TAIHAN ELECTRIC WIRE CO., LTD.

REF. NO. : TECEHV-22080-G01

DATE: 2008. 03. 25.

TERMINATING INSTRUCTION

OF

SEALING END FOR SF6 SWITCHGEAR

(or TRANSFORMER)

FOR

220kV 1C X 800SQ

CROSS-LINKED POLYETHYLENE INSULATED

POWER CABLE

SIGNED BY

Team Manager,

Acc'y Engineering Section

EHV Factory

TERMINATING INSTRUCTION

TAIHAN ELECTRIC WIRE CO., LTD.OF

SEALING END FOR SF6-SWITCHGEAR

(or TRANSFORMER)

FOR

220kV SINGLE CORE CROSS-LINKED

POLYETHYLENE INSULATED POWER CABLE

*All dimensions are for only reference

1. Introduction

This instruction explains the terminating operation for 220kV single core

cross-linked polyethylene insulated power cable.

2. Parts and Materials

The parts and materials used in the terminating operation are as follows:

Epoxy resin bushing Connector Tightening metal Case Self-bonding tape Adhesive PVC tape Tinned annealed copper tape Stress relief cone Compression ring Stopper Gasket Other materials

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3. Terminating Procedure

3-1 Preparation

For the Preparation process we are going to first of all:

- Prepare all the area with the appropriate scaffolding.

TAIHAN ELECTRIC WIRE CO., LTD.- Protect the area with a plastic cover to generate a control humidity climate, and for

dust protection.

- Before to make any work we going to make sure that ground floor are under good

conditions, without water inside the culvert and materials that can interfere with our

work.

- If is necessary to move a heavy components we are going to use the appropriate

equipment for lifting and handle this component, taking all the safety measures.

- In case of rainy days the works will be stop.

3-1-1 Raise the cable to the prescribed position, provisionally fix it to the

Structure by using with sling belt & chain block.

3-1-2 Mark the cable cutting point to the dimension given in Fig. 1 based on

the lower surface of the base plate.

3-1-3 Cut the cable at the cutting point as shown in Fig.1

Before cutting the cable, tie the cable more higher than cutting point with

sling belt or rope and connect at the chain block or other supporter.

* Be careful not to swing the cutted cable.

3-1-4 Check the Phase of the Cables and mark every cable with it’s

correspondent phase and mark the spare.

3-1-5 Protect the Ends of the cable and take all the measures to ensure to protect

the ends from humidity, overs the ends and attached silica gel bags to every phases

and Spare.

3-1-6 Install a plastic cover and protect the all the working area.

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Fig.1

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3-2 Cable Termination

3-2-1 Remove the outer covering over the metallic sheath as shown in

Fig. 3.

Fig.3

3-2-2 Wipe off the compound over the metallic sheath with gasoline.

3-2-3 Solder on the surface of the metallic sheath as soon as possible as shown

in Fig. 4. and Bond the braided copper wire on the solder.

(refer to attached drawing)

* Soldering method : Refer to attached “Appendix 1”

180

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Fig.4

-3-

3-2-4 Cut off the metallic sheath at the cutting point using the saw for the

metallic sheath, as shown in Fig. 5

Be careful not to damage the metallic shielding and the insulation.

3-2-5 Enlarge the end of the metallic sheath with the special tool and straighten

the cable once more.

Down the cable to culvert as length of epoxy resin bushing by adjusting

chain block.

Fig.5

3-2-6 Removing of semi-con tape and Metallic sheath

Removing the semi-con tape and the metallic sheath over the extruded

insulation shielding as shown in Fig.6.

180

180

TAIHAN ELECTRIC WIRE CO., LTD.Fig.6

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3-2-7 Straightening of Cable

A tape Heater shall be wrapped onto the aluminum pipe, being covered

with heat insulating mat as shown in Fig.7.

Fig.7

* Check point

If necessary, to remove the winding form of cable white winding on the reel, after wrapping vulcanized rubber tape or scrap cable sheath around cable, put the cable between AL pipe and binding tightly for at least 12 hours as shown in Fig.8. (Usually above work was carried out right after cable laying)

If the winded form can not be removed, apply a beat for approx.2 to 3 hours while straightening by above method.

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Fig.8

3-2-8 Cutting of Cable

Cut the cable as shown in Fig.9.

Fig.9

3-2-9 Cleaning the Cable Core

Remove the dust on the insulation screen with alcohol.

3-2-10 Removing Insulation

Remove the insulation of cable by using stripping tool as shown in Fig. 10.

Fig.10

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3-2-11 Removing Insulation Shield

180

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Remove the insulation of cable and shave the insulation with the

stripping tool as shown in Fig. 11.

Then polish the surface of insulation with sand paper #240, #400

in order or with glass. After polishing, check with the magnifying glass the

surface of insulation is no wound without scar .

as shown in Fig. 12. (Dimensions φD is on the attached drawing)

Fig.11

Fig.12

* In the above mentioned operation, special care must be taken not to damage

the insulation of cable, because a slight damage causes a electrical breakdown.

Practice this work using the surplus cable before commencement of actual

terminating work.

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3-2-12 Apply the Teflon heat shrinkable tube & Wrapping the shield mesh tape

Apply the Teflon heat shrinkable tube over the Outer semi-con layer

TAIHAN ELECTRIC WIRE CO., LTD.as shown in Fig. 13. and dry it using a drier for 30minutes. And then

remove the Teflon heat shrinkable tube.

Fig.13

Wrap the one layer(1/2lapped) of shield mesh tape over the outer

semi-con layer to Metallic sheath as shown in Fig.14.

Then wrap the one layer (1/2lapped) of Adhesive PVC tape over the

Shield mesh tape as shown in Fig.14

Fig.14

3-2-13 Marking

Mark the setting point of the stress relief cone and measuring point after

terminating with PVC tape as shown in Fig.14.

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3-2-14 Cover the clean seat (ex.PE sheet) over the insulation and slide the

parts onto the cable according to following order.

Then, apply the silicone grease on the inner surface of compression

ring as shown in Fig. 15.

TAIHAN ELECTRIC WIRE CO., LTD.

Fig.15

3-2-15 Insert the pre-molded stress-relief cone.

Apply the silicone oil over the insulation inner surface of pre-molded

stress relief cone.

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3-2-16 Put the pre-molded stress relief

Put the pre-molded stress relief cone on the insulation as shown in Fig.16.

Then, slide the stopper ring onto the cable.

TAIHAN ELECTRIC WIRE CO., LTD.

Fig.16

3-2-17 Compression of the connector

Insert the conductor into the connector and compress the connector

with the hexagonal dies with 1/3 over lapping of die width as shown

in Fig. 17. After compression, file the surface of connector and make

it smooth.

Fig.17

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3-2-18. Setting of terminating part

1) Wipe cleanly the inner and outer surface of epoxy resin bushing with alcohol.

2) Clean grooves for O-ring gasket of connector.

3) Silicone grease shall be applied to O-ring gaskets.

4) Set the O-ring gaskets onto the connector with silicone grease as shown in Fig.

18.

5) Hang up the epoxy resin bushing with rope and chain block

6) Insert slowly the terminating part into the epoxy resin bushing by adjusting

chain block.

* When insert the terminating part, be careful not to damage the inner surface

epoxy resin bushing by the edge of connector.

57

TAIHAN ELECTRIC WIRE CO., LTD.

Fig.18

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3-2-19. Fixing of upper part and corona shield (if needed)

Set the fixing plate and the lock nut to the conductor sleeve.

3-2-20. Slide up the Spring and Fixing of case.

1) Clean grooves for O-ring gasket of the case.

2) Silicone grease shall be applied to O-ring gasket and set the O-ring

gasket into the groove of case.

3) Fix the case to Epoxy resin bushing as shown Fig. 19.

TAIHAN ELECTRIC WIRE CO., LTD.

Fig.19

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3-2-21. Fix the assembled terminating parts to TR(GIS) chamber

* When insert the terminating part, be careful not to damage the inner

surface of chamber by adjusting chain block carefully.

* For tightening bolt, Use the torque wrench as specified value.

3-2-22. Bonding of braided copper wire on the metal case.

Bond the braided copper wire on the metal case with binding tinned

annealed copper wire and solder them. Refer to assembly drawing.

3-2-23. Wrap the tapes as shown in instruction drawing.

3-2-24. Bond the terminal to the cable protector then termination work is

finished.

383

TAIHAN ELECTRIC WIRE CO., LTD.

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Appendix 1

Soldering

(1) Using a steel wire brush, polish the solder wiping area of the aluminum sheath

   (see dimensions in drawing) until the oxide film is completely remover, creating

   a lustrous surface.

           CHECK POINT: To ensure correct plating, use a suitable wire brush.

                         The recommended brush has a width of approx.  30 to

                         50㎜ and a length of approx.  30㎜.  Make sure the

                         brush is not rusty.

           CHECK POINT: To avoid making oil flow-paths on the surface of the

                         sheath, do not polish along the cable axis.

           CHECK POINT: To make the subsequent tinning procedure easier,

                         polish the surface at different angles.

(see figure below).

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(2) Before making the solder wipe, it is necessary to perform a separate plating

   operation using an aluminum-plating solder, which is formed by friction of the

   steel wire brush during application.  The recommended plating procedure is as

   follows:

   (a) Heat up the area to be plated to a temperature (approx.  120 to 130℃)at

      which the stick-type plating solder just melts when rubbed on the aluminum

      sheath surface.

       * The plating solder is composed of 20% tin and 50% zinc and has a

         melting point of 100 to 120℃

 CHECK POINT: Wrap tape or other suitable material on the cut end of

                          the anti-corrosion layer to prevent it from melting or

                          burning during plating and pre-solder wiping.

           CHECK POINT: To avoid re-oxidation, the torch's flame should be blue.

           CHECK POINT: The supplied plating solder is stamped "AL" on its

                         surface.

   (b) Continue heating the aluminum sheath, and rub and coat the stick-type (See figure below)

         CHECK POINT: Do not melt the plating solder in the flame.

TAIHAN ELECTRIC WIRE CO., LTD.

   (c) After coating plating solder at intervals along the entire required surface

      area heat the surface again until the applied solder is molten.  Then use a

      new steel wire brush to spread the plating solder to form a uniform layer

      over the entire surface.

    CHECK POINT: Do not reuse the wire brush which was used for polishing.

   (d) Repeat steps (b) and (c) above.

           CHECK POINT: Make sure that the surface appears bright after plating,

                         indicating that the plating solder has become alloyed.

           CHECK POINT: Make sure that there are no dull or unplated areas,

                         especially on the bottom of the cable.  If a dull of

                         unplated area remains, repeat the plating operation until

                         a satisfactory finish is obtained.

Work Activities Potential Risk Control Measure

- 5 min training and AST - Lack of knowledge and

misunderstanding

- Reinstruct to all

personnel about the

procedure

- Installation of provisory

lightning or provisory

scaffolding

- Electrocution

- Fall from different level

- Hit by

- Use EPP

- Verify the good condition

of the equipment

- Working area cleared

- Material and Tool

transport

- Fall from same level

- Overexertion

- Transit for available

ways

- Clear the transit ways

- Help to each other’s if it

necessary

- Installation of supports

and secure the cable

- Fall from different level

- Hit by

- Entrapment

- Transit for available

ways

- Clear the transit ways

- Help to each other’s if it

necessary

TAIHAN ELECTRIC WIRE CO., LTD.- Correct use of the tools

and equipment

- Team coordination

- Concentration

- Adequate use of EPP

- Cable Cutting - Entrapment

- Cut

- Eye particle

- Adequate use of EPP

- Team coordination

- Cable Pulling and Retire

cover

- Entrapment

- Fall from same level

- Overexertion

- Hit by

- Help to each other’s if it

necessary

- Correct use of the tools

and equipment

- Team coordination

- Concentration

- Adequate use of EPP

- Termination Work - Entrapment

- Fall from same level

- Overexertion

- Hit by

- Help to each other’s if it

necessary

- Correct use of the tools

and equipment

- Team coordination

- Concentration

- Adequate use of EPP

- Cleaning the work area - Fall from same level

- Overexertion

- Transit for available

ways

- Clear the transit ways

- Help to each other’s if it

necessary