CABLE JOINTING

REFRESHER COURSE

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 CABLE JOINTING REFRESHER
COURSE
Date: 11th Oct – 15th Oct 2021
Course Duration: 5 days
Objectives: At the end of the course, participants should be able to;
 To replace faulted cables sections-maintenance.
 Know how to professionally terminate cable and join.
 Know all termination types.
 Comprehend all termination procedures
COURSE CONTENTS:
 Fundamentals of Cables and Conductors
 High voltage Cable Termination

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 Raychem Straight through Joint
 Techniques of Soldering Electrical Components
 Elastimold Elbow Termination
 Feeder Pillar
 Earthing
 Application of Connector
 Electric Device and Equipment
METHODOLOGY: Class room presentations, Case studies, Site/Field
visitations, Discussion of Results of Research work & Practical/Field
Session.
INSTRUCTIONAL TOOLS: Projector, Power point presentation, Live
Equipment, Engineering Laboratory

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 INTRODUCTION
ELECTRIC CABLES AND CONDUCTORS

 Cables form the necessary connections between the machine which

generate electricity and the appliance which use it. They comprise a very
wide range of sizes and types.
 Cables used in electrical circuit have three main parts
1. Conductor
2. Insulation
3. Mechanical protection.
 CONDUCTOR: A material which allow the free passage of electric current

is known as a conductor. Conductive materials vary in the degree to which

they can conduct electricity.

 INSULATION: A material which disallow the free flow of electric current.

This forms an electrical insulating medium which prevents direct contact

or unsure proximity between the conductor and the other objects.

 MECHANICAL PROTECTION: This is to protect the cable from
external damage such as chemical or electrolytic attack, fire or
any influences external to the cable.

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 FUDAMENTALS OF CABLES AND
APPLICATION
 The major conducting materials used for power cables are
Copper and Aluminium. Both materials have relative
advantages which make them relevant to different
installation areas.
 Copper has lower resistivity and thus higher conductivity
than Aluminium.
 Because of the above characteristic, Copper has smaller cross-
sectional area thus occupying less space than Aluminium for
comparative current capacity.
 Aluminium is about one-third the weight of Copper, therefore it
is lighter in weight than Copper.
 Aluminium is more cheaper than Copper conductor.
Aluminium

Copper
 Given the above advantages, the use of Copper dominates in
underground and domestic installations while Aluminium
dominates in overhead power line installations.
 In order to ensure flexibility and ease of handling, conductors
are stranded. The stranding of conductors is achieved by a
number of small wires spirally twisted together to form an
equivalent core to a single cable of the required size.
SINGLE CORE CABLE

Mechanical Insulation conductor

Protection.
THREE CORE CABLE

Mechanical Insulation Conductor

protection
FOUR CORE CABLE

Mechanical Insulation conductor

protection
 SHAPES AND SIZES OF CABLE

A. CONCENTRIC ROUND
As the name implies, this
conductor is round in shape but
loosely packed, having one
central strand which is
surrounding by six other Strands.
Each layer is greater than the
next layer by six strands. This
type of conductors are usually
found on large size single core
cables.
B. COMPACT CONCENTRIC ROUND
The shape of this conductor is round
and tightly packed. They are usually of
these sizes; 35 mm x 3 core,70 mm x 3
core,150 mm x 3 core.
SEGMENTAL
They are large size single conductor having three or more
segments, and each segment is slightly insulated. The strands
are continuously transposed from inner to outer to inner
positions along the length of the cable run. This eliminates
skin effect.

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C. SECTOR CONDUCTOR
They are sector in shape, found in
multi-core cables. The shape
provides greater space efficiency in a
cable and smaller overall cable
diameter.
THE MAIN REQUIREMENT OF JOINT

The main requirement of a joint, is that it should not

introduce any weakness into the cable system and
must be so constructed that:
a. The conductivity of the jointed conductor is not less
than that of an equivalent of unjointed conductor, and
the conductivity of the enclosing metallic sheath is
maintained unimpaired.
b. The insulation of the cable is maintained, and at the
joint, is not less effective than that of the cable cores.
c. The joint is properly enclosed to prevent mechanical
damage or the ingress of moisture. The joint will
withstand the mechanical stress imposed by a short
circuit and the thermal effect of normal or fault current.
 TOOLS USED IN CABLE JOINTING
The following are the common tools used in cable
jointing;
• Stripping and crimping tools
• Cutting pliers and cable shears
• Hack knife
• Hack saw and blade
• Pair of pliers
• Shifting spanner
• Compound bucket
• Gas furnace and its accessories
• Blow lamp
• Junior hack saw
• Vernier caliper

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Cable Shears
This is used for cutting copper and Aluminium single
conductors as well as multiple stranded cables.
HACK SAW WITH BLADE
Hack knife (Utility Knife)
This knife is needed to remove the outer jacket of a
cable.
Pair of pliers
Measuring tape: Measuring tape are used for measuring
purposes, e.g to measure length of a cable.
 CABLE ACCESSORIES
Accessories are designed to meet the following specifications:
 Withstand environmental extremes and high pollution levels over long
operating lifetimes.
 Maintain service reliability in both overhead and underground
installations.
Different manufacturers developed specially formulated insulation
materials that resist tracking, erosion and degradation caused by
ultraviolet light and other environmental stresses. Among them is
RAYCHEM TE- CONNECTIVITY that will be used for the purpose of this
course.
 REQUIREMENTS OF MODERN CABLE NETWORK

 Fewer components
 Simplified cable preparation
 Fast installation
 Safe for installer and environment
 Consistent approach for all cable types and voltage classes
 High reliability
 Qualification to international specifications, such as IEC, IEEE, ANSI etc.
FEATURES OF RAYCHEM CABLE ACCESSORIES

• Increased resistance to thermal ageing

• Shape memory
• Excellent resistance to surface electrical activity
• Improved Ultra-Violet performance
• Electrical stress control
• Void-free interfacial bonding
• Impermeability to cable oils
FEATURES OF RAYCHEM CABLE
ACCESSORIES Cont.
 Moisture blocking
 Improved flame resistance
 Elastomeric technology
 Mechanical connecting systems
 High radiation resistance
LV JOINTS ACCESSORIES
1) Heat-shrink inline joint, polymeric
2) Heat-shrink transition joint, polymeric
3) Heat-shrink safety class cable inline joint
4) Heat-shrink branch joint, polymeric
5) Gel inline joint, polymeric
6) Gel branch joint, polymeric
7) Resin inline joint
8) Resin branch joint
PICTURE OF CABLE ACCESSORIES

Heat-shrink inline joint, polymeric

Heat-shrink transition joint, polymeric

PICTURE OF CABLE ACCESSORIES Cont.

Heat-shrink branch joint, polymeric

Heat-shrink safety class cable inline joint

CABLE ACCESSORIES CONT…
 LV Terminations
 9) Heat-shrink termination
 Sealing
 10) Cold-applied duct sealing
 11) Heat-shrink wall feed through
 Components
 12) Heat-shrink breakout
CABLE ACCESSORIES CONT…
 13) Heat-shrink sealing cap
 14) Gel Wrap repair sleeve
 15) Heat-shrink wraparound
 16) Heat-shrink tubing
 17) Cold-applied insulating sleeve
PICTURE CABLE ACCESSORIES CONT…

Heat-shrink wall feed

Heat-shrink termination Cold-applied duct sealing through
 PICTURE CABLE ACCESSORIES CONT…

Heat-shrink wraparound

Heat-shrink sealing cap

Heat-shrink breakout Heat-shrink tubing
Jointing Procedures
 Joining electrical power cables can be as simple as
twisting the wires and taping them or more detailed
using a variety of inline adapters and connectors.
The method used for a particular joint depends on
the voltage, type of cable, type of joint, type of
connector, application and other factors.

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Regardless of the method used, it is important to have the
proper tools and materials. Some of the key factors that
ensure clean, safe and reliable connections are;
 Using the proper size of the connector for the particular
cable
 Proper tools
 Clean cuts and stripping
 Restoring the insulation, armor and outer-sheath
 Proper technique

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Required:

 Connectors Mechanical or crimp

 Copper mesh tape
 Constant force springs to hold the wire armor and
copper mesh tape
 Standard PVC/Vinyl tape: provide a mechanical barrier
between the over sheath layer and the armor layer.
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Preparing the cable
 Remove the oversheath and the wire-armor

 Separate the wire armor and bend the wires away

from the cable, place the support ring under the
armor at each side of the joint.
Cut back the cable insulation.

 Remove the insulation from each of the conductors

 Figure 6: Preparation or a three core armored cable | image: gtgengineering

Figure 6: Preparation or a three core armored cable

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 Crimp and insulate each cable
 Once the cable is ready, connect each end of the
three conductors to a suitable mechanical
connector or the crimp. Tightly fix the matching
connectors and test the connection.
 Tape the crimped connectors, wrap around and
extend to cover at least 25mm of the cable
insulation of the conductor entering the connectors

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.
 Bind the cables
 Bind the wires tightly and then tape them together.
When insulating both individual cables and the
whole bunch, fill in the voids to create an even
taper end to end.

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 Restore Armor and apply mesh tape
 Tightly wrap the cable from armor to armor while
applying adequate tension around the insulation.
 Join the wire armor from one end to the other end
and cut excess wire to the correct length. Ensure
the armor spread evenly over the entire joint.

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.
 Wrap the cable with the mesh tape and then use
the standard vinyl/PVC tape to wrap over the mesh
to provide a mechanical barrier against stray wire
ends. For the branch joint, bring both the main and
branch cables together before wrapping.

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Next, use standard vinyl or PVC tape to wrap over the
constant force springs placed over the under-armor
rings. The tape provides a barrier against sharp
edges

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 Re-establish the over sheath
 Use a self fusing tape to wrap over the cable and
establish the outer sheath. Start in the center and
apply one layer of tape to one end, wrapping over
the jacket with for at least 25 mm. Apply the tape
from the end towards the center so that you have
two layers on each side.

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.
For branch joints, wrap over the insulation for both
the main and the branch cable, by at least 50mm.
bring the two together and filling in with the
insulating putty from both sides. Do this up to 25
mm away from the place where the branch and the
main cables are joined.

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Put the two cables together and bind the main and
branch tightly over the filling. Finally, wrap the
crotch while pulling the branch away from the main
cable.

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 HIGH VOLTAGE CABLE TERMINATION
INTRODUCTION

Device fitted to the end of a cable to ensure electrical connection with other parts of the

system and to maintain the insulation up to the point of connection.

When the conductor of a high voltage cable is being prepared for making an electrical

connection, the conducting cable shielding, sheath and armoring must be removed for

certain distance to provide surface insulation between the live conductor and the

grounded shielding, sheath and armoring.

Termination Cont..
 The surface distance is necessitated in order to eliminate the influence of
the magnetic flux on the grounded parts.
 The equipotential lines (those parallel to the conductor between the
conductor and sheath ) are densely concentrated in the small area at the
termination of the lead sheath.
 This high concentration of flux and equipotential lines indicates a zone of
high voltage gradient.
 The resulting high electrical stress in the area can cause insulation failure.
TYPES OF TERMINATION
 Indoor Termination
 Outdoor Termination
 INDOOR TERMINATION: Termination intended for use where it is not
exposed to either solar radiation or weathering.
 OUTDOOR TERMINATION: Termination intended for use where it is
exposed to either solar radiation or weathering or both.
Outdoor Termination Indoor Termination Single Core Outdoor
(with skirt) (insulating bushing boot) Termination
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 Different Arrangement of Indoor
Terminations

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Different Arrangement of Indoor
Terminations Cont..

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INDOOR TERMINATION
OUTDOOR TERMINATION
 IMPROVING THE ELECTRICAL CHARACTERISTIC

Effects of weather and atmospheric contamination can be

eliminated and the potential at which surface flashover occurs can
be greatly increased or improved;

1. Enclosing cable termination or exposed/bare conductors/connectors

in potheads, end boxes filled with compounds, oil, Raychem
transition boots, elbow housing etc. these insulating materials have
a higher dielectric strength than air and permits a decrease in the
length of surface insulation necessary on each termination.
2. Enclosing the termination in pothead, end box, Raychem (etc)
does not materially alter the electric field characteristic, and
therefore the puncture strength of the cable insulation at the
point of maximum electric stress (sheath termination) will limit
the operating voltage of the cable. The concentration of
electrical stress at the sheath termination may be reduced by

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ending with a stress relief cone. Semi-conducting tube metric and
udder, Grounding adaptor and reducer, mastic compound, bulky
insulating tape (etc) to the exposed surface insulation or
metallized paper of the cable at the sheath termination
(crutch area).
This is known as shielding i.e. (application of a
conducting or semi-conducting material over the
conductor insulation).
Conducting shields are usually copper tape, and semi-conducting
shields are usually metallized paper tapes or tapes containing
carbon black.
One of the main purpose of shielding is to produce a symmetrical
electrical stress distribution in the insulation and to reduce
ionization and corona damage in the insulation. Other purposes
are to provide an earth return in case of a cable fault,
to improve human safety, and to protect the cable from external
electrical fields such as induced voltages caused by passing thunder
clouds, lightening discharges. The above shield are externally applied.

Sometimes to control the severe electrical stress on the insulation

next to a high voltage conductor, an internal shield is applied to the
conductor material, to soften the stress on the first layer of insulation.

Back about 1915 it was found that single conductor cables could be
made reliable to carry any desired high voltage
but with multi-conductor cable they were not reliable beyond 33kv. The
failures occurred in the space between the conductors where the dielectric
stress patterns was upset due to the filed around each conductor,
influencing the field of its neighbour.
Martin Hochstettler during 1914-15 devised the idea of wrapping on
external conducting shield. This brought ground potential symmetrical
about each conductor and solves the problem. Today this construction is
named after Hochstetler by calling it Type H.

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Usually the three shielded insulated conductors are bound
together by another conducting tape which in turn is grounded to
the sheath.

External shield must be properly carried through a splice and they

must be terminated by means of a stress cone, whether a pothead
is used or not except on Raychem.

External shield must always be grounded.

This increases the puncture strength of the insulation and
permits operation of the same cable at higher voltages. To
decrease the concentration of flux lines and increase the
electrical strength of a cable termination another electrode at
ground potential may be employed.

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 RAYCHEM COMPONENTS & FUNCTIONS
S/NO DESCRIPTION FUNCTIONS
1. High Voltage Tube To protect cables in areas extreme environmental conditions and high
Metric (HVTM) Red. electrical stress i.e. to insulate and prevent tracking.
2. Special Polyethylene (SPOE) Clear tubing and 1. To hold paper insulation and oil.
band. 2. to hold belt and carbon papers on crutch ends.
3. Semi-conducting tube metric (SCTM) Black. To control electrical stress in high voltage terminations.
4. Conducting tube metric (CMTM) Black. Conductive screen for straight through joints.
5. Medium wall tube metric (MWTM) Black. General purpose insulating tube for low and medium voltages.

6. Bus-Bar insulating tube (BBIT) Black. Insulating material for copper and aluminium busbars.
7. Combined insulating and conducting metric The inner red part performs an insulating function whole the outer
(CICM) black part acts as screen in the joint.
Black outer part and Red inner part.
8. Sealing cap. Black. Used to environmentally seal the ends of cables against M.I.N.D.
drainage, ingress of water and dirt.
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9. Transition boots. i. To seal against ingress of moisture.
ii. To provide a non-tracking insulation over the cable lug and the ends
of the cable insulation and equipment bushing.
10. Skirt (Red) To increase crippage path and improve electrical performance.

11. Tri-Skirt (Red) i. To increase crippage path in 3 core cable

ii. To hold the cores in place.
12. Breakouts or Udder. Breakouts perform one or more of the following functions:-
Black for 415 volts – 11kv, 1. To protect crutch area against ingress of moisture.
Red for 33kv and above. 2. To prevent damage to belted paper insulation at the crutch area.
3. To control electrical stress on crutch area of multi-core cable
termination
4. To provide a conducting protective cover over the crutch area of multi
core cable straight through joint.

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13. Sealant tape (red) For sealing against ingress of moisture.
14. Adhesive tape (yellow) 1. To insulate connectors.
2. To provide strain relief.
3. To fill void and sealing.
15. Conductive paint To replace graphite accidentally removed when cleaning XLPE cable.
16. Discharge Control To fill the crutch of multi-core M.I.N.D paper cables & prevent ionization and discharging (Stress-
Compound (DCC) or control)
Cable grease.
17. Moulded wedge i. 1. as above
ii. To keep the cores apart in the crutch of multi core cables.
18. Silicon grease To smoothen uneven insulation surface on screened plastic and rubber insulated cables.
19. Joint shell (Housing) Used to cover the joint area as a protection to mechanical abuse and earth continuity.

20. Copper Braid Earth leads for joint and terminations.

21. Armour Clamp Use to obtain a reliable connection between cable wire armour and the earth path conductor.

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22. T-Bracket Used in conjunction with braid to the armour of cable
terminations and joints on plastic cables.

23. Roll Spring To attach shielding braid to the armour of cable

terminations and joints on plastic cables.
24. Insulating profile or plastic 1. For forming the wedge used in multi core cables.
compound 2. Used as an insulating medium.
3. For filling voids and provides a non-tracking insulation
over the cable lugs on equipment bushings.

25. Joint sleeves Used over joint shell to seal against ingress of moisture
and chemical attack.
26. Cable repair sleeve metric To cover exposed area of cable, against ingress of
(CRSM) or wraparound moisture and replaces the POC over-sheath.

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.
.
Non-Valved Heat shrinkable Cable End

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 PARTS OF ELASTIMOLD

S/NO CONTENTS FUNCTION

1. Instruction Paper Direction to perform the termination.

2. Elbow Housing To insulate the terminal and control electrical

stress along the terminal
3. Reducer To insulate the terminal and control electrical
stress.
4. Adapter/Earth Conductor To control the radial concentration of
electrical stress at semi conductor
termination, to seal the bottom of the
termination and convey the shielding wires
out for earthing purposes.

5. Terminal Connector To be crimped on the termination and the

jumper.
6. Pin Contact Serves as terminal connector for the
termination and the equipment e.g.
transformers.

7. Earth Conductor/Lug Serves as an earthing material for

jointing the shielding wires with earth
conductor/for termination at earth to
equipment.

8. Hold-down Ball To ensure the elbow housing to the

equipment against vibration.

9. Grease For easy installation of component

e.g. Reducer.

10. Cleaning Paper For use as rag.

11. Helix Key To drive in (wrench) the pin contact.

CONTENTS OF 3M POLE MOUNTED TERMINATION AND
FUNCTION

JOINTING CONTENTS:

One kit has enough material to make three

terminations. Make sure you use the quality of

material designed in the instructions below for each

termination.

1
THE MATERIALS ARE:

Scotch Brand Tape 23

 pre-stressed tube

stress cone

silicon-grease

bottom seal

Earthing (terminal-lug
Skirted insulator

Top and terminal lug.

 TEST ON CABLE JOINTING
Moisture test
Moisture test is the type of test carried out on the first
layer of belt insulation paper of an electric cable to
find out the presence of water or moisture on such
cable.

Experiment
To test for moisture content in a PILC cable

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Materials Required
 Gas stove and its accessories
 Suspan
 Resin Oil
 Sample of PILC (paper)
 Thermometer
 Matches

Methods
 Heat the resin oil to obtain temperature of 1050c-1200c
 Insert the sample paper into the resin oil
 If it start frothing, then it indicates the presence of moisture in the cable
insulation
 While if it does not frothing, it indicates that the cable is in good
condition.
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INSULATION RESISTENCE TEST
This is the type of test carryout on an electric cable to find
out whether the cable is in good condition and whether the
dielectric strength would withstand a giving voltage before
breaking down.
METHODS OF TESTING INSULATION RESISTANCE TEST
The test should be carried out by opening the
cable ends separating the cores at both ends
Test phase to lead sheath i.e. the neutral
Test phase to phase
The correct reading obtaining will be 100
mega ohm or infinity but if the reading is zero
then the cable is bad.

103
CAPACITANCE TEST
This is used on buried cable to locate an open circuit fault in such
cable.

HIGH POTENTIAL TEST

Hi-pot test
Is performed on newly installed power cable to determine
whether the cable is good for energizing and put into service. It is
carried out on a very cool joint or termination.

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 SOLDERING TECHNIQUES
Soldering is generally required to assure permanent electrical
connections. Wires and terminal are twisted together, then solder is
melted into heated joints. When the heat us removes, the solder and
wire cool making the soldered joint look like a solid piece of metal. It
is not possible, after proper soldering, to separate the wires at a joint
except by breaking them or by unsoldering them. Solder is an allow
of lead and tin.
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 It has a low melting point and comes in wire form for
electronics use and molten form for electrical cable
connection. Electrical/Electronic solder is made up of 60
percent lead, though the composition may vary for certain
applications. Robin-core solder is used for soldering electronic
components. The rosin is a flux which flows onto the surface to
be soldered, assuring a more perfect union. Fluxite paste
should be used in electronics.
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PROCEDURE FOR SOLDERING
To begin soldering, be sure that the metal surfaces of the work are
clean, free of oils and debris that could reduce the ability of the
solder to adhere. Also be certain that the tip of the soldering
gun/touch/iron is clean and properly tinned. Place the tip of
the touch/iron/gun at the junction of the two pieces being
joined, this will insure that even heat is applied to both. After
the metal has been sufficiently heated, apply the solder at the
.

junction of the two pieces.

Do not apply solder to the tip of the gun/iron/touch itself.
The solder will flow to the hottest part of the connection.
Withdraw the iron as soon as possible and let the joint cool.
Avoid disturbing the completed joint during cool-down.
Finally, de-flux the area with an appropriate solution to
remove unwanted traces of the resin flux. Completed joint
should look bright, shiny and smooth surface.
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Proper soldering requires the following:
Clean metallic surfaces
Sufficient heat applied to the joint to melt solder when solder is applied to the heated
wire surface.
The solder must not come in direct contact with the tip of the gas torch or soldering
gun because it will melt readily. If the wires or terminal to be soldered have not been
preheated sufficiently, the molten solder will not adhere to their surface. The joint may
look well soldered, but the chances are that it is not. Cold-solder joints provide poor
electrical contact and are difficult to discover when troubleshooting defects arises from
soldering.
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

Some safety precaution during soldering

The soldering gun or torch operates at temperature high enough to cause serious

burns.

Observe these safety precautions:

• Do not permit hot solder to be sprayed into the air by shaking a hot gun,

torch ladle or soldered joint.

 Always grasp a soldering gun or ladle, torch by its insulated handle. Do not

grasp the bare metal part.

 Do not permit the metal part of soldering gun or torch to rest on combustible

material. The soldering gun or torch always rest on soldering stand.

98


SUMMARY
Good soldering is part of technician’s skills.
Solder connections must be mechanically strong,
so that they will not shake loose with resultant loss
of signal and possible damage to parts. Electrically,
solder contacts must have low resistance for
proper signal transfer.

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SOME BASIC SOLDERING RULES ARE:

Soldering tip must be tinned and clean.

Metal to be soldered must be clean.
Support the joint mechanically where possible.
Apply solder to joint, not to gun or torch. Solder must flow freely
and have a shiny, smooth appearance.
Use only enough solder to make a solid connection.

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Where additional flux is used, apply to joint, not to
soldering tip or torch. Only rosin flux should be
used.
Solder rapidly and do not permit components or
insulation to burn or overheat.

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APPLICATION OF INSULATING
MATERIALS
 The wrap around sleeves are mainly used for repairing the
outer/inner sheath/core damaged on the cable.

 These are also used for providing corrosion protection to the

metallic parts of the cable that are expose to polluted
environment.

 The application are also found in providing moisture proof

protection to corrosion prone pipelines.

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APPLICATION OF INSULATING
MATERIALS Cont.
 Wrap around sleeve provide an economic solution to cable
damage repairs which would otherwise necessitate the use of
additional length of cable and joints which are comparatively
costlier.

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 ELASTIMOLD ELBOW TERMINATIONS

There are different types of Dry-Terminations that could

be made on X.L.P.E cable and also there are two types
of straight through joint commonly made on X.L.P.E in
the system. THE MAKERS OF THE PRODUCT for the
termination and jointing are RAYCHEM and
ELASTIMOLD.
ELASTIMOLD ELBOW TERMINATIONS Cont.
PREPARATION OF ELASTIMOLD ELBOW
HOUSING
 Remove the outer jacket for a distance of 235mm/according to the area of
the termination.
 Make a raid tape marker over the outer jacket of 25mm from the edge of
the removed jacket.
 Gather together the concentric wires and bend them along the outer
jacket.
 Remove the graphite paper and cloth shield leaving 40mm of this shield
from the end of the outer jacket and score them with tape. (Don’t
remove graphite coating from the insulation).
PREPARATION OF ELASTIMOLD
ELBOW HOUSING Cont.
INSTALLATION OF THE ADAPTOR
 Wrap wire shield one turn around the cable, cut, twisted wires to
fit into connector and crimp. (Tape crimp connector to graphite
paper).
 Lubricate sparingly inside of adaptor over crimped connector
until it flushes with the tape marker.
 CRIMPING OF CONTACT
 Before crimping be sure that flat contact are facing the bushing
plug. Crimp the contact, after crimping, the distance ‘X’ must be
between 225 and 240mm.
INSTALLATION OF ELBOW HOUSING

 Remove the graphite coating thoroughly with an appropriate

solvent e.g. ELECTRO-CLEAN.
 Lubricate sparingly the cable insulation and inside surface of the
elbow. Slide the elbow over the cable until the elbow cannot
advance any further. Rotate Elbow until it is aligned with the
bushing plug. Be sure that the elbow stays in position during the
Assembly.
 Insert threaded end of the pin contact into its mating part and
tighten until wrench has taken a set.
 INSTALLING OF ELBOW ON BUSHING

 Fix the Hold-down bail to the appropriate place at the end box of the
transformer, clean the contacts free from moisture and dirts.
 Lubricate both bushing and elbow receptacle with lubricants supplied.
Push elbow on bushing with a straight steady force position bail and
tighten well.
 Insert one end of the supplied tin-plated cut wire through the grounding
eye and connect this wire to the ground of the adaptor.
 Connect to system adaptor. The elbow housing termination of
BICO/burndy product is now completed.
ELASIMOLD TYPE PRODUCT

The application of this material on X.L.P.E cable is the same process

only you have to install cable reducer separately before putting on the
elbow housing itself.
CONTENTS OF THE KITS ELBOW HOUSING
i. Instruction paper
ii. Grounding Adaptor
iii. Grounding wire with Lug
iv. Cable Reducer (in Elastimold Kit only).
v. Crimp connector/Socket
vi.Pin Contact with Helix key
 ELASIMOLD TYPE PRODUCT Cont.

vii. Lubricating grease

viii.Tissue/Cleaner
ix. Hold down Bail
x. Elbow Housing.
 ADVANTAGES OF ELBOW HOUSING
 The overall advantage of elbow housing termination on H/V side of
distribution transformer as same as we have it in 3M termination on
switch gears and pole-mountings.
RAYCHEM STRAIGHT THROUGH JOINT FOR
BELTED 3-CORE MIND PAPER INSULATED CABLE

CONTENTS OF THE KIT

1. Instruction paper
2. Special polyethylene clear tubing (SPO) – (3 long & short)
3. Conductive tubing black – (3 long & 3 short)
4. Insulating red ferrules – 3 numbers
5. Combine insulating ferrules (red & black) – 3 Nos.
6. Breakout conductive black – 2 Nos
7. Black insulating tape – 6 rolls
8. Black profile tape –1 length
CONTENTS OF THE KIT Cont.

9. Yellow insulating tape - 6 length

10.Joint case – brass – 1 No.
11.Sealing (black) sleeves – 3 Nos.
12.Copper braid (wire mesh) – 1 No.
13.Solvent (electro-clean)
 GENERAL INSTRUCTIONS

 Use propane or butane gas tank. Adjust torch to obtain a soft blue flame with a
yellow tip
 Pencil-like blue flame should be avoided. Clean and degrease all parts coming in
contact with sealant.
 Preheat metal sheath before shrinking cable breakout.
 Start shrinking the tubing molded parts at the position
 Keep the flame moving continuously to avoid scorching the tubing or burning it
 Sealant must not come in contact with oil or grease.
 Shrinking must be from one point as recommended, working spirally upwards.
 Shrink tubing smoothly all round before continuing along the core

.
 JOINTING PROCESS

1. Overlap the cable to be joined by about 200mm

2. Mark the reference line (the middle of the overlap).
3. Slide one of the short sealing sleeves over one cable end and
the long joint case sleeve on to the other cable end.
4. Remove the overall amour and metal sheath to the dimensions given in
the drawing, or as directed under demonstration.
5. Remove lead sheath in such a way that a slight bell is formed.
 JOINTING PROCESS Cont.

CAUTION:
• Be careful not to damage the belt papers
• Corrugated sheaths should be removed at the top of a corrugation
• Tear off the carbon paper at the end of the lead sheath
6. Tie a twine blinder round the belt paper 20mm from the end of the lead
7. sheath.
8. Tear off the belt paper against the twine blinder.
9. Remove the fillers, level with belt papers.
10.Separate the cores carefully so as not to damage
11. the belt or core insulation papers
JOINTING PROCESS Cont.

12.Slide the insulation tubing (clear) onto the core properly

13. Shrink down the tubing from the bottom upward
14. Ensure that tubing is shrunk down evenly and free from any
grease or air
15.Slide the conductive tubing (black) onto the cores positioning
them well into the crutch end.
16.Shrink into the place starting from the bottom
17.From the small wedge out of a piece of the insulation profile
(black) and push it well down into the crutch end
JOINTING PROCESS Cont.

18.Remove the release paper and wrap the insulation profile tightly
over the exposed belt papers
19. (a) Butting profile up against the cable sheath.
20. (b) Degrease and abrade the surface of the lead sheaths.
21.Preheat lead sheaths
 FEEDER PILLAR
Feeder pillar is a cupboard like metallic cabinet used by the authority
to feed residential and some small scale commercial consumers in
our big towns and cities. In some areas, York-Shire connectors are
used instead of feeder pillars.
 Both the feeder pillars and York-shire

38
 connectors get their power supply from the secondary side of the
transformer that feed them. feeder pillars are named according to
the number of outgoings in each namely four, six, eight, or even
ten ways feeder pillar and their sizes varies accordingly.
 The incomer into the feeder pillar is either linked or fused with
fuses of higher current rating, while the outgoing units to
overhead lines are protected with fuses between 400-300 amps
fuses.
Care should be taken not to link overhead lines since the lines will
have no protection in case of faults.
CHANGING OF BLOWN FUSES IN THE FEEDER PILLAR
Care should be taken when changing fuses in the feeder pillar as
there could be leakage in the underground cable or on the
overhead lines. A fault man should check for leakage

39
 before any blown fuse could be changed in the feeder pillar either
potential tester which could test line or phase to phase voltage or
two bulbs of the same voltage wired in series could be used to test
for the leakage.
 Proper tools should be used when changing fuse in the feeder
pillar that is you should use the fuse carrier to replace the blown
fuses
instead of using pliers, also using strands of copper conductor to
bridge the normal blown fuses should be discouraged as this
always results in accident to the fault man. It is advisable to patrol
overhead lines when more than a fuse is blown on an over head
unit in the feeder pillar before changing the fuse. When clearing
faults in the feeder pillar,
proper check should be conducted on all the contacts therein and
loosed ones to be properly tightened. Faults man should ensure
those neutral links are properly tightened as this always course high
voltage and this will burn consumer’s apparatus.
Faults men should not indulge in changing phase for consumers as
this may be to change the phase line and leave neutral.
Faults men should note that on the same shackle i.e. the point
poles supply comes from different power sources and meet there,
“that is altitude pole” this is where it could be dangerous when
changing phase for customer’s and leaving the neutral which may
be getting its power supply from another source, this causes
feedback to isolated lines.
FAULTS Man’s Cares Do and Don’t
1. Do not fuse back feeder pillar which you did not remove the
fuses.
2. Do not fuse back blown fuses without testing the circuit with
potential tester.
3. Do not fuse back your feeder pillar with pliers, always use
carriers.
4. do not fuse feeder having blown number of fuses more than
one fuse at time.
5. Always treat your circuit with underrated fuse before putting
back the full current fuses.
6. Avoid alcohol when performing your duties.
Patrol your lines thoroughly before installing blown fuses more
than once because of the hazard involved, etc.
CAUSES OF FAULTS ON FEEDER PILLARS
1. Loose connection of bolt and nuts and loose contact of fuses on
the feeder pillar male and female contacts.
2. External bridge of fuses with conductors or over rated size of
wires causing fire outbreak during fault current.
3. Burning of cable terminal lugs.
4. Overloading of units.
5. Flooding by rain on feeder pillar installed on ground level.

41
EARTHING
INTRODUCTION
Earthing is an intentional connection of all the metallic (conductive)
Parts of an Electrical appliances or installations to the general mass of
earth (ground).
In other words, to connect the metallic parts of electric machinery
and devices to the earth plate or earth electrode (which is buried in
the moisture earth) through a thick conductor wire (which has very
low resistance) for safety purpose is known as Earthing or grounding.
To earth or earthing rather, means to connect the part of electrical
apparatus such as metallic covering of metals, earth terminal of
socket cables, stay wires that do not carry current to the earth.
Earthing can be said as the connection of the neutral point of a
power supply system to the earth so as to avoid or minimize danger
during discharge of electrical energy.
Difference between Earthing, Grounding and Bonding
Earthing and Grounding are the same terms used for
earthing. Grounding is the commonly word used for earthing in
the North American standards like IEEE, NEC, ANSI and UL etc
while, Earthing is used in European, Common wealth countries
and Britain standards like IS and IEC etc.
The word Bonding used for jointing two wires (as well as
conductors, pipes or appliances together. Bonding is known as
connecting the metallic parts of different machines which is not
considered to be carrying electric current during normal
operation of the machines to bring them at the same level of
electric potential.
Reason for Earthing
The primary purpose of earthing is to avoid or minimize the
danger of electrocution, fire due to earth leakage of current
through undesired path and to ensure that the potential of a
current carrying conductor does not rise with respect to the earth
than its designed insulation.
When the metallic part of electrical appliances (parts that can
conduct or allow passage of
electric current) comes in contact with a live wire, maybe due to
failure of installations or failure in cable installation, the metal
become charged and static charge accumulates on it. If a person
touches such a charged metal, the result is a severe shock. To avoid
such instances, the power supply systems and parts of appliances
have to be earthed so as to transfer the charge directly to the
earth.
This is why we need Electrical Earthing or Grounding in electrical
installation systems.
Below are the basic needs of Earthing.
•To protect human lives as well as provide safety to electrical devices
and appliances from leakage current.
•To keep voltage as constant in the healthy phase (If fault occurs on
any one phase).
•To Protect Electrical installations and buildings from lightning.
•To avoid the risk of fire outbreak in electrical installations.
•To serve as a return conductor in electric traction system and
communication.
Different Terms used in Electrical Earthing
•Earth: The proper connection between electrical installation systems
via conductor to the buried plate in the earth is known as Earth.
Earthed: When an electrical device, appliance or wiring
systems connected to the earth through earth electrode, it is known as
earthed device or simply “Earthed”.
Solidly Earthed: When an electric device, appliance or electrical
installation is connected to the earth electrode without a fuse, circuit
breaker or resistance/Impedance, It is called “solidly earthed”.
•Earth Electrode: When a conductor (or conductive plate) buried in the
earth for electrical earthing system. It is known to be Earth Electrode.
Earth electrodes are in different shapes like, conductive plate,
conductive rod, metal water pipe or any other conductor with low
resistance.
•Earthing Lead: The conductor wire or conductive
strip connected between Earth electrode and Electrical installation
system and devices is called Earthing lead.
•Earth Continuity Conductor: The conductor wire, which is connected
among different electrical devices and appliances like, distribution
board, different plugs and appliances etc. in other words, the wire
between earthing lead and electrical device or appliance is called
earth continuity conductor.
•Earth Resistance: This is the total resistance between earth
electrode and earth in Ω (Ohms). Earth resistance is the algebraic
sum of the resistances of earth continuity conductor, earthing lead,
earth electrode and earth.
Earth Procedure
Earthing is not done anyhow. According to IE rules and IEE (Institute of
Electrical Engineers) regulations,
•Earth pin of 3-pin lighting plug sockets and 4-pin power plug should
be efficiently and permanently earthed.
•All metal casing or metallic coverings containing or protecting any
electric supply line or apparatus such as GI pipes and conduits
enclosing VIR or PVC cables,
iron clad switches, iron clad distribution fuse boards etc should be
earthed (connected to earth).
•The frame of every generator, stationary motors and metallic parts
of all transformers used for controlling energy should be earthed by
two separate and yet distinct connections with the earth.
•In a dc 3-wire system, the middle conductors should be earthed at
the generating station.
•Stay wires that are for overhead lines should be connected to
earth by connecting at least one strand to the earth wires.
Components of Earthing System
A complete electrical earthing system consists of the following
basic components.
•Earth Continuity Conductor
•Earthing Lead
•Earth Electrode
Earth Continuity Conductor or Earth Wire
The part of the earthing system which interconnects the overall
metallic parts of electrical installation e.g. conduit, ducts, boxes,
metallic shells of the switches, distribution boards, Switches, fuses,
Regulating and controlling devices, metallic parts of electrical
machines such as, motors, generators, transformers and the metallic
framework where electrical devices and components are installed is
known as earth wire or
earth continuity conductor as shown in the above fig.
The resistance of the earth continuity conductor is very low.
According to IEEE rules, resistance between consumer earth
terminal and earth Continuity conductor (at the end) should not be
increased than 1Ω. In simple words, resistance of earth wire
should be less than 1Ω.
LIMIT OF APPROACH
SAFE DISTANCE FOR WORKMEN NEAR LIVE
APPARATUS FOR UNQUALIFIED PERSONNEL:
This may be defined as the least permissible distance between live
Electrical Apparatus and the closest part of the workman’s body or
any conducting tools on materials that he may be handling.
Table No.1 refers:
NORMAL VOLTAGE RANGE DISTANCE METERS

750 up to 15,000 Volts – 11KV 3 Feet 0.9144

Over 15,000 up to 50,000 Volts – 33KV 4 Feet 1.2192

Over 50,000 up to 150,000 Volts – 132KV 5 Feet 1.524

Over 150,000 up to 250,000 Volts 7 Feet 2.1336

Over 250,000 up to 550,000 Volts-330KV 12 Feet 3.6576

57
While performing work near live electrical apparatus, we must avoid
extreme body movements or extreme movements of tools and materials.

ABSOLUTE LIMIT OF APPROACH:

May be defined as the least permissible distance between live electrical

apparatus and the position of the workman’s body (or tools and materials
he may be handling) could be in through accidental or unplanned
movements.
FOR QUALIFIED PERSONNEL TABLE 2 REFERS:

NORMAL VOLTAGE RANGE DISTANCE METERS

750 up to 15,000 Volts – 11KV 1 Foot 0.3048

Over 15,000 up to 50,000 Volts – 33KV 1.5 Feet 0.4572

Over 50,000 up to 150,000 Volts – 132KV 3 Feet 0.9144

Over 150,000 up to 250,000 Volts 4 Feet 1.2192

Over 250,000 up to 550,000 Volts-330KV 9 Feet 2.7432

58
This distance must never be reduced unless protection is provided
with approved devices, such as rubber gloves, hose, hoods or
linear polyethylene cover up.
When qualified personnel are planning to carry out work closer to
live apparatus than the general safe distance for work stated in
Table 1, they must give careful consideration to the following
points:
1. The work location and work to be done.
2. All potential hazards.
3. The work method and tools to be used.
4. The training and knowledge of the workman and the selection of
competent workmen to do the job.
5. The use of protective equipments such as Rubber Gloves, Hose
Hoods or Blanket.

59
 GROUNDING OF CABLES AND SUB-
STATIONS EQUIPMENTS
TOOLS AND MATERIALS
1. Gas torch or blow lamp
2. Sledge hammer
3. Pipe wrench/pliers/eagle claw pliers
4. Flexible copper bars/galvanized 6 feet earth rod
5. Copper earth wire
6. Sockets
7. Ferrule
8. Fluxite
9. Tin-man solder 60
EARTHING OR GROUNDING

1. Excavate the ground to a depth of about 2 meter and width 2 x 2

meter.
2. Lay copper earth mat on the floor of the pit or drive down 4
numbers 2 meters length of galvanized rod with sledge hammer.
3. Web the flexible copper bars.
4. Bind measured lengths of copper earth wires to earth mat to
connect equipments and cables.
5. Apply fluxite and tin for firm union.
6. Joint more length of earth copper wires using ferrules for
connections to various earthing points.
7. Apply sockets to terminals of earth wire and sweat.

61
 ELECTRICAL DEVICE AND EQUIPMENTS

• TRANSFORMERS: Is an electrical device without continuously

moving parts which by electro magnetic induction transforms
electrical energy from one or more circuits to one or more other
circuits at the same frequency, usually with change values of
voltage and current. It is one of the most common pieces of
electrical power equipments and without it the wide-spread

40
 distribution power would be impractical.
O.C.B: Oil Circuit Breaker is a mechanical device for breaking and
making circuit both normal and abnormal conditions such as those
of short circuit breaking the current automatically and also usually
making under hand control as maybe specified.
R.M.U.: Ring Main Unit is an electrical outdoor high voltage
distribution apparatus fitted with High Rapture Capacity fuse (HRC).
 FEEDERS PILLAR: Is an electrical outdoor low voltage distribution
apparatus.

 FUSE: Is a weak link in a conductor designed to break the circuit by

melting before the current becomes large enough to cause any
damage.

 EARTH WIRE: Is a protective conductor usually connected to any

electrical apparatus or consumer’s premises to ensure that in the
event of breakdown between the live conductor and the metal
frame work of the supply, the current will be out off before the
voltage, which a person may be exposed exceeds a dangerous
value or
 before the current attains such a value as to constituted fire risk.

 NEUTRAL WIRE: Is a common return conductor which provides an

alternating way home for current.

 CONDENSER: Is a rotating machine much like a generator, used to

control or regulate voltage at terminal station for all condition of
load.

 LIGHTING ARRESTERS: Is to provide a path to earth for any

dangerous high voltage such as may be caused by lighting.
•POTHEAD: A pothead is a device that brings three conductors out of a
cable without allowing moisture to act into destroying the insulation.
•HYDROELECTRIC GENERATION: Electricity produced by water is called
Hydro Electric Generation.
•THERMAL ELECTRIC GENERATION: Electricity produced by steam
engine run with coal gas or oil.

42
 GRID SYSTEM: It is the network where power lines from generating
stations are spread like a net through out Nigeria and are joined
together at the Main Transformer Station in different areas.

 SKY WIRE: Is to protect the power conductors from direct lighting

strokes. In connected to the ground at regular intervals to conduct the
lighting charges to earth (transmission line earthing).
 CURRENT TRANSFORMER (C.T.): Current Transformer used to
reduce measured current to a reasonable value.

 GROUNDING ISOLATOR: The purpose of grounding isolator is to

remove any electrical charge that may be on the long Transmission
Line after is isolated or put off.
APPLICATION OF CONNECTORS

INTRODUCTION
Cable connectors are materials used in jointing two lengths of cables
together to form one continuous length. Jointing the terminals of cable
to be connected to electrical equipments and overhead lines.

TYPE OF CONNECTORS AND SIZES

1. Weak – back ferrule – 16mm2 – 240mm2
2. Socket - 16mm2 – 1000mm2

1
2. Timble - 70mm2 – 1000mm2
3. Extended angle limble – 70mm2 – 500mm2
4. Barrel ferrule – 16mm2 – 240mm2
APPLICATION
 Bare cable insulation to the debt of socket, barrel ferrules, (etc)
plus 5mm.
⁻ Reshape sector shape conductor into round shape with angle claw
pliers Insert ferrule centrally on the cable, with the slot facing
upwards, embarrassing 50% on either side of the ferrule (ensure
firm butt).
⁻ Compress ferrule tightly round the conductor with eagle claw pliers
on pipe wrench.
⁻ Insert socket to butt with cable end.
⁻ Insert cable in timble to flush on the terminals.
⁻ Protect cable insulation with protective cotton tape or PVC chute to
prevent burning during sweating.
⁻ Smear connectors and cable with fluxite paste.
⁻ Heat with gas torch or blow lamp (ensure that oxides are remove or
clean before application of tin man solder).
Sweat with tin man solder (ensure flow and penetration of tin man
solder).
⁻ Clean off molten tin man solder from the surface of conductor and
connector and allow to cool.
⁻ Clean traces of fluxite and chamfer/pensile the insulation.
⁻ File – off bulbs of solder and smoothen connector with emery cloth
and clean.
Different types of Clamps and Connectors

.
 STANDARD SIZES OF COMMON
CABLES AND CONDUCTORS
S/N IMPERIAL SIZE (Sq. METRIC SIZE NO OF STRAND & CURRENT CARRYING
Inch) (mm2) DIAMETER CAPACITY (Amps)
(mm)
1. OVERHEAD
A.0.035 Sq. Inch 35 7/2.5 144
0.05 50 7/3.0 188
0.75 70 19/2.1 227
0.1 100 19/2.67 271
0.15 150 19/3.25 346
B. 7/044 Inch 6 7/1.04 36
7/064 16 7/1.70 53
19/064 35 97
2 UNDERGROUNG
C. 3-Core:
0.1 70 19/2.14 200
0.25 150 37/2.25 335
0.3 185 37/2.52 370
STANDARD SIZES OF COMMON
CABLES AND CONDUCTORS
S/N IMPERIAL SIZE (Sq. METRIC SIZE NO. OF STRAND CURRENT
Inch) (MM2) AND DIAMETER CARRYING
(MM2) CAPACITY
(Amps)

D 4-Core: 19/1.53 140

0.06 35 19/2.14 200
0.1 70 37/2.25 335
0.25 150

E Single Core:
0.3 185 37/2.52 380
0.5 300 61/2.52 550
0.75 500 61/3.20 750
Different Parts of Cable
 TYPES OF CABLES

1. XLPE – Cross-linked
Polyethylene cable used for
high voltage connection.
2.PAPER INSULATED LEAD-
SHEATHED CABLE (P.I.L.C.):
used for high voltage
connection and are available in
both single and multi-cores
cables
3. POLYVINYL CHLORIDE
CABLE (P.V.C.): This type of
cable are used for low voltage
connection. They are of both
single and multi-cores.
S/N PART MATERIALS FUNCTION
1. Conductor Stranded copper wire Transportation of electricity
2. Screen Carbon paper Prevent corona cutting into the insulation

3. Insulation Impregnated paper insulation Separating the cores building up voltage bedding cores

4. Filler Paper jute or CWF (cotton Bedding cores

woven fabric)
5. Belt Paper Impregnated paper Bedding cores

6. Screen Carbon paper Stress control material

7. Sheath Lead For earthing and housing the cores and MIND OIL

8. Inner Sheath Rubber of compounded None corrosive agent

9. Amour Steal or flat or wire Mechanical protection against damage
10. Outer Sheath PVC rubber Overall Protective covering
Cable Current Ratings and Applications