INSTALLATION INSTRUCTIONS ‫ﺍﻟﺗﺭﻛﻳﺏ ﺗﻌﻠﻳﻣﺎﺕ‬

Product Name: MEMF-PM-SJ-15kV-500/500

Premoulded Straight Joint for 3 core polymeric insulated cable, with Cu wires
screen and un-armour

Rated voltage : 8.7/15(17.5kV)

For section conductors (mm2): 3x500 AL

PRELIMINARY OPERATIONS
 Equipping the work-yard and operators (qualified for the use of high voltage electrical equipment) of the devices
required by the applicable safety regulations in the workplace, with particular reference to the construction or
maintenance of electrical infrastructure networks.
 Check the suitability of the kit with respect to the cable types and conductor cross-sections.
 Check the availability of all the tools necessary for proper jointing
GENERAL INSTRUCTIONS

Clean and degrease all parts that will need to be in contact with the heat shrinkable adhesive. Preferably use a
propane gas torch adjusted so as to obtain a non-concentrated flame and with the yellow front. Keep the flame at the
right distance and in continuous motion to avoid burns. Make sure that the tube is uniformly shrunk on its
circumference.
After shrinking, the tube surface should be smooth, without wrinkles and the profiles of the coated parts must be well-
evident. Otherwise, it is necessary to make more heat.

CABLE PREPARATION
STEP(1) PREPARING THE CABLE
1.1 Insert the transparent heat shrinkable
tube onto two cable for the preparation of
ID card application in the last step.

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1.2 Align two cables, cut off the surplus
portion leaving an overlapping portion of
100mm in length as shown.
1.3 Fold back the screen wires and
maintain the length of armor, inner sheath
& XLPE insulation as per the dimensions
mentioned in cable preparation.
NOTE
While Pulling semi conducting using nose
plier from top, ensure not to break semi
conducting layer.
Ensuring that while removing semi
conducting screen no black traces are left
on insulation layer.

PENCILING OF CUT SCREEN AREA AS

SHOWN IN DETAIL ‘A’.
DETAIL ‘A’
 Use transparent PVC tap to define
cut mark over semi conducting
screen by at least 10 layers
wrapping which will make
approximate 1mm thickness step.
 Use fine round file to abrade semi
conducting screen around roll
spring.
 File should be used carefully until
XLPE insulation is seen.
 Ensure not to damage XLPE
insulation with file.
 Carefully complete this around
periphery of cable core.
Remove spring clamp after removal of
semi conducting layer.

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Clean XLPE insulation with cleaning tissue
thoroughly moving inside to outside
direction and ensuring not to bring back
tissue paper once used for cleaning
conducting screen.

CABLE CUTTING PREPARATION

CABLE SIZE MM2 L L1 L3 L4 G F L2

3x500/35 (AL.) 50 20 210 210 670‐700 900 115

SIDE A= 3x500/35 mm 2(AL.), SIDE B = 3x500/35 mm 2(AL.)

LEGEND
L = Length of Armor ; L1 = Length of Inner Sheath ; L2 = Length of Bare Connector; L3 = Length of XLPE Insulation + L2;
L4 = Length of XLPE Insulation + L2

STEP(2) ASSEMBLY OF THE JOINT

2.1 Fold back the screen wires till inner sheath’s cut & bind them temporarily on the outer sheath (Do not cut the wires).
Insert heat shrinkable adhesive lined outer jacketing sleeves both long one and short one from each side of the cable from
the cutting end of the cable, slide sleeves up to the position where the jointing work will not be disturbed.

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2.2 Clean cable cores, wrap PVC adhesive tape as phase color over semi conducting screen & over bare conductor on all
the cores as shown below figure -2.

2.3 INSTALL STRAIGHT JOINT

Apply silicone grease into the ends of pre-moulded joint body with stick. Coat insulating and semi conductive layer with
silicone grease in side A. Insert straight joint body into three-phase, reference to figure – 3

Figure-3 Silicone Grease

Pre-moulded Joint Body

2.4 Expand the copper flexible mesh onto each core in side B, reference to figure - 4.and put on inner jacket sleeve onto
each phase accordingly.

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 Figure-4 Pre-moulded Joint Body Copper Flexible Mesh

Heat Shrinkable Tube

2.5 Remove the insulation on all cores as per given dimension ‘L2’ in the dimension table. Joint the conductors by crimping
or any other equivalent methods. Remove sharp edges if there is any.
Clean the surface of XLPE insulation and ferrule with the help of cleaning tissue along with the kit. Wrap PVC tape 25 mm
away from outside semi conductive layer as spacing mark as per figure - 5.
Apply silicone grease on XLPE insulation in side B.
NOTE- Crimping sequence: crimping along the crimping mark.

Figure-5 Silicone Grease

Spacing Mark

Heat Shrinkable Tube

2.6 Twist & Pull the joint body back to spacing mark phase by phase.
Remove remaining PVC tape from A side if there is any, ensure joint body should be direct contact with semi conducting
screen of cable cores, then remove spacing mark from B side.

Figure-6

Spacing Mark

Pre-moulded Joint Body

2.7 Wind semi conducting tape at the ends of straight joint body so that it can produce lap transition to semi-conducting
layer.

Figure-7

Semi-conductive Mastic

2.8 Use 1 or 2 scree wire to connect the joint body through the hole.

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 Figure-8

2.9 Pull the heat shrinkable tube back to the middle position with 75mm over the shield on both sides. Heat it from the
middle to the end.

Figure-9

75mm 75mm

2.10 Pull the copper flexible mesh back and wrap the joint body around the joint area. Overlap 150 mm over the shield on
both sides. Fix the copper mesh tape on shielding wires with the help of Spring clamps.
Align copper screen wires & crimp in copper ferrule as shown in figure 10.

Figure-10 Copper Ferrule Screen Wires

Spring Clamps

Copper Flexible Mesh

2.11 Abrade the outer sheath 100mm with Emery tape grit 240 and clean with cleaning tissue.

Figure-11 Copper Ferrule Screen Wires

Copper Flexible Mesh

2.12 Centre the wrap around protective cover and wrap it around the jointed area. Use steel clamps to hold it in place.
Wrap mastic sealing tape over the steel clamps and sharp edges if there is any.

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 Figure-12
Wrap Around Protective Cover

Mastic Sealing Tape Steel Clamp

2.13 Use reinforced tape to fix the joint wrap around case, the apply amour tape to wrap the joint case by 50% overlap

Figure-13
Amour tape

2.14 Slide the first outer jacketing sleeve and position on the outer sheath with overlapping the cable outer sheath at about
125 mm as shown in figure 14. Shrink the outer jacketing sleeve starting from the cable end working towards joint. Position
the second outer jacket sleeve overlapping on the cable outer sheath for about150 mm on the other side as shown and
start shrinking from cable end working towards joint, and in the last shrink the short outer jacket sleeve to cover the
overlapping position.

Figure-14
Outer Jacketing Sleeve Outer Jacketing Sleeve
150

Outer Sheath Hot Melt Adhesive

2.15 Fill the blank ID card in the field and use transparent shrinkable tube to cover and protect it.

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 Joint Assembly Drawing Of 15kv Pre-molded Straight Joint (500-500)

Before leaving the work-place, sort out the left

materials to differentiate them by type and
nature and then get rid of them in the most
appropriate way.

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