erection manuals

Erection

Book No. 14Version 0

Global Organization

InnovativeSolutions

SystemBusiness

Product &SubstationBusiness

LEC Support Programme

BA THS / BU Transmission Systems and Substations

BA THS / BU Transmission Systems and Substations LEC Support Programme2

Suggestions for improvement of this bookas well as questions shall be addressed to:

BU TS / Global LEC Support ProgrammeC/o ABB Switchgear ABSE-721 58 VstersSweden

Telephone + 46 21 32 80 00Telefax + 46 21 32 80 13Telex 40490 abbsub s

Copyright BU Transmission Systems and Substations

BA THS / BU Transmission Systems and Substations LEC Support Programme 3

SitemanErection

Welcome to the preliminary Siteman Erec-tion handbook in the series of bookletswithin the LEC Support programme of BUTransmission Systems and Substations ofBA THS. It is the intention of the BU to update thishandbook to reflect the philosophy of thewhole BU. We hope that you will find thebooklets useful in your work. This booklet is dedicated to the erection.It includes internal ABB Substations, Swe-den instructions to for example: Mobilize at a site Welding rules Cables Earthing Air Insulated Switchgear.The authors welcome any idea you mayhave to improve the quality of this bookletas well as the other ones.

Best of luck!


CONTENTSCheck on arrival mobilization........................................... page 5Welding rules.............................................................................. page 25Brazing Thermic welding process................................ page 31Cables ............................................................................................ page 51Laying, termination and jointing ofhigh voltage cables


SITEMAN 01 - 94 Check on arrival1WAT 910033-1 mobilizationEdition January 1994


List of contents

1. General ............................................................................ 7

2. Checklist arrival to the country site ........................ 7

3. Site mobilization ............................................................. 73.1 Establishing of site routines .............................................. 73.2 Site layout ......................................................................... 73.3 Temporary power supply .................................................. 83.4 Offices and indoor store ................................................... 93.5 Outdoor stores ................................................................ 113.6 Personnel compartments canteens ............................. 123.7 Site toilets (WC) .............................................................. 123.8 Waste container .............................................................. 123.9 Protection ....................................................................... 12

4. Checklist for civil works .............................................. 12

Appendix 1 ............................................................................. 13Appendix 2 ............................................................................. 20

This document and parts thereof must not bereproduced or copied without written permis-sion, and the contents thereof must not beimparted to a third party nor be used for anyunauthorized purpose. Contravention will beprosecuted.

Addtional copies of this document may beobtained from ABB at its then current rate

BU Transmission Systems and Substations of BA THS


1. GeneralThis document will, in principle, describe the following main subjects: check on arrival site mobilization check of civil worksIt has to be emphasized that this instruction only can act as a guide, since eachcountry and site is unique, even if most of the actions to be taken are universal.

2. Checklist - arrival to the country siteThe checklist, see Appendix 1, has a general character and summarizes questionsrepeated from site to site and may act as a reminder.

3. Site mobilization3.1 Establishing of site routines

For every project it is of utmust importance that the site procedures and routinesare agreed upon by all parties involved. The earlier ABB brings these questionsforward, 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 areworking in accordance with very strict protocol and are especially sensitive todirect 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 withinwhich such claims must be submitted and how to measure the work. Note thatan agreement between the customer and the local project manager shall be(issued) signed before any extra work is undertaken. Do not forget to note allclaims 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 togetherwith the consultant, customer, subcontractor, etc.

3.2 Site layoutA site layout showing the service areas shall be done at an early stage and prior tothe start of the site activities. The layout shall show the following: (See Fig. 1 and2.) 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.


3.3 Temporary power supplyThe necessary temporary power demands have to be investigated and planned forat an early stage prior to erection start. Make a sketch indicating number of supplypoints starting type of outlet amp and volt for each. The following can act as aguide: Office: ................................................................3-phase, 380 V, 25 A Air-condition: .....................................................3-phase, 380 V, 16 A Workshop/lighting:............................................. 3-phase, 380 V, 25 A Extra supply points in switchyards for

hand tools and electrical welding set: ............... 3-phase, 380 V, 16 A High-Vacuum transformer filter: ........................ 3-phase, 380 V, 200 A

(Approx. 130 kVA) Gas-high voltage test:: ......................................2-phase, 380 V, 320 A

(Approx. 210 kVA)

Fig. 2Fig. 1


3.4 Offices and indoor storeThe requirements have to be checked for each project. The following informationcan only act as an indication and show some typical solutions.

A typical ABB site office and indoor store for a larger project may be housed inone 20 foot container or more, and can be equipped as shown in figures 3-5.

Example of equipment in the office-container as follows: desks with lockable drawers desk chairs visitors chairs book shelves rack for drawings incl. hangers desk lamp air-conditioner, when required heater, when required kitchenette telephone telex telefax typewriter copying machine electronic calculator with printer safeThe kitchenette may be equipped with: refrigerator cooker coffee machine crockery

Figure 3. Typical site office.


Figure 5.Typical indoor store.

Figure 4. Container store.

20' ISO- External Internal Internalstandard without with

insulation insulationLenght, mm 6058 5862 5802Width, mm 2438 2329 2209Height, mm 2591 2400 2340Weight, kg 2400 2400 3450


Figure 6. View of an outdoor storage area.

Figure 7. Section view outdoor storage area.

3.5 Outdoor storeThe storage area can vary between 100 4000 m2, as a guideline ca 60% ofcomplete switchyard. It can be located either inside or outside the switchyard. Ithas to be fenced in, which can be done either by the customer, by ABB or by thesubcontractor.


The ground shall be level and, if possible, covered with gravel.Timber and sleepers shall be available and used to space all stored equipment

from the ground in order to protect it from water.Tarpaulins, covers have to be available in order to protect broken or damaged

cases or to cover other sensitive equipment.If required, do not forget to employ watchmen, if necessary on 24 hours basis.

3.6 Personnel compartments canteensThe size is planned according to the man-power at peak. Various portablebuildings, container or tents can be used if no stationary facilities are available. Thecompartments shall include lockable rooms for changing of clothes.

If warm meals have to be served at site, a special organization has to beappointed to handle this separately.3.7 Site toilets (WC)The site toilets have to be arranged according to local standards and regulationsand prior to start of site works. If chemical or dry types of toilets have to be used,do not forget to organize for emptying and service of these.

3.8 Waste containerThe necessary equipment for the waste and arrangement for the emptying isneeded to be arranged either by the customer, by ABB or by the subcontractor asset out in the contract.

Adjacent should sand and water be available in case of fire.

3.9 Protection First Aid-person First Aid-kit Stretcher, blankets Safety belts Helmets Ropes, Sign plates Fire extinguisher Fire-plug (hydrant) Ambulance transport Telephone to:

Hospital Police Fire-station/brigade Ambulance

Note. The requirements can vary between countries. The arrangements have to beaccording to local standards and regulations.

4. Checklist for civil workPrior to access to site and start of erection, the civil work must be checked. Thechecklist, see Appendix 2, is detailing the most frequent points to be checked.


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 becompleted 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 aspersonal luggage?

1.3 Transportation from airport? Approx. cost? Need of contact person at the

airport?

1.4 Landing card. How to befilled in?

How to declare money incustom?

1.5 Other comments regardingthe travel?

CHECKLIST Arrival to the country site PeriodOrder no.

DateDealt with by

SIte designationProject Page

Cont.

SITEMAN 01-94Appendix 1


DateDealt with by


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/Customsuseful to know?

Religion? Other languages spoken? Authorities?

2.7 Personal belongings prefer-able to be brought from homecountry?

2.8 Customs regulations forpersonal belongings?

Transport?

2.9 Currency restrictions? Travellers cheques, cash? Preferable currency? Accepted credit cards?



DateDealt with by


Cont.3

4

2. LIVING CONDITIONS (cont.)2.10 Schools?

Swedish / International? School fees? Starting date / terms?

2.11 Address, residence? Address, private mail?

2.12 Telephone, residence? Preferable time for telephone

calls (Swedish time)?

2.13 Possibilities for recreation? Clubs / club fees? Waiting list?

2.14 Contact Swedish embassy,consulate?

Contact man? Program for evacuation in

case of emergency?

2.15 Other comments regardingliving conditions?



DateDealt with by


Cont.4

5

3. MEDICAL FACILITIES

3.1 Hospital available? Standard? Address?

3.2 Private doctors available? Standard? Address / Phone number?

3.3 Dentist available? Standard? Address / Phone number?

3.4 Medicine, antibiotica, serum,etc., available?

3.5 Necessary arrangements incase of emergency sick-transportation to homecountry?

3.6 Risk of deseases like malaria,dysenteri, etc.?

3.7 Other comments regardingmedical facilities?

3.8 Address to SOS internationallocal branch?



DateDealt with by


Cont.5

6

4. WORKING CONDITIONS

4.1 Address for company mail?

4.2 Telephone number duringworking hours?

Preferable time for calls fromSweden (Swedish time)?

Time difference summer,winter?

4.3 Telex number? Telefax number?

4.4 Working hours? Local holidays?

4.5 Work permit / permit to stay?

4.6 Visit local ABB, contact man? Available assistance from

local ABB?

4.7 Visit customer, contact man?

4.8 Visit consultant, contact man?

4.9 Visit subcontractor, contactman?

Needed tools and equipmentfor erection available?

Standard of supervisors andskilled man-power?

4.10 Visit transport company, con-tact man?

Needed equipment for safeoff-loading available?

Control of lifting devices?

4.11 Visit civil contractor, contactman?

Any hinderance on site forstart of erection?

4.12 Local purchasing of erectionmaterial possible?

Approx. cost level?



DateDealt with by


Cont.6

7

4. WORKING CONDITIONS (cont.)4.13 Local purchasing of erection

tools possible? Approx. cost level?

4.14 Workshop for minor repairsand manufacturing available?

4.15 Plant for hot dip galvanizingavailable?

4.16 Bank opening accountprocedures for transfer?

4.17 Customs procedures forhardware?

Ocean freight / air-freight? Possibilities for smoothening

customs procedures?

4.18 Location of site, travellingtime?

Road description?

4.19 Electricity supply, worksite? Voltage? Frequency? Reliability?

4.20 Other comments regardingworking conditions?

4.21 Telephone number to police,ambulance, fire department?

4.22 Trafficability to site, summer,winter, raining seasons?



DateDealt with by


Cont.7

5. TRANSPORTATION

5.1 Local public transports?

5.2 Rental of cars? Approx. cost?

5.3 Purchasing of cars? Approx. cost?

5.4 Fuel availability? Approx. cost?

5.5 Driving license international /local?

5.6 Car insurance and regula-tions?

5.7 Workshop and spare partsavailable?

5.8 Heavy trucks? Road conditions?

5.9 Import license?

5.10 Other comments regardingtransportation?



DateDealt with by


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 Workto 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 trans-formers

trafficability building anderection cranes limitations,which?

1.3 Laying of ground network is expensive clearing required? is re-filling required beforehand? earth resistance?

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



DateDealt with by


Cont.2

3

2. FOUNDATIONS

2.1 Foundations (general) correct location

2.2 Individual foundations correct placing correct construction foundation bolts

l sizel placingl clean and undamaged

threadsl 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



DateDealt with by


Cont.3

4

3. CABLE ROUTES / GROUND NETWORK

3.1 Cable routesCable 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 Cleaning of cable ducts, etc.



DateDealt with by


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

l cablesl panelsl cable ducts in floorl indoor switchgearl 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




DateDealt with by


Cont.5

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 Air treatment (whole building) air condition ventilation heating water

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



SITEMAN 08 - 94 Marking of cables1WAT 910033-8Edition January 1994


List of contents

1. General .......................................................................... 27

2. Standard marking ......................................................... 272.1 Cable marking ................................................................. 272.2 Core marking .................................................................. 28

3. Mounting ........................................................................ 283.1 Cable numbers ............................................................... 283.2 Core numbers ................................................................. 28

4. Accessories and tools .................................................. 284.1 Partex ............................................................................. 284.2 Flexipart .......................................................................... 294.3 Other standards .............................................................. 294.4 Open type markers ......................................................... 29





1. GeneralThere are a great variety of cable marking systems available on the market. ABBhave 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 technicaldata are taken directly from the cable and core lists.

2. Standard markingAll 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.

2.1 Cable markingYellow markings with black characters shall be used.

Core no. Cable no.

Fig. 1 Core marking

Cable no.t

Core no.t

Fig. 2 Marking of a cable end consisting of 3cores and protective earth conductor

Partex Fleximark

Fig. 3 Cable marking standard


2.2 Core markingWhite markings with black characters shall be used.

3. Mounting3.1 Cable numbersThe marking sleeves are to be fixed on the sheath of the cable close to thestripped end, see figure 6. When cables are terminated in a connection box, themarkings are to be fixed to the cables outside the box. The markers are threadedonto a plastic strap, which is fastened around the cable (figure 3).3.2 Core numbersThe 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 theright or from bottom to the top: Core number. Cable number. See figure 6.

4. Accessories and tools4.1 PartexPlease contact Partex Fabriksaktiebolag for further information.

Address: Box 80S-547 01 Gullspng, SwedenTelephone +46 0551 20560

Fig. 4 Holder for cable markings typePartex, which are used when extramany characters are required

Fig. 5

Partex

Fleximark


Fig. 6

Core marking:White markings withblack characters.

Cable marking:Yellow markings withblack characters.

Fig. 7

For diameter2.46.2 mm

4.2 FlexipartPlease ccontact Miltronic AB for further information.

Address: Box 1022S-611 29 Nykping, SwedenTelephone +46 0155 87000

4.3 Other standardsOutside Sweden various customers may require special marking system. Thedesign office will then order the material needed and issue the necessary installa-tion instructions.4.4 Open type markersPartex can also deliver an open marker, with which already terminated wires canbe marked. See figure 7.


SITEMAN 11 - 94 Brazing1WAT 910033-11Edition January 1994 Thermic welding

process





List of Contents

A BRAZING1. General ........................................................................................................ 332. Brazing equipment..................................................................................... 333. Setting the torch pressure for acetylene and oxygen ............................ 334. Definitions, clarification of words............................................................. 345. Units of measure ........................................................................................ 346. Flame brazing ............................................................................................. 346.1 Wedling torches ........................................................................................... 346.2 Types of flame .............................................................................................. 346.3 Bunsen burner ............................................................................................. 357. Different types of solder, their characteristics and use ......................... 357.1 Silver solder ................................................................................................. 357.2 Brass solder ................................................................................................. 357.3 Phosphor-copper solder ............................................................................... 357.4 Copper solder .............................................................................................. 357.5 Heat-resistant solder .................................................................................... 367.6 Aluminium solder ......................................................................................... 368. International standard solders; preferred standard................................ 369. Flux.............................................................................................................. 3610. Description of methods ............................................................................. 3710.1 General ........................................................................................................ 3710.2 Brazing, joining of copper bars (75 x 6) ....................................................... 3710.3 Brazing of copper bars (50 x 10) with prelocated solder .............................. 3810.4 Brazing of earthing conductors/T-joints (branch-joints) ................................ 3910.5 Brazing of aluminium T-joints ....................................................................... 4011. Different types of solder and their working temperature ....................... 4212. Effective temperature ranges of different fluxes .................................... 43

B THERMIC WELDING PROCESS ................................................................ 441. Personal protection at welding ................................................................. 442. Storing/keeping of weld metal .................................................................. 443. Preparation and handling of welding moulds ......................................... 444. Preparation of conductors ........................................................................ 445. Thermic welding process .......................................................................... 456. Final treatment of connections................................................................. 45


A. BRAZING

1. GeneralBrazing is a method used for joining materials in cases when a joint of greater strength, than that obtainedby 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 istherefore ensured.

2. Brazing equipment

Fig. 1

3. Setting the torch pressure for acetylene and oxygen. Screw in the diaphragm screw 1. Turn clockwise Read off the intermediate pressure on the low-pressure

gauge 2 Adjust to approx. 5 kgf/cm2 for oxygen and to approx.

1.5 kgf/cm2 for acetylene.

Fig. 2


4. Definitions, clarification of wordsBrazing solder bonding material used in brazing of metal or metal alloy. The solder must have thecapability of wetting the bonding surface of the material to ensure the creation of an alloy.Flux is a facility in the form of a powder, paste or fluid which is applied to the bin-ding surface of themateiral in order to reduce any oxides and to protect against oxidation while the material is being heated.Working temperature is the lowest temperature of the contact point in the binding surface to ensure theflow-out and binding of the solder.Maximum brazing temperature is the highest temperature that can be allowed without causing damage tothe solder, flux or the parent material.Bonding strength of a solder is the tensile strength between the solder and the parent material, measuredat right angles to the binding surface (example: joint brazing).Brazing at a working temperature above 450 C and a brazing procedure similar to that used in gaswelding. The solder is often referred to as brazing solder (example: joint brazing).Gap brazing The surfaces which are to be joined are parallel and placed at a certain distance from eachother (brazing gap), which is normally less than 0.5 mm. The solder flows out in the gap due to capillaryaction capillary brazing (refer to Wetting).Joint brazing The surfaces to be joined are parallel and lie at a distance of more than 0,5 mm or form aV, X or fillet joint. The gap is filled with solder.Brazing with solder in direct contact In this case, the solder in the form of a wire or strip is applied byhand and melts when it comes into contact with the heated parent material.Brazing with prelocated solder Before heat is applied, the solder is placed in the gap between the twosurfaces.Wetting The ability of a molten drop of solder to spread itself out on a binding surface. Wetting can onlyoccur above a certain temperature and on clean surfaces.

5. Units of measurePressure:1 Pa = 1 N/m21 bar = 100 kPa1 lbf/m2 = 6.98 kPa1 psi = 6.98 kPa1 kp/cm2 = 98.1 kPa

6. Flame brazingThe material is heated with a burner welding torch or bunsen burner.

6.1 Welding torch with appurtenant equipment (acetylene oxygen)

Fig.3

6.2 Types of flame

Fig. 4, Carburizing flame


Fig. 5, Neutral flame

Fig. 6, Weak reducing flame

6.3 Bunsen burner An LP-gas burner which consumes oxygen from the surrounding air through injector action in the burner

norzzle.

Fig. 7

7. Different types of solder, their characteristics and useThe solder usually consists of an alloy formed between two or more metals.

The cost of brazing, the strength of the joint, the anti-corrosive properties, the similarity in colour, etc., areto a great extent dependent upon the composition of the solder.

The solder is divided into different groups, such as; silver solders brass solders phosphor-bronze solders copper solders heat resistant solders aluminium solders

Reference should also be made to page 7 and 8.

7.1 Silver soldersThese have good soldering properties. The working temperature lies between 600 and 800 C. They arerelatively expensive but this is partly outweighed by the short heating time. With the exception of aluminium,they are suitable for the majority of metals. They can be used for soldering heat-resistant stells but they arenot recommended for this purpose.

7.2 Brass soldersThese are inexpensive but their working temperature is high, 900 C. The cost of heating is relatively high.They are best suited for carbon steels, cast iron, malleable iron and low-alloyed steels. They can be used forother metals except aluminium.

7.3 Phosphor-copper soldersThese have been specially produced for copper and copper alloys (bronze, red brass, brass). That with 5 %Ag and a working temperature of 715 C is intended directly for copper (copper piping).

7.4 Copper soldersThese are inexpensive but they have a high (1000 C) working temperature. The cost of heating is high.They are suitable for brazing details of steel and for securing carbide tips on tools.

N.B! They are not suitable for brazing copper or copper alloys.


7.5 Heat-resistant solderThis solder is relatively expensive and its working temperature is also high, 960 C, which increases thecost still further. It is only suitable for brazing of stainless steel, heat-resistant steel, nickel and nickel alloys.

7.6 Aluminium solderThis is relatively inexpensive and its working temperature is low, 500 C. It is used for brazing aluminiumand aluminium alloys which have a long magnesium content.

8. International standard solders; preferred standardSolders conforming to ASEA standard and equivalent German (DIN), British (BS) and American (AWS)types:

*) No DIN BS1845: AWS ASEA ABB8513 1977 A5.8.81 article no article no

1 L-AlSil2 AL2 BAlSi4 2 4261 1124 1001-32 L-Cu CU2 BCu-1 2 50103 LCuZn40 CZ7 RBCuZn-A 2 52514 L-Ag2P CP2 BCuP-6 2 5909 1122 1110-1045 L-AG15P CP1 BCuP-5 2 5983 1122 1131-106 **)

1122 1131-111 ***)6 2 5990 1122 1171-2877 L-Ag55Sn AG14 BAg7 2 6829 1125 1040-1

*) No.1. Aluminium solder for brazing of aluminium and aluminum alloys

(Flux ASEA 1233 0012-207)2. Copper solder for brazing of steel. (Furnace brazing no flux required)3. Brass solder for brazing of steel, copper and copper alloys but not stainless steel

(Flux ASEA 1233 0012-201).4. Phosphor-copper solder for copper and copper alloys in primarily statically loaded joints;

max. 300 C. (Not suitable in atmosphere with high sulphur content).5. Phosphor-copper solder for copper and copper alloys where the joint is subject to

fatigue forces; max. 300 C. (Not suitable in atmosphere with high sulphur content).**) Flat bar 0.5 x 6.***) Flat bar 2.5 x 6.

6. Silver solder brazing in general; steel, stainless steel, copper and copperalloys. (Flux ASEA 1233 0012-201).

7. Silver solder for brazing in general; steel, stainless steel, copper and copper alloys,silver and silver alloys. Low working temperature (650 C), high tenacity solder, highlycorrosion resistant. (Flux ASEA 1233 0012-201).

9. FluxThe purpose of the flux is to dissolve the oxides on the binding surfaces and to prevent the formation of newoxides 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 onthe fact that it must be adapted to the working temperature required by the solder and, furthermore, that inthe molten state it must be so light fluid that it can be drawn into the gap between the pieces of parentmetal. 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 thebest 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 noticeshould, therefore, be read carefully.

Note! The flux does not remove rust, oil, grease, paint or otherimpurities. Brazing flux is normally supplied in powderform. Mix the flux with distilled water to form apaste and then apply it with a brush.

Fig. 8.


10. Description of methods

10.1 GeneralPreparations: Select a suitable burner. Welding burner Bunsen burner (acetylene or L.P. gas)The size of the burner depends on the dimensions of the item to be joined.

Select solder and flux as mentioned in clause 8.

Cleaning: Wipe off grease and other impurities.If the oxide layer is excessive, brush or grind it away.

Assembly: Assemble the items in the correct position. Apply flux to the appropriate surface. The width of the gap must be correct. Secure the items so that they are not displaced during the brazing and cooling-off periods.

Brazing: Ignite the burner and adjust to obtain a suitable flame.Warn the parent metal first. Apply more heat to the heaviest part or that part which dissipates heat quickest. Heat until the flux has melted and has penetrated in under the gap. Heat with a sweeping motion until the working temperature of the solder has been reached.Apply solder Place the solder against the pieces to be joined. Do not point the flame directly against solder. Heat only so much that the solder melts uniformly and is drawn into the gap. Apply solder until the gap is completely closed. Cool the joint.

Post cleaning: Remove all residual flux by brushing and flushing with warn water.

10.2Brazing, joining of copper bars (75 x 6)Preparations: Select a torch nozzle of suitable size, e.g. 700 l.Choose phosphor-copper solder L-Ag 15P CP1, 6 x 2,5 mm, page 7 no. 5.

Pre-cleaning: Wipe off grease and other impurities.Clean the joint surfaces with an abrasive tool or a brush.

Assembly: Gap width 0,2 mm

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 agap 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.


10.3 Brazing of Cu-bars (50 x 10) = with prelocated solderPre-cleaning: Clean the details and remove the oxides layer from the binding surfaces.

Preparations: Select a suitable burner; 100 l.Select suitable solder, phosphor-copper solder, e.g. 6 x 0.5 mm; see page 7 no. 5.

Cut the solder into small pieces. Adapt the length to the appearance of the joint surface (L = 50). Adapt the amount of solder so that it covers the entire surface (6 pcs.).

Assembly: To secure the details in the required position during the melting sequence, the following isrecommended:

Secure the pieces in the desired position with a welding clamp and without the pieces of solder.Retain the setting of the welding clamp and loosen the joint anew.

Fig. 10.Place the solder on the binding surface of one of the details.

Fig.11Relocate the details to their correct positions and secure them without altering the position of thewelding 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.


Inspection: Ensure that the solder har penetrated through and had adhered along all the edges of thebinding surfaces.

Fig.13.

10.4 Brazing of earthing conductors/T-joints (branch-joints)Pre-cleaning: Wipe off grease, oil and other impurities.Remove the oxides layer with at steel-wire brush or steel wool.

Preparations: Select a burner nozzle of suitable size, e.g. 300 l.Select suitable solder, phosphor-copper solder which has a working temperature of 710 715 C (refer tothe table). Flux is not necessary.

Procure approximately 1 m Cu-wire of diameter 1.5 2 mm, for lashing the joint and strips or insulatingtape.

Assembly: Place the branch line against the trunk line,approx. 50 mm, and thereafter with approx. 50 mmradius as shown in the figure.

Fig. 14.

Using plastic straps or insulating tape, fix the lines to eachother. The distance between the fixing points should beapproximately 40 mm in order to provide space for thelashing 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.


Remove the support straps/tapes

Fig. 17.

Brazing: Ignite the burner and adjust to obtain a neutral flame.Heat the trunk line first, 50 100 mm adjacent to the joint; use a sweeping movement when applying theflame.

Heat the area for the joint - alternatively only line, then the other. Heat until the material obtains a dark-red colour, approx. 700 C.

Apply the solder, commencing at the end of thebranch line.

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.

10.5 Brazing of aluminium T-jointsPre-cleaning: Clean the details and remove the oxide layer.

Preparations: Select a suitable burner, e.g. 700 l.Select a suitable solder, aluminium solder e.g. ASEA 1124 1001-3; refer to pages 17 and 7 (no. 1.).

Select a suitable flux; see group A on page 18, e.g. ASEA 1233 0012-207, page 7.Use flux in powder form on the joint; it is then most active on aluminium.

Assembly: Secure the details in the desired position with the aid of a welding clamp or other fixture.Ensure that the gap is as small as possible, preferably less than 0.5 mm.

Check the dimensions.

Brazing: Ignite the burner and adjust to a suitable flame. Weak carburizing flame.Heat the end of the solder careully and immerse it in the flux. The flux will adhere to the solderPreheat the joint Enough to enable the flux to fasten.Add flux with the aid of the solder.


Fig. 19.

Maintain a small angle to the point of the joint Move the solder, with the flux, back and forth along the joint. Heat so that the flux leaves the solder and transfers to the joint. Do not disperse the powder with the pressure from the flame. Flux must adhere to the entire length of the joint. Do not melt the solder. Do not melt the aluminium details (melting temp. of Al is 660 C).

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-cleaningRemove all residual flux. Use a wire brush and water.

InspectionEnsure that a fillet is obtained on each side.

Fig. 21.


11. Different types of solder and their working temperatures

500

600

700

800

900

1000

1100

1200

C

Workingtemperature

Solders alloysfigures states

Designation Remarks

1020 Cu87 Mn10 Co3 Copper solder

960 Ag85 Mn15

Cu48 Zn41, 8 Ni10 Si0.2

Heat resistant solder

850 Cu94 P6 Phosphor Copper solder

810 Ag20 Cu44, 9 Zn35 Si0.1 Silver solder

740730715710705

Ag32 Cu33 Zn35Ag44 Cu30 Zn26Ag5 Cu 88.8 P6.2Ag2 Cu91.5 P6.5Ag15 Cu80 P5

Silver solder *)Silver solderPhosphor Copper solderPhosphor Copper solder *)Phosphor Copper solder *)

690 Ag49 Cu16 Zn23 Mg7.5 Ni45 Silver solder

Asea 1122 1171-28

Asea 1122 1110-104Asea 1122 1131-106 -105

650640610

Ag55 Cu21 Zn22 Sn2Ag34 Cu22 Zn24 Cd20Ag40 Cu19 Zn21 Cd20

Silver solder *)Silver solderSilver solder

Asea 1125 1040-1690 Ag49 Cu16 Zn23 Mg7.5 Ni45 Silver solder

580 Al87 Si13 Aluminium solder *) Asea 1124 1001-3550 Al86 Si10 Cu4 Aluminium solder

*) Preferred standard (refer to page 7).

C


12. Effective temperature ranges of different fluxes

500

600

700

800

900

1000

1100

1200

C

SISA

FLUX

AH

SISA

FLUX

AN

190

190

NHIN

TRA-

24

AGA

AGA

CAST

OLI

NCA

STO

LIN

ELG

A

For a

lum

iniu

m}

Group A

500

65

0 C

SILC

OFLU

X 60

0, SI

LCOF

LUX

NI *)

SILC

OFL

UX A

B18

02 N

, ALB

RO *)

H-FL

UX*) S

uitab

le for

stain

less s

teel

AGA

AGA

CAST

OLI

NEL

GA

GEN

ERAL

(Not

alumi

nium)

}

Group B

500

80

0 C

BRAS

IFLE

X 75

0CO

BRAF

LUX

900

TERM

OFL

UX LV

16 A

ND 1

8KM

B 61

AGA

AGA

AGA

CAST

OLIN

ELGA

Not s

uitab

lefor

copp

eran

d cop

per-

alloy

s}Group C

700

11

00 C

Note

pur

e co

pper

sold

ered

with

out f

lux


B. THERMIC WELDING PROCESS

1. Personal protectionWelding smoke is developed during the welding operation. Precautions must be taken to minimize inhala-tion of the welding smoke, especially in narrow and poorly ventilated rooms. Arrange for efficient generalventilation as well as local evacuation of the smoke. If, for one reason or another, general protectiveequipment is impossible to use, then individual personal protections have to be used.

The welding smoke contains thin dispersed metallic oxides from zinc, copper, magnesium, etc. and mightat casting and welding operations cause acute poisoning with fever and symptoms similar to those ofinfluenza. Special treatment is usually not required. The symptoms on otherwise healthy persons. Whendoing the final treatment (for example removing the slag) of the weld joint there is a risk that hot slag will flyaround. Furthermore, handling the hot welding mould must be done with care to avoid burning damages.Always use protective goggles and gloves.

Suitable protective gloves against heat ant thermal radiation is for example gloves made at Namexfilt (donot contain asbestos).

2. Storing/keeping of weld metalWeld metal shall be stored in a dry and fire secure room. Stored in a dry place the storage time is practicallyunlimited.

Weld metal boxes must not be subject to chocks during transport and handling as the ignition powder -being pressed together in the bottom of the container, might mix with the welding powder, and therebycausing porous welding joints when being used.

3. Preparation and handling of welding mouldsPrior to start of the welding the mould must be heated to min. 100 C.

Use gasol fire (preferably gasol stove) for heating. The welding mould must be kept absolutely dry duringthe welding operation. A damp mould may give a porous welding joint. If it is difficult to keep the mould dryfor example during rain, it is preferable to postpone the welding until better weather conditions appear.A damp welding mould can also cause ejection of welding material (melt) from the mould.The welding must be cleaned from slag, soot and possible remains of tightening cement. For cleaning, usea melting pot scraper, file-brush and radiator-brush.Screwdrivers, knives or other sharp tools must no be used!Remaining hot slag (badly cleaned mould) might cause self-ignition of next charge.The life-cycle of the mould is estimated to be 70-100 joints. Thereafter it is usually scrapped. Make sure thatspare moulds are ordered in sufficient numbers.Welding moulds must be modified to fit other wire dimensions than originally specified.

4. Preparation of conductors (wires and bars)Oxide, dirt, etc. must be removed. Use wire-brush or file-brush. Oily/greasy conductors must be cleanedwith a suitable solvent, for example varnolene or percloretylne.

Wires shall be cut with cable cutter or scissors and in right angle. Do not nut through a tape bandage.

Fig. 22

Wet or damp conductors must first be dried out through heating with a gasol flame or by placing themimmediately 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.


5. Thermic weldingInsert 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 weldmould type plate.

Insert accompanying steel disc into the mould with the cone down. Pour the welding powder carefully intothe 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 evenlyon top of the welding powder and on the mould lip at the cover opening. The latter in order to facilitate theignition.Check that the mould is correctly closed around the conductors and standing in vertical positionbefore ignition.Close the mould cover and fire the ignition powder with a flint gun or other means without risk for burninginjuries.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 wetand damp conditions it is recommended that firing is made through a firing tape. Cut an approx. 10 cm longfiring 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 usedthe 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-offwire is cut and a new weld is made beside. Alternatively, the bad connection may be shunted according tothe figure below:

Fig. 23

6. Final Treatment of connectionsRemove solified slag remains on the connection. No other final treatment is required.

Note! When welding copper wire to galvanized rods or wires, the connection shall after having cooleddown to below 100 C be covered with cable compound, treated with insulating varnish or zinc-rich paint tomake it resistant against galvanic corrosion.


Joint Type: TA

Fig.24 Regarding personal protection equipment, see item 1.1) Preparation of welding mould according to item 3.2) Preparation of wires according to item 4.3) Insert wires in the mould according to above figure.Note: If the run wire is 240 mm2 or above and the tap wire 120 mm2 or above the run wireshall be cut and with a 3 mm gap be positioned under the cast cavity centre.Always place the tap wire in contact with the run wire.4) Close the cover well. Make sure that the wires have not moved out of position.5) Carry out the thermic welding operation as described under item 5.6) Make the final treatment of the joint according to item 6.


Joint Type: XA

Fig.25 1) Preparation of welding mould according to item 3.2) Preparation of wires according to item 4.3) Insert wires in the mould according to above figure.Note: Always place the tap wire in contact with the run wire.4) Close the cover well. Make sure that the wires have not moved out of position.5) Carry out the thermic welding operation as described under item 5.6) Make the final treatment of the joint according to item 6.


Joint Type: XB

Fig.26 1) Preparation of welding mould according to item 3.2) Preparation of wires according to item 4.3) Insert wires in the mould according to the above figure.4) Close the cover well.5) Carry out the thermic welding operation as described in item 5.6) Make the final treatment of the joint according to item 6.


Joint Type: GR

Fig.27 1) Preparation of welding mould according to item 3.2) Preparation of wire and rod according to item 4.3) Position the wire on top of earthing rod under the cast cavity centre.4) Close the cover well. Make sure that the wires have not moved out of position.Note: Hold the mould, with for example a self-locking plier applied around the rod, toguarantee that the mould will not slide down during welding.5) Carry out the thermic welding operation as described under item 5.6) Make the final treatment of the joint according to item 6.


Joint Type: GT

Fig.28 1) Preparation of the welding mould according to item 5.2) Preparation of wire and rod according to item 4.3) Position the wires on top of the earthing rod with a 3 mm gap under the cast cavity

centre.4) Close the cover well. Make sure that the wires have not moved out of position.Note: Hold the mould, with for example a self-locking plier applied around the rod, toguarantee that the mould will not slide down during welding.5) Carry out the thermic welding operation as described under item 5.6) Make the final treatment of the joint according to item 6.


SITEMAN 12 - 94 Cables1WAT 910033-12Edition May 1996


List of Contents1. General ..............................................................................................531.1 Classification of cables ......................................................................531.2 Stretch force .......................................................................................531.3 Temperature .......................................................................................531.4 Bending radius ...................................................................................531.5 Distance between cable planes .........................................................531.6 Interrelations and location of different classes of cables....................541.7 Distance between cables and rated data ...........................................541.8 Cable drums.......................................................................................541.9 Handling of cable drums at site ..........................................................541.10 Rotation of cable drums .....................................................................551.11 Braking of cable drums ......................................................................552. Method of laying ..............................................................................562.1 Laying by hand ...................................................................................562.2 Laying by motor-driven equipment, general .......................................572.3 Crossing of roads ...............................................................................582.4 Laying cables indoors ........................................................................582.5 Cable channel ....................................................................................582.6 Cable ladder .......................................................................................602.7 Section trays ......................................................................................612.8 Conduits .............................................................................................622.9 Cable table .........................................................................................633. Fixing of cables ................................................................................643.1 Supporting bar ...................................................................................643.2 Profiled bars .......................................................................................653.3 Suspension wire .................................................................................663.4 Free suspension ................................................................................673.5 Clamps for cables and conduits .........................................................683.6 Clips and cable straps ........................................................................683.7 Cable straps .......................................................................................693.8 Lashing wire .......................................................................................703.9 Expansion bolts and plugs .................................................................704. Marking of cables .............................................................................714.1 Standard marking ..............................................................................714.2 Cable marking ....................................................................................714.3 Core marking .....................................................................................724.4 Cable numbers ...................................................................................724.5 Core numbers ....................................................................................724.6 Partex .................................................................................................724.7 Flexipart .............................................................................................734.8 Other standards .................................................................................734.9 Open type markers ............................................................................735. Terminations.....................................................................................735.1 Length of cable ends ..........................................................................735.2 Termination sheet ..............................................................................746. Sensitive cables ...............................................................................757. Fireproof cables ...............................................................................76000. Examples of typical installations ...................................................77





1. GeneralThis instruction describes standard method for laying and installation of cables. It does not cover cable-laying in special environments, such as in high temperature areas.

1.1 Classification of cablesThe following ABB cable standard and classification shall be applied on each installation:K0 POWER CABLES. LESS THAN 1000 VK1 POWER CABLES. MORE THAN 1000 VThe high current in these cables may induce parasitic currents in screens and conductors of cables whichare 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 SIGNALThe relay and signal cables shall be laid at least 300 mm from both power and measuring cables.K3 CURRENT and VOLTAGE MEASURINGThe cables shall be laid at least 300 mm from other types of cables.K4 SENSITIVE MEASUREMENTSThese cables shall be laid in separated and completely screened channels of copper or galvanised steelpipes.K5 OPTICAL CABLESThese cables are not effected electrically by adjacent cables, however, these cables shall be considered ashigh risk of mechanical damage and shall be treated accordingly. For more details please refer toSITEMAN 13-94.K6 PREFABRICATED CABLESThese are cables that carry control and communication signals between differenct control panels, mainly inthe same room. The cables have been prefabricated and tested with their intended end connection, thecables therefore have to be installed as per the manufacturers instructions.

1.2 Stretch forceThe 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 TemperatureIf the ambient temperature is below 10 C the cable must be heated before laying. Otherwise it will be toorigid 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 lengthvariations in the cables and they must therefore be laid in gentle curves when the cables are long.

1.4 Bending radiiThe bending radii of the cables shall not exceed the following:Type of cable For laying When installedMulti-core 15 diameter 10 diameterThree-core 15 diameter 10 diameterSingle-core 15 diameter 10 diameterPEX 20 diameter 15 diameterFibre optic cables 100 mm *) 200 mm *)*) Refer to manufacturers instructions and SITEMAN 13-94.

1.5 Distance between cable planesThe vertical distance between cable planes and the distance to the ceiling should not be less than 300 mm.


1.6 Interrelations and location of different K classes of cablesThe different classes of cables are grouped separately on racks. K0, High voltage cable K1, Low voltage power K2, Control and signal K3, Current and voltage measuring K4, Sensitive measurements K5, Optical cables K6, Prefabricated cables

1.7 Distance between cables at rated dataCables shall be laid as shown in the installation documentation, and as described in section 1.1 of thisreport (Classification of cables). In general, spacing between power cables should be one cable diameter,but not more than 30 mm. More space will not improve the cooling of the cables. Sufficient cooling of single-core cables in a trefoil configuration is obtained with a spacing not less than 30 mm.

1.8 Cable drumsCable drums are made to 16 standard sizes and weight.K4 K6 K7 K8 K9 K11 K12 K14 K16 K18 K20 K22 K24 K26 K28 K30.

The drum required depends on the length, the weight and the outer diameter of the cable.

1.9 Handling of cable drums at siteA ramp, crane or forklift may be used for unloading cable drums. If neither of these are available, aprovisional ramp of square timbers or steel beams should be erected. The angle of inclination should notexceed 1 in 4. The timber and beams must be strong enough to support the weight of the drum.

Cable drums and coils, even if they are small and not heavy, should never be thrown onto the groundwhen unloading, the cable is likely to be damaged.

A suitable tractor trailor or forklift truck should be used for transporting the cable drums within the sitearea. The drums should never be rolled over longer distances.

Fig. 1 Lifting with crane


1.10 Rotation of cable drumsStandard cable drums have an arrow marked on the side. This arrow is showing the direction for rolling thedrum on the ground during short transits in order not to loosen the cable wound on the drum.

The cable should be pulled off from the top of the drum in such a way that the arrow shows in theopposite direction to the pull.

Fig. 2 The drum must be rolled in the direction of the arrow.

1.11 Braking of drumsWhen pulling off the cable, drum stands with hydraulic jacks and mechanical brakes are preferred to beused. The cable shall be pulled from the cable drum at a controlable and easy stopable rate. If the stand isnot equipped with a mechanical brake, a wooden plank or suitable impliment can be used for braking.

It must be made possible to easily stop the rotation of the cable drum at any given time.

Fig. 3 Braking of drums. Please note: The arrow shows direction of rolling on theground, not pulling.

ABB Cables

ABB

Cable

s


2. Methods of layingBefore installing any type of cable, the entire cable route shall be thoroughly inspected to ensure that thereare no obstacles or hazards that may cause damage to the cables that shall be installed. This inspectionshall 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 handRollers placed at distances of 3 to 4 m will facilitate laying. Corner rollers or similar devices should beprovided where there are bends in the route, the minimum bending radii of the cables shall be maintained atall 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 alongthe cable route.

Fig. 4 Layingby hand by theuse of cablerollers

Fig. 5 Cornerrollers


2.2 Laying by motor-driven equipmentMotor-driven equipment is normally used where there are a large number of cables to be installed in longruns where the routing is not too sophisticated. This system is not normally used in HV switchtyard areas.

The laying with motor-driven equipment is here divided into two groups: Laying by motor-driven rollers Laying by winches and cable-pushers.When motor-driven equipment is considered to be used, the following simplified conditions can act as aguide: The cable volume, i.e. the volume of cables, has to be of such a proportion that the time gained by using

the equipment is not lost in the transporting and handling of the motor-driven equipment. The cable diameter should not be less than 30 mm, more than one cable can be pulled simultaneously. The length of the cables should in average be more than 150 m. The cable routes shall be designed in a manner making it possible to postion the cables directly on their

final place when pulling. Experienced personnel has to be available.The following should be observed when pulling with machinery:

When a heavy cable is laid, a cable stocking or a pulling eye should be used. The cable stocking shall beplaced over the outer sheath of the cable to the total length of the cable stocking. When a pulling eye isused, care shall be taken to ensure that all conductor strands are evenly stressed, see fig. 9 and 10.

Fig. 6 Cable stocking


Fig. 7 Cable pulling eye

2.3 Crossing of roadsIt is always advisable to provide spare pipes in order to avoid having to dig up the road if further cables areto be laid. Ducts which are not used at once should be plugged. The cables should not rest on the sharpedges at the ends of the ducts. Steel pipes should have funnel-shaped ends, if possible.

If the end of a pipe or duct is levelled with the trench bed, the surface soil immediately before the openingshall be removed prior to pulling in the pulling in the cable in order to prevent stones or coarse soil fromgetting into the duct.

Fig. 8 Surface soil cleared at the entry to a duct or pipe

2.4 Laying cables indoorCables which must be protected mechanically or against electrical disturbances should be laid in steelducts, trays or pipes.

13 cables may be clamped directly onto walls, foundations and structures in the building, if the distanceis not more than 1020 mm.

2.5 Cable channelThe cable channels in outdoor switchyards are mostly made of concrete and covered with concrete slaps.

Indoor the channels are often integrated in the floors of the building and covered with metal plates.The cables can either be placed directly at the bottom of the channel or on cable support ladders.The main advantage of using cable channels is that cables may easily be replaced, added or inspected.


Fig. 10 Cable channel in outdoor switchboardplant.

Fig. 11 Cable channel in concrete floor.

Fig. 9 Cablechannels outdoor


2.6 Cable ladderDefinition of cable ladders specifies that the distance between the rungs may be a maximum of 300 mm. Ifthe rungs have a flat top surface they should be at least15 mm wide and round rungs should have a diame-ter of at least 19 mm.

Ladders are available in widths of 200, 300, 400, 500, 600 and 1000 mm.All cables shall be secured at bends when laying in order to obtain a neat installation. No further means

of securing are necessary when the cables are laid horizontally, apart from high tension single core cables.These cables should be laid in threefoil and fixed with terylene cord according to SITEMAN 14-94.

Fig. 12 Cable laddersfitted on ceiling pendant

Fig. 13 Wrapping a1-phase cable

At bends or where a cable leaves the cable ladder, the cable should be secured with plastic straps orlashing wire. In the case of vertical assembly, the cable is aslo fixed to every second rung. Cable over40 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 particularlysuitable due to their great mechanical strength and good cooling properties.


2.7 Section traysVarious sections are available. Most frequently used are L and U perforated sections.

Trays (U section) are available up to 600 mm.If used outdoor, all sections must be hot dipped galvanized, indoor electro-plated with zinc.

See Fig. 14. Perforated Sections

See Fig. 15. Tray


2.8 ConduitsConduits 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.

Fig. 16 Steel conduit FIg. 17 Flexible metal conduit with plastic sheath

Fig. 18 Hot dipped galvanized steel conduits


2.9 Cable tableThe cable table constitutes a list of the cables in the cable network. The following are specified for eachcable: type of cable number of conductors and their sizes cable length cable number cable classification K1, K2 etc. destination point A destination point A

Fig. 19 Cable Table


3. Various fastening materialThe following selection of material is only indicative. When ordering fastening material it is of utmostimportance to choose stainless material of the right quality for the purpose: outdoor, use hot dipped galvanized, brass, stainless steel or UV-resistant plastic material indoor, use the same material as for outdoor or at least zinc electro-plated steel.

3.1 Supporting barThe ASEA standard supporting bar is hot dipped galvanzied and form pressed in order to provide space forthe cable straps between the iron and the base on which it is installed.

SUPPORTING BARMaterial: Steel, hot dipped galvanized 80 .The bar is intended for installation of cables and tubes.

Fig. 20 Supporting bar

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.

Fig. 21 Bar mounted on conc


Fig. 22 Cable drawing on strip iron in transformerassembly

Fig. 23 Cable drawing on strip iron along concretewall

3.2 Profiled barsThe section of the profiled bar is designed to act as a holder for special types of cable clamps. The barshould be hot dipped-galvanized or of other stainless material.

Fig. 24 Profile Bars and Clamps

Normally the profiled bar is screwed permanently to walls or structures. A special bar is available forembedment in concrete.

The distance between bars used to support cables should be approximately 500 mm. Cables may befixed 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 cableinsulation.


3.3 Suspension wireThe suspension wire is a wire either galvanized or of stainless steel used to support the cable, see fig. 25,26 and 27.

The cable may be fixed to the wire by means of plastic or stainless steel straps.

Fig. 25 Suspension wire typical installations

Fig. 26 Illuminationassembly with suspensionwire. The cable is fastenedto the wire with plastic straps


Fig. 27 Suspension wirewith turnbuckle

3.4 Free suspensionWhen parts of machinery are moving in relation to each other one method to solve the interconnection is touse freely suspended flexible cables.

The cables should be fastened in their ends by means of special supporting clamps releasing the strainfrom the conductors.

A multi cable loop may be kept together by brackets or terylene string where mechanical forces can occurdue to short-circuit.

Fig. 28 Freely suspended cables in a furnaceassembly


3.5 Clamps for cable and conduitsThere are a lot of both metal and plastic clamps for cables available on the market. The cable is mostlyscrewed onto the base, but it may also be pressed or hooked to various flanges and profiled bars. Some-times also wooden clamps are used.

The distance between the clamps should be maximum 500 mm.Clamps may be used to secure a small number of cables (15).

Fig. 29 and 30 Typical installations with clamps

3.6 Clips and strapsClips may be of stainless steel, hot dipped galvanized steel or plastic.

Cable straps are made of plastic (resistant to UV-radiation) or stainless steel.Clips and straps are used to fix cables directly to walls or structures when installing cables for separately

placed apparatuses. The distances between fixing point vary but should maximum be 500 mm.

Fig. 31 Adjustable installation clips of plastic


Fig. 32 Installation clips Fig. 33 Various types of clips

3.7 Cable straps

Fig. 34 Plastic cable straps around tubes on transformer

Fig. 35 Cable straps (must be of plastic resistant to UV-radiation or stainless steel)UV = Ultra violet (light). See also SITEMAN 84-011

Stainless steel

Plastic


3.8 Lashing wireThe lashing wire consists of a plastic coated galvanized steel wire. The wire is basically used to secure thecables to cable ladder rungs in bends and when the cable is leaving the ladder.Diameter Braking load Weight/100 mLashing wire white PVC 1.5 mm 25 kp 1.8 kgLashing wire black PVC 1.5 mm 25 kp 1.8 kg

Fig. 36 Lashing wire

3.9 Expansion bolts and plugsThe following figures show some samples of bolts and plugs used in concrete.

Fig. 37 Expander bolt type HILTI (hot dip galvanized) for cable racks, boxes etc.

Fig. 38 Nail plug for supporting and supporting bars etc.

Fig. 39 Plastic plug with screw for lighter details


4. Marking of CablesThere are a great variety of cable marking systems available on the market. ABB have choosen to work withthe two following suppliers: Partex Fleximark.Each of these two systems is divided into two different marking systems: Preprinted cable markings Computerized cable markingsThese markings are produced by the use of computerized printer. The technical data are taken directly fromthe cable and core lists.

4.1 Standard markingAll 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. 40 Core marking

Fig. 41 Marking of a cable and consisting of 3 cores and protective earth conductor

4.2 Cable markingYellow markings with black characters shall be used.

Fig. 42 Cable marking standard

Fig. 43 Holder for cable markings type Partex, which are used when extra many characters are required


4.3 Core markingWhite markings with black characters shall be used.

Fig. 44

4.4 Cable numbersThe marking sleeves are to be fixed on the steath of the cable close to the stripped end, see fig. 45. Whencables are terminated in a connection box, the markings are to be fixed to the cables outside the box. Themarkers are threaded onto a plastic strap, which is fastened around the cable (fig. 42).

4.5 Core numbersThe 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 thetop: Core number Cable numberSee fig. 45.

4.6 PartexPlease contact Partex Fabriksaktiebolag for further information.Address: Box 80

S-547 02 Gullspng, SWEDEN Telephone +46-551-20560

Fig. 45


4.7 FlexipartPlease contact Miltronic AB for further information.Address: Box 1022

S-611 29 Nykping, SWEDENTelephone +46-155-87000

4.8 Other standardsOutside Sweden various customers may require special marking system. The design office will thencoordinate the material needed and issue the necessary installation instructions.

4.9 Open type markersPartex 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 endsIt is of utmost importance that both cable ends are measured to the correct length before cutting the cable.Enough is sufficient.

Fig. 47 Cable ends to various equipmentThe termination of the cable screens shall be done according to the information on the termination sheet.

The cable cores shall be terminated at the assigned terminal point with sufficient length to reach thefurthest terminal in the main terminal group.


5.2 Cable termination sheetThe sheet has the following information cable type cable size cable number end destination A terminal point end destination B instructions schematic diagram sheet number

See fig. 48 Termination details for cable Nr 94106 at destination point +ETA 1


See fig. 49 Termination details for cable Nr 94106 at destination point =AL-AK. A21.

6. Sensitive CablesCables that are designed to provide a high level of interference immunity are considered to be sensitivecables.

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


7. Fireproof CablesThe 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 cablesResulting from test as recommended in IEC 332-1. Cat. A, B, C. (Tests on electrical cables under fireconditions). 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.

Low smoke cablesLow smoke cables give off less smoke than conventional plastic and rubber cables. Low smoke cables arealso difficult to ignite and show little flame propagation during testing. There are two kinds of low smokecables. Zero-halogen (LSZH) cables and low-halogen (LSLH) cables.

LSZH cables shall be used where people are present every day and where evacuation could take time.The test method used for classification of low smoke cables involves determining how much light can

pass through smoke from an ignited cable sample in a sealed chamber.Places where low smoke cables should be used.

Mass transit vehicles and equipment Hospitals, hotels, restaurants and offices Industrial premises and power plant control buildings Offshore installations and ships

Fire resistant cablesFire resistant cables fulfil several important demands. Besides being operationally dependable in fires, theyare also difficult to ignite, and limit the spread of fire. The fire resistant cables have good electrical andmechanical strength properties, load capacity and flexibility.

Fire resistant cables meet the demands of fire test class B30, in which the cables must retain its electricalfunction while being heated in an oven for 30 minutes from room temperature to 821 C. During this time thecable must be connected to the supply, and the fuses shall not interrupt the current.

In addition the fire resistant cables shall fufil the demands of the IEC test, where the cable is exposed toan open gas flame for 3 hours at 750 C, during which time the cable must retain its electrical function. Thecable shall withstand its rated voltage for 12 hours after the fire.


000. Examples of

erection manuals

Documents

substations ofba ths

site mobilization

site welding rules cables

country site

site routines

site layout

internal abb substations

site toilets wc