Training document on 220KV cable by TBEA China

1. BRIEF INTRODUCTION ON
CABLE ACCESSORIES
MS. RITTA HAN
July 25, 2015
1

2. CABLE ENGENEERING COMPANY
SUMMARY OF CABLE ACCESSORIES
CLASSIFICATION OF ACCESSORIES
CONSTRUCTION PROCESS
2
A
B
C
D

3. 3
A. CABLE ENGENEERING COMPANY
 TBEA Shandong Luneng Taishan Cable Co. Ltd. has the
professional cable laying and cable accessories construction team
with rich experience of more than 10 years in construction field.
 There is a staff of 30 persons, including 2 senior engineers,
7 intermediate engineers and 20 construction technicians, so that
we can carry on four projects at the same time. All of the
constructors have passed the cable accessories construction
technical training of 500kV and below, organized by China Electric
Power Research Institute (formerly known as Wuhan High Voltage
Research Institute), and got the cable accessories construction
qualification certificate finally.

4.  Our cable engineering company has already completed safely more
than five thousand sets of 110kV and 220kV cable accessories
construction with all successful power transmission at one time, and
the accessories installation qualification rate is 100%. In the year
2008, we finished China's first 220kV optic fiber intelligent cable
transmission line, and the cable was produced and researched in our
own company
 In the year 2013, we finished successfully the accessories construction
work, required in Type test and PQ (prequalification) test of 500kV
cable and their accessories, which has created a firm foundation
for exploring 500kV cable market.
 Cable engineering company can undertake all kinds of cable
accessories installation project of 500kV and below, and cable laying
project of 220kV and below in China and other countries.
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5. BASIC KNOWLEDGE
OF CABLE ACCESSORIES
5

6. Cable accessories are the total components used for connecting the
power cable line with other cable line or other electrical equipments,
are essential parts of cable line. Without them, the cable can not pass
through the entire circuit to complete the transmission task.
All requirements on the cable body, such as the requirements on
the cross-section and surface properties of conductor, semi
conductive layer, metal screen layer, insulation layer, sheath and
other parts, are also suitable for cable accessories, especially for the
intermediate joint, that means each part of the intermediate joint
should correspond to each part of the cable.
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B. SUMMARY OF CABLE AACCESSORIES

7. The design principle of cable accessories (termination): It is the
continuation of cable, whether it's the outdoor termination (EBA),
the GIS termination (EBG), or the intermediate joint (RBJ)
termination, it must meet or exceed the mechanical properties and
electrical performance of the cable. The design requirements of the
GIS termination (EBG) also need to meet some requirements of the
corresponding switch. For example, the design of the cable joint
and the intermediate joint should meet the following requirements:
(1). high compression strength, well conductor connection; (2).
high mechanical strength, small dielectric loss; (3) simple
structure, good sealing; (4) partial discharge, tensile strength,
environmental stress cracking, ease of construction, economy, etc.
All of these are the design principles.
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8. 8
C. THE CLASSIFICATION OF CABLE ACCESSORIES
THE OUTDOOR
TERMINATION
THE GIS
TERMINATION
THE INTERMEDIATE
JOINTS

9. ①The full dry type termination
The silicon rubber overall prefabricated dry type outdoor termination adopts
the technology patent of no longitudinal joint sealing, including
the injection molding of umbrella skirt in one time, all umbrella skirt has no
longitudinal joint sealing. Adopting expansion composite structure to ensure
the safety of the transportation and handling, which is convenient for field
installation. Mainly used for the voltage of 110kV and below.
②The pre die pressing type termination
Rely on the elasticity of the rubber parts itself to keep the interface pressure
to achieve its electrical properties.
③The prefabricated type termination
Adopt the mechanical device such as top tight spring to keep the interface
pressure to achieve its electrical properties.
④The capacitance cone type termination
This termination is mainly used for the cable of 345kV and above, adding an
oil filled cylinder capacitance cone on the base of the stress cone and the
epoxy resin sleeve to ensure the longitudinal voltage distributes evenly at the
termination. 9
(1) THE OUTDOOR TERMINATION

10. 66kV 110kV
THE FULL DRY TERMINAL
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11. THE SILICON RUBBER
OUTDOOR TERMINATION
THE PORCELAIN TYPE
OUTDOOR TERMINATION
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12. ① The full dry type GIS termination
On the base of the stress cone and epoxy resin bushing, filling
nothing inside the epoxy resin bushing, it is called the
full dry type GIS termination.
Effect: Mainly connect with switch composite apparatus to
transmit electricity.
②The fluid filled GIS termination
On the base of the stress cone and the epoxy resin bushing,
filling with the fluid insulating material inside the epoxy resin
bushing, it is called the fluid filled GIS termination.
Effect: Mainly connect with switch composite apparatus to
transmit electricity.
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(2) THE GIS TERMINATION

13. On the base of the stress cone and the epoxy resin bushing,
the oil-immersed termination is basically the same with SF6
gas termination, the difference is that there is a junction pole
at the outlet, just like outdoor termination.
Effect: Mainly connect with the transformer to
transmit electricity.
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(3) THE OIL-IMMERSED TERMINATION

14. THE GIS SWITCHING
STATION
THE ASSEMBLED
GIS ACCESSORIES
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15. (3) THE OIL-IMMERSED TERMINATION
15

16. (4)The intermediate joints
The pre die pressing type intermediate joints
Rely on the elasticity of the rubber parts itself to keep the interface pressure to
achieve its electrical properties, use the expansion cone method and the tapering
method when installation.
The prefabricated type intermediate joints
Adopt the mechanical device （such as top tight spring） to keep the interface
pressure to achieve its electrical properties.
Effect: Mainly connect with two pieces of cable to transmit electricity.
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17.  For cross linked cable accessories, besides the correct and reasonable
physical design, the most important problem is the construction problem.
The most common problem in construction is parts cleaning problem.
Especially for the involved insulation interface of accessories, it is the
area where electric field easy to distortion, once there are impurities, air
gap, etc, insulating property will drop so significantly that the cable
accessories will be scrapped.
 All of the technical problems of power cable accessories can
consider and solve from two aspects: on the one hand, from the
electric field distribution and its improvement measures(that is
physical design). The primary technology for improving the
electric field distribution is to solve the treatment technology of stress
concentration problem in accessories. On the other hand, from
improving the insulation electric strength(material selection and
improvement).
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CONSTRUCTION PROCESS OF CABLE ACCESSORIES

18. 1.Strip off the aluminum sheath of the
cable
The termination
platform
XLPE cable
The termination support
The cable clamp
The cable clamp
1). At least 1.5 meters below the
termination platform, XLPE cable is in
the vertical section.
2) XLPE cable in the vertical section is
fixed by at least two cable clamps
3) Other sections can be bent, should
also be fixed by cable clamps according
to design.
4) The bending section of the cable
should meet the requirements of bending
radius of 15/D.
５) After stripping off the aluminum
sheath of the cable, heat the cable to
remove the internal stress of the cable
and straighten the cable.
About
800mm
About
800mm
Horizon
According
to
the
actual
height
on
the
field
THE OUTDOOR TERMINATION
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19. 2-3mm glass sheet
The outer shield
The conductor lead-out rod
2. Crimp the conductor lead-out rod , strip off
the external shield of the cable.
The cable insulation layer
1) Strip off the
cable insulation layer to
expose a conductor by
special tools and strip the
cable insulation into a cone.
2) Crimp the conductor
lead-out rod to the
conductor by 100—200T
press.
3) Clean the outer shield by
the shielded strip cutter and
the glass sheet
(as shown in the figure)
then sand the insulation
section.
The cable
conductor
The metal sheath
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20. The cable insulation layer
The bottom flange
The supporting
insulator
3. The component installation
1.Wind the corresponding strip.
2. Install the components on the
cable in sequence according to the
requirements of drawing.
3.Seal the crimping parts and the
conductor by the strip.
The tail
tube
The heat-
shrinkable tube
The tail tube
Metal
Integrated
stress cone
The connecting
flange
The link fitting
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21. The porcelain bushing
( polymer bushing)
4. Lift the bushing , pour the oil
and seal.
1) Lift the bushing by the crane.
2) Pour the insulating oil into the
bushing.
3) seal the upper and lower section.
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22. The typical outdoor termination arrangement method
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23. THE GIS TERMINAL
1.Strip off the aluminum sheath of
the cable
1). At least 1.5 meters below the termination
platform, XLPE cable is in the vertical section.
2) After the termination goes into the cable tank,
XLPE cable in the vertical section should be
fixed by at least two cable clamps.
3) Other sections can be bent, should also be
fixed by cable clamps according to design.
4) The bending section of the cable should meet
the requirements of bending radius of 15/D.
５) After stripping off the aluminum sheath of the
cable, heat the cable to remove the internal stress
of the cable and straighten the cable.
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24. 2-3mm glass sheet
The outer shield
2. Strip off the outer
shield of the cable.
The cable insulation layer
1) Clean the outer shield
by the glass sheet
(as shown in the figure )
then sand the insulation
section.
2) Strip off the
cable insulation layer to
expose a conductor by
special tools
The cable
conductor
The metal sheath
24

25. The semi conductive molding
The semi conductive
layer molding (heat)
The temperature controller
The semi conductive layer
The
heat shrinkable tube
The heating belts
3.semi conductive molding
1）Confirm the beginning size of the cable end, wrap the semi conductive strip.
2）Confirm that there is no foreign matter inside the heat shrinkable tube.
3）Put the heat shrinkable tube into the cable, shrink from the central to both
ends by the drier, wrap the strip from the point of 10 mm of the
heat shrinkable tube.
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26. The cable insulation layer
The cable
conductor
The heat-
shrinkable tube
The tail tube
The connection
flange
The spring mechanism
The stress cone
4. The pre installation of the components
Preinstall the component to
the cable in order
The semi
conductive layer
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27. The conductor lead-out rod
The epoxy resin bushing
5. Crimp the conductor lead-out rod and install
epoxy resin bushing.
1) After installing the pre installation component, crimp
the conductor lead-out rod to the cable conductor by
100—200T press.
2) Install epoxy resin bushing to the cable
as shown in the figure.
The locating ring
27

28. 6.Fix and seal the upper and the lower
section
1) Install the upper parts by the
fixing flange and the seal ring.
2) Install the spring device, tail tube
and the seal ring in the lower parts.
3) Connect the tail tube with the
metal sheath.
4) Install the epoxy mud and the
heat-shrinkable tube.
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29. The GIS cable tank
The GIS termination
EB-G
7.Entirety entry
After installing the
GIS cable
termination, lift the
entirety to the GIS
cable tank by the
lifting chain and do
the sealing
treatment.
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30. About
800
About
800
Two cable clamps
8.The cable fixation
1). At least 1.5 meters below
the termination platform,
XLPE cable is in the
vertical section.
2) After the termination
goes into the cable tank,
XLPE cable in the vertical
section should be fixed by at
least two cable clamps.
3) Other sections can be
bent, should also be fixed
by cable clamps according
to design.
4) The bending section of
the cable should meet the
requirements of bending
radius of 15/D.
30

31. The typical GIS termination arrangement method
31

32. THE INTERMEDIATE JOINTS
1.Adjust the cable and strip off the aluminum sheath
1) At least 1.5 meters on the both sides of the central point, XLPE cable is in
the straight section
2) After installing the intermediate joints, XLPE cable in the straight section should be
fixed by at least two cable clamps.
3) Other sections can be bent, should also be designed to be fixed by cable clamps.
4) The bending section of the cable should meet the requirements of bending radius of
15/D.
5) After stripping off the aluminum cable sheath, heat the cable to remove the internal
stress of the cable and straighten the cable.
The central point
The cable
The cable
32

33. 2-3mm glass sheet
The outer shield
2.Strip off the outer shield of the cable
The cable insulation layer
1) Clean the external shield by the
glass sheet as shown in the figure
then sand the insulation section.
2) Strip off the
cable insulation layer to expose
a conductor by special tools
The cable conductor
2-3mm glass sheet
The outer shield
The cable insulation layer
The cable conductor
33

34. 3. The pre installation of the components
1) Install the pre installation components to the specified
location of the cable.
2) Install the stress cone to the pre installation location of the
cable.
3) Adjust the cable on the two sides to the straight section.
The stress
cone
4.Crimp the conductor
connecting pipe and install the
components.
1) After installing the pre installation, crimp
the conductor connecting pipe to the
conductor on the two sides by 100—200T
press.
2) Extract the expanding strip out of the stress
cone, the stress cone will shrink to the final
installation position.
The conductor
connecting pipe
The shielding case
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35. 5.The water proof sealing treatment
and fix the joints in position
1) Do the water proof sealing treatment after
installing the components.
2) After the cable and cable accessories are in
the final place, cable accessories should install
two cable clamps used for fixing. There should
be 1.5 meters straight line cable in the two sides
and at least two cable clamps fixed in the
straight section.
The cable clamp
The joint clamp
The installed
intermediate joint
3) Other sections can be bent, should also be
fixed by cable clamps according to design.
4) The bending section of the cable should meet
the requirements of bending radius of 15/D.
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36. The typical joints arrangement method
36

37. The main installation performance
No. Time Project name
Cable
specifications
Manufacturer
Of accessories
Quantity of
accessories
1 Aug. 2010 The expansion construction of Huaneng weihai power plant 220kV-1*2000 Ankao 24
2 Dec. 2010 Sichuang Jinniu newline construction project 220kV-1*1600 Tengcang 66
3 Mar. 2010 Hubei Qinshang power plants 220kV-1*2000 Huidong 18
4 Mar. 2011 The national road upgrading project of Tianjin 220kV-1*2000 Shenyang Kaiweida 33
5 Mar. 2011 Hunan Xiangtou power plants project 110kV-1*800 Zhaohe 12
7 Apr. 2011 Dezhou Xingfang new high speed rail construction project 220kV-1*800 Huidong 21
8 Apr. 2011 Shijiazhuang new railway station construction project 110kV-1*630 Zhaohe 12
9 Jun. 2011 New construction of Hefei Suzhou road 220kV-1*1600 Germany KP 48
10 Jun. 2011
New transformer substation construction of Wuhan Lichang yierhui
and Wangjiadun
220kV-1*1000 Zhaohe 36
11 Feb. 2012 Sichuang Chengdu development-west high-tech zone project 220KV-1*1200 KP 66
12 Dec. 2011 Hubei Huangshi cihu scenic buried project 220kV-1*1200 Zhaohe 15
13
Sep. 2012
Hebei Shijiazhuang high speed rail construction project
220kV-1*1200 KP 21
220kV-1*1600 KP 37
Oct. 2012
14 Dec. 2012
Transformer substation expansion construction of Tianjin Lingang
and Hangu
220kV-1*800 Zhaohe 24
15 Apr. 2012 Line upgrading project of Qinghai Huanghe xingye 170kV-1*800 Zhaohe 48
16 Dec. 2012 Transformer substation construction to Xidu of Jiangsu Nanjing 220kV-1*1000 Zhaohe 12
17 Mar. 2013 Line five construction of Tianjin metro 220kV-1*2000 Zhaohe 33
18 Mar. 2013
Hebei hongxin power plants construction, transformer substation
expansion construction of Hantong Shihua
220kV-1*800 Zhaohe 18
19 Apr. 2013
Aerial power 200KV transmission line engineering in east
industry of Hebei Cangzhou Bohai
220kV-1*2500 Zhaohe 18
20 Apr. 2013 Four-circuit lines project of Wuhan Ganggui 220kV-1*2000 Zhaohe 48
37

38. 21 May. 2013 Line project of Hebei Handan Xialengxiaqi 220kV-1*1600 Zhaohe 18
22 May. 2013
Transmission and transformation project of
Chongqing Longtou temple
220kV-1*2000 Zhaohe 30
23 Jun. 2013 Wuhan yingwuzhou Project 110kV-1*1000 Zhaohe 12
24 Aug. 2013 Nuclear power project of Fujian Fuqing 220kV-1*630 Zhaohe 12
26 Oct. 2013 Petrochemical construction of Hebei hantong 220kV-1*2000 Zhaohe 12
27 Oct. 2013 Sichuan Shuangqiao-Taoxiang project 220kV-1*2500 Zhaohe 84
28 Oct.2013
Expansion construction of Tianjin Beitang
power plants
220kV-1*2500 Zhaohe 9
29 Nov. 2013 Sichuan Jinma Hudong project 110kV-1*630 Zhaohe 12
30 Feb. 2014 Wuhang Jianghan No.6 bridge project 110kV-1*1000 Zhaohe 18
32 Feb. 2014 Jining Jinyu Road project 110kV-1*630 Zhaohe 9
33 Feb. 2014 Shanghai Hangji project 110kV-1*1200 Zhaohe 24
34 Mar. 2014
Two-circuit project of Wuhan Qingjiang
Shangshui Fengguan
220kV-1*2000 Zhaohe 27
35 Apr. 2014 Shanxi Taiyuan Yinxi project 220kV-1*1000 Zhaohe 24
36 May. 2014
Transformer substation construction of Xiepo
to Hanwei in Xuchang Henan
220kV-1*1600 Zhaohe 12
37 Aug. 2014
Electric power project of Hebei Langfang
Minyuan
220kV-1*1600 Zhaohe 12
38
Sep. 2014
Transformer substation construction of Fujian
Power Huatang Zhuyu
220kV-1*2500 Zhaohe 54
39
Nov. 2014
Neimeng Holin Lake project 220kV-1*1600 Zhaohe 18
40
Dec. 2014
Hubei Mulan transformer substation project 220kV-1*2500 Zhaohe 48
41
Jan. 2015
Jinan Panlong transformer substation project 220kV-1*2500 Zhaohe 36
38

39. The configuration table of main tools and
instruments of the construction
N0. Name Remarks No. Name Remarks
1
The
hydraulic clamp
2
The manual
hydraulic clamp
3
The cable
bending
machine
4 The heating box
5
The insulation
grinding
machine
6
The heating
strips
7
The insulation
cut tool
8 The cable coils
9
The
reciprocating
saw
10 The heat gun
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40. 11
The vernier
caliper
12 The wrench set
13
The torque
wrench
14
The
psychrometer
15
The nut
fastening
tool
16 Lifting belts
17
The
aluminum
right angle
adjuster
18
The
electric wrench
Note: The configuration table of main tools and instruments of the construction is
equipped in according to the project-quantity-scale system designing.
40