Masterclass : 110kV Cable Preparation & Termination Using Prysmian Outdoor Sealing Ends

By Chris Dodds on 20th January, 2016

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Masterclass : 110kV Cable Preparation & Termination Using Prysmian Outdoor Sealing Ends

We are highly privileged and grateful to Andrew Brezovszky ((EHV Cable Jointer at Energex Australia)) for contributing again to our PhotoBlog. 

The following sequence of site photographs and commentary provided by Andrew details the stages of cable installation, preparation and termination using EHV outdoor sealing ends - work was completed on a normal 8 hour/day basis over 5 days with an additional day to install sheath bonding cables and linkbox.

Cable Specification : 110kv XLPE Taihan Cable with 1600sqmm Milliken copper conductor and corrugated copper sheath.

Outdoor Sealing End (Termination) Manufacturer : Prysmian.

T&D are distributors for Prysmian Cable Components which includes their range of Bicon cable joints, cable cleats, cable glands and jointer tooling for LV, MV and HV cables.

Prysmian

Getting Started : temporary cable caps are wiped on to protect the 110kV cable from moisture.

Cable Joint

Standing and cleating cables is next.

Cable Joint

The scaffold is built, which will house our jointing team for a week. We have a generator to power the site and a mobile aircon to control temperature and humidity.

Cable Joint

Here's a shot from the inside before we start...

Cable Joint

Removing the copper sheath is next and installing the cable heating and straightening blankets. The duration is always as recommended by the cable manufacturer, but it also depends by size too.

Cable Joint

 

Cable Joint

Cable straightening is a very important stage of the cable installation prior to preparation and termination.

Cable Joint

Preparing the aluminium glands, so they can be plumbed on. We also 'preload ' them, to shorten the time the cable is under heat stress. This is very important, as the longer plumbing time can cause irreversible damage to the semiconducting layer as well as the cable insulation.

Cable Joint

We strip our EHV cables with Alroc tools and cut the chamfers with glass. Old school, labour intensive, etc., I know. The corrugated sheath is scored circumferentially then pulled off. The semiconductor layer and insulation is peeled off with Alroc stripping tool.

Cable Joint

Cable Joint

This is followed by lots of sanding and polishing. Both manual techniques and machine tooling including orbital sanders and linichers are used to achieve this finish.

Cable Joint

It is very important to prepare the conductor properly.

Cable Joint

Crimping guide block - the cable crimping sequence is important.

Cable Joint

Crimping complete using ram/Milliken style crimping head with basic Ryken hydraulic pump.

Cable Joint

Stress control installed. Removing the semi-conducting screen and installing the premoulded cable joint sleeve or sealing end sleeve is a critical stage of jointing 110kV cables - we covered the calculation for the length of the premoulded sleeves in an earlier article Cable Jointing - An Art or Science?

Cable Joint

Jointing tapes are next...

Cable Joint

Cable Joint

Insulator is lowered onto the cable.

Cable Joint

Plumbing completed.

Cable Joint

Armour tape used to reinforce the wipe and cable sheath.

Cable Joint

The insulator is then filled with special silicone oil to a specific level and the top arrangements are installed.

Cable Joint

 

Cable Joint

Completed installation of 110kV Prysmian Outdoor Sealing Ends to Taihan Cable. 

Cable Joint

 

  • Further reading courtesy of Andrew Brezovszky :  

110kV Oil Filled Cable Joint With Cross Bonding Leads & Link Box 

110kV Oil Filled Taihan High Voltage Cable Joints 

110kV Prysmian Plug-In Cable Termination For SF6 Gas Insulated Switchgear 

110kV Prysmian Screen Break Cable Joint - EHV Extra High Voltage : 

11kV Raychem Cable Termination Installed Into 11kV/33kV Transformer Box 

33kV Raychem Heat Shrink Terminations (Rain Sheds) In A Metering Unit 

33kV XLPE Lat Structure MV Cable Termination Using Raychem Heat Shrink Kits

33kV Trifurcating Transition Cable Joint : 3 Single XLPE Cables to 3 Core HSL PILC Cable

 

Thorne & Derrick Specialist Electrical Distributor

Established since 1985, T&D distribute the most extensive range of LV, MV & HV Cable Jointing, Terminating, Pulling & Installation Equipment - contact us today for a competitive quotation.

Key Products : MV Joints & Terminations, Cable Cleats, Duct Seals, Cable Transits, Underground Cable Protection, Jointing Tools, Feeder Pillars, Cable Duct, Earthing & Lightning Protection, Electrical Safety, Cable Glands, Arc Flash Protection & Fusegear.

Distributors for : 3M, Pfisterer, Nexans Euromold, Elastimold, Catu, Roxtec, Emtelle, Centriforce, Lucy Zodion, Alroc, Hivotec, Cembre, Prysmian, Ellis Patents, ABB & Furse.

Cable Joints Terminations Tools Cleats

 

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Discussion subjects include cable installations, cable jointing, electrical substation, overhead line and electrical construction at LV, 11kV, 33kV and EHV.

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Category:  Cable Jointing - PhotoBlog

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