Page : 1 of 15

Doc. No. : LSC – EBA

Issued : Feb. 2014
Rev. : O

BETTER FRIEND THROUGH BETTER PRODUCTS

Jointing Manual
Outdoor Sealing End
For 132kV XLPE Power Cables
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CONTENTS

1. Cable erection and cutting

2. Removal of outer layers

3. Annealing for cable straightening

4. Exposure of cable conductor and penciling of cable insulation

5. Compression of leading conductor

6. Removal of insulation screen and smoothing of cable insulation

7. Reinforcement of insulation screen

8. Positioning of the parts

9. Setting of premolded termination sleeve

10. Assembly of porcelain insulator and oil filling

11. Assembly of upper parts.

12. Setting of protective casing

13. Waterproof procedure of protective casing

14. Earthing

15. Assembly of terminal lug

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※ All works should be done according to the dimension of installation drawing.

※ Unless otherwise noted, bolts used here are hexagonal bolts.

1. Cable erection and cutting

(1) Measure the real length of porcelain insulator (L1)
(2) Straighten the cable considering the minimum radius of curvature and raised to the
prescribed position. Fix it with the clamp and cleat temporarily.
(3) Considering extra length of 300mm, cut off the surplus length of cable.

2. Removal of outer layers

(1) Removal of PE jacket
Metallic sheath PE Jacket

300 L1+A 200

- Remove 200mm of graphite coating on PE jacket by glass.

(2) Removal of metallic sheath

- Remove the metallic sheath to expose insulation screen.

Swellable tape
Insulation screen

300 L1+B
30 C

(3) Remove swellable tape, leaving 30mm from the edge of metallic sheath.
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3. Annealing for cable straightening

(1) Check the belt heater.

(2) Wrap two layers of PS tape with 50% overlap over cables.

(3) Wrap one layer of aluminum foil.

(4) Wrap the belt heater.

(5) Place the thermocouple underneath the belt heater.

Caution :  Thermocouple must be underneath the belt heater.

 Do not wrap the belt heater too tightly.

(6) Wrap aluminum foil with 50-50 overlap and slightly press it with hands.

(7) Set the temperature at 900C and maintain this temperature for 6 hours

depending on the cable insulation .

(8) Straighten both cables using steel or aluminum angle as soon as annealing process
is completed.
Caution : At least 5 hours of cooling is required.
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4. Exposure of cable conductor and penciling of cable insulation

(1) Place the marking tape at (L1+B)mm from the edge of insulation screen in order to cut the
surplus length of 300mm.

300 L1+B
30 C

(2) Mark the conductor exposure length from the cable end.

(3) Using the tool provided, make square cut until conductor is exposed.
Caution : After conductors are exposed, smooth the edge of cable insulation

(4) Make the cable insulation in the shape of a pencil as shown in the picture below.

5. Compression of leading conductor

(1) Insert the leading conductor into the exposed cable conductor.

Leading conductor

(2) Compress the leading conductor.

(3) Wrap three layers of No.130C tape and two layers of No.117 PVC tape.

No.130C + No.117 PVC tape

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6. Removal of insulation screen and smoothing of cable insulation

(1) Place the marking tape at (L1-E)mm from the cable end.
(2) Remove insulation screen with a peeling tool at first and use glass to expose the cable
insulation.
Cable insulation Marking tape

L1-E

Note : Standard of cable insulation diameter ΦF(-2,+2)

(3) Using glass, chamfer the edge of insulation screen in order to make smooth transition

from cable insulation to insulation screen according to assemble drawing.

40~100(chamfer)

(4) Smooth the chamfered edge of insulation screen and cable insulation with the emery

cloth # 400, #600 and # 800 in order.

Caution : Do not smooth cable insulation with the emery cloth used in insulation
screen
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(5) Clean the cable insulation as well as insulation screen with ethanol.

Cleaning direction

Caution : Be sure not to contaminate cable insulation with semi-conductive

particles

7. Reinforcement of insulation screen

(1) Clean the cable insulation and insulation screen with ethanol.
(2) Wrap one layers of 3M.13 tape (Semi-conductive), one layer of copper mesh and
one layer of No. 117 pvc tape with 50% overlap.

8. Positioning of the parts

(1) Supporting insulator (4EA)

(2) Heat shrinkable tube (3) O-ring
(4) Protective casing (5) Base plate
(6) O-ring (7) Sleeve supporter

Caution : Make sure that all necessary parts are in place with above order before
setting the termination sleeve
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9. Setting of the premolded termination sleeve

(1) Measure the distance from the edge of leading conductor to the setting adapter, L2,
and from the edge of insulation screen to the setting adapter, L3.
Caution : If the distance measured is different from the drawing, adjust the distance.
(2) Visually check inside of the termination sleeve for possible contaminants. If any, clean
them with ethanol.
(3) Clean the cable insulation with ethanol and completely volatilize the surface for at least
five minutes.
(4) Lubricate inside of the termination sleeve and the cable insulation with silicone grease.
(5) Wrap one layer of marking tape on the termination sleeve at L4mm from the top of
termination sleeve.

L4

(6) Insert the termination sleeve onto the cable insulation to the marking line of sleeve
supporter.
(7) Measure the distance from the edge of leading conductor to the setting adapter, L2, again
for possible movement of cable during insertion of the termination sleeve.
Caution : If the distance measured is different from the previous measurement,
adjust the distance.
(8) Measure the distance from edge of leading conductor to the marking tape, L5.
(9) With L3, and L5, check the setting position of the termination sleeve as below.
- L3 – L5 = L6 , if L6 = 30 ± 2 mm, the termination sleeve is properly located.
(10) After the termination sleeve is set at desired position, wrap three layers of Teflon tape
and use two hose bands to clamp the termination sleeve.
(11) Connect tinned copper braid to the sleeve supporter and hose bands.
(12) Wrap five layers of No. 130C tape and two layers of PVC tape with 50% overlap.
(13) Clean the cable insulation and termination sleeve with ethanol.
Caution : Be sure to remove silicone grease completely.
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L5
L2
L3

Termination
Sleeve sleeve
supporter

Flat washer Spring

Base plate washer
O-ring

Supporting
insulator

Supporting
structure
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Taconic-tac
Teflon tape
2sq Tinned No.130C tape
copper braid Hose band
+ 117PVC tape
+ Teflon tape
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10. Assembly of porcelain insulator and oil filling

(1) Assemble the Porcelain insulator

(2) Fill the polybutene oil in the Porcelain insulator.

Caution :  Heat polybutene oil until the temperature reaches

150℃ and cool it to 115~120℃ for filling
 Fill the polybutene oil from top of polymer
insulator by using the lift crane.
(3) Desired oil level is 150mm from the top of Porcelain insulator.

11. Assembly of upper parts

(1) O-ring (2) Upper metal (1)

(3) O-ring (4) Upper metal (2)
(5) Fixing plate (6) Locking plate
Porcelain insulator
(7) O-ring (P-60) (8) Shield cover

Shielding
cover Flat head
screw
Locking
O-ring plate

Spring
washer O-ring
Spring Fixing
Upper washer plate
metal (1)

O-ring
Upper
metal (2)
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12. Setting of protective casing

(1) Connect the protective casing to the base plate.

Spring washer
O-ring

Protective casing

(2) Insert the lead spacer between protective casing and metallic sheath and uniformly spread
tinned copper braids over the entire surface of metallic sheath protective casing and bind
them tightly with copper wires. Solder tinned copper braids and copper wire onto metallic
sheath.

Tinned copper braids

Tinned
Lead spacer copper wire
Hammer
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13. Waterproof procedure of protective casing

(1) Mix base resin and hardener of epoxy putty until the color of mixture becomes uniform.
(2) Apply mixed epoxy putty and glass tape alternately for three times at the ends of
protective casing.

Epoxy putty

(3) Preposition the heat shrinkable tube and wrap one layer of NF-500 tape.

NF-500 tape

Epoxy putty

Heat shrinkable tube

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(4) Apply heat shrinkable tube over the fully cured epoxy putty. Shrink
them from center to both ends.
(5) Wrap three layers of Insulating tape, and two layers of PVC tape with 50% overlap at
both edges of heat shrinkable tubes.

14. Earthing
(1) Connect the earthing terminal to earthing terminal lug in the protective casing.

Earthing terminal
Earthing terminal lug

Flat washer
Spring washer

(2) Insert earthing lead into earthing terminal.

Earthing lead

(3) Compress the earthing terminal.

(4) Wrap one layer of NF-500 tape.

NF-500 tape
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(5) ) Wrap five layers of No. 130C tape and two layers of 117 PVC tape with 50% overlap
over at both edges of heat shrinkable tube and region specified in the picture below.

No.130C tape +117 PVC tape

15. Assembly of terminal lug (If any)

(1) Connect the terminal lug to the leading conductor.

Terminal lug

Spring washer
Flat washer