Approved Heatshrink Joint Kits ............................................. 4216.2 Core Connectors ................................................................... 4316.3 Earth Continuity..................................................................... 4416.4 Stripping Dimensions ............................................................ 4416.5 Other Requirements .............................................................. 44

17. STRAIGHT THROUGH JOINT (STUB TEE) SCREENED ANDBELTED PAPER INSULATED MULTI-CORE CABLES (HV 2-72) .... 4617.1 Core Connectors ................................................................... 4617.2 Paper Insulation and Insulating Tapes .................................. 4617.3 Stress Cones......................................................................... 4717.4 Earth Continuity..................................................................... 4717.5 Stripping Dimensions ............................................................ 4817.6 Troughing-in of Completed Joints.......................................... 4817.7 Commissioning of Joints........................................................ 48

18. LAY-ON TEE JOINTS FOR SCREENED AND BELTED PAPERINSULATED CABLES ......................................................................... 5318.1 Core Connectors ................................................................... 5318.2 Paper Insulation and Insulating Tapes .................................. 5318.3 Stress Cones......................................................................... 5418.4 Earth Continuity..................................................................... 5418.5 Stripping Dimensions ............................................................ 5518.6 Troughing-in of Completed Joints.......................................... 5518.7 Commissioning of Joints........................................................ 55

19. QUALITY OF WORK........................................................................... 6119.1 Warranty and Public Liability ................................................. 61

20. STORES AND MATERIALS................................................................ 6121. REFERENCES.................................................................................... 62

21.1 EnergyAustralia Drawings ..................................................... 6221.2 Acts and Regulations ............................................................ 62

APPENDICES

A Cable Description Codes..................................................................... 63B Installation Instruction HV 1-41 ........................................................... 65C Installation Instruction HV 1-42 ........................................................... 75D Installation Instruction HV 1-43 ........................................................... 86E Installation Instruction HV 1-44 ........................................................... 98

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1. INTRODUCTION

This Network Standard specifies EnergyAustralia’s construction requirementsfor High Voltage (HV) cable joints, terminations, and Underground toOverhead (UG/OH) connections.

Although there are many types of HV joints, terminations and UGOHconnections on EnergyAustralia’s reticulation system, only the approvedconstruction standards currently in use are detailed in this document.

The requirements of this standard must always be adhered to. Any deviationsfrom this standard must be submitted to EnergyAustralia for approval prior tobeing implemented.

In general, EnergyAustralia’s current policy provides for the contestability ofcustomer connections, recoverable works and some system augmentations.Work on EnergyAustralia’s supply system can only be performed byaccredited contractors. Details of the accreditation procedure may be obtainedfrom any of EnergyAustralia’s Customer Service centres.

This Network Standard should be read in conjunction with EnergyAustralia’sdocuments NS 0127 - Specification for Low Voltage Cable Joints andTerminations and NS 0130 - Specification for Underground Cable Laying forURD.

Construction details for joints, terminations, and UG/OH connections whichare not covered in this standard should be sought from EnergyAustralia asrequired.

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2. RESPONSIBILITIES

2.1 ClientsIt is the responsibility of clients to ensure that only accredited personnel areengaged on the design and construction of electricity reticulation installations.

The construction of electricity reticulation installations undertaken by clientsmust be managed by accredited Project Managers.

2.2 EnergyAustralia RepresentativesA representative will be appointed by EnergyAustralia for each projectundertaken by accredited contractors. The representatives will be responsiblefor organising audits and will act as liaison between the Client andEnergyAustralia.

Audits will be carried out either progressively or at the completion of the workdepending on the specific requirements of each project.

2.3 Electrical Safety RulesAll accredited personnel will be required to be appropriately trained for thework concerned, and will need to have a thorough knowledge ofEnergyAustralia’s Electrical Safety Rules. In particular, they shall have a fullunderstanding of the procedures and documentation associated with EquippingPermits and high and low voltage access permits before they commence workon any part of EnergyAustralia’s reticulation system.

EnergyAustralia’s Electrical Safety Rules are designed to ensure compliancewith the Electrical (Worker’s Safety) Regulation 1992, which applies to allwork on high and low voltage electrical apparatus or near exposed highvoltage conductors and to persons who enter electrical stations or generatingstations. The regulation applies to people employed by electricity supplyauthorities, customers taking supply at high voltage, electrical contractors andaccredited contractors working on electrical apparatus, and to any otheremployee or person including visitors.

2.4 Admittance to EnergyAustralia PremisesAdmission to EnergyAustralia’s premises is granted to accredited contractorsonly under EnergyAustralia’s supervision and at the accredited contractors’cost under the following conditions:

• EnergyAustralia does not hold itself responsible to the accreditedcontractor or anyone claiming through the accredited contractor in respectof any loss, damage or injury which may be suffered or received during orarising from their presence upon EnergyAustralia’s premises or any partthereof or any other premises or works connected therewith.

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• The accredited contractor accepts all risks involved in making any visit tothe said premises and works whether there are concealed dangers orotherwise and whether such dangers are known to EnergyAustralia or not.

• EnergyAustralia does not guarantee that the premises or works are freefrom concealed dangers or risks.

• EnergyAustralia shall not be liable for or be bound by any of the liabilitiesor duties to or by which it would otherwise be liable or bound under thelaw relating to the liability and/or responsibility of an owner or occupier ofpremises to or in relation to licensees and/or invitees.

• Accredited contractors agree to safeguard any person who may accompanythem or be under their control or direction and shall acquaint any suchperson with the terms upon which admission is granted by EnergyAustraliato its premises or work sites.

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3. CONSTRUCTION OF UNDERGROUND TO OVERHEAD(UG/OH) PILC CABLE TERMINATIONS

This specification provides the requirements for the construction of 11kVunderground-to-overhead (UG/OH) PILC cable terminations. Thisspecification should be read in conjunction with the installation instructionsfor Outdoor Coldshrink Terminations.

There are two types of 11kV underground-to-overhead (UG/OH) PILC cableterminations, they are the Type K2 and Type K3.

The Type K2 UG/OH is a single core cable termination used for terminating500 mm2 multicore cables by first trifurcating the multicore cableapproximately 3 metres away from the foot of the UG/OH pole; or when aUG/OH termination is to be constructed within 25 metres of the substation it issupplying. The Type K3 UG/OH is for terminating multicore cables less than500 mm2.

The construction of pole mounted 11kV underground-to-overhead (UG/OH)cable terminations must be completed to the requirements of Drawing 6210311kV Underground to Overhead (UG/OH) Construction for Single Core PILCCables Type K2 for single core cables and Drawing 119643 11kVUnderground to Overhead (UG/OH) Construction for Multicore PILC CablesType K3 for multicore cables. Copies of these drawings are included in thisStandard. Larger prints may be obtained from EnergyAustralia.

The cables must be erected on the side of the pole away from oncoming traffic(except if the mains terminate on the traffic side of the pole, or there areproblems such as a driveway or underground obstructions).

The cable shall not be bent tighter than the manufacturer’s specified minimuminternal bending radius, both during installation and after it has been set inposition.

The erection and termination of the cable on the pole should be completedtogether wherever possible to minimise the number of outages required.Where it is intended to terminate the UG/OH cable at a later date, the cableshould:

• Be cut long enough to allow construction of the termination at the correctheight. This would normally require the cable to extend 300mm above theUG/OH support bracket. Above ground joints on UG/OH cables are notallowed.

• Be shorted and sealed in accordance with the requirements of NS 0130 -Specification for Underground Cable Laying

• Be securely saddled to the pole. The cable should not be coiled orexcessively bent - refer to the manufacturer’s specification for minimuminternal bending radius.

• Have sufficient electrical clearance from the overhead mains if these mainsare intended to be energised before the cable termination is completed.

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Drawings 62103 and 119643 provide an alternative arrangement for UG/OHterminations which involves using polymeric surge arresters to provideprotection against electrical surges as well as mechanical support for theterminated cores. This arrangement must be used wherever possible.

Where an earth fault indicator (EFI) is required to be installed on UG/OHcable, the pole must be appropriately dressed to suit the current transformer(CT) before the cable is erected on the pole. Mounting and wiring details forthe CT and EFI will be provided by EnergyAustralia as required.

The earth down lead must be kept clear of all metalwork, braces, coachscrews, etc, on the pole.

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4. CONNECTION OF UNDERGROUND MULTI-CORE CABLETO HV ABC

This specification provides the requirements for constructing connectionpoints between underground cables and overhead aerial bundled cables (HV

ABC).

Figure 3.1 Front View of HV ABC to underground cable construction

The construction of pole mounted 11kV underground-to-overhead (UG/OH)multicore cable terminations type K3 must be completed to the requirementsof Section 3 of this Network Standard.

TYPICAL HV ABC TO UNDERGROUND CABLE CONSTRUCTION

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Figure 3.2 Side view of HV ABC to underground cable construction

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4.1 HV ABC to Underground Cable ConstructionItem Description Stockcode Drawing

1 Helically split tube 1 m long (note 2) 712902 Copper link plate 569373 19/2.00 GI preformed termination -4 Clevis thimble for GI catenary -5 M20 eyebolt with link plate-length to suit - A3-138376 Pole cap - A2-218527 Plastic coated steel cable ties -8 Copper crimp link 35 mm2 57091

120 mm2 571589 Screen bonding cable 35 mm2 59535

120 mm2 6011110 Bimetallic earthing tee clamp 9116511 Split bolt clamp type C 61374 1890812 UGOH mounting bracket 66365 A1-6201113 Cantilever standoff insulator 11kV 9022514 ABC heatshrink termination 11 kV 35 mm2 74252

120 mm2 7426015 Compression lug (bimetallic) 35 mm2 58347

120 mm2 5832116 M12 x 35 SS bolt and nut 4502117 M12 flat and spring washers 49429,

14385918 Termination plate (item 3 on drawing) 91132 A2-11698919 UG cable heatshrink termination 11 kV -20 Earth-wire (19/2.00 Cu) -21 Support assy of ABC suspension clamp 35 mm2 63040

120 mm2 63016

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5. SUBURBAN TYPE TRANSFORMER CABLETERMINATION (HV1-20)

Note: Heatshrink glands must not be used on gland entry transformers, asthere are no suitable heatshrink glands currently available for an oilvapour environment. Brass glands must be used, in accordance withthe following diagram.

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6. INDOOR COLDSHRINK TERMINATION, PAPERINSULATED CABLES

This specification provides the requirements for constructing coldshrinkpressure sealing terminations on indoor 11kV single core and multicore paperinsulated, screened, metal sheathed, polymeric oversheathed cables.

The design of this termination is such that it is capable of withstanding highinternal pressures.

Only personnel who have been trained and assessed as being competent in theinstallation of 3M pressure rated coldshrink terminations can install theseterminations. Either EnergyAustralia or 3M can perform this training.

Approved Coldshrink Kits

Currently, the only approved supplier of coldshrink pressure sealingtermination kits suitable for this application is 3M, in accordance with thetechnical kit specification for the stockcodes listed below. Other coldshrinkpressure sealing termination kit designs or other suppliers for similar designsmust not be used unless specifically approved by EnergyAustralia.

Earthing kits for single core cables are progressively being incorporated in thetermination kits. Contact 3M on 1300 363 787 if the earthing kits have notbeen supplied.

Coldshrink Kit Description Coldshrink KitStockcode No.

3 x single core indoor coldshrink termination kit(including earthing) suitable for 11 kV 95mm² - 185mm²paper insulated, screened, lead sheathed, polymericoversheathed cables –3M’s part number EAIT-11-1C-P-S-95/185

175341

3 x single core indoor coldshrink termination kit(including earthing) suitable for 11 kV 240mm² - 300mm²paper insulated, screened, lead sheathed, polymericoversheathed cables –3M’s part number EAIT-11-1C-P-S-240/300

175343

Multicore indoor coldshrink termination kit (includingearthing) suitable for 11kV 95 mm² paper insulated,screened, lead sheathed, polymeric oversheathed cables -3M's part number EAIT-11-3C-P-S-95

175883

Multicore indoor coldshrink termination kit (includingearthing) suitable for 11kV 185 mm² - 300 mm² paperinsulated, screened, lead sheathed, polymericoversheathed cables –3M's part number EAIT-11-3C-P-S-185/300

175884

Cable Lugs

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The lugs used can be of the sweated type or the compression type. In eithercase, the lugs must have sealed palms and barrels (except for the cable entryend). Compression lugs must be installed in strict compliance with themanufacture’s recommendations for crimping dies, and the number andposition of crimps.

EnergyAustralia’s stockcodes of approved lugs are provided in the tablebelow.

Stockcode of Crimp Lugs for Indoor TerminationsCable Size Copper Cables Aluminium Cables

95 mm² 175531 H102442185 mm² 175532 57927240 mm² 175533 H107706300 mm² 175534 57687

Requirements

The following requirements must be satisfied when constructing coldshrinkpressure sealing terminations:

• The cables must not be bent tighter than the manufacturers’ specifiedminimum bending radii during the termination process or after they havebeen set in position.

• The termination shall be constructed in accordance with the installationinstruction supplied in the termination kit. The installation instructionsupplied is Version 1, dated 12th April 2001. Refer to Appendix B forsingle core cables and Appendix D for multicore cables.

• No jagged edges shall be left on terminated screen papers.

• Paper insulation must be tested for moisture. If moisture is found, therelevant EnergyAustralia representative must be immediately notified.

• Tapes will be applied over the lug barrels and the cable metal sheath toprevent water entry into the termination area. These areas must be properlycleaned and degreased before the tapes are applied..

• The design of multicore terminations incorporates the use of resin toprovide for a high cable operating pressure. This resin is best applied usinga resin gun. So, it is highly recommended that a resin gun be used to injectresin into the cable crotch. This gun can be obtained fromEnergyAustralia’s Logistics Branch on stockcode 175885 or purchaseddirectly from 3M (Part No. E4 Resin Gun).

• Coldshrink tubings must be properly and evenly shrunk and must be free ofvoids.

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• Restriction tape is used to improve the pressure sealing abilities of thetermination. This tape does not stretch and will break if over tensioned.Avoid creasing when applying this tape.

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Earth Fault Indicator (EFI) CT Support Bracket

Some of the designs for indoor heatshrink terminations utilised wiped copperbangles for earthing of the cable sheaths. These bangles were also used tosupport EFI CTs where appropriate. The new coldshrink termination designincorporates the use of roll springs and copper braids for earthing, but is notsuitable for supporting the EFI CTs. To support the EFI CT, a cable mountingbracket is installed on each of the outer single core cables, with the EFI CTresting on top of the mounting brackets (refer to Figure 1 below). The cablemounting brackets are available on stockcode 177066 for 95 mm2 PILCcables, and stockcode 177067 for 185 mm2 to 300 mm2 PILC cables.

Endbox(if applicble)

100mm below the outerSilicon Tubing for terminationsin free air (no end box)

100mm min

Upper oversheath cut

80mm below the glandplate of the cable endbox

To MainEarthing Point

Mountingbracket

EFI CT arrangement

if required

Cable Oversheath

EFI CT

Figure 1 - EFI CT Arrangement If Required

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7. OUTDOOR COLDSHRINK TERMINATION, PAPERINSULATED CABLES

This specification provides the requirements for constructing coldshrinkpressure sealing terminations on outdoor 11kV single core and multicorepaper insulated, screened, metal sheathed, polymeric oversheathed cables.This specification should be read inconjuction with Section 4 (construction ofUG/OH Multicore Cable Termination Type K3) and Construction of UG/OHSingle Core Cable Termination Type K2 of NS 0129 Construction Standardsfor HV Cable Joints and Terminations.

The design of this termination is such that it is capable of withstanding highinternal pressures.

Only personnel who have been trained and assessed as being competent in theinstallation of 3M pressure rated coldshrink terminations can install theseterminations. Either EnergyAustralia or 3M can perform this training.

Approved Coldshrink Kits

Currently, the only approved supplier of coldshrink pressure sealingtermination kits suitable for this application is 3M, in accordance with thetechnical kit specification for the stockcodes listed below. Other coldshrinkpressure sealing termination kit designs or other suppliers for similar designsmust not be used unless specifically approved by EnergyAustralia.

Earthing kits for single core cables are progressively being incorporated in thetermination kits. Contact 3M on 1300 363 787 if the earthing kits have notbeen supplied.

Coldshrink Kit Description Kit Stockcode No.3 x single core outdoor coldshrink termination kit (includingearthing) suitable for 11 kV 95mm² - 185mm² paper insulated,screened, lead sheathed, polymeric oversheathed cables –3M’s part number EAOT-11-1C-P-S-95/185

175342

3 x single core outdoor coldshrink termination kit (includingearthing) suitable for 11 kV 240mm² - 300mm² paperinsulated, screened, lead sheathed, polymeric oversheathedcables –3M’s part number EAOT-11-1C-P-S-240/300

175344

Multicore outdoor coldshrink termination kit (includingearthing) suitable for 11kV 95 mm² paper insulated, screened,lead sheathed, polymeric oversheathed cables -3M's part number EAOT-11-3C-P-S-95

175881

Multicore outdoor coldshrink termination kit (includingearthing) suitable for 11kV 185 mm² - 300 mm² paperinsulated, screened, lead sheathed, polymeric oversheathedcables -3M's part number EAOT-11-3C-P-S-185/300

175882

Cable Lugs

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The lugs used can be of the sweated type or the compression type. In eithercase, the lugs must have sealed palms and barrels (except for the cable entryend). Compression lugs must be installed in strict compliance with themanufacture’s recommendations for crimping dies, and the number andposition of crimps.

EnergyAustralia’s stockcodes of approved lugs are provided in the tablebelow.

Stockcode of Crimp Lugs for Outdoor TerminationsCable Size Copper Cables Aluminium Cables

95 mm² 151050 H102442185 mm² 90183 57927240 mm² H95901 H107706300 mm² 57695 57687

Requirements

The following requirements must be satisfied when constructing coldshrinkpressure sealing terminations:

• The cables must not be bent tighter than the manufacturers’ specifiedminimum bending radii during the termination process or after they havebeen set in position.

• The termination shall be constructed in accordance with the installationinstruction supplied in the termination kit. The installation instructionsupplied is Version 1, dated 12th April 2001. Refer to Appendix C forsingle core cables and Appendix E for multicore cables.


• Paper insulation must be tested for moisture. If moisture is found, therelevant EnergyAustralia representative must be immediately notified.

• Tapes will be applied over the lug barrels and the cable metal sheath toprevent water entry into the termination area. These areas must be properlycleaned and degreased before the tapes are applied.

• The design of multicore terminations incorporates the use of resin toprovide for a high cable operating pressure. This resin is best applied usinga resin gun. So, it is highly recommended that a resin gun be used to injectresin into the cable crotch. This gun can be obtained fromEnergyAustralia’s Logistics Branch on stockcode 175885 or purchaseddirectly from 3M (Part No. E4 Resin Gun).

• Coldshrink tubings must be properly and evenly shrunk and must be free ofvoids.

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• Restriction tape is used to improve the pressure sealing abilities of thetermination. This tape does not stretch and will break if over tensioned.Avoid creasing when applying this tape.

• The earth braids used on outdoor terminations must be covered. All newearthing kits will be supplied with covered earth braids, in the interim theearth braids in the existing earthing kits must be covered with VM tape.

8. (DELETED BY CIA 1170, 15 MAY 2001)

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9. INDOOR AND OUTDOOR SINGLE-CORE HEATSHRINKTERMINATIONS, XLPE-INSULATED CABLES (HV1-27)

This specification provides the requirements for terminating 11 kV XLPEinsulated wire screened single-core cables for indoor and outdoor applications.

9.1 GeneralThis termination design is not suitable for installation in environments subjectto transformer oil or heavy transformer oil vapour contamination, such asinside oil transformer tanks.

Current approved suppliers of heatshrink termination kits suitable for thisapplication are Raychem and Sigmaform, in accordance with the technical kitspecifications for the stockcodes listed below. Other termination kit designs orother suppliers for similar designs must not be used unless specificallyapproved by EnergyAustralia.

Table 1 Termination Kits and LV Heatshrink Tubing

STOCKCODESCable size Termination

typeTermination kit

stockcodeLV

Heatshrinktubing

BimetalCrimp lug

35 mm2 Indoor 74278 60186 58347Outdoor 74252 60186 58347

120 mm2 Indoor 74286 60186 58321Outdoor 74260 60186 58321

630 mm2 Indoor 60038 60319 -Outdoor 60053 60319 -

The termination construction details, including stripping dimensions for theapproved Raychem and Sigmaform termination kits are shown in figures 8.1to 8.5.

The cable connectors used can be of the sweated type or the compression type.In either case, the connectors must be of the sealed type to safeguard againstthe ingress of moisture into the core conductors. The barrel of the connectorsmust be long enough to allow the outer heatshrink tubing of the termination tooverlap them by a minimum of 30mm on 35mm2 cables and 60mm on120mm2 and larger cables.

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Compression type connectors must be installed in strict compliance with themanufacturer’s recommendations for crimping dies, and the number andposition of crimps.

The following requirements must be satisfied when constructing heatshrinkcable terminations on XLPE cables:

• The termination kit contents and the prepared cable ends must be kept freeof foreign matter, and must not be damaged during the termination process

• Cables must not be bent tighter than their manufacturers’ specifiedminimum bending radii, either during the termination process or after theyhave been set in position.

• The insulation semi-con shall be neatly terminated. Special care must betaken to ensure that the XLPE insulation is not damaged while removingthe semi-con.

• Cable connectors must be preheated prior to installation

• All components involved in the termination (including cable components)which will come into contact with either mastic tape or adhesive sealantsmust be thoroughly cleaned prior to the application of such sealing agents.Cleaning must only be done using lint-free cloth.

• Heatshrink tubings must be properly and evenly shrunk, free of voids, andmust not be damaged due to overheating. Heatshrink components withadhesive sealant coatings must provide effective sealing against moistureingress when installed

• The specified stripping dimensions must be adhered to.

9.2 Special RequirementsThe Electricity Reticulation Designer will specify the type of cable connectorto be used on the terminations, and the earth screens termination requirements.

If EFI CTs (Earth Fault Indicator Current Transformers) are required, twoadditional rain-sheds (stockcode 141564) per phase will be required to supportthe CT (see Detail C of Figure 8.1). (These rain-sheds are larger than thestandard termination rain-sheds included in the termination kit.)

If the wire screens are not required to be earthed LV heatshrink tubings areused (see Detail B of Figure 8.1). EFI CTs must not be installed where thewire screens are not earthed.

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Figure 8.1 Special Construction Requirements

connector

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Cable Components

1 Conductor

2 XPLE Insulation

3 SemiconductingScreen

4 Wire ScreensNote: where earthing ofwire screens is notrequired, see Detail B ofFigure 8.1 for details ofwire screen termination.

5 Polymeric Sheath

Heatshrink KitComponents

6 Mastic Tape (red)

7 Non-tracking,weather resistanttubing (red)

8 Stress controltubing (black)

9 Void-filling Tape(yellow)

*Refer to Clause 8.1 fordetails

Figure 8.2 Construction requirements for approved RaychemIndoor XLPE Cable Terminations

*

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Cable Components

1 Conductor

2 XPLE Insulation

3 Semiconducting Screen

4 Wire Screens

Note: where earthing of wire screensis not required, see Detail B ofFigure 8.1 for details of wire screentermination.

5 Polymeric Sheath

Heatshrink Kit Components

6 Mastic Tape (red)

7 Non-tracking, weatherresistant tubing (red)

8 Stress control tubing(black)

9 Void filling Tape (yellow)

10 Rain-shed

*Refer to Clause 8.1 for details

Figure 8.3 Construction requirements for approvedRaychem outdoor XLPE Cable Terminations

*

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Cable Components

1 Conductor

2 XPLE Insulation

3 SemiconductingScreen

4 Wire ScreensNote: where earthing ofwire screens is notrequired, see Detail B ofFigure 8.1 for details ofwire screentermination.

5 Polymeric Sheath

Heatshrink KitComponents

6 Mastic Tape (red)

7 Non-tracking,weather resistanttubing (red)

8 Stress controltubing (black)

*Refer to clause 8.1 fordetails

Figure 8.4 Construction requirements for approvedSigmaform Indoor XLPE Cable Terminations

*

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Cable Components

1 Conductor2 XPLE Insulation3 Semiconducting Screen4 Wire Screens

Note: where earthing of wire screens is not required,see Detail B of Figure 8.1 for details of wire screentermination.

5 Polymeric Sheath

Heatshrink Kit Components6 Mastic Tape (red)7 Non-tracking, weather resistant tubing

(red)8 Stress control tubing (black)9 Rainshet*Refer to clause 8.1 for details

Figure 8.5 Construction requirements for approvedSigmaform Outdoor XLPE Cable Terminations

*

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10. TRANSFORMER HEATSHRINK TERMINATIONSINGLE-CORE, PAPER-INSULATED CABLES (HV1-28)

This specification provides the details for a heatshrink termination on 11 kV95mm2, single-core, paper-insulated, metal-sheathed cables.

The termination is suitable for installation above the oil inside the tank ofgland-entry transformers.

Currently, the only approved supplier of heatshrink termination kits suitablefor this application is Raychem, in accordance with the technical kitspecification for the stockcode listed below. Other termination kit designs orother suppliers for similar designs must not be used unless specificallyapproved by EnergyAustralia.

HEATSHRINK KITDESCRIPTION

HEATSHRINK KITSTOCKCODE NO.

3 x single core cable heatshrinkterminations suitable for 95mm2

screened paper insulated cables157081

The termination construction details, including stripping dimensions for theapproved Raychem termination kit are shown in figure 9.1.

The lugs used can be of the sweated type or the compression type. In eithercase, the lugs must have sealed palms and barrels (except for the cable entryend). The barrels of the lugs must be long enough to allow the outer heatshrinktubing of the termination to overlap them by a minimum of 50mm.Compression lugs must be installed in strict compliance with themanufacturer’s recommendations for crimping dies, and the number andposition of crimps.

CABLE SIZE STOCKCODE OF CRIMPLUGS FOR COPPER CABLES

95mm2 151050

The following requirements must be satisfied when constructing heatshrinkcable terminations inside transformer tanks.

• The termination kit contents and the prepared cable ends must be kept freeof foreign matter, and must not be damaged during the termination process.

• The transformer oil must not be contaminated with foreign matter duringthe termination process.

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• The cables and their individual cores must not be bent tighter than themanufacturers’ specified minimum bending radii, either during thetermination process or after they have been set in position.

• No jagged edges shall be left on terminated screen papers

• Lugs must be preheated prior to installation

• All components involved in the termination (including cable components)which will come into contact with either mastic tape or adhesive sealantsmust be thoroughly cleaned prior to the application of such sealing agents.Cleaning must only be done using lint-free cloth.

• Heatshrink tubings must be properly and evenly shrunk, free of voids, andmust not be damaged due to overheating. Heatshrink components withadhesive sealant coatings must provide effective sealing against moistureingress when installed.

• The outer heatshrink tubing must overlap the barrel of the lug by aminimum of 50mm

• The specified stripping dimensions must be adhered to.

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Cable Components

1 Conductor

2 Paper Insulation

3 Screen Papers

4 Lead Sheath

Kit Components

5 Void-filling Tape(yellow)

6 Non-tracking, oilresistant tubing

7 Stress ControlTubing

Other Components

8 Lug

Figure 9.1 Raychem Heatshrink Termination forinstallation inside transformer tanks

Abrade metal sheath before installing outer tubing

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11. POT END (LIVE END SEAL) HEATSHRINK TERMINATIONSINGLE-CORE, PAPER-INSULATED CABLES (HV1-35)

This jointing instruction specifies the requirements for a pot end (live endseal) termination on 11 kV, single-core, paper-insulated, screened, metalsheathed, polymeric oversheathed cables.

Currently, the only approved supplier of heatshrink termination kits suitablefor this application is Raychem, in accordance with the technical kitspecification for the stockcode listed below. Other termination kit designs orother suppliers for similar designs must not be used unless specificallyapproved by EnergyAustralia.

HEATSHRINK KIT DESCRIPTION HEATSHRINK KITSTOCKCODE NO.

1 single core cable heatshrink pot end (liveseal) suitable for 185 mm2 screened paperinsulated cables

152116

1 single core cable heatshrink pot end (liveseal) suitable for 300 mm2 screened paperinsulated cables

152124

The pot end construction details, including stripping dimensions for theapproved Raychem termination kits are shown in figures 10.1.

Figure 10.1 Stripping dimensions for approved Raychem Pot endTermination kits

The following requirements must be satisfied when constructing heatshrinkcable pot ends:


• The cable must not be bent tighter than its manufacturers’ specifiedminimum bending radius, either during the termination process or after ithas been set in position.


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• All components involved in the termination (including cable components)which will come into contact with either mastic tape or adhesive sealantsmust be thoroughly cleaned prior to the application of these sealing agents.Cleaning must only be done using lint-free cloth.


• The outer heatshrink tubing must overlap the cable oversheath by aminimum of 100 mm

• The specified stripping dimensions must be adhered to

• The completed termination must be allowed to cool before applyingmechanical load to it

Figure 10.2 Completed View of Single CoreCable Pot End Terminations

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12. POT END (LIVE END SEAL) HEATSHRINK TERMINATIONMULTICORE, PAPER-INSULATED CABLES (HV1-36)

This specification provides the requirements for a pot end (live end seal)termination on 11 kV, multicore, paper-insulated, screened, metal sheathed,polymeric oversheathed cables.

Currently, the only approved supplier of heatshrink kits suitable for thisapplication is Raychem, in accordance with the technical kit specification forthe stockcode listed below. Other kit designs or other suppliers for similardesigns must not be used unless specifically approved by EnergyAustralia.

HEATSHRINK KIT DESCRIPTION HEATSHRINK KITSTOCKCODE NO.

1 multicore cable heatshrink pot end (live endseal) suitable for 95 mm2 screened paperinsulated cables

152132


152140


152157

The pot end construction details, including stripping dimensions for theapproved Raychem termination kits are shown in figure 11.1.

Figure 11.1 Stripping Dimensions

The following requirements must be satisfied when constructing heatshrinkcable pot ends:


• The cable cores must not be bent tighter than the manufacturers’ specifiedminimum bending radii, either during the termination process or after it hasbeen set in position.

Armour (if any) MetalSheath

Screen PaperPapers Insulation

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• All components involved in the termination (including cable components)which will come into contact with either mastic tape or adhesive sealantsmust be thoroughly cleaned prior to the application of these sealing agents.Cleaning must only be done using lint-free cloth.


• The outer heatshrink tubing must overlap the cable oversheath by aminimum of 100 mm

• The specified stripping dimensions must be adhered to

• The completed termination must be allowed to cool before applyingmechanical load to it.

Figure 11.2 Completed Pot End Termination on Multicore Cable

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13. STRAIGHT THROUGH HEATSHRINK JOINTSINGLE-CORE, PAPER-INSULATED CABLES (HV2-2)

This specification provides the requirements for a straight through heatshrinkjoint on 11 kV single-core, paper-insulated, screened, metal-sheathed,polymeric oversheathed cables.

Currently, the only approved supplier of heatshrink straight through joint kitssuitable for this application is Raychem, in accordance with the technical kitspecification for the stockcodes listed below. Other joint kit designs or othersuppliers for similar designs must not be used unless specifically approved byEnergyAustralia.

STOCKCODE NO.Heatshrink Kit

DescriptionHeatshrink

KitCopper

CompressionLinks

AluminiumCompression

Links1 single core cableheatshrink straightthrough joint kit suitablefor screened paperinsulated cables in thesize range 95-185 mm2

90316 150268-95mm2

57141-120 mm2

150250-185 mm2

−

1 single core cableheatshrink straightthrough joint kit suitablefor 300 mm2 screenedpaper insulated cables

148155 80929 148320

The stripping dimensions and construction details of the joint shall be strictlyin accordance with Raychem’s installation specification. Heatshrink tubingsreferred to by Raychem as “compression sleeves” are not used byEnergyAustralia and so they will not be supplied in the above kits.

The outer tubing of 300 mm2 cable joint kits shall be replaced with areinforced wrap-around sleeve (stockcode 148395) for all joints which aremade in pits within the Sydney CBD, and for joints made in pits outside theSydney CBD where they would be subject to regular disturbance.

The cable connectors used can be of the sweated type or the compression type.The connector material shall match the conductor material on which to beused; i.e. for copper cables the connectors shall be copper, and for aluminiumcables the connectors shall be aluminium. For transition joints from copper toaluminium, the connectors shall be of the bi-metal type. For size transitionjoints the connectors shall match both the transition sizes and the conductormaterials. All connectors shall be of the blocked type. Where compressionconnectors are used, they shall be installed strictly in accordance with themanufacturer’s specification for crimping dies, number of crimps, and position

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of crimps. Installed connectors shall not diminish either the load currentcarrying capacity or the fault current carrying capacity of the jointed cables.

Joints shall have tinned copper sheath continuity braids installed with earthfault current capacities matching those of the cables being jointed. Theminimum cross sectional area of the braids shall be:

• 25mm2 for 95mm2 , 120 mm2 , and 185 mm2 cables; and

• 30mm2 for 300mm2 cables

Installed sheath continuity braids shall not limit the earth fault rating of thejointed cables.

The following requirements must be satisfied when constructing heatshrinkstraight through joints:

• The joint kit contents and the prepared cable ends must be kept free offoreign matter, and must not be damaged during the termination process.


• All metal sheath terminations must be belled

• The cable cores must not be bent tighter than the manufacturers’ specifiedminimum bending radii during the jointing process. The completed jointand the first 500mm of each associated cable must be straight when set inposition.

• All components involved in the joint (including cable components) whichwill come into contact with either mastic tape or adhesive sealants must bethoroughly cleaned and degreased prior to the application of these sealingagents. Cleaning must only be done using lint-free cloth.


• The outer heatshrink tubing (and the reinforced wrap-around sleeve whereused) must overlap the cable oversheaths by a minimum of 100 mm each.

• The completed joint must be allowed to cool down before applyingmechanical load to it

Figure 12.1 Completed 11 kV heatshrink straight through joint on single-core, paper-insulated screened, metal-sheathed cables.

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14. STRAIGHT THROUGH HEATSHRINK JOINT UP TO 300mm2

MULTICORE, PAPER-INSULATED CABLES (HV2-3)

This specification provides the requirements for straight-through heatshrinkjoints on 11kV multi-core paper insulated, screened, metal sheathed,polymeric oversheathed, armoured and unarmoured cables. The design of thejoints covered by this specification is only suitable for cables up to 300 mm2

in cross sectional area. For joints on 300-500mm2 cables, refer to the relevantsection of this Network Standard.

14.1 Approved Heatshrink Joint KitsCurrently, the only approved supplier of heatshrink straight-through joint kitssuitable for this application is Raychem, in accordance with the technical kitspecification for the stockcodes listed below. Other joint kit designs or othersuppliers for similar designs must not be used unless specifically approved byEnergyAustralia.

STOCKCODE NO.Heatshrink Kit Description Special

Heatshrink Kit(See Note 1)

StandardHeatshrink Kit

(See Note 2)1 multi-core cable heatshrinkstraight-through joint kit suitablefor screened paper insulated cablesin the size range 50-95 mm2

− 109496

1 multi-core cable heatshrinkstraight-through joint kit suitablefor screened paper insulated cablesin the size range 185 - 300 mm2

148312 148304

Notes: 1. The special kit has a re-enforced wrap-around outer sleeve forenvironmental protection in lieu of the standard tubularsleeves. It shall be used in pits and other open spaceinstallations where joints are likely to be physically disturbedand/or where they are not given adequate side support.

2. The standard kit has two tubular outer sleeves for environmentalprotection. It shall be used where joints are intended to beburied, and in open space installations where joints are givenadequate side support and where they are not likely to bephysically disturbed while in service.

14.2 Core ConnectorsThe cable connectors used can be of the sweated type or the compression type.Certain mechanical connectors were under evaluation at the time of preparingthis Standard. Where mechanical connectors are intended to be used, theyshall be submitted to EnergyAustralia first for approval.

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Sweated type connectors shall be made of high conductivity copper. Theyshall be tinned and suitable for the cable size(s) to be jointed.

For compression type connectors, the connector material shall match theconductor material on which they are used; ie for copper cables the connectorsshall be copper, and for aluminium cables the connectors shall be aluminium.For transition joints from copper to aluminium, the connectors shall be of thebi-metal type. For size transition joints the connectors shall match both thetransition sizes and the conductor materials. Where compression connectorsare used, they shall be installed strictly in accordance with the manufacturer’sspecification for crimping dies, number of crimps, and position of crimps.Jointed cores shall be of the same length (ie. bird-caging of cores will not beaccepted).

Installed connectors shall maintain the load current carrying capacity of thejointed cores.

EnergyAustralia’s stockcodes of approved connectors are provided in the tablebelow.

STOCKCODES NO.Cable Size Sweated Weak-

Back FerulesCopper

CompressionLinks


Links50 mm2 − 57174 −95 mm2 63818 150268 −

185 mm2 63826 150250 −240 mm2 − − −300 mm2 63834 80929 148320

14.3 Earth ContinuityThe metal sheaths of jointed cables shall be made continuous by joining themwith tinned copper braids of the appropriate size. The installed braids on eachjoint shall collectively have a 1 second earth fault current carrying capacitymatching that of the cables being jointed. Where the cables being jointed varyin size, the larger cable shall be used to determine the appropriate size ofbraids to be used.

The minimum total cross sectional area of the copper braids used shall be:

43 mm2 for 95 mm2 multi-core cables;62 mm2 for 185 mm2 multi-core cables;72 mm2 for 240 mm2 multi-core cables; and85 mm2 for 300 mm2 multi-core cables.

Tinned copper braids shall be attached either by wiping or by means ofapproved mechanical connectors. Installed sheath continuity braids shall notlimit the earth fault rating of the jointed cables.

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14.4 Stripping DimensionsThe stripping dimensions and construction details of the joint shall be strictlyin accordance with Raychem’s installation specification. Where jointing spaceis restricted, the stripping dimensions for cables in the size range 185 - 300mm2 may be reduced to the minimum dimensions shown in the sketch below.These dimensions must only be used where jointing space is restricted.

Where a joint involves cables of different sizes, the larger cable shall be on thelonger side of the joint.

Figure 13.1 Reduced Stripping Dimensions for185mm2-300mm2 joints only

14.5 Other RequirementsThe following requirements must be satisfied when constructing heatshrinkstraight-through joints:

• The joint kit contents and the prepared cable ends must be kept free offoreign matter, and must not be damaged during the jointing process.


• All metal sheaths terminations must be belled.

• The cable cores must not be bent tighter than the manufacturers’ specifiedminimum bending radii during the jointing process. The completed jointand the first 500 mm of each associated cable must be straight when set inposition.


• Heatshrink tubings must be properly and evenly shrunk, free of voids, andmust not be damaged due to overheating. Heatshrink components with

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adhesive sealant coatings must provide effective sealing against moistureingress when installed.

• The outer heatshrink tubings (and the reinforced wrap-around sleeve whereused) must overlap the cable oversheaths by a minimum of 100 mm each.Where standard heatshrink kits are used, the outer tubular sleeves mustoverlap each other by a minimum of 100 mm.

• The completed joint must be allowed to cool down before applyingmechanical load to it

Figure 13.2 Completed joint with tubular sleeves

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15. STRAIGHT THROUGH HEATSHRINK JOINT MULTICORE,PAPER-INSULATED CABLES 300 TO 500mm2 (HV2-4)

This specification provides the requirements for straight-through heatshrink joints on11kV multi-core paper insulated, screened, metal sheathed, polymeric oversheathed,armoured and unarmoured cables. The design of the joint covered by thisspecification is only suitable for cables in the size range 300mm2-500mm2 in crosssectional area. For joints on cables up to 300mm2 in cross sectional area, refer to therelevant section of this Network Standard.

15.1 Approved Heatshrink Joint KitsCurrently, the only approved supplier of heatshrink straight through joint kits suitablefor this application is Tyco Electronics, in accordance with the technical kitspecification for the stockcode listed below. Other joint kit designs or other suppliersfor similar designs must not be used unless specifically approved by EnergyAustralia.

Heatshrink Kit Description Stockcode No.of Heatshrink Kit

1 multi-core cable heatshrink straight throughjoint kit suitable for screened paper insulatedcables in the size range 300 - 500 mm2 152884*

* The insulation shims included in the heatshrink kit (stockcode 152884) areto be used on 500 mm2 cable when the step between the connector and thecore insulation is greater than 5 mm (see Figure 15.1). Three additionalshims will be required for a 500 mm2 to 500 mm2 straight through jointand are available direct from Tyco Electronics by quoting TycoElectronics Part No AUST- SY114.

Figure 15.1 Straight Through Joint Compression Link

15.2 Core ConnectorsThe cable connectors used can be of the sweated type or the compression type.Certain mechanical connectors were under evaluation at the time of preparing thisStandard. Where mechanical connectors are intended to be used, they shall besubmitted to EnergyAustralia first for approval.Sweated type connectors shall be made of high conductivity copper. They shall betinned and suitable for the cable size(s) to be jointed.For compression type connectors, the connector material shall match the conductormaterial on which they are used; ie for copper cables the connectors shall be copper,and for aluminium cables the connectors shall be aluminium. For transition jointsfrom copper to aluminium, the connectors shall be of the bi-metal type. For size

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transition joints the connectors shall match both the transition sizes and the conductormaterials. Where compression connectors are used, they shall be installed strictly inaccordance with the manufacturer’s specification for crimping dies, number ofcrimps, and position of crimps. Jointed cores shall be of the same length (ie. bird-caging of cores will not be accepted).Installed connectors shall maintain the load current carrying capacity of the jointedcores.EnergyAustralia’s stockcodes of approved connectors are provided in the table below.

Stockcodes No.Cable Size Sweated

Weak-BackFerrules

CopperCompression

Links


Links

BimetalCompression

Links300 mm2 63834 80929 148320 −500 mm2 63891 − 176372 −

500 mm2 Al -300 mm2 Cu

− − − 152603

The dimensions of the connectors to be used shall not exceed those specified in thetable below.

Maximum Connector DimensionsBefore Installation

Cable Size Diameter (mm) Length (mm)300 36 190500 48 190

15.3 Earth ContinuityThe metal sheaths of jointed cables shall be made continuous by joining them withtinned copper braids of the appropriate size. The installed braids on each joint shallcollectively have a 1 second earth fault current carrying capacity matching that of thecables being jointed. Where the cables being jointed vary in size, the larger cable shallbe used to determine the appropriate size of braids to be used.The minimum total cross sectional area of the copper braids used shall be:85 mm2 for 300 mm2 multi-core cables; and117 mm2 for 500 mm2 multi-core cables.Tinned copper braids shall be attached either by wiping or by means of approvedmechanical connectors. Installed sheath continuity braids shall not limit the earth faultrating of the jointed cables.

15.4 Stripping DimensionsThe stripping dimensions and construction details of the joint shall be strictly inaccordance with Raychem’s installation specification.Where a joint involves cables of different sizes, the larger cable shall be on the longerside of the joint.

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15.5 Other RequirementsThe following requirements must be satisfied when constructing heatshrink straight-through joints:


• No jagged edges shall be left on terminated screen papers.• All metal sheaths terminations must be belled.• The cable cores must not be bent tighter than the manufacturers’ specified

minimum bending radii during the jointing process. The completed jointand the first 500 mm of each associated cable must be straight when set inposition.



• The outer heatshrink tubings (and the reinforced wrap-around sleeve whereused) must overlap the cable oversheaths by a minimum of 100 mm each.Where standard heatshrink kits are used, the outer tubular sleeves mustoverlap each other by a minimum of 100 mm.

• The completed joint must be allowed to cool down before applyingmechanical load to it.

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16. THREE-TO-ONE HEATSHRINK TRANSITION JOINTPAPER-INSULATED CABLES (HV2-5)

This specification provides the requirements for a transition joint frommulticore, paper-insulated, screened, metal sheathed, polymeric oversheathed,armoured and unarmoured cabled to three single core, paper insulated,screened, metal sheathed, polymeric oversheathed cables.

This design is suitable for cables up to 500 mm2 in cross sectional area.

16.1 Approved Heatshrink Joint KitsCurrently, the only approved supplier of heatshrink joint kits suitable for thisapplication is Tyco Electronics, in accordance with the technical kit specification forthe stockcodes listed below. Other joint kit designs or other suppliers for similardesigns must not be used unless specifically approved by EnergyAustralia.

Transition jointfrom multicore to single-core

Heatshrink kitStockcode

185 mm2 95 mm2 *185 mm2 185 mm2 151290300 mm2 95 mm2 151290**300 mm2 185 mm2 151290300 mm2 300 mm2 151290500 mm2 185 mm2 152215 and 175804500 mm2 300 mm2 152215500 mm2 500 mm2 152215***

* Not a standard EnergyAustralia stock item. It may be purchased directlyfrom Tyco Electronics by quoting Tyco Electronics part number AUST-SY81.

** Additional components are required for a 300mm2 to 95mm2 transitionjoint and are available direct from Tyco Electronics by requesting thefollowing: Three BBIT 40/16-300/U red shim sleeves, and three OBTF-35/12-300/U transparent barrier tubings. These transparent barriertubings must replace the barrier tubings supplied in the kit (stockcode151290).

*** Three additional shims will be required for a 500mm2 to 500mm2

transition joint if the step between the connector and the core insulationis greater than 5 mm. These shims are available direct from TycoElectronics by quoting Tyco Electronics part number AUST-SY114.

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16.2 Core ConnectorsThe cable connectors used can be of the sweated type or the compression type.Certain mechanical connectors were under evaluation at the time of preparing thisStandard. Where mechanical connectors are intended to be used, they shall besubmitted to EnergyAustralia first for approval.Sweated type connectors shall be made of high conductivity copper. They shall betinned and suitable for the cable size(s) to be jointed.For compression type connectors, the connector material shall match the conductormaterial on which they are used; ie for copper cables the connectors shall be copper,and for aluminium cables the connectors shall be aluminium. For transition jointsfrom copper to aluminium, the connectors shall be of the bi-metal type. For sizetransition joints the connectors shall match both the transition sizes and the conductormaterials. Where compression connectors are used, they shall be installed strictly inaccordance with the manufacturer’s specification for crimping dies, number ofcrimps, and position of crimps.

Installed connectors shall maintain the load current carrying capacity of the jointedcores.

EnergyAustralia’s stockcodes of approved connectors are provided in the tablesbelow.

Stockcodes No.Cable Size Sweated Weak-

Back FerulesCopper

CompressionLinks


Links95 mm2 63818 150268 −185 mm2 63826 150250 −240 mm2 − − −300 mm2 63834 80929 148320500 mm2 63891 − 176372

Cable Sizes Bimetal Compression Lugs for Size TransitionsStockcode No.

185 mm2 Al - 185 mm2 Cu 57018300 mm2 Al - 95 mm2 Cu Utilux No. H15424X11 (BK 300/95)*300 mm2 Al - 185 mm2 Cu 56994500 mm2 Al - 185 mm2 Cu Links included in heatshrink kit (stockcode 175804)500 mm2 Al - 300 mm2 Cu 152603

* Other links may be used but must be submitted to EnergyAustralia for approval.

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The dimensions of the connectors to be used shall not exceed those specified in thetable below.

Maximum Connector dimensions (mm)before installation

Cable Size Diameter Length95 mm2 28 140185 mm2 36 190300 mm2 36 190500 mm2 48 190

16.3 Earth ContinuityThe metal sheaths of the single core cables shall be made continuous with the metalsheath of the multi-core cable by joining them with tinned copper braids of theappropriate size. One tinned copper braid shall be used for each single core cable.Each braid shall have a minimum 1 second earth fault rating equivalent to 1/3 the 1second earth fault rating of the multi-core cable.Tinned copper braids shall be attached to the metal sheath of single core cables usingthe roll springs supplied in the kit. Attaching the tinned copper braids to the multi-core cable shall be either by wiping or by means of approved mechanical connectors.Installed sheath continuity braids shall not limit the earth fault rating of the jointedcables.

16.4 Stripping DimensionsThe stripping dimensions and construction details of the joint shall be strictly inaccordance with Raychem’s installation specification.

16.5 Other RequirementsThe following requirements must be satisfied when constructing heatshrink straight-through joints:


• No jagged edges shall be left on terminated screen papers.• All metal sheaths terminations must be belled.• The cable cores must not be bent tighter than the manufacturers’ specified

minimum bending radii during the jointing process. The completed jointand the first 500 mm of each associated cable must be straight when set inposition.



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• The insulation shims included in the heatshrink kit for 500 mm2 cables are

to be used when the step between the connectors and the core insulation isgreater than 5 mm (See Figure 16.1).

Figure 16.1 Straight Through Joint Compression Connector.

• The outer tubular heatshrink tubings must overlap each other and the cableoversheaths by a minimum of 100 mm each.

• The completed joint must be allowed to cool down before applyingmechanical load to it.

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17. STRAIGHT THROUGH JOINT (STUB TEE) SCREENEDAND BELTED PAPER INSULATED MULTI-CORE CABLES(HV 2-72)

This specification provides the requirements for constructing straight through tapedjoints (stub tee) on paper insulated, screened or belted, metal sheathed, polymericoversheathed, armoured and unarmoured cables.

17.1 Core ConnectorsThe cable connectors shall be of the sweated type (ie. weak back ferrules).Mechanical connectors may be used, however they shall be submitted toEnergyAustralia first for approval.EnergyAustralia’s stockcodes of approved connectors are provided in the table below.

Cable Sizes Stockcode of weak-Back Ferrule185-185 mm2 UFO 190 6 3842185-300 mm2 UFO 194 6 3891300-300 mm2 UFO 196 6 3917

Installed connectors shall be free of sharp edges and burrs, and shall maintain the loadcurrent carrying capacity of the jointed cores.

17.2 Paper Insulation and Insulating TapesThe paper insulation on all cores must be tapered over a 6 mm length as shown inFigure 2. The full length of exposed paper insulation, including the tapered section,must be free of dust and moisture, and must not be touched with bare hands.The crepe paper jointing tapes approved by EnergyAustralia for 11kV jointing areimpregnated with rosin/oil compound, and packed in sealed tins. Tins of insulatingpaper tapes must be examined prior to opening. If a tin is damaged or any compoundleakage is evident, the contents must not be used.Tins must not be opened until the tapes are ready to be used. Insulating tapes must betested for moisture content before they are used. Tapes which appear to contain anyamount of moisture must not be used.Insulating tapes must be applied with an overlap of approximately 50% either directfrom the roll or from a former. Surplus tapes must be discarded - they must never beused.

EnergyAustralia’s stockcodes of approved insulating paper tapes are provided in thetable below.

Details StockcodeTin of crepe paper rolls each containing: 18rolls x 50mm wide, 8 rolls x 20mm wide, and8 rolls x 10mm wide. All rolls are 35mm ODx 3m long

58024

Tin of crepe paper rolls each containing: 25rolls x 50mm wide, 8 rolls x 20mm wide, and

76018

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4 rolls x 10mm wide. All rolls are 35m OD x3m long

17.3 Stress ConesSome joints will require the construction of stress cones. Where required,construction of stress cones shall comply with the following requirements:

1. The screens must be removed to 90mm from the metal sheath termination.Where carbon impregnated paper is used as screen, the outer layer of paperinsulation must also be removed to the screen termination.

2. Two half lapped layers of crepe paper tape must be applied to the exposedcore paper insulation following the same direciton of lay as the core paperinsulation.

3. A stress cone foundation must be built using crepe paper tape. Thefoundation must start at the end of the screen, and must gradually reach amaximum diameter of 13mm larger than the diameter of the core insulation.The maximum diameter must occur 13mm from the end of the screen.

4. A half lapped layer of tinned copper mesh (25 mm wide) must be appliedover the stress cone foundation starting onto the metal sheath. The meshmust be stretched to less than half its width while it is being applied.

5. The tinned copper mesh must be soldered to the metal sheath, and thereturn spiral must be tack soldered to the stress cone.

6. Any sharp projections must be smoothed off. Any metal dust resulting fromthis operation must be carefully removed.

17.4 Earth ContinuityThe metal sheath of the jointed cables shall be made continuous by wiping the leadsleeve directly onto them. The tinning and wiping of the sleeve and metal sheathsshall provide water tight seals and durable contacts capable of withstanding earth faultcurrents of the same magnitude as the fault ratings of the cable sheaths involved.EnergyAustralia’s stockcodes of approved lead sleeves for 11kV joints are providedin the table below.

Details Stockcode1500mm long lead sleeve, copperized, 28mmID x 3mm wall thickness

80150

1500mm long lead sleeve, copperized, 32mmID x 3mm wall thickness

68700


68809


68791


68783


68767


68817

1500mm long lead sleeve, copperized, 68759

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100mm ID x 3mm wall thickness1500mm long lead sleeve, copperized 125mmID x 3mm wall thickness

68742

1800mm long lead sleeve, copperized,150mm ID x 5mm wall thickness

68734


68833


68726

17.5 Stripping DimensionsThe stripping dimensions and construction details shall be strictly in accordance withthe construction requirements provided in Figures 1 and 2.

17.6 Troughing-in of Completed JointsCompleted joints intended to be directly buried shall be placed in suitable troughingsand completely encapsulated with either approved polyurethane compound ortroughing-in bitumen. The stockcodes of approved troughing-in bitumen is 52811.

17.7 Commissioning of JointsTaped joints shall not be commissioned before the joint filling and troughing-incompounds have set.Completed joints and associated cable installations shall be tested prior tocommissioning in accordance with the requirements of NS 0161 - Testing CablesAfter Installation.

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Figure 1 - 11kV Screeened Cable STJ (Stubtee)Construction Details

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Figure 2 - 11kV Screened Cables Stub Tee JointsSectional Details

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Figure 3 - 11kV Belted - Screened S.T.J. (Stubtee)Construction Details

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Figure 4 - 11kV Belted/Belted or Belted/Screened StubteeSectional Details

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18. LAY-ON TEE JOINTS FOR SCREENED AND BELTEDPAPER INSULATED CABLES

This specification provides the requirements for constructing the following lay-on teejoints:

• Single core tee cable (paper insulated, screened, metal sheathed, polymericoversheathed) to single core main cable (paper insulated, screened, metalsheathed, polymeric oversheathed).

• 3 Single core tee cables (paper insulated, screened, metal sheathed,polymeric oversheathed) to multi-core main cable which may be eitherscreened, or belted, or a joint between a screened and a belted paper cable.The multi-core cable can be armoured or unarmoured.

• Multi-core cable tee (which may be either belted or screened) to multi-corecable main (which may be either belted or screened). Both cables may bearmoured or unarmoured.

18.1 Core ConnectorsThe cable connectors shall be of the sweated type (ie. weak back ferrules).Mechanical connectors may be used, however they shall be submitted toEnergyAustralia first for approval.EnergyAustralia’s stockcodes of approved connectors are provided in the table below.

Cable Sizes Stockcode of weak-Back Ferrule185-185 mm2 63842185-300 mm2 63891300-300 mm2 63917

Installed connectors shall be free of sharp edges and burrs, and shall maintain the loadcurrent carrying capacity of the jointed cores.

18.2 Paper Insulation and Insulating TapesThe paper insulation on all cores must be tapered over a 6 mm length as shown inFigure 2. The full length of exposed paper insulation, including the tapered section,must be free of dust and moisture, and must not be touched with bare hands.The crepe paper jointing tapes approved by EnergyAustralia for 11kV jointing areimpregnated with rosin/oil compound, and packed in sealed tins. Tins of insulatingpaper tapes must be examined prior to opening. If a tin is damaged or any compoundleakage is evident, the contents must not be used.Tins must not be opened until the tapes are ready to be used. Insulating tapes must betested for moisture content before they are used. Tapes which appear to contain anyamount of moisture must not be used.Insulating tapes must be applied with an overlap of approximately 50% either directfrom the roll or from a former. Surplus tapes must be discarded - they must never beused.EnergyAustralia’s stockcodes of approved insulating paper tapes are provided in thefollowing table.

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Details StockcodeTin of crepe paper rolls each containing: 18rolls x 50mm wide, 8 rolls x 20mm wide,and 8 rolls x 10mm wide. All rolls are35mm OD x 3m long

58024

Tin of crepe paper rolls each containing: 25rolls x 50mm wide, 8 rolls x 20mm wide,and 4 rolls x 10mm wide. All rolls are35mm OD x 3m long

76018

18.3 Stress ConesSome joints will require the construction of stress cones. Where required,construction of stress cones shall comply with the following requirements:

1. The screens must be removed to 90 mm from the metal sheath termination.Where carbon impregnated paper is used as screen, the outer layer of paperinsulation must also be removed to the screen termination.

2. Two half lapped layers of crepe paper tape must be applied to the exposedcore paper insulation following the same direction of lay as the core paperinsulation.

3. A stress cone foundation must be built using crepe paper tape. Thefoundation must start at the end of the screen, and must gradually reach amaximum diameter of 13mm larger than the diameter of the core insulation.The maximum diameter must occur 13mm from the end of the screen.

4. A half lapped layer of tinned copper mesh (25mm wide) must be appliedover the stress cone foundation starting onto the metal sheath. The meshmust be stretched to less than half its width while it is being applied.

5. The tinned copper mesh must be soldered to the metal sheath, and thereturn spiral must be tack soldered to the stress cone.

6. Any sharp projections must be smoothed off. Any metal dust resulting fromthis operation must be carefully removed.

18.4 Earth ContinuityThe metal sheath of the jointed cables shall be made continuous by wiping the leadsleeve directly onto them. The tinning and wiping of the sleeve and metal sheathsshall provide water tight seals and durable contacts capable of withstanding earth faultcurrents of the same magnitude as the fault ratings of the cable sheaths involved.EnergyAustralia’s stockcodes of approved lead sleeves for 11kV joints are providedin the table below.

Details Stockcode1500mm long lead sleeve, copperized, 28mmID x 3mm wall thickness

80150


68700


68809


68791

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68783


68767


68817


68759

1500mm long lead sleeve, copperized 125mmID x 3mm wall thickness

68742


68734


68833


68726

18.5 Stripping DimensionsThe stripping dimensions and construction details shall be strictly in accordance withthe construction requirements provided in Figures 1, 2, 3, 4, and 5.

18.6 Troughing-in of Completed JointsCompleted joints intended to be directly buried shall be placed in suitable troughingsand completely encapsulated with either approved polyurethane compound ortroughing-in bitumen. The stockcodes of approved troughing-in bitumen is 52811.

18.7 Commissioning of JointsTaped joints shall not be commissioned before the joint filling and troughing-incompounds have set.Completed joints and associated cable installations shall be tested prior tocommissioning in accordance with the requirements of NS 0161 - Testing CablesAfter Installation.

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Figure 1 - Lay On Tee Joint - Single Core to Single Core Screened Cables

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Figure 2 - 11kV Lay on Tee Joint - Screened SingleCore onto Multi-Core Cables

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Figure 3 - 11kV Lay on Tee Joint - Multicore Screened/Belted Cables

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Figure 4 - Lay On Tee Joints - 11kV Screened CableSectional Details

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Figure 5- Lay On Tee Joints - 11kV Belted/Belted and Belted/Screened Cables -Sectional Details

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19. QUALITY OF WORK

Supply of electricity will not be made available until all specified work issatisfactorily completed.

The responsibility for correcting any defects will be that of the client.

19.1 Warranty and Public LiabilityThe client is to warrant any undertaken electrical work which will become partof EnergyAustralia’s reticulation systems to be free of defects for a period of36 calender months after the date of acceptance, and will be required to payfor or carry out any required repairs within that period.

The client is required to have and keep a $10,000,000 (ten million dollars)public liability insurance policy for the duration of the construction work anduntil ownership is officially transferred to EnergyAustralia. the client mustprovide a certificate of currency of the insurance policy on request.

20. STORES AND MATERIALS

Contractors must only use approved products on the network. EnergyAustraliashould be contacted regarding approved products. Alternative products may besubmitted to EnergyAustralia for approval. A fee for the approval ofalternative products for use on the network will be negotiated.

To purchase materials from EnergyAustralia, the Project Manager mustcontact the "Project Officer Network Procurement" on telephone number (02)9394 6034. All materials will be made available for the Client to pick up from:

Central Warehouse2 Mayvic Street

Chullora NSW 2190

Alternatively, the client may obtain material from other sources provided thequality assurance and environmental management system requirements aremet. Materials must comply with EnergyAustralia's relevant specifications.

All materials used for network projects must be new.

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21. REFERENCES

21.1 EnergyAustralia Drawings

119643 11kV Overhead Construction - Pole Mounting of MulticoreCable Terminations Type K3

21.2 Acts and RegulationsThis is not a full listing but should be used as a guide only.

Electricity Act 1945Construction Safety Regulations 1950 Reg No. 133AWork Cover Certificate of Exemption 5099Electricity (Workers’ Safety) Regulation 1992Occupational Health & Safety (Confined Space) RegulationConstruction Safety Act

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APPENDIX A CABLE DESCRIPTION CODES

This is what the code letters mean:

415 V 240 AL3 XQ CU (NW) Z /SAC| | | | | | |

VoltageRating

Conductor(Size (mm2)

ConductorType and No.

of Cores

Insulation Neutral(if

applicable)

Sheath OtherInformation

(ifapplicable)

Before slash/

Phase-to-phase Voltage, Cross-sectional Area (mm2), Number of Cores

AL Aluminium (N) Concentric NeutralAW Alumoweld (NW) Wavewound Concentric NeutralBR Butyl Rubber NY Nylon InsulationCDCU Cadmium Copper P Paper InsulationCM Cambric PR PairCQ Cellular Polythene Q Polythene InsulationCU Copper R Rubber InsulationCW Copper Weld SF Single Fibre-reinforced Plastic

Rod ArmourDB Double Brass Tape SL Single Lead SheathDRT Double Steel Reinforcing Tape ST Single Steel Tape ArmourDT Double Steel Tape Armour SW Single Steel Wire ArmourDW Double Steel Wire Armour TR Tough Rubber InsulationF Filter Core (TS) Taped ScreenFE Steel (WS) Stranded Wire ScreenH Hochstadter Screen XQ Cross-linked PolytheneJ Jute or Hessian Sheath YQ High-density PolytheneL Lead Sheath Z PVC SheathMB Moisture Barrier

Examples:

415V 240 AL3 XQ CU(NW)Z/SAC

415 volts phase-to-phase, 240 mm2 3-core solid aluminium conductors, cross-linked polyethylene insulation, copper wavewound concentric neutral, PVCsheath.

415V 240 AL4 XQ Z/SAC

415 volts phase-to-phase, 240 mm2 4-core solid aluminium conductors, cross-linked polyethylene insulation, PVC sheath.

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11kV 500 AL3 PHL SWJ

11 kV phase-to-phase, 500 mm² 3-core stranded aluminium conductors, paperinsulated, screened, lead alloy sheathed, single wire armoured, jute sheathed.

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APPENDIX B INSTALLATION INSTRUCTION HV 1-41

Installation Procedure for3M Coldshrink Pressure Sealing Terminations on

Indoor Single Core Paper Lead CablesVersion 1, 12th April 2001

This installation instruction HV 1-41 details the installation procedure of 3Mcoldshrink pressure sealing terminations on 11kV indoor single core screenedpaper cables that are made in accordance with AS1026. This instruction is notapplicable to any other type of termination.

Installation instruction HV 1-41 has been prepared for use by EnergyAustraliastaff, contractors employed by EnergyAustralia and Accredited ServiceProviders, exclusively for work on EnergyAustralia’s network assets.

This instruction is to be read in conjunction with the relevantEnergyAustralia’s Network Standards.

CONTENTS

1. General

2. Termination Procedure

3. Completed Termination

4. Earthing the Termination

5. Typical Earthing Arrangement

3M Approved By: P.Broderick Date: 12/4/01

EnergyAustralia Approved By: N.Issa Date: 12/4/01

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General1. Keep the coldshrink kit in its packaging until the components are required

in order to minimise exposure to dust contamination. After opening thepackaging, components which are not immediately required must beprotected against potential dust contamination.

2. Tapes will be applied over the lug barrels and the cable metal sheath toprevent water entry into the termination area. These areas must beproperly cleaned and degreased before the tapes are applied.

3. The tapes referred to in this instruction are proprietary 3M tapes, and aresupplied as part of the termination kit. No substitution for these tapes shallbe made without Network's prior approval. The tapes involved are:

Self amalgamating tape Scotch no. 23Restriction tape Scotch no. 20Stress control tape Scotch no. 2220Mastic sealant tape Scotch no. 2900R

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Prepare Cable1 Set the cables into position after determining the

phasing requirements.

2 Cut the cables to the required length after allowingfor fitting of the sealed terminal lugs.

3 Remove the polymeric oversheath from the end ofeach of the cables to a distance of 220 mm plusthe internal depth of the sealed terminal lug.

4 Clean the metal sheath, and then abrade it for adistance of 50 mm above the polymericoversheath cut.

5 Clean the polymeric oversheath, and then abrade itfor a distance of 60 mm below the metal sheath.

6 Remove the metal sheath to a distance of 40 mmabove the polymeric oversheath cut.

7 Bell the metal sheath

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Install Terminal Lugs1 Remove the paper screens and insulation from the

end of each cable for a distance equal to the lengthof the lug barrel + 15 mm.

2 Test the paper insulation for moisture content. Ifmoisture exists, notify the relevant fieldcoordinator/supervisor for immediate action.

3 Unwind 30 mm off the paper screens to allowcompletion of the next step.

4 Install sealed terminal lugs in accordance withmanufacturer's specification. If using solder lugs,the cables must be suitably protected againstexcessive heat or flame. If using compressionlugs, remove excess grease after installation, andde-grease the barrel of each of the lugs.

Note: The lug must comply with the specifiedmaximum dimensions.

5 Using self amalgamating tape (Scotch No. 23),smoothly profile the barrel of each of the lugs inorder to facilitate achieving a good oil seal.Ensure that at least two half-lapped layers of tapeare applied to the lower 30 mm of the barrel andthe exposed conductor between the lug and thepaper insulation. Also extend the tape for 10 mmonto the paper insulation to stop it fromunwinding. Stretch the tape to 50% of its originalwidth while applying it.

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Install Stress Control Tape1 Using a twine binder, remove the paper screens

down to 25 mm above the edge of the metalsheath. Ensure that the screen cut is neat and freeof any jagged edges.

2 Apply two half-lapped layer of Stress ControlTape (Scotch No. 2220) at the edge of the metalsheath, working towards the cable end for adistance of 70 mm. Leave an even front edge, thentape back to the starting point.

Note: Scotch tape No. 2220 should be appliedsilver side out, and stretched to 3/4 of itsoriginal width. Remove the liner beforestretching the tape.

3 Apply one half-lapped layer of White RestrictionTape (Scotch No. 20) at the metal sheath end ofthe stress control tape to protect it from anydamage while shrinking the black oil barriertubing. Start the restriction tape 10 mm onto themetal sheath and finish it 25 mm onto the stresscontrol tape.

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Install Oil Barrier Tubing1 Slide a black oil barrier tubing over one of the

cables, and position it 20 mm onto the metalsheath.

2 Shrink the tubing into position by pulling andunwinding the pull-tab of the tubing in an anti-clockwise direction.

3 Check that the tubing overlaps the lug barrel by aminimum of 20 mm. Carefully trim any excesstubing (portion of tubing extending beyond thebarrel of the lug), making sure that the cut startsand finishes at the same spot (ie. a uniform cut) toavoid tearing of the tubing.

4 If the tubing is trimmed, apply three full turns ofself amalgamating tape (Scotch No. 23) to the endof the tubing to ensure that it does not tear.

5

Apply self amalgamating tape (Scotch No. 23)over the black oil barrier tubing at the gapbetween the paper insulation and the terminal lug,making sure the black tubing is pulled down intothe gap. Fill the gap up to the level of insulation,and then apply two extra half-lapped layers,overlapping the lug barrel and the insulation by15 mm each. Stretch the tape to 50% of itsoriginal width while applying it.

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Install Oil Barrier Tubing6 Apply four half-lapped layers of White Restriction

Tape (Scotch No. 20) to cover the full length ofthe black oil barrier tubing + 10 mm either side.

Caution: The white restriction tape DOES NOTSTRETCH. So avoid creasing when applying it.

Install Silicon Tubing1 Apply four full turns of self amalgamating tape

(Scotch No.23) over the lug barrel at the end ofthe white restriction tape.

2 Apply two half-lapped layers of selfamalgamating tape (Scotch No. 23) over theremaining exposed portion of the metal sheath andcontinue for 30 mm onto the polymericoversheath.

3 Slide the grey silicon tubing over the cable andposition the silicon tubing to overlap thepolymeric oversheath by 50 mm. Shrink thetubing into position by pulling and unwinding thepull-tab in an anti-clockwise direction.

4 This tubing should fully cover the band of selfamalgamating tape applied over the lug. If it is toolong, carefully trim any excess tubing, makingsure that the cut starts and finishes at the samepoint to avoid tearing of the tubing.

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Completed Termination

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Earthing the Termination1 Remove 80 mm of the polymeric oversheath on each

cable starting 80 mm below the gland plate of the cableendbox. If the terminations are in free air (ie. no cableendbox), remove 80 mm of the polymeric oversheath oneach cable starting 100 mm below the outer silicontubing.

2 Clean, degrease and abrade the full length of eachexposed metal sheath and 30 mm of the polymericoversheath at each end.

3 Apply one half-lapped layer of tinned copper mesh overeach exposed metal sheath starting and finishing 10 mmclear of the corresponding polymeric oversheath cuts.

4 Wrap two full turns of sealant tape (Scotch No. 2900R)over the polymeric oversheath on each cable, either sideof the exposed metal sheath.

5 Determine the length of tinned copper braid required foreach cable, allowing for the braid to be folded back onitself at the roll spring position, plus an extra length ofapproximately 30 mm.

6 Flatten out the braid at the roll spring end by pulling onit sideways in order to achieve maximum surface areacoverage.

7 Position the braid over the tinned copper mesh so thatthere is sufficient length to be folded back over the rollspring.

8 Starting on the opposite side of the cable, wrap the rollspring twice over the copper braid in the direction of thecopper braid. Position the roll spring centrally over theexposed metal sheath.

9 Fold the braid back over the roll spring then wrap therest of the roll spring around the core.

10 Tighten the roll spring with a twisting action, and thenapply four full turns of self amalgamating tape (ScotchNo.23) over the roll spring to hold it in position.

11 Apply two full turns of sealant tape (Scotch No.2900R)over the earth braid at the lower oversheath cut.

12 Apply the supplied vinyl mastic tape over the earthconnection on each cable, fully covering the two bandsof sealant tape (Scotch No.2900R). Half-lap the tapewhile applying it.

13 Connect the lower end of the earth braid to the mainearthing point using M12 bolt, nut and washers.

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Install Silicon Tubing

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APPENDIX C INSTALLATION INSTRUCTION HV 1-42


Outdoor Single Core Paper Lead CablesVersion 1, 12th April 2001

This installation instruction HV 1-42 details the installation procedure of 3Mcoldshrink pressure sealing terminations on 11kV outdoor single corescreened paper cables that are made in accordance with AS1026. Thisinstruction is not applicable to any other type of termination.


This instruction is to be read in conjunction with the relevantEnergyAustralia’s Network Standards and EnergyAustralia’s Drawing 62103,11 kV Underground-to-Overhead (UG/OH) Construction for Single CorePILC Cables, Type K2.

CONTENTS

1. General


3. Completed Termination


5. Typical Earthing Arrangement



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Self amalgamating tape Scotch no. 23Restriction tape Scotch no. 20Stress control tape Scotch no. 2220Mastic sealant tape Scotch no. 2900R

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Prepare Cable

1 Set the cables into position after determiningthe phasing requirements.

2 Cut the cables to the required length afterallowing for fitting of the sealed terminallugs.

3 Remove the polymeric oversheath from theend of each of the cables to a distance of305 mm plus the internal depth of the sealedterminal lug.

4 Clean the metal sheath, and then abrade it fora distance of 50 mm above the polymericoversheath cut.

5 Clean the polymeric oversheath, and thenabrade it for a distance of 60 mm below themetal sheath.

6 Remove the metal sheath to a distance of40 mm above the polymeric oversheath cut.

7 Bell the metal sheath.

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Prepare Install Terminal Lugs

1 Remove the paper screens and insulation fromthe end of each cable for a distance equal tothe length of the lug barrel + 15 mm.

2 Test the paper insulation for moisture content.If moisture exists, notify the relevant fieldcoordinator/supervisor for immediateaction.


4 Install sealed terminal lugs in accordance withmanufacturer's specification. If using solderlugs, the cables must be suitably protectedagainst excessive heat or flame. If usingcompression lugs, remove excess grease afterinstallation, and de-grease the barrel of eachof the lugs.

5 Using self amalgamating tape (ScotchNo. 23), smoothly profile the barrel of each ofthe lugs in order to facilitate achieving a goodoil seal. Ensure that at least two half-lappedlayers of tape are applied to the lower 30 mmof the barrel and the exposed conductorbetween the lug and the paper insulation. Alsoextend the tape for 10 mm onto the paperinsulation to stop it from unwinding. Stretchthe tape to 50% of its original width whileapplying it.

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Install Stress Control Tape

1 Using a twine binder, remove the paper screensdown to 25 mm above the edge of the metalsheath. Ensure that the screen cut is neat and freeof any jagged edges.

2 Apply two half-lapped layer of Stress ControlTape (Scotch No. 2220) at the edge of the metalsheath, working towards the cable end for adistance of 70 mm. Leave an even front edge,then tape back to the starting point.

Note: Scotch tape No. 2220 should be appliedsilver side out, and stretched to 3/4 of itsoriginal width. Remove the liner beforestretching the tape.

3 Apply one half-lapped layer of White RestrictionTape (Scotch No. 20) at the metal sheath end ofthe stress control tape to protect it from anydamage while shrinking the black oil barriertubing. Start the restriction tape 10 mm onto themetal sheath and finish it 25 mm onto the stresscontrol tape.

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Install Oil Barrier Tubing

1 Slide a black oil barrier tubing over one of thecables, and position it 20 mm onto the metalsheath.

2 Shrink the tubing into position by pulling andunwinding the pull-tab of the tubing in ananti-clockwise direction.

3 Check that the tubing overlaps the lug barrelby a minimum of 20 mm. Carefully trim anyexcess tubing (portion of tubing extendingbeyond the barrel of the lug), making surethat the cut starts and finishes at the same spot(ie. a uniform cut) to avoid tearing of thetubing.

4 If the tubing is trimmed, apply three full turnsof self amalgamating tape (Scotch No. 23) tothe end of the tubing to ensure that it does nottear.

5 Apply self amalgamating tape (Scotch No.23) over the black oil barrier tubing at the gapbetween the paper insulation and the terminallug, making sure the black tubing is pulleddown into the gap. Fill the gap up to the levelof insulation, and then apply two extra half-lapped layers, overlapping the lug barrel andthe insulation by 15 mm each. Stretch the tapeto 50% of its original width while applying it.

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6 Apply four half-lapped layers of WhiteRestriction Tape (Scotch No. 20) to cover thefull length of the black oil barrier tubing + 10mm either side.


Install Silicon Tubing1 Apply four full turns of self amalgamating tape

(Scotch No.23) over the lug barrel at the end ofthe white restriction tape.

2 Apply two half-lapped layers of selfamalgamating tape (Scotch No. 23) over theremaining exposed portion of the metal sheathand continue for 30 mm onto the polymericoversheath.

3 Slide the grey silicon tubing over the cable andposition the silicon tubing to overlap thepolymeric oversheath by 50 mm. Shrink thetubing into position by pulling and unwindingthe pull-tab in an anti-clockwise direction.

4 This tubing should fully cover the band of selfamalgamating tape applied over the lug. If it istoo long, carefully trim any excess tubing,making sure that the cut starts and finishes at thesame point to avoid tearing of the tubing.

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Install Skirt Tubing

1 Slide a Silicon Skirt Tubing over the trackresistant tubing and shrink it approximatelymid way along the termination.

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Completed Termination

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Earthing the Termination

1 Remove 80 mm of the polymeric oversheath oneach cable starting 100 mm below the outersilicon tubing.

2 Clean, degrease and abrade the full length of eachexposed metal sheath and 30 mm of the polymericoversheath at each end.

3 Apply one half-lapped layer of tinned coppermesh over each exposed metal sheath starting andfinishing 10 mm clear of the correspondingpolymeric oversheath cuts.

4 Wrap two full turns of sealant tape (Scotch No.2900R) over the polymeric oversheath on eachcable, either side of the exposed metal sheath.

5 Determine the length of tinned copper braidrequired for each cable, allowing for the braid tobe folded back on itself at the roll spring position,plus an extra length of approximately 30 mm.

6 Flatten out the braid at the roll spring end bypulling on it sideways in order to achievemaximum surface area coverage.

7 Position the braid over the tinned copper mesh sothat there is sufficient length to be folded backover the roll spring.

8 Starting on the opposite side of the cable, wrapthe roll spring twice over the copper braid in thedirection of the copper braid. Position the rollspring centrally over the exposed metal sheath.

9 Fold the braid back over the roll spring then wrapthe rest of the roll spring around the core.

10 Tighten the roll spring with a twisting action, andthen apply four full turns of self amalgamatingtape (Scotch No.23) over the roll spring to hold itin position.

11 Apply two full turns of sealant tape (ScotchNo.2900R) over the earth braid at the loweroversheath cut.

12 Slide the sealing sleeve over the earth connection,with the loose pull-tab pointing away from theend of the cable.

13 Position the sleeve to fully cover the sectionbetween the two bands of sealant tape. Shrink thesleeve into position by pulling and unwinding thepull-tab in a clockwise direction.

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Typical Earthing Arrangement

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APPENDIX D INSTALLATION INSTRUCTION HV 1-43


Indoor Multicore Paper Lead CablesVersion 1, 12th April 2001

This installation instruction HV 1-43 details the installation procedure of 3Mcoldshrink pressure sealing terminations on 11kV indoor multicore screenedpaper cables that are made in accordance with AS1026. This instruction is notapplicable to any other type of termination..


This instruction is to be read in conjunction with the relevantEnergyAustralia’s Network Standards.

CONTENTS

1. General

2. Special Tools

3. Safety Information when using Resin



6. Completing the Termination



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Self amalgamating tape Scotch no. 23Restriction tape Scotch no. 20Silicon rubber tape Scotch no. 70Stress control tape Scotch no. 2220Rubber mastic tape Scotch no. 2228Mastic sealant tape Scotch no. 2900RVinyl mastic tape

Special ToolsThe design of this range of terminations incorporates the use of resin toprovide for a high cable operating pressure. This resin is best applied using aresin gun. So, it is highly recommended that a resin gun be used to inject resininto the cable crotch. This gun can be obtained from EnergyAustralia'sLogistics Branch on stockcode 175885 or purchased directly from 3M (PartNo. E4 Resin Gun).

Safety Information when using ResinRefer to the manufacture’s safety information sheet supplied in this kit fordetails on safety precautions, spillage procedures and disposal methods for theresin contained in this kit.

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Prepare Cable

1 Set the cable up-straight and in line with thecentre phase bushing.

2 Mark the centre line of the lug-mountingholes on the cable as a reference line.

3 Remove the polymeric oversheath to 820 mmbelow this reference line.

4 Clean the metal sheath, then abrade it for adistance of 230 mm above the polymericoversheath cut.

5 Remove the metal sheath to a distance of220 mm above the polymeric oversheath cut.


7 Unwind the core binding fabric tape down tothe metal sheath cut. Apply a few turns of thistape around the three cores immediatelyabove the metal sheath cut, covering adistance of not more than 20 mm. Remove theexcess fabric tape.

8 Remove all cable fillers level with the appliedfabric tape.

9 Cut the cores 650 mm from the metal sheathcut for easier handling within the endbox.

10 Test the paper insulation for moisture content.If moisture exists, notify the relevant FieldCoordinator / Supervisor for immediateaction.

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Install Lower Oil Barrier Tubings

1 Gently spread the cores apart ensuring thatthey are not over-bent.

2 Wipe off any cable compound on the surfaceof the cores with a clean rag. Do Not usesolvents.

3 Slide a black oil barrier coldshrink tubingover one of the three cores. Position it 45 mmabove the metal sheath cut and shrink it downby pulling and unwinding the pull-tab in ananti-clockwise direction.

4 Repeat for the other two cores.

5 Apply two half-lapped layers of WhiteRestriction Tape (Scotch No. 20) firmly overeach of the black oil barrier tubings. Start20 mm below the top end of each tubing andwork towards the lower end, then turn back tothe starting point.

Caution: The white restriction tape DOESNOT STRETCH. So avoid creasing whenapplying it.

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Install Glove and Inject Resin

1 For 95 mm2 cables only: Apply a 25 mm wideband of rubber mastic tape (Scotch No. 2228)around the metal sheath. Position the tape 50 mmbelow the metal sheath cut, and build it up to athickness of 8 mm. Moderately stretch the tapewhile applying it.

For 185 mm2 to 300 mm2 cables only: Apply a50 mm wide band of rubber mastic tape (ScotchNo. 2228) around the metal sheath. Position thetape 50 mm below the metal sheath cut, andbuild it up to a thickness of 8 mm. Moderatelystretch the tape while applying it.

2 Prepare the 3-way glove for installation bycarefully unwinding the pull-tab in each fingeruntil the pull-tab core is level with the bottom ofthe finger.

3 Carefully position the glove over the three cablecores at the lug end, ensuring that the main bodypull-tab runs straight down the side of the glove(ie. It does not pass between the cable cores).

4 While holding the main body pull-tab firm to thebody of the glove, ease the glove over the cablecores towards the crotch area. Push the glove asfar down as it goes. The body of the gloveshould fully cover the applied rubber mastictape.

5 While holding the glove in this position, shrinkthe main body by pulling and unwinding themain body pull-tab in an anti-clockwisedirection.

6 Shrink down two of the glove fingers by pullingand unwinding their pull-tabs in an anti-clockwise direction.

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7 Apply silicon grease to the plastic filling tube,and insert it into the third finger. Position thetube on the inner side of the cable core (ie. closeto the other cable cores). This will ensure thatwhen the resin is applied it will fill the crotch ofthe cable.

8 Shrink down the third finger to hold the fillingtube firm in position.

9 Thoroughly mix the resin as per the instructionson the pack.

10 Inject resin gently into the cable crotch areathrough the filling tube. Keep injecting resinuntil the glove is full (ie. until the resin starts toescape through the gap between the filling tubeand the finger of the glove). More than one mixpack might be required to fill the crotch area.

Note: A resin gun is highly recommended forthis purpose.

11 Carefully remove the filling tube from the finger.

12 Clean off any excess resin using solvent pads.

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Note: The earthing kit is separately packaged within thetermination kit.

1 Ensure that the metal sheath has been degreased andfully abraded.

2 Apply one half-lapped layer of tinned copper mesh tothe exposed metal sheath.

3 Apply two full turns of sealant tape (ScotchNo. 2900R) at the top end of the polymericoversheath.

4 Position the earth braid(s) onto the metal sheath sothat they overlap the glove by 80 mm (the end fittedwith a lug should point away from the glove). Use atemporary binder (tie or tape) to hold the earthbraid(s) in position.Note: Only 1 braid (39 mm2) is required for

95 mm2 cables, and two braids (2x39 mm2)for 185-300 mm2 cables. If using twobraids, position them directly opposite eachother.

5 Position a roll spring 20 mm below the bottom of theglove and wrap two full turns over the earth braid(s).

6 Position a second roll spring 30 mm below the firstroll spring, and wrap two full turns over the earthbraid(s).

7 Fold the earth braid(s) back over the roll springs(after removing the temporary binder), and wrap theremaining lengths of both roll springs over the earthbraid(s).

8 Tighten both roll springs with a twisting action, andthen apply four full turns of self amalgamating tapeover each of them to hold them in position. This tapeis not provided with the earthing kit; use the tapesupplied with the main termination kit.

9 Apply two full turns of sealant tape (ScotchNo. 2900R) at the lower end of the glove.

10 Apply two full turns of sealant tape (ScotchNo. 2900R) over the earth braid(s) at the top end ofthe polymeric oversheath (ie. where previouslyapplied).

11 Apply the supplied vinyl mastic tape over the earthconnection fully covering the two bands of sealanttape (Scotch No. 2900R). Half-lap the tape whileapplying it.

12 Connect the lower end of the earth braid(s) to themain earthing point using M12 bolt, nut and washers.

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Install Terminal Lugs

1 Attach a lug to each of the terminal posts insidethe endbox.

2 Determine the phasing and position of each core.

3 Set one core at a time into its final position and,mark and remove the excess core length.

4 Remove the paper screens and insulation fromthe end of each core for a distance equal to thelength of the lug barrel + 15 mm.


6 Install sealed terminal lugs in accordance withmanufacturer's specification. If using solder lugs,the cable cores must be suitably protectedagainst excessive heat or flame. If usingcompression lugs, remove excess grease afterinstallation, and de-grease the barrel of the lugs.

7 Using self amalgamating tape (Scotch No. 23),smoothly profile the barrel of each of the lugs inorder to facilitate achieving a good oil seal.Ensure that at least two half-lapped layers oftape are applied to the lower 30 mm of the barreland the exposed conductor between the lug andthe paper insulation. Also extend the tape for10 mm onto the paper insulation to stop it fromunwinding. Stretch the tape to 50% of itsoriginal width while applying it.

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1 Using a twine binder, remove the paper screensdown to 25 mm above the black oil barriertubings. Ensure that the screen cut is neat andfree of any jagged edges. The screen cutbackshould be at least 220 mm from the end of thepaper insulation.

2 Apply two half-lapped layers of Stress ControlTape (Scotch No. 2220) at the end of the blackoil barrier tubing, working towards the core endfor a distance of 70 mm. Leave an even frontedge, then tape back to the starting point.

Note: Scotch tape No. 2220 should be appliedsilver side out, and stretched to 3/4 ofits original width. Remove the linerbefore stretching the tape.

3 Apply one half-lapped layer of White RestrictionTape (Scotch No. 20) at the black tubing end ofthe stress control tape to protect it from anydamage while shrinking the second oil barriertubing. Start the Restriction Tape 10 mm ontothe black oil barrier tubing and finish it 25 mmonto the stress control tape.

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Install Upper Oil Barrier Tubings

1 Slide a second black oil barrier tubing over oneof the outer phases and position it to overlap thetubing already installed by 20 mm (ie. at the endof the white restriction tape previously applied).

2 Check that the tubing overlaps the lug barrel byat least 15 mm. The tubing will grow in lengthby approximately 15 mm when shrunk. If afterallowing for this growth, the tubing does notoverlap the lug barrel by 15 mm, contact therelevant Field Coordinator/ Supervisor forinstructions. If, on the other hand the tubing istoo long, position it so that the overlap with thelug barrel before shrinking is approximately25 mm.

3 Shrink the tubing into position by pulling andunwinding the pull-tab in an anti-clockwisedirection.

4 Apply self amalgamating tape (Scotch No. 23)over the black oil barrier tubing at the gapbetween the paper insulation and the terminallug, making sure the black tubing is pulled downinto the gap. Fill the gap up to the level ofinsulation, and then apply two extra half-lappedlayers, overlapping the lug barrel and theinsulation by 15 mm each. Stretch the tape to50% of its original width while applying it.

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5 Apply two half-lapped layers of WhiteRestriction Tape (Scotch No. 20) to cover thefull length of the upper black oil barrier tubing +30 mm of the lower oil barrier tubing.

6 Repeat the above procedure for the remainingcores.

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Install Outer Silicon Tubings

1 Slide a short outer silicon tubing over one of theouter phases and push it down to fully overlapthe finger of the glove. Shrink it into place bypulling and unwinding the pull-tab in an anti-clockwise direction.

2 Slide a long outer silicon tubing over the samecable core and position it to overlap the shorttubing by 20 mm. Check that the tubing willfully cover the remaining length of the core afterallowing for 15 mm of growth in length. If itrequires a slight adjustment to achieve fullcoverage, the overlap with the short tubing canbe reduced to 15 mm. If the shortfall is morethan 15 mm, two half-lapped layers of siliconerubber tape (Scotch No. 70) can be used. On theother hand, if the tubing is too long, the overlapwith the short tubing can be increasedaccordingly.

3 Shrink the tubing into place.


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APPENDIX E INSTALLATION INSTRUCTION HV 1-44


Outdoor Multicore Paper Lead CablesVersion 1, 12th April 2001

This installation instruction HV 1-44 details the installation procedure of 3Mcoldshrink pressure sealing terminations on 11kV outdoor multicore screenedpaper cables that are made in accordance with AS1026. This instruction is notapplicable to any other type of termination.


This instruction is to be read in conjunction with the relevantEnergyAustralia’s Network Standards and EnergyAustralia’sDrawing 119643, 11 kV Underground-to-Overhead (UG/OH) Construction forMulticore PILC Cables, Type K3.

CONTENTS

1. General

2. Special Tools

3. Safety Information when using Resin



6. Completing the Termination



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General1. This installation instruction assumes that:

• The multicore cable has been pulled up the pole and saddled intoposition.

• The UGOH mounting bracket, standoff insulators/surge arresters andtermination plates are properly installed.

Note 1: The slots in the termination plates must be centred onto thestandoff insulators, and the lower end of the plates must pointtowards the trifurcating point of the cable, which isapproximately 1 metre below the standoff insulators.

Note 2: The standoff insulators must be installed strictly inaccordance with the details given in drawing A1-119643.

• Adequate clearance exists above the OHLV to allow the ElevatedWorking Platform to be manoeuvred comfortably (clearances aredetailed in drawing A1-119643).

2. Keep the coldshrink kit in its packaging until the components are requiredin order to minimise exposure to dust contamination. After opening thepackaging, components which are not immediately required must beprotected against potential dust contamination.



Self amalgamating tape Scotch no. 23Restriction tape Scotch no. 20Silicon rubber tape Scotch no. 70Stress control tape Scotch no. 2220Rubber mastic tape Scotch no. 2228Mastic sealant tape Scotch no. 2900RVinyl mastic tape

Special ToolsThe design of this range of terminations incorporates the use of resin toprovide for a high cable operating pressure. This resin is best applied using aresin gun. So, it is highly recommended that a resin gun be used to inject resininto the cable crotch. This gun can be obtained from EnergyAustralia'sLogistics Branch on stockcode 175885 or purchased directly from 3M (PartNo. E4 Resin Gun).

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Safety Information when using ResinRefer to the manufacture’s safety information sheet supplied in this kit fordetails on safety precautions, spillage procedures and disposal methods for theresin contained in this kit.

Prepare Cable

1 Cut the multicore cable 100 mm above the top ofthe UGOH mounting bracket.

2 Attach a lug to the termination plate on thecentre phase.

3 Using the removed length of cable, test the paperinsulation for moisture content. If moistureexists, notify the relevant Field Coordinator /Supervisor for immediate action.

Remove Polymeric Oversheath

1 Set the multicore cable into the position of thecentre phase to allow the stripping dimensions tobe marked.

2 Mark the position of the polymeric oversheathcut (point A) 870 mm from the lower end of thelug barrel.

3 Remove the polymeric oversheath to point A.

4 Clean the metal sheath, then abrade it for adistance of 230 mm above the polymericoversheath cut.

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Remove Metal Sheath and Prepare Crotch

1 Remove the metal sheath to a distance of220 mm above point A (polymeric oversheathcut).


3 Unwind the core binding fabric tape down to themetal sheath cut. Apply a few turns of this tapearound the three cores immediately above themetal sheath cut, covering a distance of not morethan 20 mm. Remove the excess fabric tape.

4 Remove all cable fillers level with the appliedfabric tape.

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Install Lower Oil Barrier Tubings

1 Gently spread the cores apart ensuring that theyare not over-bent.

2 Wipe off any cable compound on the surface ofthe cores with a clean rag. Do Not use solvents.

3 Slide a black oil barrier coldshrink tubing overone of the three cores. Position it 45 mm abovethe metal sheath cut and shrink it down bypulling and unwinding the pull-tab in an anti-clockwise direction.


5 Apply two half-lapped layers of WhiteRestriction Tape (Scotch No. 20) firmly overeach of the black oil barrier tubings. Start 20 mmbelow the top end of each tubing and worktowards the lower end, then turn back to thestarting point.


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Install Glove and Inject Resin

1 For 95 mm2 cables only: Apply a 25 mm wideband of rubber mastic tape (Scotch No. 2228)around the metal sheath. Position the tape 50 mmbelow the metal sheath cut, and build it up to athickness of 8 mm. Moderately stretch the tapewhile applying it.

For 185 mm2 to 300 mm2 cables only: Apply a50 mm wide band of rubber mastic tape (ScotchNo. 2228) around the metal sheath. Position thetape 50 mm below the metal sheath cut, andbuild it up to a thickness of 8 mm. Moderatelystretch the tape while applying it.

2 Prepare the 3-way glove for installation bycarefully unwinding the pull-tab in each fingeruntil the pull-tab core is level with the bottom ofthe finger.

3 Carefully position the glove over the three cablecores at the lug end, ensuring that the main bodypull-tab runs straight down the side of the glove(ie. It does not pass between the cable cores).

4 While holding the main body pull-tab firm to thebody of the glove, ease the glove over the cablecores towards the crotch area. Push the glove asfar down as it goes. The body of the gloveshould fully cover the applied rubber mastictape.

5 While holding the glove in this position, shrinkthe main body by pulling and unwinding themain body pull-tab in an anti-clockwisedirection.

6 Shrink down two of the glove fingers by pullingand unwinding their pull-tabs in an anti-clockwise direction.

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7 Apply silicon grease to the plastic filling tube,and insert it into the third finger. Position thetube on the inner side of the cable core (ie. closeto the other cable cores). This will ensure thatwhen the resin is applied it will fill the crotch ofthe cable.

8 Shrink down the third finger to hold the fillingtube firm in position.

9 Thoroughly mix the resin as per the instructionson the pack.

10 Inject resin gently into the cable crotch areathrough the filling tube. Keep injecting resinuntil the glove is full (ie. until the resin starts toescape through the gap between the filling tubeand the finger of the glove). More than one mixpack might be required to fill the crotch area.

Note: A resin gun is highly recommended forthis purpose.

11 Carefully remove the filling tube from the finger.

12 Clean off any excess resin using solvent pads.

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Note: The earthing kit is separately packaged within thetermination kit.

1 Ensure that the metal sheath has been degreased andfully abraded.

2 Apply one half-lapped layer of tinned copper mesh tothe exposed metal sheath.

3 Apply two full turns of sealant tape (ScotchNo. 2900R) at the top end of the polymericoversheath.

4 Position the earth braid(s) onto the metal sheath sothat they overlap the glove by 80 mm (the end fittedwith a lug should point away from the glove). Use atemporary binder (tie or tape) to hold the earthbraid(s) in position.Note: Only 1 braid (39 mm2) is required for

95 mm2 cables, and two braids (2x39 mm2)for 185-300 mm2 cables. If using twobraids, position them directly opposite eachother.

5 Position a roll spring 20 mm below the bottom of theglove and wrap two full turns over the earth braid(s).

6 Position a second roll spring 30 mm below the firstroll spring, and wrap two full turns over the earthbraid(s).

7 Fold the earth braid(s) back over the roll springs(after removing the temporary binder), and wrap theremaining lengths of both roll springs over the earthbraid(s).

8 Tighten both roll springs with a twisting action, andthen apply four full turns of self amalgamating tapeover each of them to hold them in position. This tapeis not provided with the earthing kit; use the tapesupplied with the main termination kit.

9 Apply two full turns of sealant tape (ScotchNo. 2900R) at the lower end of the glove.

10 Apply two full turns of sealant tape (ScotchNo. 2900R) over the earth braid(s) at the top end ofthe polymeric oversheath (ie. where previouslyapplied).

11 Apply the supplied vinyl mastic tape over the earthconnection fully covering the two bands of sealanttape (Scotch No. 2900R). Half-lap the tape whileapplying it.

12 Connect the other end of the earth braid(s) to themain earth using two split bolt clamps.

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Install Terminal Lugs

1 Attach a lug to each of the termination plates onthe outer phases.

2 Determine the phasing and position of each core.

3 Set one core at a time into its final position and,mark and remove the excess core length.

4 Remove the paper screens and insulation fromthe end of each core for a distance equal to thelength of the lug barrel + 15 mm.


6 Install sealed terminal lugs in accordance withmanufacturer's specification. If using solder lugs,the cable cores must be suitably protectedagainst excessive heat or flame. If usingcompression lugs, remove excess grease afterinstallation, and de-grease the barrel of the lugs.

7 Using self amalgamating tape (Scotch No. 23),smoothly profile the barrel of each of the lugs inorder to facilitate achieving a good oil seal.Ensure that at least two half-lapped layers oftape are applied to the lower 30 mm of the barreland the exposed conductor between the lug andthe paper insulation. Also extend the tape for10 mm onto the paper insulation to stop it fromunwinding. Stretch the tape to 50% of itsoriginal width while applying it.

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1 Using a twine binder, remove the paper screensdown to 25 mm above the black oil barriertubings. Ensure that the screen cut is neat andfree of any jagged edges. The screen cutbackshould be at least 220 mm from the end of thepaper insulation.

2 Apply two half-lapped layers of Stress ControlTape (Scotch No. 2220) at the end of the blackoil barrier tubing, working towards the core endfor a distance of 70 mm. Leave an even frontedge, then tape back to the starting point.

Note: Scotch tape No. 2220 should be appliedsilver side out, and stretched to 3/4 ofits original width. Remove the linerbefore stretching the tape.

3 Apply one half-lapped layer of White RestrictionTape (Scotch No. 20) at the black tubing end ofthe stress control tape to protect it from anydamage while shrinking the second oil barriertubing. Start the Restriction Tape 10 mm ontothe black oil barrier tubing and finish it 25 mmonto the stress control tape.

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Install Upper Oil Barrier Tubings

1 Slide a second black oil barrier tubing over oneof the outer phases and position it to overlap thetubing already installed by 20 mm (ie. at the endof the white restriction tape previously applied).

2 Check that the tubing overlaps the lug barrel byat least 15 mm. The tubing will grow in lengthby approximately 15 mm when shrunk. If afterallowing for this growth, the tubing does notoverlap the lug barrel by 15 mm, contact therelevant Field Coordinator/ Supervisor forinstructions. If, on the other hand the tubing istoo long, position it so that the overlap with thelug barrel before shrinking is approximately25 mm.

3 Shrink the tubing into position by pulling andunwinding the pull-tab in an anti-clockwisedirection.

4 Apply self amalgamating tape (Scotch No. 23)over the black oil barrier tubing at the gapbetween the paper insulation and the terminallug, making sure the black tubing is pulled downinto the gap. Fill the gap up to the level ofinsulation, and then apply two extra half-lappedlayers, overlapping the lug barrel and theinsulation by 15 mm each. Stretch the tape to50% of its original width while applying it.

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5 Apply two half-lapped layers of White RestrictionTape (Scotch No. 20) to cover the full length of theupper black oil barrier tubing + 30 mm of the loweroil barrier tubing.

6 Repeat the above procedure for the remaining cores.

Install Outer Silicon Tubings

1 Slide a short outer silicon tubing over one of theouter phases and push it down to fully overlap thefinger of the glove. Shrink it into place by pullingand unwinding the pull-tab in an anti-clockwisedirection.

2 Slide a long outer silicon tubing over the samecable core and position it to overlap the short tubingby 20 mm. Check that the tubing will fully coverthe remaining length of the core after allowing for15 mm of growth in length. If it requires a slightadjustment to achieve full coverage, the overlapwith the short tubing can be reduced to 15 mm. Ifthe shortfall is more than 15 mm, two half-lappedlayers of silicone rubber tape (Scotch No. 70) canbe used. On the other hand, if the tubing is too long,the overlap with the short tubing can be increasedaccordingly.

3 Shrink the tubing into place.


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Install Skirt Tubings

1 Slide a skirt tubing over one of the cores andposition it 170 mm from the top of the long silicontubing.

2 Shrink the tubing into place by pulling andunwinding the pull-tab in an anti-clockwisedirection.


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Copyright Engineering Consulting,EnergyAustralia.

This document must not be reproduced in whole or in part or converted to machine readable form or stored in a computer or imaging system without the written permission of Engineering Consulting Branch, EnergyAustralia.

Revision History

Initial issue: October 1995

Revision October 1997

Document Control

Authorised By:

Document Number: NS 0129

UNCONTROLLED COPY

hv cable joints and terminations

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