Jointing manual

Insulated straight through joint for

230kV single core 1400㎟ XLPE cables
• Contents
1. Part of Insulated straight through joint
2. Cable preparation
3. Cable annealing
4. Smoothing cable insulation
5. Appling Teflon Tube
6. Cutting the conductor & Cap Welding
7. Positing of the parts
8. Initial setting of PMJ unit
9. Welding of the conductor
10. Grooving of cable insulation
11. Assembling fastener & corona shield
12. Final setting the PMJ unit
13. Supplementary treatment
14. Setting of copper outer casing and insulating plate
15. Waterproof procedure of copper case
16. Earthing
17. Assembly of coffin box
1. Part of Insulated straight through joint

① Corona shield ② PMJ unit

③ Copper outer case (B) ④ Copper outer case (A) ⑤ Insulator

2. Cable Preparation
Long side

1260 1500 Cutting point

Marking tape

Long side 2000 805

1328±10(1260+150-82) Short side

1350
170 30
140

Short side

873±10(850+150-82)
1850
* Bend back the optical fiber and wind 30 170
it on the exposed AL-sheath. Do not
140
cut the optical fiber
( remain longer then 1~1.5m at long
side,1.5~2m at short side)
3. Cable annealing
AL Foil(1layer)

Silicone Rubber Heater

PET Tape(1/2 Lap Layer)

Sensor
◆ Procedure
1) Place the thermocouple on the semi-conductive layer.
2) Wrap PET tape
3) Place silicone Rubber Heater
4) Wrap one layer of AL-Foil with ½ lap
5) Set Tem. Controller as 80℃ for more than 3hours(depending on the cable insulation thickness)
6) Heating during more than 5hours
7) Remove AL-Foil and silicone Rubber Heater
8) Place the AL Angle (100mm*100mm*10t*1200mm) on the cable with PET tape and fixing band
9) Cooling temperature below 65℃
4. Smoothing cable insulation
1) Place reference mark on cable according center of joint to drawing. Use tape
2) Exposure of the cable conductor with a removing tool

1178±10
150
170 30

Short side

723±10
150
Long side 30 170
 4. Smoothing cable insulation(Exposing conductor)

3) Removing Water Swellable Tape by long-nose plier

a. Stretch conductors with ‘-’driver
b. Remove all the water swellable tape among each layers of stretched conductor
by long-nose plier
c. Re-gathering of stretched conductors
WIRES OF CONDUCTOR

REMOVING THE
WATER BLOCKING TAPE INSULATION LAYER WATER BLOCKING TAPE
4) Exposure of the cable insulation
a. remove the outer semi-conductive layer to expose the cable insulation with a
removing tool
b. Round off the end of outer semi-conductive layer with a sharp glass flake

The end of outer semi-conductive layer

Long side
Short side
c. The diameter of the cable insulation after finishing shall be 94.4~94.9mm

Short side
 (O) (X) (X)

◆.caution
✓ Do not smudge cable semi-con onto the cable insulations
✓ Make sure there is no trace of cable semi-con on exposed

cable insulation
✓ Semi-con particles on the insulations can cause cable failure
5. Appling Teflon heat Shrinkable Tube

1) Insert the heat shrinkable tube to the cable insulation as shown

below fig, more than 100mm from interface of outer semi-con and
insulation as shown below
2) Heat the Teflon tube for 20min by heat gun.
-During the heating on the surface of Teflon tube, rub the Teflon
tape on the surface of Teflon tube as shown in below fig

Long side 100 500 500 100 Short side

6. Cutting the conductor & Cap Welding
1) Wrap the protective cloth on the insulation
2) Cut the conductor end with cutting jig which has 40 degree angle face as shown
below

82 82

3) Clean the cut surface of the conductor with ethyl alcohol and dry it
4) Make cap welding of the cut end of the conductor as follow.
- Fit the conductor cutting jig to the end of conductor and earth it with a earthing wire
of Welding Machine
- Attach the sensor on the surface of conductor
- Welding the cut face of the conductor as shown the next schematic.
Make the thickness of welding to 5mm
 Sensor

5mm Arc Start

Caution : During welding, occasionally wipe off welding sludge with a wire brush.
Check the temperature of conductor not to exceed 80℃
5) Use a grinder to finish the welded portion smoothly. Make the thickness of
cap welding to 3mm by grinding
Caution: Before filling, cover the insulation to protect from aluminum dust.
6) Clean up the cap welding surface of conductor by washing and blowing
with suitable ethyl alcohol and nitrogen gas.
7. Positing of the parts

1) Long side 2) Short side

(1) coffin box (B) (1) coffin box (A)
(2) Heat shrinkable tube (2) Heat shrinkable tube
(3) Outer Case (B) (3) Outer Case (A)
(4) O-ring (4) O-ring
(5) insulator

Caution : Make sure that all necessary parts are in place with
above order before the initial setting of PMJ unit.
8. Initial setting of PMJ unit
1) Setting of the Mounting tool
2) Clamp the long side cable tightly
clamp
Marking tape

Mobile frame

3) Remove the Teflon Tube 450

4) Mark the marking tape on the both semi-con layer of cables

5) Visually check inside of PMJ unit for possible contaminate and clean them with ethyl
alcohol
6) Apply silicone grease inside of the PMJ unit and cover the PMJ unit hole
7) Wrap one layer of Teflon tape with 1/3lap on the semi-conductive layer tightly

Start point Guide Teflon cone

8) Apply silicone grease on the cable insulation and semi-conductive layer
9) Set a Guide Teflon cone on cable and apply silicone grease on the Guide Teflon
cone surface
10) Place the PMJ unit in the mobile frame Mobile frame

11) Operate the controller to move the PMJ unit completely to end of the sheath
and remove the Guide Teflon cone

50~100mm

* Caution : After inserting PMJ unit, the cable insulation must be exposed 50~100mm in
order to groove cable insulation.
9. Main welding of the conductor

1) Protect the insulation surface by Kim-wipers and cloth

2) Straighten the cable and conductor and attach the welding supporter for
main welding to the conductor and connector as shown below
3) Earth it with a earth wire of welding machine
4) Attach the sensor on the surface of conductor as like cutting conductor

Welding jig

Half Ring (Cu)

Half Ring (Al)

5) Accumulate welding from bottom side to upper side

Caution: During the welding work, polish the welding surface frequently
using a wire brush

6) Remove surplus metal of welding portion with an electric grinder and

sander up to the diameter of cable aluminum conductor
7) Remove the protective cloth over the cable and check the cable surface
is clean. If not, wipe cleanly cable insulation surface again.
10. Grooving of cable insulation

1) When grooving is completed, temporarily fit the corona shield to ensure

that it fits correctly
2) Set up the grooving tool onto conductor
3) Using the grooving tool, cut grooves in the cable insulation as shown fig.
Grooving
Guide

Grooving
tool

Caution : Dimension of outer insulation must check every step when strip off
the cable insulation
11. Assembling fastener & corona shield
1) When grooving is completed, temporarily fit the corona shield to ensure that it fits
correctly
2) Clean and polish the cable insulation with Roll sand paper #400, #600 and Round
the edge of cable insulation
3) Wash and clean the exposed conductor
4) Clean the fastener and corona shield
5) Assemble the fastener on the groove
6) Connect fastener to corona shield by braided copper wire
7) Fit the corona shield in the grooved cable insulation
8) Clean the surface of corona shield and cable insulation with alcohol
Polish and Round the
edge of cable insulation

0.3~1.0㎜
0.5~1.0㎜

Cable Insulation Corona shield Cable Insulation

12. Final setting the PMJ unit

1) Apply silicone grease on the insulation

2) Operate auto insert M/C and make the PMJ unit to move to the exact position as
shown in fig. and remove Teflon tape carefully and completely
3) After setting, remove the auto insert M/C
4) Remove marking tapes on both long and short side
Caution : Make sure that the installation tolerance of L1 and L2 must be within the
range of ±1mm

L1 L2
 13. Supplementary treatment & FOC Joint
1) Wrap one layer of EPR tape(semi-conductive pate) with ½ overlap on the
PMJ unit
IJ portion

2) Wrap one layer of copper mesh shield tape with ½ lap on the EPR tape and
bind copper mesh shield tape with copper wires tightly. Solder copper
mesh shield tape and copper wires together

Copper wire (soldering)

3) Wrap one layer of N-tape and PVC-tape with ½ lap on copper mesh
shield tape
4) Set the FOC Joint box and connect it.
Fiber Optics Connector
Joint boxs

EPR N-tape
tape C-tape

Mesh FOC Joint

shield box
tape
14. Setting of copper outer casing and insulating plate.

1) Move the copper outer case (A), insulator and outer case (B)

Copper outer case (A) Copper outer case (B)

Insulator

2) Insert the N-tape spacer between copper outer casing and metallic
sheath
3) Bend the copper wires on to the copper out case
4) Uniformly spread tinned copper braids over the entire surface of metallic
sheath and copper outer case and bind them tightly with copper wires
5) Soldering using the Pb soldering material

Tinned copper braids

Copper wires with soldering

15. Waterproof procedure of copper case
1) Mix base resin and hardner of epoxy putty
2) Apply mixed epoxy putty at the ends of copper outer case (A), (B) and exposed
metallic sheath
3) Wrap 2~3layers of putty tape with ½ lap at both edge of epoxy putty
4) Wrap 2~3layers of N-tape with ½ lap over the region specified
5) After moving heat shrinkable tubes over the epoxy putty and N-tape, shrink them
from center to both ends
6) Wrap 2~3layers of PVC tape with ½ lap at both edge of shrinkable tube
5) Wrap 3layers of N-tape and one layer of PVC-tape with ½ lap over the
region specified
6) Apply the heat shrinkable tube over the region specified shrink them from
center to both ends
7) Wrap 2~3 layer of N-tape and one layer of PVC-tape with ½ lap at both
edges of heat shrinkable tube

N-tape

PVC-tape
 16. Earthing
1) Connect the earthing terminal to earthing terminal lug in the outer case (A), (B)
2) Compress the earthing terminal
3) Wrap the putty-tape, N-tape, PVC-tape in the picture below

1 layer N-tape, 1 layer PVC-tape

Putty tape(1~2 layers)

N-tape(2~3 layers)
PVC tape(1~2 layers)
17. Assembly of coffin box
1) Assembly coffin box
2) Apply mixed epoxy putty at the ends of coffin box (A), (B)
3) Wrap two layers of N-tape and one later of PVC tape
4) Move the heat shrinkable tube and shrink the heat shrinkable tubes from center to
both ends
5) Wrap the N-tape and PVC tape at both edges of heat shrinkable tube
6) Mix base resin and hardener of waterproof compound together and pour them into
the coffin box
7) Cover the caps