Oil-paper insulated cable 10 (6) kV outdoor Terminal production process

1 scope

This technology is applicable to general industrial and civil building electrical installation engineering 10 (6) kV outdoor terminations made of oil-paper insulated cable.

2 construction preparation

2.1 devices and materials requirements:

2.1.1 cable terminal type, specification should conform to the voltage level, environment and design requirements.

2.1.2 cable terminal, should be supplied by the cable accessories manufacturers supporting, and its main components, accessories should be complete, insulating sleeve shall not be cracks and damage, and the user manual and certificate.

2.1.3 type and the voltage level of the cable insulation adhesive shall conform to the requirements and to have chemical and electrical performance testing and certification.

2.1.4 metal fasteners are galvanized.

2.1.5 other accessories: black glass, seal, stearic acid, copper wire, white and yellow lead powder, glycerin oil, gas, cable, etc.

2.2 the main tools:

2.2.1 production machinery: wind fences, plastic sheeting, oil pressure wiring pliers, blowtorches, iron pots, aluminum pots, ceramic plates, aluminum pots, iron scoop, a slotted spoon, glove, funnels, electric stove, hacksaw, wire brush, thermometer, scissors, etc.

2.2.2 Installing machines: pulley, rope, wrenches, bench drill, welding and gas welding tools.

2.2.3 testing tool: shake table, a steel tape measure, steel ruler, and test equipment and so on.

2.3 operating conditions

2.3.1 an outdoor cable terminal making should choose sunny windless weather construction, ambient temperature above + 5 ℃, relative humidity below 70%.

2.3.2 construction site and its surroundings should be clean and dry, and platforms should be strong, setting April wind fences.

2.3.3 should be equipped with 220V power supply at construction site and safe power supply.

2.3.4 construction site should comply with the fire safety requirements, combustible for safekeeping.

2.3.5 cable terminal production staff should receive specialized training and examinations, before construction operations.

3 operational processes

3.1 process:

Equipment inspections and preparations → shake test point cable and verify the tidal stripping the protective layer of the cable and strip → →

Stripping lead and gland → round copper into copper bars and exhaust wrap insulation Assembly cable terminal box → →

Cable terminal insulation adhesive installation → perfusion → commissioning and acceptance

3.2 cable terminal making made according to the following procedure. Strip cut from the beginning to make filling must be continuous, once completed, to avoid damp.

3.3 equipment inspection and preparation:

3.3.1 opening checking and construction units and supply units, or units (engineer), checks, and completes the record.

3.3.1.1 cable terminal boxes shall be conducted according to technical data or manuals, accessories complete and without damage.

3.3.1.2 types must conform to the design requirements of the cable end box and all accessories fit.

3.3.2 copper gland and wire copper bars hanging Tin. Remove the copper gland, sealing parts Tin Copper bar wiring and outlet hole in the wall.

3.3.3 cable inside the terminal box with a wire brush to remove dirt and rust, and cloth with gasoline, along with porcelain bushing shell wipe clean inside and outside.

3.3.4 all ready for cable terminal box seal cover with rubber pad or feather pad, ceramic casing and additive, holes are made of chicken feathers and paper pad.

3.3.53 tube fitting, should be closely and correct.

3.3.6 ceramic casing and cover with seam and yellow lead and Glycerin mixing glue in order to seal.

3.3.7 processed anti-torque clamp, cable retention bracket.

3.4 roll cable insulation measurement and calibration of moisture:

3.4.1 the cable head turn, 2500V side table side insulation resistance measurement, after passing tide.

3.4.2 tide: since the end of the cable 100mm cable saw, inner and outer layer of paper torn off several turnkey and wire insulation paper, cable oils into 140~150℃ (such as no cable available transformer oil Rosin mixture and 25%), such as moisture, oil will be suffused with bubbles and make a hissing sound (Figure 2-5).

Another boom is burning method: paper torn off, fire, moisture, insulation paper surface will bubble up and making a hissing sound.

3.4.3 cable insulating paper tidal immersion, should be removed piece by piece, until the tide right so far. In school will be processed before the tide of black paint with GE in 140~150℃ cable oil and net moisture and set aside in a colander.

3.5 stripped cable layer (Figure 2-6).

3.5.1 peeling bark or plastic sheath, from 900mm at the end of the cable, held together by 2mm turns of bare copper wire cable ties along the three lines, and then use the electric knife to skin layer.

3.5.2 Peel strips:

3.5.2.1 clean with petrol cotton silk to steel, from the end of the cable 830mm~880mm, same 2mm bare copper wire lashing two, tied every three turns of wire, or strip width two-thirds clamp the cable itself, using the method of the bite, clamp firm, fixed two clips to prevent steel straps.

3.5.2.2 saw steel band must first clamp the edge at the time saw a ring of dark marks and a depth not exceeding two-thirds of steel belt thickness, not saws, steel tip with a screwdriver pry the tear up and steel band clamp with pliers, steel band saw blank repairs steel burrs to make it smooth.

3.6 welding ground:

3.6.1 cotton silk with gasoline the lead Pack wipe clean, winter construction used a blowtorch to heat will lead to wipe clean. The strips with a hacksaw or file file up.

3.6.2 multiple plastic copper wire (16 mm2, 120 mm2 cable for 120mm2 cable with 25 mm2 copper), Peel 10~15cm and copper wire straightening, tiling on the steel belt and lead, φ 2 turns of copper wire lashing 3~5 on the lead sheet, steel band clamp on the bite card in prison.

3.6.3 welding line for the steel belt and lead sheet heated with a torch, stearic acid wash and coating on the steel welded oil, ground wire welding with a seal, and require smooth surface, should weld the steel belt, should not be cold solder joint.

3.7 stripping lead and expanded lead and copper into the CAP:

3.7.1 stripping lead: the lead tip into the copper gland. At the end of the cable at 530mm, in the lead pack with electric knife carving a ring of dark marks, its depth shall not exceed the thickness of the lead Pack one-second and chipping knife strip between the end of the cable to the ring-shaped scar lead. How: use electrician's knife from the ends at the ring marks two parallel gouges, the depth to the thickness of the lead Pack one-second, two-line a distance of about 10 mm2, and then from the end broke the lead, the lead Pack peeling (Figure 2-7).

3.7.2 expansion lead as shown in Figure 2-9, Shun turnkey paper winding direction 30 ° ~45 ° angle with the expanded lead, the lead Pack expanded into a 45 ° flare, no burrs to smooth and symmetrical. Expansion flare shown schematically in Figure 2-8.

3.7.3 release turnkey insulation paper, from heaving out of the lead, in turnkey paper wrapped with 25mm temporary oil-impregnated yarns with about 5 layers, from the Terminal to the edge of the oil-impregnated gauze to turnkey insulation with shredded paper, followed by electric knife to cut filler, pay attention to the knife blade should be remove without damage wire insulation paper.

3.7.4 broke core line: see Figure 2-9, a only hand forced hold core line roots, another a only hand gently to broke core line, shall not forced had slammed, so as not to injury core line, core line separate Hou, with clean of hand split cotton silk dipped alcohol wipe to cable oil, Shun cable core insulation paper winding of direction, with oil dip yarn with to half overlap method package wrapped around a layer temporary protection package cloth, oil dip yarn with package to away from cable end of distance is equal to outlet copper bar hole of depth added 10MM. In three separate core to PCM and then wrap a layer of oil-impregnated gauze.

3.8.1 cut off each end of the wire insulation paper, cut away plus 10MM is equal to the length of the copper bar outlet hole depth (when not injured bad core), then use the gauze to remove oxide layer on the wire, cotton dipped in gasoline to wipe dirt, then private reduced oil pressure wiring clamp fasten.

3.8.2 demolition of temporary oil-impregnated gauze and paper chromatography, dismantling the temporary oil on wire gauze (Commission on packages of paper without dismantling) phase chromatography paper tear each.

3.8.3 winding oil-filled black lacquer with isolation: Shun cable insulation on each wire-wound direction, with the half overlap wrap 4 layers. 200mm up at the three-core split half overlap for 4.

3.8.4 exclude moisture: turnkey temporary oil-impregnated gauze paper removed, swap the black paint across, a total of eight layers of smooth, and tied in the three core root, with heating oil from the roots to the wire of the cable end of the cable to water for moisture.

3.9 assembled cable terminal box seal (Figure 2-10, 2-11).

3.9.1 Assembly cable terminal box: terminal box cover on upper-layer phenolic gluing paint surface of the rubber pad, the half sleeve into the cable terminal box, according to phase into the casing lid and porcelain, round copper bars respectively porcelain bushings and

Lower terminal box screw tight (it should be noted that litter the correct location), copper bar outlet rubber washer, copper and brass cap tightly.

3.9. the lead 2: lay the cable terminal box and seal, to center the cable terminal box and cable line and smooth, open, additive hole nut, seal. Seal using a blowtorch, baking, and fats essential decontamination. Seal lead drops: using a blowtorch to seal of roasted, in lead and copper plating on the gland evenly, then roast to seal paste, and cloth lead forming smooth, fine and fat (also called stearic acid), cooling decontamination. Sealing time too long, must be done in 15~20min. Ratio of lead-free solder: lead 65%, SN 35%.

3.9.3 sealed cable terminal before lifting, with yellow transfers and glycerol lead powder into a paste, Terminal cover with paint to prevent moisture, final installation has been processed against twisted hoop.

3.10 cable terminal box installation fixed: will be processed well in advance of the Hoop and branch according to the design and specifications for installation. The cable terminal box with a pulley and rope lift and fixed firmly.

3.11 pouring insulation adhesive:

3.11.1 infusion line voltage levels must be insulated and cable, and test data and factory certificate.

3.11.2 operation personnel must safeguard, Spider-man to cooperate.

3.11.3 when pouring insulation adhesive, place porcelain bushing shell nut and at the top of hat-take it down, moving wire of copper bolts, all around there are gaps, so that when a bored to remove air.

3.11.4 before filling plastic cable housing should be heated to 60~70 °, and then heated to 180~190 ° plastic insulation pumped into housing.

3.11.5 the rubber filling filling, filling plastic hole put a long neck funnel, place a sieve funnel top to filter, glue method is shown in Figure 2-12.

3.11.6 cable rubber normally watered three times. First filling ceramic casing until the second filling when cooled to 60 ℃ to vases and catchy, gum irrigation after all the cooling time. Then remove the funnel, clean up the shell plastic, tighten the nut filling plastic hole.

3.11.7 to check every part of the cable head housing screws are tight, but not too, and finally brush paint on the shell.

3.12 commissioning acceptance;

3.12.1 the first cable production has been completed, as required by the test Department pressure and test.

3.12 2 acceptance: the no load test run 24h, no abnormal phenomenon, for the acceptance procedures unit.

4 quality criteria

4.1 guarantee project;

4.1.1 cable terminal voltage test result, leakage current and insulation resistance code requirements must be met.

4.1.2 cable terminals must be closed tight, packing infusion full, no bubbles, no oil leakage, wire connections tight.

Inspection method: Visual check and inspection and test records.

4.2 Basic project:

Cable head good looks, smooth, with no sand hole, wire bends without creasing. Securely and phase sequence is correct.

Inspection method: Visual check.

5 finished product protection

5.1 the manufactured cable head, wearing parts with care, actions, be careful to prevent chipped cable porcelain bushings wearing parts of the head.

5.2 when the fastening screws of the cable head, to prevent excessive force which part is damaged.

5.3 head lifting cables, install torsion-proof Hoop, and equipped with loop, so as not to damage the cable and break the magnetic sleeve, fix cables to pad a good rubber or lead sheet.

6 quality problems to be noticed

6.1 in the making in cable head, to keep clean, oil-impregnated gauze and black insulation tape to stamp in the aluminum pan, hand-to-mouth, and moisture on the hand to wipe. In the tool on a clean dish.

6.2 cable wire paper insulation cannot be damaged, particularly in three separate core broke off when not overexert, in wrapping the insulation layer, no back and forth broke wire.

6.3 sealing faster, otherwise it will affect the dielectric strength of the cable. Baking-lead package, flames should be uniform to avoid damaging the lead.

6.4 filling cable gel, temperature control, high temperatures can damage the insulation paper, temperature too low perfusion is not true.

7 quality records

7.1 product certificate.

7.2 cable test report form.

7.3 inspection equipment and materials.

7.4 compound test report form.

7.5 mutual inspection records.

7.6 change record of negotiation.