Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
Book No. 14
Version 0
Innovative
Solutions
Product &
Substation System
Business Business
Erection
+ 46 21 32 80 00
+ 46 21 32 80 13
40490 abbsub s
Siteman
Erection
Welcome to the preliminary Siteman Erection handbook in the series of booklets
within the LEC Support programme of BU
Transmission Systems and Substations of
BA THS.
It is the intention of the BU to update this
handbook to reflect the philosophy of the
whole BU. We hope that you will find the
booklets useful in your work.
This booklet is dedicated to the erection.
It includes internal ABB Substations, Sweden instructions to for example:
Mobilize at a site
Welding rules
Cables
Earthing
Air Insulated Switchgear.
The authors welcome any idea you may
have to improve the quality of this booklet
as well as the other ones.
Best of luck!
CONTENTS
Check on arrival mobilization ........................................... page 5
Welding rules .............................................................................. page 25
Brazing Thermic welding process ................................ page 31
Cables ............................................................................................ page 51
Laying, termination and jointing of
high voltage cables <80 kV .................................................. page 87
Cubicles in electrical rooms Touch-up
painting ........................................................................................ page 113
Earthing ....................................................................................... page 131
Air insulated switchgear ..................................................... page 157
SITEMAN 01 - 94
1WAT 910033-1
Edition January 1994
Check on arrival
mobilization
List of contents
1.
General ............................................................................ 7
2.
3.
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
4.
Appendix 1 ............................................................................. 13
Appendix 2 ............................................................................. 20
1. General
This document will, in principle, describe the following main subjects:
check on arrival
site mobilization
check of civil works
It has to be emphasized that this instruction only can act as a guide, since each
country and site is unique, even if most of the actions to be taken are universal.
3. Site mobilization
3.1 Establishing of site routines
For every project it is of utmust importance that the site procedures and routines
are agreed upon by all parties involved. The earlier ABB brings these questions
forward, the greater chance to introduce our routines.
Below follow examples of points and routines to be negotiated and agreed upon.
Routines for inspection, approval, progress reports, etc.
Routines for communication between customer, consultant, etc. and ABB site
representatives have to be agreed on. Remember that most consultants are
working in accordance with very strict protocol and are especially sensitive to
direct contacts between customer and contractors.
Routines for access to buildings and switchyard.
Routines for planning and recording of staff and man-power.
Rules for extra work. The contract normally specifies in detail how claims for
extra work and extension of time shall be handled. It also gives time limits within
which such claims must be submitted and how to measure the work. Note that
an agreement between the customer and the local project manager shall be
(issued) signed before any extra work is undertaken. Do not forget to note all
claims in all directions in the SITE-DIARY.
It does not matter how much information given in the contract documents earlier,
the practical application of these routines have to be established at site together
with the consultant, customer, subcontractor, etc.
3.2 Site layout
A site layout showing the service areas shall be done at an early stage and prior to
the start of the site activities. The layout shall show the following: (See Fig. 1 and
2.)
Areas allocated to ABB for offices, stores, outdoor storage area, workshop.
Supply points for electricity, telephone, telefax.
Supply points for water (incl. drinking water) and sewage.
Bench marks for checking of foundations.
The site layout shall also state the areas for the consultants, customer and
others.
BA THS / BU Transmission Systems and Substations LEC Support Programme
Fig. 1
Fig. 2
20' ISOstandard
External
Internal
without
insulation
Lenght, mm
Width, mm
Height, mm
Weight, kg
6058
2438
2591
2400
5862
2329
2400
2400
Internal
with
insulation
5802
2209
2340
3450
Figure 5.
Typical indoor store.
10
11
12
SITEMAN 01-94
Appendix 1
CHECKLIST
Period
Project
SIte designation
Order no.
Page
Dealt with by
Date
Cont.
1
2
This checklist is supposed to be filled in with a few words answering following questions.
Return one copy soonest to your company. The whole list does not necessarily have to be
completed at one time, it can be returned part by part.
1.
TRAVEL
1.1
Travel time?
Routine?
Alternative routines?
1.2
Custom procedure?
Problems?
Need of visa, etc.?
Health check, compulsary
vaccinations?
Problems to get spare parts
etc. through customs as
personal luggage?
1.3
1.4
1.5
13
SITEMAN 01-94
Appendix 1
CHECKLIST
Period
Project
SIte designation
Order no.
Page
Dealt with by
Date
Cont.
2
3
2.
LIVING CONDITIONS
2.1
Hotel?
Rental of house / flat?
Approx. cost?
Cost?
Laundry?
Standard?
2.2
Cost of living?
Shortage of important
commodities?
Shortage of foodstuffs?
Possibilities to import
European food?
Canteens, restaurants?
Distance to site?
2.3
Drinking water,
need of boiling?
2.4
Electricity supply?
Voltage?
Frequency?
Reliability?
Adapter?
2.5
Climate?
Recommendable clothes?
Insects?
2.6
Laws/Regulations/Customs
useful to know?
Religion?
Other languages spoken?
Authorities?
2.7
2.8
2.9
Currency restrictions?
Travellers cheques, cash?
Preferable currency?
Accepted credit cards?
SITEMAN 01-94
Appendix 1
CHECKLIST
Period
Project
SIte designation
Order no.
Page
Dealt with by
Date
Cont.
3
4
2.
2.10 Schools?
Swedish / International?
School fees?
Starting date / terms?
SITEMAN 01-94
Appendix 1
CHECKLIST
Period
Project
SIte designation
Order no.
Page
Dealt with by
Date
Cont.
4
5
3.
MEDICAL FACILITIES
3.1
Hospital available?
Standard?
Address?
3.2
3.3
Dentist available?
Standard?
Address / Phone number?
3.4
3.5
Necessary arrangements in
case of emergency sicktransportation to home
country?
3.6
3.7
3.8
SITEMAN 01-94
Appendix 1
CHECKLIST
Period
Project
SIte designation
Order no.
Page
Dealt with by
Date
Cont.
5
6
4.
WORKING CONDITIONS
4.1
4.2
4.3
Telex number?
Telefax number?
4.4
Working hours?
Local holidays?
4.5
4.6
4.7
4.8
4.9
SITEMAN 01-94
Appendix 1
CHECKLIST
Period
Project
SIte designation
Order no.
Page
Dealt with by
Date
Cont.
6
7
4.
SITEMAN 01-94
Appendix 1
CHECKLIST
Period
Project
SIte designation
Order no.
Page
Dealt with by
Date
Cont.
5.
TRANSPORTATION
5.1
5.2
Rental of cars?
Approx. cost?
5.3
Purchasing of cars?
Approx. cost?
5.4
Fuel availability?
Approx. cost?
5.5
5.6
5.7
5.8
Heavy trucks?
Road conditions?
5.9
Import license?
SITEMAN 01-94
Appendix 2
CHECKLIST
Period
Project
SIte designation
Order no.
Page
Dealt with by
Date
Cont.
1
2
This checklist is supposed to be filled in with a few words answering following questions.
The main purpose however, is to remind the Site Construction Manager of all Civil Work
to be checked before the erection shall start.
1.
OUTDOOR
1.1
Roads
to the site
inside the site
1.2
Trafficability
trafficability large / heavy
equipment such as transformers
trafficability building and
erection cranes limitations,
which?
1.3
1.4
Cable excavation
operating space available?
excavation for fencing?
1.5
Material unloading
in store
switchgear room
battery room
control room
is it possible / convenient?
1.6
Outdoor storing
steelwork
cable drums
free and levelled area size?
sleepers / beams protection?
fencing?
1.7
Fencing
foundations
connection ground network
gates function / locks
corrosion protection
1.8
Snow clearing
SITEMAN 01-94
Appendix 2
CHECKLIST
Period
Project
SIte designation
Order no.
Page
Dealt with by
Date
Cont.
2
3
2.
FOUNDATIONS
2.1
Foundations (general)
correct location
2.2
Individual foundations
correct placing
correct construction
foundation bolts
size
placing
clean and undamaged
threads
nuts and washers fitted
2.3
Large foundations
(transformer / reactor)
dimensions
rails
embedded steelplates for
jacks / eyelets
foundation bolts
2.4
Oil pit
capacity
filling
cover
oil outlet
2.5
Cable routes
2.6
Ground network
SITEMAN 01-94
Appendix 2
CHECKLIST
Period
Project
SIte designation
Order no.
Page
Dealt with by
Date
Cont.
3
4
3.
3.1
Cable routes
Cable ducts / shelves
placing
design (acc. drawings)
brackets
ladders
embeddings
tops for placing of covers
covers
openings for cables in cable
ducts, etc.
correct inclination (ducts)
drainage
3.2
Ground network
correct running acc. drawing
test link
extra earth rods
joints
cathodic protection
3.3
SITEMAN 01-94
Appendix 2
CHECKLIST
Period
Project
SIte designation
Order no.
Page
Dealt with by
Date
Cont.
4
5
4.
STATION BUILDING
4.1
Station building
function
quality
trafficability
painting
water
heating
4.2
Floor
basement for panels
quality, finish
measures
fixing for
cables
panels
cable ducts in floor
indoor switchgear
foundation bolts
level
making of holes
4.3
Cable routes
placing
measures
fixings
brackets
ladders
intakes
4.4
Others
availability lockable rooms
water, showers, WC ready
for use
drainage correct inclination
lifting devices available
cleaning
SITEMAN 01-94
Appendix 2
CHECKLIST
Period
Project
SIte designation
Order no.
Page
Dealt with by
Date
Cont.
5.
VARIOUS / ACCESS
5.1
Security
fence and gates ready?
lockable stores?
site guarded?
5.2
Battery room
design
ventilation
holes
explosive-proof light fittings
water
painting
5.3
5.4
Electricity
fittings
outlets
panel
5.5
Access
(estimated in % of full access)
completed
started but not completed
not yet started
estimated start date
estimated completed date
documentation by photos
24
SITEMAN 08 - 94
Marking of cables
1WAT 910033-8
Edition January 1994
25
List of contents
1.
General .......................................................................... 27
26
1. General
There are a great variety of cable marking systems available on the market. ABB
have chosen to work with the two following suppliers:
Partex.
Fleximark.
Each of these two systems is divided into two different marking systems:
Preprinted cable markings.
Computerized cable markings.
These markings are produced by the use of a computerized printer. The technical
data are taken directly from the cable and core lists.
2. Standard marking
All cables shall be provided with durable markers at both ends.
Each cable shall be marked with cable number.
Each core shall be marked with:
Core number.
Cable number.
Cable no.
Core no.
Fig. 2
Cable no.
Partex
Fig. 3
Fleximark
27
Fig. 4
Partex
Fig. 5
3. Mounting
3.1 Cable numbers
The marking sleeves are to be fixed on the sheath of the cable close to the
stripped end, see figure 6. When cables are terminated in a connection box, the
markings are to be fixed to the cables outside the box. The markers are threaded
onto a plastic strap, which is fastened around the cable (figure 3).
3.2 Core numbers
The markings are to be placed near to the points of connections.
The cable core marking should state in the following order from the left to the
right or from bottom to the top:
Core number.
Cable number.
See figure 6.
28
Core marking:
White markings with
black characters.
Cable marking:
Yellow markings with
black characters.
Fig. 6
4.2 Flexipart
Please ccontact Miltronic AB for further information.
Address:
Box 1022
S-611 29 Nykping, Sweden
Telephone +46 0155 87000
4.3 Other standards
Outside Sweden various customers may require special marking system. The
design office will then order the material needed and issue the necessary installation instructions.
4.4 Open type markers
Partex can also deliver an open marker, with which already terminated wires can
be marked. See figure 7.
For diameter
2.46.2 mm
Fig. 7
BA THS / BU Transmission Systems and Substations LEC Support Programme
29
30
SITEMAN 11 - 94
Brazing
1WAT 910033-11
Edition January 1994
Thermic welding
process
31
List of Contents
A
1.
2.
3.
4.
5.
6.
6.1
6.2
6.3
7.
7.1
7.2
7.3
7.4
7.5
7.6
8.
9.
10.
10.1
10.2
10.3
10.4
10.5
11.
12.
BRAZING
General ........................................................................................................ 33
Brazing equipment ..................................................................................... 33
Setting the torch pressure for acetylene and oxygen ............................ 33
Definitions, clarification of words ............................................................. 34
Units of measure ........................................................................................ 34
Flame brazing ............................................................................................. 34
Wedling torches ........................................................................................... 34
Types of flame .............................................................................................. 34
Bunsen burner ............................................................................................. 35
Different types of solder, their characteristics and use ......................... 35
Silver solder ................................................................................................. 35
Brass solder ................................................................................................. 35
Phosphor-copper solder ............................................................................... 35
Copper solder .............................................................................................. 35
Heat-resistant solder .................................................................................... 36
Aluminium solder ......................................................................................... 36
International standard solders; preferred standard................................ 36
Flux .............................................................................................................. 36
Description of methods ............................................................................. 37
General ........................................................................................................ 37
Brazing, joining of copper bars (75 x 6) ....................................................... 37
Brazing of copper bars (50 x 10) with prelocated solder .............................. 38
Brazing of earthing conductors/T-joints (branch-joints) ................................ 39
Brazing of aluminium T-joints ....................................................................... 40
Different types of solder and their working temperature ....................... 42
Effective temperature ranges of different fluxes .................................... 43
B
1.
2.
3.
4.
5.
6.
32
A. BRAZING
1. General
Brazing is a method used for joining materials in cases when a joint of greater strength, than that obtained
by soldering, is required. The strength of the joint can be the same as that of the materials to be joined.
In this instruction brazing solder will be called solder only.
The working temperature of the solder and the materials to be joined is, however, to be least 450 C.
Copper and copper alloys can be easily brazed, but tin, lead and aluminium additives make brazing more
difficult.
Carbon stells and alloyed steels can be easily brazed, but the brazeability will be reduced when the
carbon content and the alloy content, respectively, are increased.
In the case of cast iron, the graphite opposes the wetting ot the solder.
Aluminium and aluminium alloys can also be brazed.
The strength of the joint varies, depending on the metals and the type of solder. As a guiding value for
steel, copper and brass, an initial tensile strength of 200 N/mm2 can be reckoned with. Adequate safety is
therefore ensured.
2. Brazing equipment
Fig. 1
Fig. 2
33
5. Units of measure
Pressure:
1 Pa =
1 bar =
1 lbf/m2
1 psi
1 kp/cm2
1
100
=
=
=
N/m2
kPa
6.98 kPa
6.98 kPa
98.1 kPa
6. Flame brazing
The material is heated with a burner welding torch or bunsen burner.
6.1 Welding torch with appurtenant equipment (acetylene oxygen)
Fig.3
34
Fig. 7
35
*)
**)
***)
1
2
3
4
5
L-AlSil2
L-Cu
LCuZn40
L-Ag2P
L-AG15P
AL2
CU2
CZ7
CP2
CP1
BAlSi4
BCu-1
RBCuZn-A
BCuP-6
BCuP-5
2 4261
2 5010
2 5251
2 5909
2 5983
6
7
L-Ag55Sn
AG14
BAg7
2 5990
2 6829
1124 1001-3
1122 1110-104
1122 1131-106 **)
1122 1131-111 ***)
1122 1171-287
1125 1040-1
No.
1.
9. Flux
The purpose of the flux is to dissolve the oxides on the binding surfaces and to prevent the formation of new
oxides during the preheating stage. The flux is applied before heating.
The composition of the flux is partly dependent on the metal oxides, which it is to dissolve, and partly on
the fact that it must be adapted to the working temperature required by the solder and, furthermore, that in
the molten state it must be so light fluid that it can be drawn into the gap between the pieces of parent
metal. It must also be possible to remove it. The flux is fully active for a few minutes after it has melted.
The figure on page 16 shows examples of the active working ranges, of different fluxes, within which the
best results will be obtained. The relationship between the solder and a suitable flux is given in clause 8.
Note! Pure copper can be brazed with advantage without the use of flux.
Note! The flux consists to a great extent of borax and boric acid but it also contains
additives which can be dangerous or poisonous. The precautionary notice
should, therefore, be read carefully.
Note! The flux does not remove rust, oil, grease, paint or other
impurities. Brazing flux is normally supplied in powder
form. Mix the flux with distilled water to form a
paste and then apply it with a brush.
Fig. 8.
36
Fig. 9.
L = t x 5 mm = 6 x 5 = 30 mm
Place the bars on a heat-insulating base, e.g. bricks and secure them in position with 30 mm overlap and a
gap width of 0.2 mm.
Brazing: Ignite the burner and adjust to obtain a suitable flame.
Neutral flame
Warn the bars first, alternatively until they obtain a dark-red colour; both bars
should reach the working temperature, approx. 700 C, simultaneously.
Apply the solder.
37
Fig. 10.
Place the solder on the binding surface of one of the details.
Fig.11
Relocate the details to their correct positions and secure them without altering the position of the
welding clamp.
Fig.12.
Brazing: Ignite the burner and adjust to obtain a neutral flame.
Alternatively heat the copper bars.
use a sweaping movement when applying the flame
the copper bars should simulaneously reach working temperature, approx. 750 C.
heat until the solder melts, flows out and wets the binding surfaces.
38
Inspection: Ensure that the solder har penetrated through and had adhered along all the edges of the
binding surfaces.
Fig.13.
Fig. 14.
Using plastic straps or insulating tape, fix the lines to each
other. The distance between the fixing points should be
approximately 40 mm in order to provide space for the
lashing wire.
Fig. 15.
Wrap on the copper lashing wire, hard and tight, approx. 25 mm between the fixing points.
Twine the two ends of the wire to secure the joint.
Fig. 16.
39
Fig. 17.
Fig. 18.
Do not point the flame directly against the solder.
Heat only so much that the solder melts and flows in between the wires.
Apply solder to the lashing wire until it is completely covered.
Repeat the procedure on the other side.
Post-cleaning: Since no flux is used. post-cleaning is not normally necessary.
Inspection: Ensure that the solder has penetrated in between the wires and that no holes exist in the joint.
40
Fig. 19.
Continue heating
Heat a 50 100 mm zone on all sides of the joint.
Apply the flame with a sweeping movement.
The details should simultaneously reach a working temperature (580 C).
Heat until all flux has melted to a clear fluid.
Apply the solder
Apply the flame with a sweeping movement
Apply the solder.
Heat in the vicinity of but not directily on the solder.
Heat until the solder begins to melt.
Fig. 20.
Apply the solder at an even rate along the length of the joint
Heat only so much that the solder melts evenly and flows into the gap.
Adapt the amount of solder so that a fillet is formed on each side of the joint.
Post-cleaning
Remove all residual flux.
Use a wire brush and water.
Inspection
Ensure that a fillet is obtained on each side.
Fig. 21.
41
Working
Solders alloys
temperature figures states
C
Designation
Remarks
1200
1100
1020
Copper solder
960
Ag85 Mn15
1000
800
700
600
850
Cu94 P6
810
740
730
715
710
705
690
Silver solder *)
Asea 1122 1171-28
Silver solder
Phosphor Copper solder
Phosphor Copper solder *) Asea 1122 1110-104
Phosphor Copper solder *) Asea 1122 1131-106
-105
Silver solder
650
640
610
Silver solder *)
Silver solder
Silver solder
580
Al87 Si13
Aluminium solder *)
550
Aluminium solder
500
*) Preferred standard (refer to page 7).
42
700
600
Group A
GENERAL
(Not aluminium)
700 1100 C
AGA
AGA
CASTOLIN
ELGA
AGA
AGA
AGA
CASTOLIN
ELGA
Not suitable
for copper
and copperalloys
Group B
BRASIFLEX 750
COBRAFLUX 900
TERMOFLUX LV
16 AND 18
KMB 61
800
For aluminium
900
500 800 C
AGA
AGA
CASTOLIN
CASTOLIN
ELGA
1000
SISAFLUX AH
SISAFLUX AN
190
190 NH
INTRA-24
1100
1200
500 650 C
500
Group C
43
Fig. 22
Wet or damp conductors must first be dried out through heating with a gasol flame or by placing them
immediately in the heated mould where they remain until completely dried.
In the meantime preparations for next welding can be made.
It is possible to weld a copper wire using a welding mould designed for a bigger area. In that case wrap on
a copper foil to the copper wire as a filling.
44
5. Thermic welding
Insert the conductors into the mould according to the applicable instruction (for each type of connection).
Damaged/cracked or worn-out moulds must not be used! Scrap them.
When a sealing tightening kit is used, it must only be applied in the outer edge of the conductor channel,
not inside the weld cavity.
Check that the right size of the welding metal container is chosen. Compare with the number of the weld
mould type plate.
Insert accompanying steel disc into the mould with the cone down. Pour the welding powder carefully into
the mould in order not to move the position of the steel disc.
Knock the ignition powder out - it is pressed together in the bottom of the container and spread it evenly
on top of the welding powder and on the mould lip at the cover opening. The latter in order to facilitate the
ignition.
Check that the mould is correctly closed around the conductors and standing in vertical position
before ignition.
Close the mould cover and fire the ignition powder with a flint gun or other means without risk for burning
injuries.
When fire use protective gloves and goggles. Dont stand in front of the cover opening.
When welding in narrow compartments or where it is an obvious risk that the mould will be affected by wet
and damp conditions it is recommended that firing is made through a firing tape. Cut an approx. 10 cm long
firing tape and insert it into the mould in such a way that the cover will keep it in position.
After welding, wait until the melted metal is solidified before opening the mould as described under item 3.
Should the melted metal have been leaking out in spite of the fact that sealing kits have been used
the mould is probably worn out and should be scraped.
Note! Material flown out from the mould means decreased mould quality.
Should the welding for some reason have been unsuccessful, it is recommended that the branched-off
wire is cut and a new weld is made beside. Alternatively, the bad connection may be shunted according to
the figure below:
Fig. 23
45
Joint Type: TA
Fig.24
46
Joint Type: XA
Fig.25
47
Joint Type: XB
Fig.26
48
1)
2)
3)
4)
5)
6)
Joint Type: GR
Fig.27
49
Joint Type: GT
Fig.28
50
SITEMAN 12 - 94
Cables
1WAT 910033-12
Edition May 1996
51
List of Contents
1.
General .............................................................................................. 53
1.1 Classification of cables ...................................................................... 53
1.2 Stretch force ....................................................................................... 53
1.3 Temperature ....................................................................................... 53
1.4 Bending radius ................................................................................... 53
1.5 Distance between cable planes ......................................................... 53
1.6 Interrelations and location of different classes of cables .................... 54
1.7 Distance between cables and rated data ........................................... 54
1.8 Cable drums ....................................................................................... 54
1.9 Handling of cable drums at site .......................................................... 54
1.10 Rotation of cable drums ..................................................................... 55
1.11 Braking of cable drums ...................................................................... 55
2.
Method of laying .............................................................................. 56
2.1 Laying by hand ................................................................................... 56
2.2 Laying by motor-driven equipment, general ....................................... 57
2.3 Crossing of roads ............................................................................... 58
2.4 Laying cables indoors ........................................................................ 58
2.5 Cable channel .................................................................................... 58
2.6 Cable ladder ....................................................................................... 60
2.7 Section trays ...................................................................................... 61
2.8 Conduits ............................................................................................. 62
2.9 Cable table ......................................................................................... 63
3.
Fixing of cables ................................................................................ 64
3.1 Supporting bar ................................................................................... 64
3.2 Profiled bars ....................................................................................... 65
3.3 Suspension wire ................................................................................. 66
3.4 Free suspension ................................................................................ 67
3.5 Clamps for cables and conduits ......................................................... 68
3.6 Clips and cable straps ........................................................................ 68
3.7 Cable straps ....................................................................................... 69
3.8 Lashing wire ....................................................................................... 70
3.9 Expansion bolts and plugs ................................................................. 70
4.
Marking of cables ............................................................................. 71
4.1 Standard marking .............................................................................. 71
4.2 Cable marking .................................................................................... 71
4.3 Core marking ..................................................................................... 72
4.4 Cable numbers ................................................................................... 72
4.5 Core numbers .................................................................................... 72
4.6 Partex ................................................................................................. 72
4.7 Flexipart ............................................................................................. 73
4.8 Other standards ................................................................................. 73
4.9 Open type markers ............................................................................ 73
5.
Terminations ..................................................................................... 73
5.1 Length of cable ends .......................................................................... 73
5.2 Termination sheet .............................................................................. 74
6.
Sensitive cables ............................................................................... 75
7.
Fireproof cables ............................................................................... 76
000. Examples of typical installations ................................................... 77
52
1. General
This instruction describes standard method for laying and installation of cables. It does not cover cablelaying in special environments, such as in high temperature areas.
1.1 Classification of cables
The following ABB cable standard and classification shall be applied on each installation:
K0 POWER CABLES. LESS THAN 1000 V
K1 POWER CABLES. MORE THAN 1000 V
The high current in these cables may induce parasitic currents in screens and conductors of cables which
are laid in their vicinity. Well screened power cables can be laid in the same cable trench with other cables,
but control and measuring cables require a minimum distance fo 300 mm from any power cable.
K2 CONTROL and SIGNAL
The relay and signal cables shall be laid at least 300 mm from both power and measuring cables.
K3 CURRENT and VOLTAGE MEASURING
The cables shall be laid at least 300 mm from other types of cables.
K4 SENSITIVE MEASUREMENTS
These cables shall be laid in separated and completely screened channels of copper or galvanised steel
pipes.
K5 OPTICAL CABLES
These cables are not effected electrically by adjacent cables, however, these cables shall be considered as
high risk of mechanical damage and shall be treated accordingly. For more details please refer to
SITEMAN 13-94.
K6 PREFABRICATED CABLES
These are cables that carry control and communication signals between differenct control panels, mainly in
the same room. The cables have been prefabricated and tested with their intended end connection, the
cables therefore have to be installed as per the manufacturers instructions.
1.2 Stretch force
The maximum stretch force when laying cables shall not exceed:
copper conductors ..................................................... 70N/mm2 (7 kg/mm2)
aluminium conductors ................................................ 40N/mm2 (4 kg/mm2)
1.3 Temperature
If the ambient temperature is below 10 C the cable must be heated before laying. Otherwise it will be too
rigid to handle and the insulation could be damaged during bending.
Preheat the cable indoors at a minimum of 15 C for 24 hours. Temperature fluctucation results in length
variations in the cables and they must therefore be laid in gentle curves when the cables are long.
1.4 Bending radii
The bending radii of the cables shall not exceed the following:
Type of cable
For laying
When installed
Multi-core
Three-core
Single-core
PEX
Fibre optic cables
15 diameter
15 diameter
15 diameter
20 diameter
100 mm *)
10 diameter
10 diameter
10 diameter
15 diameter
200 mm *)
53
54
bles
ABB Ca
AB
B
Ca
ble
s
Fig. 3 Braking of drums. Please note: The arrow shows direction of rolling on the
ground, not pulling.
55
2. Methods of laying
Before installing any type of cable, the entire cable route shall be thoroughly inspected to ensure that there
are no obstacles or hazards that may cause damage to the cables that shall be installed. This inspection
shall be made regularly during the cable installation period.
The following methods may be employed for allying of cables:
Laying by hand
Laying by motor-driven equipment.
2.1 Laying by hand
Rollers placed at distances of 3 to 4 m will facilitate laying. Corner rollers or similar devices should be
provided where there are bends in the route, the minimum bending radii of the cables shall be maintained at
all times, see fig. 4 and 5.
The cables are to be carried by hand, if not supported by rollers, with the men standing 4 to 6 m apart along
the cable route.
Fig. 4 Laying
by hand by the
use of cable
rollers
Fig. 5 Corner
rollers
56
57
58
Fig. 9 Cable
channels outdoor
59
Fig. 13 Wrapping a
1-phase cable
At bends or where a cable leaves the cable ladder, the cable should be secured with plastic straps or
lashing wire. In the case of vertical assembly, the cable is aslo fixed to every second rung. Cable over
40 mm should however, be secured with brackets type KSV, if the vertical run is more than 10 m.
A maximum of five cables may be located under the same attachment device.
In most cases the cable ladder offers the best solution when building cable ways. In case of great
mechanical load, high short-circuiting currents and high ambient temperature cable ladders are particularly
suitable due to their great mechanical strength and good cooling properties.
60
61
2.8 Conduits
Conduits are protective pipes which may be of plastic or metal, rigid or flexible.
The conduits have to be secured to structures, machinery, building or equivalent.
In harsh environments when the cable sheath gives insufficient protection, conduits should be used to
protect the cable. Steel pipes also offer an excellent protection against electrical disturbances.
Flexible conduits may be used to mechanically protect flexible cables connecting electrical units.
62
63
The bar should be mounted on the concrete with screws and plastic plugs or nailplug.
When it is mounted on steel, self-tapping screws or standard screws can be used. The bar may even be
tack-welded.
The bar is used for supporting a small number of cables (15) running to separately placed units.
64
Normally the profiled bar is screwed permanently to walls or structures. A special bar is available for
embedment in concrete.
The distance between bars used to support cables should be approximately 500 mm. Cables may be
fixed with clamps or with cable straps together with a special support.
The cable clamps shall not be re-tightened, since this can cause cold floating damaging the cable
insulation.
65
Fig. 26 Illumination
assembly with suspension
wire. The cable is fastened
to the wire with plastic straps
66
67
68
Stainless steel
Plastic
Fig. 35
69
1.5 mm
1.5 mm
25 kp
25 kp
1.8 kg
1.8 kg
Fig. 37 Expander bolt type HILTI (hot dip galvanized) for cable racks, boxes etc.
70
4. Marking of Cables
There are a great variety of cable marking systems available on the market. ABB have choosen to work with
the two following suppliers:
Partex
Fleximark.
Each of these two systems is divided into two different marking systems:
Preprinted cable markings
Computerized cable markings
These markings are produced by the use of computerized printer. The technical data are taken directly from
the cable and core lists.
4.1 Standard marking
All cables shall be provided with durable markers at both ends.
Each cable shall be marked with cable number
Each core shall be marked with: Core number and Cable number.
Fig. 41 Marking of a cable and consisting of 3 cores and protective earth conductor
4.2 Cable marking
Yellow markings with black characters shall be used.
Fig. 43 Holder for cable markings type Partex, which are used when extra many characters are required
71
Fig. 44
4.4 Cable numbers
The marking sleeves are to be fixed on the steath of the cable close to the stripped end, see fig. 45. When
cables are terminated in a connection box, the markings are to be fixed to the cables outside the box. The
markers are threaded onto a plastic strap, which is fastened around the cable (fig. 42).
4.5 Core numbers
The markings are to be placed near to the points of connections.
The cable core marking should state in the following order from the left to the right or from bottom to the
top:
Core number
Cable number
See fig. 45.
4.6 Partex
Please contact Partex Fabriksaktiebolag for further information.
Address:
Box 80
S-547 02 Gullspng, SWEDEN
Telephone +46-551-20560
Fig. 45
72
4.7 Flexipart
Please contact Miltronic AB for further information.
Address:
Box 1022
S-611 29 Nykping, SWEDEN
Telephone +46-155-87000
4.8 Other standards
Outside Sweden various customers may require special marking system. The design office will then
coordinate the material needed and issue the necessary installation instructions.
4.9 Open type markers
Partex can also deliver an open marker, with which already terminated wires can be marked. See fig. 46.
Fig. 46
5. Terminations
5.1 Length of cable ends
It is of utmost importance that both cable ends are measured to the correct length before cutting the cable.
Enough is sufficient.
73
See fig. 48 Termination details for cable Nr 94106 at destination point +ETA 1
74
See fig. 49 Termination details for cable Nr 94106 at destination point =AL-AK. A21.
6. Sensitive Cables
Cables that are designed to provide a high level of interference immunity are considered to be sensitive
cables.
The most common interfaces are;
low frequency magnetic fields (from large currents in power cables)
electrical radiation (overvoltages caused by short circuit in power cables)
cross talk between cores/cores and between twisted pairs/twisted pairs.
These cables can be constructed as follows;
twisted pairs
screen of aluminium foil
screened by steel, aluminium or copper tape
screened by copper wire braid (90 %)
individual screened pairs
By combining different kinds of screens one can achieve a desired protection level.
Sensitive signals;
analog signals (010V)
digital signals
thyristor firing pulses
75
7. Fireproof Cables
The fire behaviour of cables is assessed and classified in terms of:
Flame propagation
flame protected cables
Smoke generation
low smoke cables
Function during a fire fire resistant cables
When cables are buried in the ground, fire behaviour has no significance.
Where cables are terminated indoors, there is a need for flame protection.
Where cables are laid openly indoors, flame protected cables must be used.
Flame protected cables
Resulting from test as recommended in IEC 332-1. Cat. A, B, C. (Tests on electrical cables under fire
conditions). Cables are classified as follows;
Cable propagates flame, this type of cable shall only be used in buried installations.
Self extinguisher after ignition with a small flame
Difficult to ignite and low flame propagation
Very difficult to ignite and very low flame propagation.
76
= Standard
= Not recommended
KSVbracket
Installation
bracket
Plastic
straps
Lash
wire
Method of laying
Stainless
steel
straps
Clamp
bracket
No means
of
securing
Laying in
Cable channel
Laying in
Cable duct
Laying on
Cable ladder
Section rails/trays
installation
Conduits
Supporting
bar
Profile bar
Installation
Suspension line
Installation
Free
Suspension
Bracket
Installation
) Cable strap support must be used, see page 29, Fig. 49.
77
Anchor
rail
Ladder
Cable channel
CONTROL ROOM
Ladder
Cable channel
Section beam
Strip iron
TERMINAL BOX
Section beam
Direct
laying
Conduit
Motors /
apparatus
78
Motors /
apparatus
Strip iron
Motors /
apparatus
Motors /
apparatus
79
80
81
82
83
84
85
86
SITEMAN 14 - 94
1WAT 910033-14
Edition January 1994
87
List of contents
1.
General .............................................................................................. 89
2.
Laying of high voltage cables <80 kV ............................................ 89
2.1 Cable drums ....................................................................................... 89
2.2 Handling of cable drums at site .......................................................... 89
2.3 Rotation of cable drums ..................................................................... 90
2.4 Braking of cable drums ...................................................................... 90
3.
Methods of laying ............................................................................ 91
3.1 General rules when laying of cables .................................................. 91
3.1.1 Stretch force ....................................................................................... 91
3.1.2 Bending radius ................................................................................... 91
3.1.3 Distance between cable planes ......................................................... 91
3.1.4 Interrelations and location of different classes of cables .................... 91
3.1.5 Distance between cables at rated data .............................................. 91
3.1.6 Cable table ......................................................................................... 92
3.1.7 Cable laying card ............................................................................... 92
3.2 Laying from a trailer ........................................................................... 92
3.3 Laying by hand ................................................................................... 92
3.4 Laying by motor-driven equipment, general ....................................... 94
3.4.1 Laying by motor-driven rollers ............................................................ 95
3.4.2 Laying by winches and cable pushers ............................................... 96
3.5 Laying in ground ................................................................................ 99
3.6 Crossing of roads ............................................................................... 99
3.7 Laying indoors .................................................................................... 99
3.8 Temporary marking ............................................................................ 99
3.9 Length of cable ends ........................................................................ 100
4.
Description of cable ways ............................................................. 100
4.1 Cable channel .................................................................................. 100
4.2 Cable duct ........................................................................................ 101
4.3 Cable ladder .....................................................................................103
4.4 Section rails/trays ............................................................................. 106
5.
Termination and jointing of high voltage cables <80 kV ............ 107
5.1 Termination and jointing ...................................................................107
5.2 Crimping of conductors .................................................................... 107
5.2.1 General ............................................................................................107
5.2.2 Points to bear in mind when crimping .............................................. 107
5.2.3 Cu-terminals .................................................................................... 108
5.2.4 Al and Al/Cu-terminals ..................................................................... 109
5.2.5 Marking of terminals ........................................................................ 110
5.2.6 Dimension checking .........................................................................111
5.3 Tools ................................................................................................. 112
88
1. General
The intention with this document is to give site personnel a guide-line regarding methods when handling
and laying of high voltage cables from 1 kV up to 80 kV.
Regarding termination and jointing it is impossible to give universal information because it is a difference
between the different suppliers. Consequently, it is of utmost importance to follow the manufacturers
instruction when terminating and jointing of high voltage cables
89
90
3 Methods of laying
It is of utmost importance to follow instructions regarding bending radius, ambient temperature, stretch
force, etc. given by the manufacturer when laying of power cables.
The following methods and recommendations may be a guide-line for laying of high voltage cables.
3.1 General rules when laying of cable
3.1.1 Stretch force
In general, the maximum stretch force when laying cable may be:
with copper cables 5 Kp/mm2 (50 N) lead area
with aluminium cables 3 Kp/mm2 (30 N) lead area
3.1.2 Temperature
If the ambient temperature is below 10 C the cable must be heated before laying. Otherwise it will be too
stiff to handle and the insulation could be damaged during bending.
Preheat the cable in a store at a minimum of 15 C for 24 hours.
Temperature fluctuation result in length variations in the cables and they must therefore be laid in gentle
curves if the cables are long.
3.1.3 Bending radius
The bending radius of the cable shall be minimum:
Type of cable
For laying
When installed
Three-core
Single-core
PEX
15 diameter
15 diameter
20 diameter
10 diameter
10 diameter
15 diameter
91
92
93
If obstacles in the trench prevent laying of the second half of the cable, it should be laid out in a configuration of 8 on the side of the drum towards direction A. It should be noted that the cable can only be
pulled off again in the direction from which it was first looped.
94
95
1.
23
4.
Accessories:
1 pc
1 pc
50 pcs
12 pcs
Cable stocking
Roller for pulling cables in pipes
Cable rollers
Corner rollers
96
Fig. 14
Cable winch.
Fig. 16 Cable
stocking.
97
98
Fig. 24 Mark with cable No. and with cubicle, box No. etc.
99
100
101
102
Fig. 31 Wrapping a
1-phase cable.
103
104
105
Fig. 35 Cable
protection.
106
A, mm
49
87
124
162
236
311
461
Fig. 37 Tray.
107
Markings
In order to avoid mistakes, both tools and terminations must carry unique and permanent markings,
which must also appear on the packaging. On crimping, the identification mark of the tool must be
impressed automatically on the termination.
Dimension checking
The quality of the crimped connection and the condition (wear) of the crimping tool is checked by
measuring the dimensions of the termnation at the completed crimp.
A supplier of terminations and crimping tools should be able to provide details of nominal dimensions and
tolerances for the terminations before and after crimping, and to supply special measuring equipment for
this, where needed.
Cu-terminations
Take great care not to damage any of the strands when stripping the copper cable.
Strip about 5 mm more of the insulation than the depth of the barrel of the cable lug or splice (i.e. up to
the inspection hole or cable stop).
Check carefully that the type number of the die corresponds to the marking of the cable lug or splice.
Normally one crimp is needed up to 400 mm2. For round compressed conductors 185 mm2 and above,
two adjacent crimps are needed.
Al-terminations
Take great care not to damage any of the strands when stripping the aluminium cable.
The stripped length must be 5 mm more than the depth of the socket in the termination.
Circular performing with the appropriate tool may be necessary if stranded or sector-shaped cable is
used.
Two crimps with a punch are always made in the aluminium termination barrel.
The barrel of the aluminium terminations is serrated internally and protected against corrosion by a thin
layer of vaseline.
No preparation such as cleaning or application of compound is needed. There is no need to wire-brush
the stripped cable end.
5.2.3 Cu-terminals
Copper type terminals type KR/KRF:
Used mainly to terminate cables at copper busbars and equipment terminals.
The same terminal is used for both flexible and stranded or sector-shaped
conductors.
Spliced type KS/KSF:
Used primarily to splice copper conductors in underground cable systems.
The same splice is used for both flexible and stranded or sector-shaped
conductors. These splices can also be used for straight jointing of earthing lines.
108
Aluminium/Copper Terminals:
The Al/Cu terminals are manufactured by friction-welding the two component parts together, a method in
which the aluminium and copper are bonded together by the heat produced as one metal rotates against
the other under pressure. The result is a totally hermetic joint, immune to corrosion and galvanic action
even under outdoor conditions.
109
Cu conductor
Area in mm2
Bolt size mm
Type No. of
hexagonal die
Cu conductor
120150 mm2
Cu conductor
7095 mm2
Die identification
number
Max. diameter
of conductors
Aluminium terminals
Stranded Al
conductor
in mm2
110
Solid Al
conductor
in mm2
Bolt size
M12
Measuring points
Al conductor, mm2
Stranded
Solid
D = 52
D = 52
Tool
Matrix
Punch
T
mm
16
25
35
25
35
50
P13M
P13M
P20M
P13D
P13D
P20D
6.8
6.8
10.8
50
70
95
70
95
120
P20M
P20M
P25M
P20D
P20D
P25D
10.8
10.8
13.5
120
150
185
150
185
240
P25M
P25M
P32M
P25D
P25D
P32D
13.5
13.5
18.4
P32M
P36M
P40M
P40M
P52M
P52M
P32D
P36D
P40D
P40D
P52D
P52D
18.4
21.0
22.8
22.8
31.0
31.0
240
300
400
500
500 A
630 A
Copper terminals:
The dimension N is checked on the hexagon faces that have the impression of the dies. Measure with a
calliper on one or both sides of the impression.
Types KR and KS
Area mm2
N mm
10
16
25
6.4
7.6
8.8
35
50
70
10.3
12.1
13.9
95
120
150
16.5
16.3
20.3
185
240
300
400
20.6
23.4
24.6
27.4
Measurement surfaces
111
C-sleeves
For C-sleeves, the dimension h is checked, preferably with a calliper, on maximum height of the crimped
oval.
C-sleeve
h max. mm
C4
C5
C6
10.6
13.7
15.8
22.0
23.2
27.0
34.5
38.5
5.3 Tools
In order to guarantee a good quality of cable work it is important to follow the general information or guidelines from the actual supplier.
It is also very important to point out that some tools must be checked periodically. Regarding tools for
crimped connections, the tools must be checked periodically according to ABB Quality System Guide-lines
chapters No. 4.11 and 4.12 respectively.
Note: It is the responsibility of the user to ensure this is done.
Regarding tools for crimping connectors, see ABB Corporate Standard book C8.
112
SITEMAN 16 - 94
1WAT 910033-16
Edition January 1994
Cubicles in
electrical rooms
Touch-up painting
113
List of contents
A.
1.
2.
2.1
2.2
2.3
2.4
2.5
2.6
3.
3.1
3.2
3.3
3.4
4.
4.1
4.2
4.3
4.4
B.
5.
5.1
5.2
5.3
5.4
5.5
5.6
5.7
5.8
5.9
5.10
5.11
5.12
6.
6.1
6.2
6.3
Touch-up painting........................................................................... 17
General ............................................................................................ 17
Definitions ......................................................................................... 17
Cleaning prior to grinding .................................................................. 17
Grinding of damaged surfaces .......................................................... 18
Application of filler ............................................................................. 18
Grinding after stopping up ................................................................ 18
Primer coating ................................................................................... 18
Cleaning and masking prior areosol spray painting .......................... 18
Finishing coat .................................................................................... 19
Finishing coating with areosol paint .................................................. 19
Finishing coating brush painting .................................................... 19
Choice of fillers and paints ................................................................ 19
Tools, accessories, etc. .................................................................... 19
Touch-up painting of galvanized steel with zinc-rich paint ........ 20
General ............................................................................................. 20
Work steps general ........................................................................ 20
Choice of galvanopaste .................................................................... 20
114
115
2.2 Unloading
Handle the cubicle carefully when unloading or moving them.
The easiest way to unload from a truck is to use a forklift truck. Note that the forklift
must be equipped with wheels big enough to make the handling of cases safe and
steady. The roads at site are often of poor quality during the erection period.
If possible, unload and transport the cubicles directly to their final position in their
packings, see figure 2.
Fig. 2
To unload the cubicle from the pallet, move it forward or backwards on the pallet until the
cubicle can be tilted. While holding the cubicle in a tilted position, pull away the pallet and
set the cubicle down on the floor carefully, see figure 3.
Fig. 3
Fig. 4
2.3 Checking
Check the consignment against the accompanying packing list to ensure that the correct
items have been delivered. Any complaints are to be remitted as soon as possible to ABB
in order to avoid delay in the installation work. Do not forget to make a check-up on
separately packed apparatus.
116
Fig. 5
117
2.5 Storage
Sometimes the cubicles, due to various reasons, cannot be installed immediately upon
their arrival to site, but have to be stored.
The cubicles delivered on transport pallets covered with plastic wrapping are to be
stored in clean, dry and dust-free premises. When the cubicles are equipped with heating
elements, these should be temporarily connected during storage in order to avoid
corrosion.
The cubicles delivered in wooden cases with sealed air tight plastic bags and moisture
absorbing material should be stored indoor or under cover. Do not open these cases if
they are stored oudoor. The check of the content should then be carried out when the
cubicles are installed.
Always use timber to space the cases from the ground.
The equipment may be stored for a couple of months in unopened cases. If longer
storing periods should occur, the manufacturer should be contacted for advice.
2.6 Temporary marking
Temporary marking of the cubicles can be necessary sometimes. Be careful when using
labels or tapes on painted surfaces. A special marking tape can be ordered from your
ABB-supplier.
3. Control
3.1 Access roads It is always very important to check the transport ways in order to
ensure that no obstacles can cause hinderance. The following check points can act as a
guide:
Can the road be used by our transport vehicle?
Are there any electrical wires or pipes crossing the road?
Is it necessary to build temporary unloading platforms?
Are door openings large enough?
Hoisting wells?
Staircases?
3.2 Floors
The cubicles are designed to be erected on an even and thoroughly levelled base to
enable the interjoining of cubicles without any extra measures. See figure 6.
Experience proves that above tolerances are hard to obtain. ABB therefore recommend
that steel profiles are embedded in the concrete in a manner as shown in figures 7 and 8.
The civil work drawings have to show in detail the foundation design for all cubicles and
to specify the tolerances required for each project.
If the floor is not in level, it will be difficult to open and close the doors. Cubicles with
drawable circuit breaker may be more sensitive. Here the contact function between
breaker and the fixed contact can be jeopardized.
Check that the floor is even and in level, and that iron profiles are correctly embedded
as stated in the civil drawings. Holes for cable entries in the floor have to be carefully
checked regarding size and location.
118
Description
Measured
length (m)
Allowed
deviation (mm)
Class 2
Warpage
2.0
4.0
L
3
5
E
Declivity
119
Fig. 9
120
1) Note that the loose floor slabs under the cubicles have to be secured
to the beams as well as the cubicles.
Fig. 10 Fastening of cubicles to suspended floors.
121
122
123
124
Above
There must be at least 150 mm free space above
the cubicle. Where cables run in from above, the
distance also depends on the cable type and the
way in which it is laid.
Against walls
The minimum distance between the rear of the
cubicle and the wall behind, as well as between the
end panels and wall at the side, should be at least
40 mm.
Cubicles with handles in the doors should have at
least 150 mm between the left end panel and the
wall to allow the doors to open more than 90.
125
126
B. Touch- up painting
5. General
This document is a guide-line for touch-up painting of products delivered to sites. It is
based on ABB:s quality requirements of today and the painting methods used by the
manufacturers.
In ABB we have both normal wet painted products and powder painted products. Since
powder spraying cannot be used on site, a one-component, alkyd based paint system is
utilized for touch-up painting. As far as possible, however, touch-up painting should
achieve the same quality and finish as the original and adjacent surface.
Surfaces with no particular requirements regarding finish may be brush painted. In
more exacting cases repair painting should be done by arerosol spraying. Examples of
such surfaces are the outsides of control cabinets, desks, connection boxes, etc.
In cases where there are considerable damages, a local contractor, with suitable equipment, should be engaged. Do not forget to ask for a fixed price and check wether it
should be cheaper to order a spare part.
If touching up the paint yourself, do so in a room suitable for this, well ventilated and
free of dust.
Before applying the filler and painting, carefully straighten the damaged steel sheet so
that the layer of filler can be kept as thin as possible.
5.1 Definitions
Alkyd paint has a binding agent composed of an acid and alcohol (synthetic resin),
also called alkyd.
Two-component filler a filler containing hardener. The advantage of this type of filler is
that it is stronger and more elastic and hardens more rapidly than a one-component filler.
It does not crackle so readily, is easy to rub down and gives a good finish.
White spirit has various commercial names, e.g. petroleum spirits or mineral spirits. It
is the most common and least toxic medium for degreasing, diluting and cleaning.
Xylene or dimethylbenzene is an extremely flammable solvent, mainly used as a paint
diluent.
Diluent reducer a general term for white spirits, xylene, etc.
5.2 Cleaning prior to grinding
Both the damaged and the adjacent surfaces must be cleaned so that all grease, dust
and other dirt are removed. Otherwise impurities can be trapped in the abrasive paper
and rubbed into the surface.
Clean with an organic solvent such as xylene or white spirit, using a non-fluffing rag
dipped in the solvent.
5.3 Grinding of damaged surfaces
Large damaged areas, which are to be stopped up, should preferably be machine grinded
(drilling machine with a wire brush or rubbed disc or an oscillating grinder).
Damages which are limited to the paint should carefully be grinded so that no marks
are visual, thus avoiding the necessity of stopping. Start with a relatively coarse rubbing
paper No 100. Then rub the area around the damaged part with a finer paper, e.g. No.
150 or 180.
All grinding should be done so that the transition becomes less and less visible towards
the adjacent surface.
127
128
129
130
SITEMAN 18 - 94
Earthing
1WAT 910033-18
Edition January 1994
131
List of Contents
1.
1.1
1.2
1.3
2.
2.1
2.2
2.3
2.4
2.5
2.6
3.
4.
4.1
4.2
4.3
4.4
4.5
5.
132
1. General
n order to promote the understanding of earthing it is usual to divide the term under two general headings,
namely system earthing and protective earthing.
1.1 System earthing
Primarily systems earthing is considered as the permanent connection of a system or part of a system
which would normally be under tension to earth. Normally it is the system or part of the systems zero point
which is connected to earth, direct or via a neutral earthing equipment.
The fact that a point in the system is earthed, means that any part of system which is galvanically
connected is also earthed. A system earthing does not effect parts of the system which are magnetically
coupled, e.g. via a transformer to an earthed net.
In a power network there can be found several system earths e.g. each voltage level can have its own
earthing.
The primary reasons for bonding the network potential to earth are to protect people and equipment.
1.2 Protective earthing
The level of protection from high voltage for personnel that can be achieved by the selection of good
insulation and thoughtful plant design is inadequate. The require-ments of high current instructions are that
exposed details shall be protective earthed in a way that ensures complete safety.
An exposed detail is understood to be one which can be touched, accessed or is of a prominent nature,
but which under normal conditions is not under tension. However due to its material nature or coating could
under insulation failure conditions come under tension.
Examples of exposed details could be frames, covers and supports for machinery, transformer and
equipment, mountings for insulators and bushings, lead sheating, reinforcement bar, screening and termination boxes for cables, metal transformer housing, fencing and other such like plant details.
The purpose and requirement of protective earthing of exposed details is that during earth fault
conditions it will direct the flow of current to earth in such a manner that voltage that:
a) could be dangerous to personnel on the plant or for people in general are prevented
b) could create fire are prevented.
It is particularly important that the protective earthing is effective against the onset of fire when the exposed
details are flammable, particularly wood. Metal poles with stays should normally be earthed, whereas stayed wooden poles are generally not earthed. The necessary protection is achieved via the fact that the stays
are mounted sufficiently long from the insulator pins or they are fastened to the pole via a stay insulator.
1.3 Electrical hazard
An estimate of level of danger from an electrical hazard can not be achieved solely by evaluating the voltage the person will be exposed to, the magnitude and duration of the current the body could be exposed to
has great significance as well as the current path through the body.
The magnitude of the current flowing through a body is in part determined by the voltage and current
path resistance. The bodies resistance drops normally to some value under 5000 ohms with the onset of
perspiration. This obviously means that the risk for electrocution is proportionally greater in humid and wet
areas as opposed to dry areas.
Fig. 1 shows example of step and touch voltages in the vicinity of an earthing electrode in the overload
on-state during an earth fault.
Fig. 1
133
2. Earthing outdoor
2.1 Earth grid, earthing rods, pits etc.
The earth grid normally consists of some form of symmetrical grid net in order to achieve an even
dissipation of voltage across the net.
The number of squares in an earth network for a station which is to have a direct earthed high voltage
net should be in the order of 25, for a small station 16 squares should be sufficient. An increase in the
number of squares gives at best a marginal reduction in the station earth resistance.
Even a short vertically placed earth rod provides excellent earthing capability.
Fig. 2
134
Earthing pit
The earthing pits are usually composed of 14 earthing rods connected together via test link to the main
earth grid. The rods are copper clad steel rods of 12 meter length, which may be extended with other rods
by threaded joints.
The test links can be utilized for resistance measurement both of the earth grid and of the earthing pit.
Earthing pits can be added, if needed.
2.2 Steel structures
Gantry steelwork and high voltage equipment supports are earthed by connecting at least one of the legs
to the grid. Structures standing on more than one foundation have an earth connection at each foundation if
the earth fault current path through the steel is >10 m.
Fig. 5
135
Fig. 6
Fig. 7
Fig 8
Fig. 9
1) This wire is only included if required by the project specification. Normally the
overhead wire is terminated directly to the mast. To be installed if shown on the
erection drawings for the project.
2.5 Surge arresters
For overvoltage protection of high voltage equipment surge arresters are used.
Modern surge arresters have contributed towards better protection of transformer stations not to mention
substantial economic savings.
Connection of the surge arrester to the earth grid shall be as direct as possible.
WARNING! The surge arrester must never be separately earthed as it then may cancel the
protection of the transformer.
136
Fig. 10
Surge arresters can be designed with a counter that registers the number of times the arrester strikes. The
counter does not need to be mounted above touch height protection level. The recommended mounting
height is approximately 1.8 metres above ground level. The connection between the counter and the surge
arresters foot should be insulated for 3 kV (air insulated or cable). The cable shall have as a minimum a
25 square millimetre.
2.6 Fences
Fences of metallic material shall be earthed by connecting a number of the fence posts at about 50 m
intervals to the main earth grid. In some instances separate earthing of fences is specified.
If the substation belongs to a solidly earthed high voltage system, an earthing conductor shall be buried
about 0.3 0.5 m one metre outside the fence. All gate posts and earthed fence posts must be connected
to this conductor.
Fig 11
137
Fig 12
3. Earthing indoor
3.1 General
The basic objectives of an equipment-grounding system are the following:
To reduce the risk of electric shock to personnel.
To provide adequate current carrying capability, both in magnitude and duration, to accept the ground
fault current permitted by the overcurrent protection system without creating a fire or explosive hazard to
buildings or contents.
To provide a low impedance return path for ground fault current necessary for the timely operation of the
overcurrent protection system.
Wherever a grounding conductor crosses cable trenches, underground service ducts, pipes, tunnels,
railway tracks, etc., it shall be laid at least 300 mm below them and shall be rerouted around equipment /
structure foundations.
Grounding conductor around the building shall be buried in the ground at a minimum distance of
1500 mm from the outer boundary of the building. If high temperature is encountered at any location, the
grounding conductor shall be laid at least 1500 mm away from such location.
Grounding conductors embedded in concrete shall have approximately 50 mm concrete cover. If grounding conductor is required to be embedded in major foundations, then it shall be laid in a sleeve.
All steel columns and metallic stairs shall be connected to the nearest grounding conductor by two
grounding leads. Electrical continuity shall be ensured by bonding the different sections of hand-rails and
metallic stairs.
Metallic pipes, conduits and cable tray sections for cable installation shall be bonded to ensure electrical
continuity and connected to grounding conductor at not more than 10 m intervals. Apart from intermediate
connections, both ends shall also be connected to the grounding system.
Metal conduits and lattice structures shall not be used as ground continuity conductor.
A separated grounding conductor shall be provided for grounding lightning fixtures, receptacles, switches,
junction boxes, lightning conduits, etc.
Wherever grounding conductors cross or run along metallic structures such as gas, water or steam
conduit or pipes, steel reinforcement in concrete etc. it shall be bonded to the same.
138
139
140
141
142
Fig 20 HF Grounding.
143
144
Fig 23
145
146
147
148
4 Installation
4.1 Precautions and planning
The installation of the earth grid is one of the jobs which needs planning, not to come into conflict with the
other jobs, i.e. erection of steel structures, cable ducts, etc.
Too much excavation at the same time may make the area too rough for achieving an efficient workflow.
It is often convenient to excavate for laying the earth grid after erecting the steel structures and before
mounting insulators, busbars and other conductors.
4.2 Material
The earth grid is usually made of copper wires clamped, brazed or thermic-welded together. See fig. 3638.
The conductor for the earth grid should be supplied in sufficient lengths to minimize the number of joints.
Annealed copper wires are softer to handle than standard wire and therefore recommended.
4.3 Installation
The earth grid with its numerous connection must be installed with utmost care. The following points are
emphasized:
the grid is of vital importance for personal safety
the material is buried and not available for inspection and repair after installation
certain corrosion may take place
short-circuit and earth-fault currents usually increase with time which means increased stress on the
grid.
Also parts of the earth grid above ground must be made safe. Follow carefully the instructions given by
the design office for:
earthing of steel structure
earthing of towers (masts) with earth wires
earthing of apparatus and boxes
earthing switches
disconnecting earthing switches
maintenance earthing
transformer tanks
surge diverters and counters
cable screens
4.4 Tools
Brazing
Welding and heating equipment of right capacity. High quality of right grade of brazing material shall be
available. Ref. to Siteman 94-11.
Compression
Hydraulic compression tools of sufficient capacity fitting the actual compression clamps. Ref. to Siteman
94-12.
Thermic welding
Welding moulds. Disc-grinder. Ref. to Siteman 94-11.
Cleaning
A good selection of steel brushes, separate ones for each type of metal.
4.5 Temporary earthing
To carry out work in a switchyard in service or with the system outside in service it is not sufficient to open
and lock the disconnectors in question. To be safe the phase conductors must be effectively grounded on
the work-side.
Due to increasing earth-fault currents and higher demand on portable earthing equipment, the
introduction of fixed earthing switches is becoming more and more frequent. However, portable earthing is
still the most commonly used method. See Appendix 1.
149
150
Fig. 31
151
152
153
Fig. 38 Thermic-welding
154
Fig. 39
Earthing rods are used to reach deep earth levels where invariable low earth resistance can be obtained.
See diagram above.
155
Appendix 1
156
SITEMAN 20 - 94
1WAT 910033-20
Edition January 1994
Air insulated
switchgear
157
List of Contents
1.
General .......................................................................................... 159
1.1 Design characteristics ..................................................................... 159
1.2 The single-line diagram ................................................................... 159
1.3 Modifications, extensions .. ..............................................................160
1.4 Insulation ......................................................................................... 160
1.5 Pollution .......................................................................................... 160
2.
Civil Work ....................................................................................... 160
2.1 Drawings ......................................................................................... 160
2.2 Foundations .................................................................................... 160
3.
Heavy loads, such as transformers, reactors, etc ...................... 162
3.1 Transport, roads, access roads and surveys .................................. 162
4.
Insulators ....................................................................................... 162
4.1 Types of insulators .......................................................................... 162
4.2 Pollution .......................................................................................... 164
5.
Busbars and wires ........................................................................ 165
5.1 Types of busbars ............................................................................. 165
5.2 Materials ......................................................................................... 165
5.3 Rigid and flexible conductors .......................................................... 166
5.4 Mechanical strength ........................................................................ 166
5.5 Corona ............................................................................................167
6.
Clamps ........................................................................................... 167
6.1 Types of clamps .............................................................................. 167
6.2 Design ............................................................................................. 169
6.3 Material ........................................................................................... 170
7.
Erection .......................................................................................... 170
7.1 Access and work start ..................................................................... 170
7.2 Steel structure ................................................................................. 170
7.3 Outdoor earthing ............................................................................. 172
7.4 Insulators ........................................................................................ 172
7.5 Busbars and wires .......................................................................... 173
7.6 Clamps ............................................................................................176
7.7 High voltage apparatus ................................................................... 179
8.
Inspection, quality control ........................................................... 181
9.
Testing and commissioning ......................................................... 181
Appendices 1 2 ............................................................................ 182183
158
1. General
This document will, in principle, be a guideline for the installation of Air Insulated Switchgear and shall be
followed if no other information is given on the drawings.
1.1 Design characteristics
When projecting a switchyard the main points to consider are:
System security
Future extensions
Costs
Flexibility of operation
Maintenance
Environment
Available space
There are two major types of high voltage switchyards:
Line switching stations
Transformer stations
When designing steel structures and foundations, the stress calculations are based on the maximum force
which any part of the equipment can be expected to withstand in its lifetime.
The mechanical forces acting on the electrical equipment and supporting structures are:
Dead weight
Normal loads from conductors
Ice load
Wind load
Short-circuit forces
Mechanical operation forces
Earthquake forces
When designing the busbar the following main factors have to be considered:
Maximum load current
Maximum withstand impulse voltage
Mechanical strength to withstand dynamic forces
Atmospheric contamination
1.2 The single-line diagram
The design of an outdoor substation is
based on the single-line diagram. This
diagram should show the connection
arrangements of all electrical equipment,
i.e. busbars, overhead lines, power
cables, connection points, power transformers, high voltage apparatuses, AC/
DC converters, reactive power
compensation equipment etc.
When designing the single-line diagram
the bus switching arrangements and the
degree of service flexibility and reliability
must be considered.
The most frequent bus arrangements
are shown in Appendix 1.
159
2. Civil Work
2.1 Drawings
For outdoor switchyards the civil engineering design represents a large portion of the total design work.
Drawing for levelling of the ground, dimensioning of the foundations, layout of cable ducts etc., have to be
produced.
The foundation drawings from an ABB design office shall show the foundation tops on which towers,
apparatus structures etc. shall be fixed.
2.2 Foundations
It is important that our site construction manager works in close cooperation with the site civil contractor in
order to guarantee a successful foundation work.
Normally the foundation bolts are embedded in the foundations from the begin-ning.
However, pockets are sometimes left in the foundations and the bolts are casted in under our supervision.
Note that approved expansion concrete must be used.
Templates
Templates are used for fixing the foundation bolts. For small foundations up to 0.5 0.5 m and in large
quantities, steel templates as shown in fig. 2 are suitable.
Fig. 2.
For larger foundations steel templates will be too heavy. A suitable material, which is usually easily
obtainable, is plywood (1/2 to 3/4 thick). The plywood template design can be similar to that of the steel
version. For really large foundations, the wooden template may be split into two parts as shown in fig. 3.
Fig. 3
160
Checking
It is often the responsibility of ABB, as the switchgear contractor, to check the location and the allignment of
the foundation bolts, independently of who has done the civil works. When measuring the distance between
bolts within large foundation, a long steel tape-measure may be used. The same method can also be used
for measuring between foundations when distances are not too long.
A levelling instrument is required for levelling of the foundations. A transparent plastic hose filled with
water or a spirit-level can also be used for shorter distances.
The client shall allocate a bench mark, i.e. a fix point to which all our measurements shall refer, when
checking the foundations.
Note that all concrete has to cure 23 weeks before load can be applied.
Special care is to be taken to check that the foundation bolts are reliably fixed at the bottom end so that
they will not move during the filling and vibration of the con-crete.
The bolts shall be available 23 weeks before they are embedded in the foundations.
No erection shall be carried out on the foundation before a letter of access is issued by the civil
contractor.
All alterations regarding the foundations must be entered into the drawings in red and sent to the design
office for updating.
Check for thread damage and that sufficent threads are over the top of the foundation.
Grouting (option)
After the steel structures have been erected, the distance between the steel and the concrete may be filled
up with concrete (=grouting).
Fig. 5
Foundations and
cable ducts
161
4. Insulators
4.1 Types of insulators
Insulators in outdoor switchyards are used for supporting conductors and for providing insulation between
phases and to earth. Sheds on the insulators provide the necessary creepage distance.
Insulators used are basically of two types:
support insulators for static arrangements
chain insulators for flexible buswires.
In addition to electrical requirements insulators must withstand the mechanical forces caused by short
circuit and earthquakes. This is especially important for support insulators.
Also environmental conditions, such as pollution and salt have to be considered.
Support insulators
There are two types of support insulators, solid core and pin and cap.
For the lower voltage range the support insulators are made as one unit. For higher voltage ranges,
however, the insulators (insulator stacks) are made up of several units bolted together.
Chain Insulators
The strings are composed of insulator elements with non-rigid connecting details.
Fig. 8
Fig. 9
Insulator strings are used as tension and suspension insulators for overhead wires.
162
Tension strings
Fig. 11 V-string
In order to protect the insulators against damage due to flash-over the insulator string is fitted with arcing
horns or rings.
Connecting fittings must be able to carry the rated short time current without serious damage. When the
short-circuit current is higher than the fittings can withstand, these must be by-passed by flexible conductors
dimensioned for the rated value.
Insulator strings in outdoor switchyards are used for stringing flexible conductors between gantries.
Single, duplicate or even triplicate strings may be used depending on conductor tensions etc.
An assembly with more than two insulator strings must satisfy the following conditions:
Equal tension sharing between insulator strings.
If one of the insulator strings is broken the remaining ones must be undamaged.
Tension clamps of either bolted or compression type hold the wire to the insulator. A turnbuckle is also
provided for adjusting the sag.
163
164
165
166
Vibrations
A special problem with tubular conductors is their sensitivity to vibrations. Vibrations often occur at moderate wind velocities, when the wind initiates a frequency which coincides with the systems own frequency,
perhaps only 13 Hz.
Vibrations could possibly cause the following defects:
Fatigue failure of the busbar
Fatigue (or impact) failure of the end fixings
Incorrect functioning of pantograph isolators
Damage to support insulators
Therefore the following methods for damping of tubular conductors are used.
Loose wire inside the tube
Clamps with damping effects
Auxiliary mass dampers.
5.5 Corona
On extremely high voltage installations corona rings and large radius bends are used and care is taken to
achieve a low value of electric stress on the conductor surface.
6. Clamps
6.1 Types of clamps
There are principally two types of clamps
Mechanical pressure
compressed
bolted
Welded
The mechanical pressure clamps (compressed or bolted) are the most commonly used in outdoor
switchyards designed by ABB. Of the two types the bolted design is almost exclusively used for connection
above ground.
Fig. 20
167
Bolted clamps
There are fundamentally four different groups of bolted clamps depending on the principle of connection to
the conductor i.e.:
Fixed clamps
See fig. 21
Sliding clamps
See fig. 22
Flexible clamps
See fig. 23
Support clamps
(as conductor support only) See fig. 22
168
Welded methods
The welding seam must be protected by an inert shielding gas flow such as argon (MIG or TIG-welding).
Fig. 26
Weld type straight coupler. Chamfered ends for easy insertion. Center
stop for accurate centering of coupler.
Fig. 27
Streamlined, weld type T-connector.
Tap element socket deep enough to
allow for error in cut-off
We have only mentioned the welding methods here. In case it will be applied, see SITEMAN 08-94 (Welding
rules) and SITEMAN 17-94 (Aluminium welding).
Compression clamps
The use of compression clamps is most common when connecting the earth wires both under and above
ground.
For more details see SITEMAN 12-94. However, other frequent methods are brazing using bronz-alloy and
thermic welding process described in SITEMAN 11-94.
When rectangular earth bars are used they are mostly brazed together.
6.2 Design
Electrical connections must be made so that maintenance never will be required. This is indeed a stringent
requirement.
Clamps used for connection of conductors in outdoor switchyards must be designed and dimensioned to
guarantee uninterrupted current supply and also not yield to mechanical forces between conductors due to
short-circuit or other severe stresses.
Contact resistance
One extremely important characteristic is the contact resistance which is responsible for the temperature
rise and which must be kept as low as possible. The resistance must not increase significantly during the
switchyards lifetime.
Some important design characteristics are:
compression bolts placed as close as possible to the conductor
compression bolts placed opposite to one another
bolts must exert the required pressure
the cast section must have sufficiently large cross
section to be able to conduct the rated current.
Fig. 29
169
Fig. 30
6.3 Material
Clamps for copper conductors
Connection clamps for copper conductors are manufactured exclusively of copper or of corrosion resistant
bronze. Bronze is the more common material. Brass must not be used due to risk of stress corrosion.
Copper and bronze connectings cause less problems than the aluminium ones, since the oxides are more
easily removed.
Clamps for aluminium conductors
Connection clamps for aluminium conductors are manufactured of corrosion resistant copper-free aluminium alloy.
The corrosion resistance of aluminium depends to a large extent on the difficulty to reduce oxides which
develop on its surface. These oxides are electrically insulating and must therefore be removed as effectively
as possible from the contact surfaces.
Bolts
Generally, three types of material are used.
high alloyed, high strength aluminium (sensitive to corrosion). Used by EDF, France
hot dipped galvanized steel. Used in Germany
high alloyed Swedish stainless steel (expensive). Used by the Swedish State Power Board.
7. Erection
7.1 Access and work start
When a co-contractor is responsible for the civil work the engineer in charge (customer or representative)
shall grant access to site in writing and in due time.
If allowed by the time schedule, the erection of high-voltage apparatuses shall not commence until the
erection material such as steelwork, support and string insulators, conductors etc., have been erected and
the ground refilled and levelled. This applies also to the concrete cable ducts, which shall be ready at the
same time.
7.2 Steel structures
High towers
In order to facilitate more than one team to work with steel structures, it is recommended to start with the
towers. If the crane does not have sufficient height lifting capacity, the tower may be erected in two parts.
The lower part is hoisted with a crane. The upper part is then erected manually, piece by piece, as
illustrated in fig. 31. It is not necessary to fasten the hook of the crane at the top of the tower. If it is fastened
above the center of gravity, it is safe enough.
170
When the crane has insufficient height lifting capacity, the upper parts can be erected piece by piece.
Fig. 31.
Tightening of bolts
When the towers, the cross-beams or apparatus structures are assembled, the bolts must not be
completely tightened. The final tightening shall be done after adjustment in straight position.
Adjustment
The adjustment to straight position is most conveniently controlled with a teodolite. The measurements are
taken from two directions at 90 angle as shown in figure 32. The levelling could be done by shims or
levelling nuts. If levelling nuts are used grouting may be required.
Fig. 32
For security reasons should the towers be grounded immediatly after erected.
171
Fig. 33
Cross beams
Cross beams are to be erected on the ground and hoisted up by means of a derrick or, more convenient, a
mobile crane.
Apparatus structures
Before the erection of Apparatus structures the Overhead lines and the Overhead ligtning protection wires
should be installed for security reasons and the convenience of having more space. The erection of
Apparatus structures will usually not involve any lifting problems.
7.3 Outdoor earthing
For the erection of the outdoor earthing refer to SITEMAN 18-94.
7.4 Insulators
Handling, checking and storing
Of all the components going into the material handling process of a project the insulators are the most
easily damaged. Only in case of minor damages on the surface there is a chance of acceptance. The
design office must be contacted for further instructions.
Furthermore insulators are expensive items and they are also expensive to air freight due to their heavy
weight. This called for keen precautions and care during the whole handling process.
When ordering it is always advisable to include some spare insulators of each type (up to 5 %).
Checking must be done immediately upon arrival, especially if the packing is damaged or there is the
slightest suspicion of careless handling.
Installation
Assembly
Arrange a protected and controllable assembly area in the switchyard.
Assemble all the components, insulator elements and fittings, to composite units at ground level.
Fit the insulator assembly into place.
Follow a sequential plan which will give good control.
Tighten the bolts to right torque.
A torque wrench is recommended, manual or electric.
Use tools with care not to knock off porcelain chips.
172
Lifting
Most insulators are erected at high levels. The lowest part of a support insulator is normally 2.5 metres
above ground. Suspension insulators may be more than 10 metres above ground and of considerable
weight.
If possible, a mobile crane with suitable soft slings should be used.
Some maintenance questions
During maintenance work including transport in the switchyard care shall be taken to protect the insulators.
Switchyard steelwork may have to be painted or re-painted after some years. If sand blasting of the
steelwork is proposed as part of the painting process, it should generally be refused due to the
extraordinary difficulties in protecting insulator surfaces. For minor repair of scratches galvanization may be
used.
Tools
The tools requirement is modest, except for the lifting devices. Good soft slinging devices and a torque
wrench are needed.
7.5 Busbars and Wires
Handling, checking and storing
Conductor material, such as wire drums and tubes, will usually be stored outdoor because of size and
weight. It is important that they do not come into contact with earth and sand which may jeopardize contact
properties and increase corona in case of surface scratches.
Furthermore, it may be necessary to build wooden platforms or similar to keep the material above water
level. This is perhaps also the best protection against earth and sand influences as above.
Usual checking and handling routines shall apply.
Installation
After erection of steel structures and insulators follow the installation of conductors, which must be done
with care not to damage the insulator.
It is important that the material is kept clean. Parts to be connected together by means of clamps shall be
subject to the same careful cleaning and protection as described for the clamps. See Clause 7.6.
WARNING! Never use the same steelbrush for copper and aluminium as it will accelerate corrosion.
Wire busbars
Stringing of wires must be done according to the sag and tension chart.
Great care should be taken to avoid caging i.e. bending the wire so the strands go apart.
When cutting the wire always remember to tape the ends or use a special tool before cutting in order to
keep the strands in place.
Below follow some methods to measure the length of buswire including the sag, both on the ground and
between gantries.
a) The distance between the gantries is measured as illustrated in fig. 34. To this
length is added a figure for the sag as stated in the sag and tension chart. Note that
this figure is temperature dependent. If compression clamps are used, their extension also has to be added.
The complete buswire including string insulators with hardware are assembled on the
ground.
Note! Always use cover and wood as protection against earth and sand.
b) The buswire is assembled with a string insulator in one end on the ground. This end
is pulled up. A wire puller is fitted in the other end and connected to a rope, see
fig. 35. Two measuring boards are fitted so that the sag can be measured. The
second end is pulled up to the right sag and a tape marking is applied to the rope.
The buswire is taken down and the total length is recorded and the second string
insulator is fitted. The complete buswire is then finally installed as shown in fig. 36.
173
A=
B=
C=
174
Fig. 37 Welding of
tubular connectors
175
176
Contact paste
Immediately (within 5 min.) after cleaning, the contact surface shall be coated with the delivered contact
paste which shall be brushed through with a steel brush all over the surface. For cable conductors, ensure
that the paste penetrates as deeply as possible between the strands of the cable.
The grease will help to seal the surface from renewed oxidation, although not completely effective. Ample
used it will also seal off contact surfaces from water penetration.
WARNING! Never use the same steel brush for copper and aluminium as it will accelerate corrosion.
Installation of rigid connections
Make sure that the conductor completely fills the groove. At the end of the groove there is cavity to keep
the conductor end free, a space shall be left between the conductor and the end of the conductor groove,
see fig. 39.
Fig. 39
When installing the cap on the body make sure that approximately the same gap is left on both sides
between cap and body of the connector, see fig. 40.
Fig. 40
Installation of expansion connectors
When mounting an expansion connector the positioning of the bus relative to the connector must take
ambient temperature into account.
Measure the total travel (L) of the bus. The distance (P) from the minimum temperature end position can
be taken from the diagram in fig. 51 by following the vertical line from L to the curve for actual ambient
temperature and then read P horizontally from the point of intersection. The meanings of L and P are indicated in figure 41 43.
Example: Ambient temperature 40 C
Maximum travel (L): 80 mm
P = 56 mm
Fig. 41
Fig. 42
Fig.43
177
Fig. 44
Tightening torque
Every clamp manufacturer specifies a recommended tightening pressure i.e. the required torque for tightening the bolts. It is of utmost importance that the correct torque is applied.
The tightening torque for M12 is 6085 Nm for dry or slightly oiled screws.
Pre-tighten the bolts in the sequence shown in fig. 45 and 46 to 60 % of the recommended torque. Retighten all bolts to their recommended torque following the same sequence.
It may be needed to check the torque before handing over to commissioning.
Fig. 45
Fig. 46
Fig. 47
Fig. 48
Fig. 49
Fig. 50
178
Tools
The following tools are required:
For all types of clamps:
Use suitable steel brushes, separate ones for copper and aluminium respectively.
Fig. 51
179
Circuit breakers
Erection of circuit breakers is a comprehensive work and must be carried out according to the erection
instructions.
Precaution: If the equipment is stored outdoor, which often is the case, it must be positioned so that it,
during rainy periods, is not exposed to water. For longer storage periods the equipment must be covered
and the anti-condensation heaters be connected.
Lifting devices with sufficient capacity (check with dimension print) must be available.
The flexible connectors between the breaker and the current transformers are included in the delivery.
180
Earthing switches
Connections to earthing switches shall be made with shortest possible route to the earth grid.
181
Duplicate busbars
1 12 breaker sysytem
Double circuit-breaker
182
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Book No. 14
Version 0
Erection
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