Erection Manuals

Global Organization
Book No. 14
Version 0
Innovative
Solutions
Product &
Substation System
Business Business
Erection
BA THS / BU Transmission Systems and Substations

LEC Support Programme
Suggestions for improvement of this book

as well as questions shall be addressed to:
BU TS / Global LEC Support Programme
C/o ABB Switchgear AB
SE-721 58 Vsters
Sweden
Telephone
Telefax
Telex
+ 46 21 32 80 00
+ 46 21 32 80 13
40490 abbsub s
Copyright BU Transmission Systems and Substations
BA THS / BU Transmission Systems and Substations LEC Support Programme
Siteman
Erection
Welcome to the preliminary Siteman Erection handbook in the series of booklets
within the LEC Support programme of BU
Transmission Systems and Substations of
BA THS.
It is the intention of the BU to update this
handbook to reflect the philosophy of the
whole BU. We hope that you will find the
booklets useful in your work.
This booklet is dedicated to the erection.
It includes internal ABB Substations, Sweden instructions to for example:
Mobilize at a site
Welding rules
Cables
Earthing
Air Insulated Switchgear.
The authors welcome any idea you may
have to improve the quality of this booklet
as well as the other ones.
Best of luck!
CONTENTS
Check on arrival mobilization ........................................... page 5
Welding rules .............................................................................. page 25
Brazing Thermic welding process ................................ page 31
Cables ............................................................................................ page 51
Laying, termination and jointing of
high voltage cables <80 kV .................................................. page 87
Cubicles in electrical rooms Touch-up
painting ........................................................................................ page 113
Earthing ....................................................................................... page 131
Air insulated switchgear ..................................................... page 157
SITEMAN 01 - 94
1WAT 910033-1
Edition January 1994
Check on arrival
mobilization
List of contents
1.
General ............................................................................ 7
2.
Checklist arrival to the country site ........................ 7
3.
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
Site mobilization ............................................................. 7

Establishing of site routines .............................................. 7
Site layout ......................................................................... 7
Temporary power supply .................................................. 8
Offices and indoor store ................................................... 9
Outdoor stores ................................................................ 11
Personnel compartments canteens ............................. 12
Site toilets (WC) .............................................................. 12
Waste container .............................................................. 12
Protection ....................................................................... 12
4.
Checklist for civil works .............................................. 12
Appendix 1 ............................................................................. 13
Appendix 2 ............................................................................. 20
This document and parts thereof must not be

reproduced or copied without written permission, and the contents thereof must not be
imparted to a third party nor be used for any
unauthorized purpose. Contravention will be
prosecuted.
Addtional copies of this document may be
obtained from ABB at its then current rate
BU Transmission Systems and Substations of BA THS
1. General
This document will, in principle, describe the following main subjects:
check on arrival
site mobilization
check of civil works
It has to be emphasized that this instruction only can act as a guide, since each
country and site is unique, even if most of the actions to be taken are universal.
2. Checklist - arrival to the country site

The checklist, see Appendix 1, has a general character and summarizes questions
repeated from site to site and may act as a reminder.
3. Site mobilization
3.1 Establishing of site routines
For every project it is of utmust importance that the site procedures and routines
are agreed upon by all parties involved. The earlier ABB brings these questions
forward, the greater chance to introduce our routines.
Below follow examples of points and routines to be negotiated and agreed upon.
Routines for inspection, approval, progress reports, etc.
Routines for communication between customer, consultant, etc. and ABB site
representatives have to be agreed on. Remember that most consultants are
working in accordance with very strict protocol and are especially sensitive to
direct contacts between customer and contractors.
Routines for access to buildings and switchyard.
Routines for planning and recording of staff and man-power.
Rules for extra work. The contract normally specifies in detail how claims for
extra work and extension of time shall be handled. It also gives time limits within
which such claims must be submitted and how to measure the work. Note that
an agreement between the customer and the local project manager shall be
(issued) signed before any extra work is undertaken. Do not forget to note all
claims in all directions in the SITE-DIARY.
It does not matter how much information given in the contract documents earlier,
the practical application of these routines have to be established at site together
with the consultant, customer, subcontractor, etc.
3.2 Site layout
A site layout showing the service areas shall be done at an early stage and prior to
the start of the site activities. The layout shall show the following: (See Fig. 1 and
2.)
Areas allocated to ABB for offices, stores, outdoor storage area, workshop.
Supply points for electricity, telephone, telefax.
Supply points for water (incl. drinking water) and sewage.
Bench marks for checking of foundations.
The site layout shall also state the areas for the consultants, customer and
others.
Fig. 1
Fig. 2
3.3 Temporary power supply

The necessary temporary power demands have to be investigated and planned for
at an early stage prior to erection start. Make a sketch indicating number of supply
points starting type of outlet amp and volt for each. The following can act as a
guide:
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)
3.4 Offices and indoor store

The requirements have to be checked for each project. The following information
can 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 in
one 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
safe
The kitchenette may be equipped with:
refrigerator
cooker
coffee machine
crockery
Figure 3. Typical site office.
Figure 4. Container store.
20' ISOstandard
External
Internal
without
insulation
Lenght, mm
Width, mm
Height, mm
Weight, kg
6058
2438
2591
2400
5862
2329
2400
2400
Internal
with
insulation
5802
2209
2340
3450
Figure 5.
Typical indoor store.
10
Figure 6. View of an outdoor storage area.
Figure 7. Section view outdoor storage area.
3.5 Outdoor store

The storage area can vary between 100 4000 m2, as a guideline ca 60% of
complete switchyard. It can be located either inside or outside the switchyard. It
has to be fenced in, which can be done either by the customer, by ABB or by the
subcontractor.
11
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 canteens
The size is planned according to the man-power at peak. Various portable
buildings, container or tents can be used if no stationary facilities are available. The
compartments shall include lockable rooms for changing of clothes.
If warm meals have to be served at site, a special organization has to be
appointed to handle this separately.
3.7 Site toilets (WC)
The site toilets have to be arranged according to local standards and regulations
and 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 container
The necessary equipment for the waste and arrangement for the emptying is
needed to be arranged either by the customer, by ABB or by the subcontractor as
set 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 be
according to local standards and regulations.
4. Checklist for civil work

Prior to access to site and start of erection, the civil work must be checked. The
checklist, see Appendix 2, is detailing the most frequent points to be checked.
12
SITEMAN 01-94
Appendix 1
CHECKLIST
Period
Arrival to the country site
Project
SIte designation
Order no.
Page
Dealt with by
Date
Cont.
1
2
This checklist is supposed to be filled in with a few words answering following questions.
Return one copy soonest to your company. The whole list does not necessarily have to be
completed at one time, it can be returned part by part.
1.
TRAVEL
1.1
Travel time?
Routine?
Alternative routines?
1.2
Custom procedure?
Problems?
Need of visa, etc.?
Health check, compulsary
vaccinations?
Problems to get spare parts
etc. through customs as
personal luggage?
1.3
Transportation from airport?

Approx. cost?
Need of contact person at the
airport?
1.4
Landing card. How to be

filled in?
How to declare money in
custom?
1.5
Other comments regarding

the travel?
13
SITEMAN 01-94
Appendix 1
CHECKLIST
Period
Project
SIte designation
Order no.
Page
Dealt with by
Date
Cont.
2
3
2.
LIVING CONDITIONS
2.1
Hotel?
Rental of house / flat?
Approx. cost?
Cost?
Laundry?
Standard?
2.2
Cost of living?
Shortage of important
commodities?
Shortage of foodstuffs?
Possibilities to import
European food?
Canteens, restaurants?
Distance to site?
2.3
Drinking water,
need of boiling?
2.4
Electricity supply?
Voltage?
Frequency?
Reliability?
Adapter?
2.5
Climate?
Recommendable clothes?
Insects?
2.6
Laws/Regulations/Customs
useful to know?
Religion?
Other languages spoken?
Authorities?
2.7
Personal belongings preferable to be brought from home

country?
2.8
Customs regulations for

personal belongings?
Transport?
2.9
Currency restrictions?
Travellers cheques, cash?
Preferable currency?
Accepted credit cards?
SITEMAN 01-94
Appendix 1
CHECKLIST
Period
Project
SIte designation
Order no.
Page
Dealt with by
Date
Cont.
3
4
2.
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 regarding

living conditions?
SITEMAN 01-94
Appendix 1
CHECKLIST
Period
Project
SIte designation
Order no.
Page
Dealt with by
Date
Cont.
4
5
3.
MEDICAL FACILITIES
3.1
Hospital available?
Standard?
Address?
3.2
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 in
case of emergency sicktransportation to home
country?
3.6
Risk of deseases like malaria,

dysenteri, etc.?
3.7
Other comments regarding

medical facilities?
3.8
Address to SOS international

local branch?
SITEMAN 01-94
Appendix 1
CHECKLIST
Period
Project
SIte designation
Order no.
Page
Dealt with by
Date
Cont.
5
6
4.
WORKING CONDITIONS
4.1
Address for company mail?
4.2
Telephone number during

working hours?
Preferable time for calls from
Sweden (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, contact

man?
Needed tools and equipment
for erection available?
Standard of supervisors and
skilled man-power?
4.10 Visit transport company, contact man?

Needed equipment for safe
off-loading available?
Control of lifting devices?
4.11 Visit civil contractor, contact
man?
Any hinderance on site for
start of erection?
4.12 Local purchasing of erection
material possible?
Approx. cost level?
SITEMAN 01-94
Appendix 1
CHECKLIST
Period
Project
SIte designation
Order no.
Page
Dealt with by
Date
Cont.
6
7
4.
WORKING CONDITIONS (cont.)
4.13 Local purchasing of erection

tools possible?
Approx. cost level?
4.14 Workshop for minor repairs

and manufacturing available?
4.15 Plant for hot dip galvanizing

available?
4.16 Bank opening account

procedures for transfer?
4.17 Customs procedures for

hardware?
Ocean freight / air-freight?
Possibilities for smoothening
customs procedures?
4.18 Location of site, travelling

time?
Road description?
4.19 Electricity supply, worksite?

Voltage?
Frequency?
Reliability?

working conditions?
4.21 Telephone number to police,

ambulance, fire department?
4.22 Trafficability to site, summer,

winter, raining seasons?
SITEMAN 01-94
Appendix 1
CHECKLIST
Period
Project
SIte designation
Order no.
Page
Dealt with by
Date
Cont.
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 regulations?
5.7
Workshop and spare parts

available?
5.8
Heavy trucks?
Road conditions?
5.9
Import license?

transportation?
SITEMAN 01-94
Appendix 2
CHECKLIST
Period
Project
SIte designation
Order no.
Page
Dealt with by
Date
Cont.
1
2
This checklist is supposed to be filled in with a few words answering following questions.
The main purpose however, is to remind the Site Construction Manager of all Civil Work
to be checked before the erection shall start.
1.
OUTDOOR
1.1
Roads
to the site
inside the site
1.2
Trafficability
trafficability large / heavy
equipment such as transformers
trafficability building and
erection cranes limitations,
which?
1.3
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
SITEMAN 01-94
Appendix 2
CHECKLIST
Period
Project
SIte designation
Order no.
Page
Dealt with by
Date
Cont.
2
3
2.
FOUNDATIONS
2.1
Foundations (general)
correct location
2.2
Individual foundations
correct placing
correct construction
foundation bolts
size
placing
clean and undamaged
threads
nuts and washers fitted
2.3
Large foundations
(transformer / reactor)
dimensions
rails
embedded steelplates for
jacks / eyelets
foundation bolts
2.4
Oil pit
capacity
filling
cover
oil outlet
2.5
Cable routes
2.6
Ground network
SITEMAN 01-94
Appendix 2
CHECKLIST
Period
Project
SIte designation
Order no.
Page
Dealt with by
Date
Cont.
3
4
3.
CABLE ROUTES / GROUND NETWORK
3.1
Cable routes
Cable ducts / shelves
placing
design (acc. drawings)
brackets
ladders
embeddings
tops for placing of covers
covers
openings for cables in cable
ducts, etc.
correct inclination (ducts)
drainage
3.2
Ground network
correct running acc. drawing
test link
extra earth rods
joints
cathodic protection
3.3
Cleaning of cable ducts, etc.
SITEMAN 01-94
Appendix 2
CHECKLIST
Period
Project
SIte designation
Order no.
Page
Dealt with by
Date
Cont.
4
5
4.
STATION BUILDING
4.1
Station building
function
quality
trafficability
painting
water
heating
4.2
Floor
basement for panels
quality, finish
measures
fixing for
cables
panels
cable ducts in floor
indoor switchgear
foundation bolts
level
making of holes
4.3
Cable routes
placing
measures
fixings
brackets
ladders
intakes
4.4
Others
availability lockable rooms
water, showers, WC ready
for use
drainage correct inclination
lifting devices available
cleaning
SITEMAN 01-94
Appendix 2
CHECKLIST
Period
Project
SIte designation
Order no.
Page
Dealt with by
Date
Cont.
5.
VARIOUS / ACCESS
5.1
Security
fence and gates ready?
lockable stores?
site guarded?
5.2
Battery room
design
ventilation
holes
explosive-proof light fittings
water
painting
5.3
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
24
SITEMAN 08 - 94
Marking of cables
1WAT 910033-8
25
List of contents
1.
General .......................................................................... 27
2. Standard marking ......................................................... 27

2.1 Cable marking ................................................................. 27
2.2 Core marking .................................................................. 28
3. Mounting ........................................................................ 28
3.1 Cable numbers ............................................................... 28
3.2 Core numbers ................................................................. 28
4.
4.1
4.2
4.3
4.4
Accessories and tools .................................................. 28

Partex ............................................................................. 28
Flexipart .......................................................................... 29
Other standards .............................................................. 29
Open type markers ......................................................... 29

prosecuted.
26
1. General
There are a great variety of cable marking systems available on the market. ABB
have chosen to work with the two following suppliers:
Partex.
Fleximark.
Each of these two systems is divided into two different marking systems:
Preprinted cable markings.
Computerized cable markings.
These markings are produced by the use of a computerized printer. The technical
data are taken directly from the cable and core lists.
2. Standard marking
All cables shall be provided with durable markers at both ends.
Each cable shall be marked with cable number.
Each core shall be marked with:
Core number.
Cable number.
Cable no.
Core no.
Fig. 1 Core marking

Core no.
Fig. 2
Cable no.
Marking of a cable end consisting of 3

cores and protective earth conductor
2.1 Cable marking

Yellow markings with black characters shall be used.
Partex
Fig. 3
Fleximark
Cable marking standard
27
Fig. 4
Holder for cable markings type

Partex, which are used when extra
many characters are required
2.2 Core marking

White markings with black characters shall be used.
Fleximark
Partex
Fig. 5
3. Mounting
3.1 Cable numbers
The marking sleeves are to be fixed on the sheath of the cable close to the
stripped end, see figure 6. When cables are terminated in a connection box, the
markings are to be fixed to the cables outside the box. The markers are threaded
onto a plastic strap, which is fastened around the cable (figure 3).
3.2 Core numbers
The markings are to be placed near to the points of connections.
The cable core marking should state in the following order from the left to the
right or from bottom to the top:
Core number.
Cable number.
See figure 6.
4. Accessories and tools

4.1 Partex
Please contact Partex Fabriksaktiebolag for further information.
Address:
Box 80
S-547 01 Gullspng, Sweden
Telephone +46 0551 20560
28
Core marking:
White markings with
black characters.
Cable marking:
Yellow markings with
black characters.
Fig. 6
4.2 Flexipart
Please ccontact Miltronic AB for further information.
Address:
Box 1022
S-611 29 Nykping, Sweden
Telephone +46 0155 87000
4.3 Other standards
Outside Sweden various customers may require special marking system. The
design office will then order the material needed and issue the necessary installation instructions.
4.4 Open type markers
Partex can also deliver an open marker, with which already terminated wires can
be marked. See figure 7.
For diameter
2.46.2 mm
Fig. 7
29
30
SITEMAN 11 - 94
Brazing
1WAT 910033-11
Thermic welding
process
31
List of Contents
A
1.
2.
3.
4.
5.
6.
6.1
6.2
6.3
7.
7.1
7.2
7.3
7.4
7.5
7.6
8.
9.
10.
10.1
10.2
10.3
10.4
10.5
11.
12.
BRAZING
General ........................................................................................................ 33
Brazing equipment ..................................................................................... 33
Setting the torch pressure for acetylene and oxygen ............................ 33
Definitions, clarification of words ............................................................. 34
Units of measure ........................................................................................ 34
Flame brazing ............................................................................................. 34
Wedling torches ........................................................................................... 34
Types of flame .............................................................................................. 34
Bunsen burner ............................................................................................. 35
Different types of solder, their characteristics and use ......................... 35
Silver solder ................................................................................................. 35
Brass solder ................................................................................................. 35
Phosphor-copper solder ............................................................................... 35
Copper solder .............................................................................................. 35
Heat-resistant solder .................................................................................... 36
Aluminium solder ......................................................................................... 36
International standard solders; preferred standard................................ 36
Flux .............................................................................................................. 36
Description of methods ............................................................................. 37
General ........................................................................................................ 37
Brazing, joining of copper bars (75 x 6) ....................................................... 37
Brazing of copper bars (50 x 10) with prelocated solder .............................. 38
Brazing of earthing conductors/T-joints (branch-joints) ................................ 39
Brazing of aluminium T-joints ....................................................................... 40
Different types of solder and their working temperature ....................... 42
Effective temperature ranges of different fluxes .................................... 43
B
1.
2.
3.
4.
5.
6.
THERMIC WELDING PROCESS ................................................................ 44

Personal protection at welding ................................................................. 44
Storing/keeping of weld metal .................................................................. 44
Preparation and handling of welding moulds ......................................... 44
Preparation of conductors ........................................................................ 44
Thermic welding process .......................................................................... 45
Final treatment of connections ................................................................. 45

prosecuted.
32
A. BRAZING
1. General
Brazing is a method used for joining materials in cases when a joint of greater strength, than that obtained
by soldering, is required. The strength of the joint can be the same as that of the materials to be joined.
In this instruction brazing solder will be called solder only.
The working temperature of the solder and the materials to be joined is, however, to be least 450 C.
Copper and copper alloys can be easily brazed, but tin, lead and aluminium additives make brazing more
difficult.
Carbon stells and alloyed steels can be easily brazed, but the brazeability will be reduced when the
carbon content and the alloy content, respectively, are increased.
In the case of cast iron, the graphite opposes the wetting ot the solder.
Aluminium and aluminium alloys can also be brazed.
The strength of the joint varies, depending on the metals and the type of solder. As a guiding value for
steel, copper and brass, an initial tensile strength of 200 N/mm2 can be reckoned with. Adequate safety is
therefore ensured.
2. Brazing equipment
Fig. 1
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
33
4. Definitions, clarification of words

Brazing solder bonding material used in brazing of metal or metal alloy. The solder must have the
capability 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 the
mateiral 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 the
flow-out and binding of the solder.
Maximum brazing temperature is the highest temperature that can be allowed without causing damage to
the solder, flux or the parent material.
Bonding strength of a solder is the tensile strength between the solder and the parent material, measured
at 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 gas
welding. 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 each
other (brazing gap), which is normally less than 0.5 mm. The solder flows out in the gap due to capillary
action 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 a
V, 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 by
hand 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 two
surfaces.
Wetting The ability of a molten drop of solder to spread itself out on a binding surface. Wetting can only
occur above a certain temperature and on clean surfaces.
5. Units of measure
Pressure:
1 Pa =
1 bar =
1 lbf/m2
1 psi
1 kp/cm2
1
100
=
=
=
N/m2
kPa
6.98 kPa
6.98 kPa
98.1 kPa
6. Flame brazing
The material is heated with a burner welding torch or bunsen burner.
6.1 Welding torch with appurtenant equipment (acetylene oxygen)
Fig.3
6.2 Types of flame
Fig. 4, Carburizing flame
34
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 use

The 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., are
to 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 solders
These have good soldering properties. The working temperature lies between 600 and 800 C. They are
relatively 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 are
not recommended for this purpose.
7.2 Brass solders
These 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 for
other metals except aluminium.
7.3 Phosphor-copper solders
These 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 solders
These 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.
35
7.5 Heat-resistant solder

This solder is relatively expensive and its working temperature is also high, 960 C, which increases the
cost still further. It is only suitable for brazing of stainless steel, heat-resistant steel, nickel and nickel alloys.
7.6 Aluminium solder
This is relatively inexpensive and its working temperature is low, 500 C. It is used for brazing aluminium
and aluminium alloys which have a long magnesium content.
8. International standard solders; preferred standard

Solders conforming to ASEA standard and equivalent German (DIN), British (BS) and American (AWS)
types:
*)
No
DIN
BS1845:
AWS
ASEA
ABB
8513
1977
A5.8.81
article no
article no
*)
**)
***)
1
2
3
4
5
L-AlSil2
L-Cu
LCuZn40
L-Ag2P
L-AG15P
AL2
CU2
CZ7
CP2
CP1
BAlSi4
BCu-1
RBCuZn-A
BCuP-6
BCuP-5
2 4261
2 5010
2 5251
2 5909
2 5983
6
7
L-Ag55Sn
AG14
BAg7
2 5990
2 6829
1124 1001-3
1122 1110-104
1122 1131-106 **)
1122 1131-111 ***)
1122 1171-287
1125 1040-1
No.
1.
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 copper
alloys. (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, highly
corrosion resistant. (Flux ASEA 1233 0012-201).
9. Flux
The purpose of the flux is to dissolve the oxides on the binding surfaces and to prevent the formation of new
oxides during the preheating stage. The flux is applied before heating.
The composition of the flux is partly dependent on the metal oxides, which it is to dissolve, and partly on
the fact that it must be adapted to the working temperature required by the solder and, furthermore, that in
the molten state it must be so light fluid that it can be drawn into the gap between the pieces of parent
metal. It must also be possible to remove it. The flux is fully active for a few minutes after it has melted.
The figure on page 16 shows examples of the active working ranges, of different fluxes, within which the
best results will be obtained. The relationship between the solder and a suitable flux is given in clause 8.
Note! Pure copper can be brazed with advantage without the use of flux.
Note! The flux consists to a great extent of borax and boric acid but it also contains
additives which can be dangerous or poisonous. The precautionary notice
should, therefore, be read carefully.
Note! The flux does not remove rust, oil, grease, paint or other
impurities. Brazing flux is normally supplied in powder
form. Mix the flux with distilled water to form a
paste and then apply it with a brush.
Fig. 8.
36
10. Description of methods

10.1 General
Preparations: 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.
10.2
Brazing, 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:
Fig. 9.
Gap width 0,2 mm
L = t x 5 mm = 6 x 5 = 30 mm
Place the bars on a heat-insulating base, e.g. bricks and secure them in position with 30 mm overlap and a
gap width of 0.2 mm.
Brazing: Ignite the burner and adjust to obtain a suitable flame.
Neutral flame
Warn the bars first, alternatively until they obtain a dark-red colour; both bars
should reach the working temperature, approx. 700 C, simultaneously.
Apply the solder.
37
10.3 Brazing of Cu-bars (50 x 10) = with prelocated solder

Pre-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 is
recommended:
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.11
Relocate the details to their correct positions and secure them without altering the position of the
welding clamp.
Fig.12.
Brazing: Ignite the burner and adjust to obtain a neutral flame.
Alternatively heat the copper bars.
use a sweaping movement when applying the flame
the copper bars should simulaneously reach working temperature, approx. 750 C.
heat until the solder melts, flows out and wets the binding surfaces.
38
Inspection: Ensure that the solder har penetrated through and had adhered along all the edges of the
binding surfaces.
Fig.13.
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 to
the table). Flux is not necessary.
Procure approximately 1 m Cu-wire of diameter 1.5 2 mm, for lashing the joint and strips or insulating
tape.
Assembly: Place the branch line against the trunk line,
approx. 50 mm, and thereafter with approx. 50 mm
radius as shown in the figure.
Fig. 14.
Using plastic straps or insulating tape, fix the lines to each
other. The distance between the fixing points should be
approximately 40 mm in order to provide space for the
lashing wire.
Fig. 15.
Wrap on the copper lashing wire, hard and tight, approx. 25 mm between the fixing points.
Twine the two ends of the wire to secure the joint.
Fig. 16.
39
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 the
flame.
Heat the area for the joint - alternatively only line, then the other. Heat until the material obtains a darkred colour, approx. 700 C.
Apply the solder, commencing at the end of the
branch 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-joints

Pre-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 solder
Preheat the joint
Enough to enable the flux to fasten.
Add flux with the aid of the solder.
40
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-cleaning
Remove all residual flux.
Use a wire brush and water.
Inspection
Ensure that a fillet is obtained on each side.
Fig. 21.
41
11. Different types of solder and their working temperatures
Working
Solders alloys
temperature figures states
C
Designation
Remarks
1200
1100
1020
Cu87 Mn10 Co3
Copper solder
960
Ag85 Mn15
Heat resistant solder
1000
Cu48 Zn41, 8 Ni10 Si0.2

900
800
700
600
850
Cu94 P6
Phosphor Copper solder
810
Ag20 Cu44, 9 Zn35 Si0.1 Silver solder
740
730
715
710
705
690
Ag32 Cu33 Zn35

Ag44 Cu30 Zn26
Ag5 Cu 88.8 P6.2
Ag2 Cu91.5 P6.5
Ag15 Cu80 P5
Ag49 Cu16 Zn23 Mg7.5 Ni45
Silver solder *)
Asea 1122 1171-28
Silver solder
Phosphor Copper solder
Phosphor Copper solder *) Asea 1122 1110-104
Phosphor Copper solder *) Asea 1122 1131-106
-105
Silver solder
650
640
610
Ag55 Cu21 Zn22 Sn2

Ag34 Cu22 Zn24 Cd20
Ag40 Cu19 Zn21 Cd20
Silver solder *)
Silver solder
Silver solder
Asea 1125 1040-1
580
Al87 Si13
Aluminium solder *)
Asea 1124 1001-3
550
Al86 Si10 Cu4
Aluminium solder
500
*) Preferred standard (refer to page 7).
42
700
600
Group A
GENERAL
(Not aluminium)
700 1100 C
AGA
AGA
CASTOLIN
ELGA
AGA
AGA
AGA
CASTOLIN
ELGA
Not suitable
for copper
and copperalloys
Group B
BRASIFLEX 750
COBRAFLUX 900
TERMOFLUX LV
16 AND 18
KMB 61
*) Suitable for stainless steel
SILCOFLUX 600, SILCOFLUX NI *)

SILCOFLUX AB
1802 N, ALBRO *)
H-FLUX
800
For aluminium
900
500 800 C
AGA
AGA
CASTOLIN
CASTOLIN
ELGA
1000
SISAFLUX AH
SISAFLUX AN
190
190 NH
INTRA-24
1100
Note pure copper

soldered without flux
1200
500 650 C
12. Effective temperature ranges of different fluxes
500
Group C
43
B. THERMIC WELDING PROCESS

1. Personal protection
Welding smoke is developed during the welding operation. Precautions must be taken to minimize inhalation of the welding smoke, especially in narrow and poorly ventilated rooms. Arrange for efficient general
ventilation as well as local evacuation of the smoke. If, for one reason or another, general protective
equipment 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 might
at casting and welding operations cause acute poisoning with fever and symptoms similar to those of
influenza. Special treatment is usually not required. The symptoms on otherwise healthy persons. When
doing the final treatment (for example removing the slag) of the weld joint there is a risk that hot slag will fly
around. 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 (do
not contain asbestos).
2. Storing/keeping of weld metal

Weld metal shall be stored in a dry and fire secure room. Stored in a dry place the storage time is practically
unlimited.
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 thereby
causing porous welding joints when being used.
3. Preparation and handling of welding moulds

Prior 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 during
the welding operation. A damp mould may give a porous welding joint. If it is difficult to keep the mould dry
for 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, use
a 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 that
spare 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 cleaned
with 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 them
immediately in the heated mould where they remain until completely dried.
In the meantime preparations for next welding can be made.
It is possible to weld a copper wire using a welding mould designed for a bigger area. In that case wrap on
a copper foil to the copper wire as a filling.
44
5. Thermic welding
Insert the conductors into the mould according to the applicable instruction (for each type of connection).
Damaged/cracked or worn-out moulds must not be used! Scrap them.
When a sealing tightening kit is used, it must only be applied in the outer edge of the conductor channel,
not inside the weld cavity.
Check that the right size of the welding metal container is chosen. Compare with the number of the weld
mould type plate.
Insert accompanying steel disc into the mould with the cone down. Pour the welding powder carefully into
the mould in order not to move the position of the steel disc.
Knock the ignition powder out - it is pressed together in the bottom of the container and spread it evenly
on top of the welding powder and on the mould lip at the cover opening. The latter in order to facilitate the
ignition.
Check that the mould is correctly closed around the conductors and standing in vertical position
before ignition.
Close the mould cover and fire the ignition powder with a flint gun or other means without risk for burning
injuries.
When fire use protective gloves and goggles. Dont stand in front of the cover opening.
When welding in narrow compartments or where it is an obvious risk that the mould will be affected by wet
and damp conditions it is recommended that firing is made through a firing tape. Cut an approx. 10 cm long
firing tape and insert it into the mould in such a way that the cover will keep it in position.
After welding, wait until the melted metal is solidified before opening the mould as described under item 3.
Should the melted metal have been leaking out in spite of the fact that sealing kits have been used
the mould is probably worn out and should be scraped.
Note! Material flown out from the mould means decreased mould quality.
Should the welding for some reason have been unsuccessful, it is recommended that the branched-off
wire is cut and a new weld is made beside. Alternatively, the bad connection may be shunted according to
the figure below:
Fig. 23
6. Final Treatment of connections

Remove 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 cooled
down to below 100 C be covered with cable compound, treated with insulating varnish or zinc-rich paint to
make it resistant against galvanic corrosion.
45
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 wire
shall 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.
46
Joint Type: XA
Fig.25

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.
47
Joint Type: XB
Fig.26
48
1)
2)
3)
4)
5)
6)
Preparation of welding mould according to item 3.

Preparation of wires according to item 4.
Insert wires in the mould according to the above figure.
Close the cover well.
Carry out the thermic welding operation as described in item 5.
Make the final treatment of the joint according to item 6.
Joint Type: GR
Fig.27

2) Preparation of wire and rod according to item 4.
3) Position the wire on top of earthing rod under the cast cavity centre.
Note: Hold the mould, with for example a self-locking plier applied around the rod, to
guarantee that the mould will not slide down during welding.
49
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.
Note: Hold the mould, with for example a self-locking plier applied around the rod, to
guarantee that the mould will not slide down during welding.
50
SITEMAN 12 - 94
Cables
1WAT 910033-12
Edition May 1996
51
List of Contents
1.
General .............................................................................................. 53
1.1 Classification of cables ...................................................................... 53
1.2 Stretch force ....................................................................................... 53
1.3 Temperature ....................................................................................... 53
1.4 Bending radius ................................................................................... 53
1.5 Distance between cable planes ......................................................... 53
1.6 Interrelations and location of different classes of cables .................... 54
1.7 Distance between cables and rated data ........................................... 54
1.8 Cable drums ....................................................................................... 54
1.9 Handling of cable drums at site .......................................................... 54
1.10 Rotation of cable drums ..................................................................... 55
1.11 Braking of cable drums ...................................................................... 55
2.
Method of laying .............................................................................. 56
2.1 Laying by hand ................................................................................... 56
2.2 Laying by motor-driven equipment, general ....................................... 57
2.3 Crossing of roads ............................................................................... 58
2.4 Laying cables indoors ........................................................................ 58
2.5 Cable channel .................................................................................... 58
2.6 Cable ladder ....................................................................................... 60
2.7 Section trays ...................................................................................... 61
2.8 Conduits ............................................................................................. 62
2.9 Cable table ......................................................................................... 63
3.
Fixing of cables ................................................................................ 64
3.1 Supporting bar ................................................................................... 64
3.2 Profiled bars ....................................................................................... 65
3.3 Suspension wire ................................................................................. 66
3.4 Free suspension ................................................................................ 67
3.5 Clamps for cables and conduits ......................................................... 68
3.6 Clips and cable straps ........................................................................ 68
3.7 Cable straps ....................................................................................... 69
3.8 Lashing wire ....................................................................................... 70
3.9 Expansion bolts and plugs ................................................................. 70
4.
Marking of cables ............................................................................. 71
4.1 Standard marking .............................................................................. 71
4.2 Cable marking .................................................................................... 71
4.3 Core marking ..................................................................................... 72
4.4 Cable numbers ................................................................................... 72
4.5 Core numbers .................................................................................... 72
4.6 Partex ................................................................................................. 72
4.7 Flexipart ............................................................................................. 73
4.8 Other standards ................................................................................. 73
4.9 Open type markers ............................................................................ 73
5.
Terminations ..................................................................................... 73
5.1 Length of cable ends .......................................................................... 73
5.2 Termination sheet .............................................................................. 74
6.
Sensitive cables ............................................................................... 75
7.
Fireproof cables ............................................................................... 76
000. Examples of typical installations ................................................... 77

prosecuted.
52
1. General
This instruction describes standard method for laying and installation of cables. It does not cover cablelaying in special environments, such as in high temperature areas.
1.1 Classification of cables
The following ABB cable standard and classification shall be applied on each installation:
K0 POWER CABLES. LESS THAN 1000 V
K1 POWER CABLES. MORE THAN 1000 V
The high current in these cables may induce parasitic currents in screens and conductors of cables which
are laid in their vicinity. Well screened power cables can be laid in the same cable trench with other cables,
but control and measuring cables require a minimum distance fo 300 mm from any power cable.
K2 CONTROL and SIGNAL
The relay and signal cables shall be laid at least 300 mm from both power and measuring cables.
K3 CURRENT and VOLTAGE MEASURING
The cables shall be laid at least 300 mm from other types of cables.
K4 SENSITIVE MEASUREMENTS
These cables shall be laid in separated and completely screened channels of copper or galvanised steel
pipes.
K5 OPTICAL CABLES
These cables are not effected electrically by adjacent cables, however, these cables shall be considered as
high risk of mechanical damage and shall be treated accordingly. For more details please refer to
SITEMAN 13-94.
K6 PREFABRICATED CABLES
These are cables that carry control and communication signals between differenct control panels, mainly in
the same room. The cables have been prefabricated and tested with their intended end connection, the
cables therefore have to be installed as per the manufacturers instructions.
1.2 Stretch force
The maximum stretch force when laying cables shall not exceed:
copper conductors ..................................................... 70N/mm2 (7 kg/mm2)
aluminium conductors ................................................ 40N/mm2 (4 kg/mm2)
1.3 Temperature
If the ambient temperature is below 10 C the cable must be heated before laying. Otherwise it will be too
rigid to handle and the insulation could be damaged during bending.
Preheat the cable indoors at a minimum of 15 C for 24 hours. Temperature fluctucation results in length
variations in the cables and they must therefore be laid in gentle curves when the cables are long.
1.4 Bending radii
The bending radii of the cables shall not exceed the following:
Type of cable
For laying
When installed
Multi-core
Three-core
Single-core
PEX
Fibre optic cables
15 diameter
15 diameter
15 diameter
20 diameter
100 mm *)
10 diameter
10 diameter
10 diameter
15 diameter
200 mm *)
*) Refer to manufacturers instructions and SITEMAN 13-94.

1.5 Distance between cable planes
The vertical distance between cable planes and the distance to the ceiling should not be less than 300 mm.
53
1.6 Interrelations and location of different K classes of cables

The 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 data
Cables shall be laid as shown in the installation documentation, and as described in section 1.1 of this
report (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 singlecore cables in a trefoil configuration is obtained with a spacing not less than 30 mm.
1.8 Cable drums
Cable 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 site
A ramp, crane or forklift may be used for unloading cable drums. If neither of these are available, a
provisional ramp of square timbers or steel beams should be erected. The angle of inclination should not
exceed 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 ground
when 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 site
area. The drums should never be rolled over longer distances.
Fig. 1 Lifting with crane
54
1.10 Rotation of cable drums

Standard cable drums have an arrow marked on the side. This arrow is showing the direction for rolling the
drum 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 the
opposite direction to the pull.
bles
ABB Ca
Fig. 2 The drum must be rolled in the direction of the arrow.
AB
B
Ca
ble
s
1.11 Braking of drums

When pulling off the cable, drum stands with hydraulic jacks and mechanical brakes are preferred to be
used. The cable shall be pulled from the cable drum at a controlable and easy stopable rate. If the stand is
not 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 the
ground, not pulling.
55
2. Methods of laying
Before installing any type of cable, the entire cable route shall be thoroughly inspected to ensure that there
are no obstacles or hazards that may cause damage to the cables that shall be installed. This inspection
shall be made regularly during the cable installation period.
The following methods may be employed for allying of cables:
Laying by hand
Laying by motor-driven equipment.
2.1 Laying by hand
Rollers placed at distances of 3 to 4 m will facilitate laying. Corner rollers or similar devices should be
provided where there are bends in the route, the minimum bending radii of the cables shall be maintained at
all times, see fig. 4 and 5.
The cables are to be carried by hand, if not supported by rollers, with the men standing 4 to 6 m apart along
the cable route.
Fig. 4 Laying
by hand by the
use of cable
rollers
Fig. 5 Corner
rollers
56
2.2 Laying by motor-driven equipment

Motor-driven equipment is normally used where there are a large number of cables to be installed in long
runs 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 a
guide:
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 be
placed over the outer sheath of the cable to the total length of the cable stocking. When a pulling eye is
used, care shall be taken to ensure that all conductor strands are evenly stressed, see fig. 9 and 10.
Fig. 6 Cable stocking
57
Fig. 7 Cable pulling eye

2.3 Crossing of roads
It is always advisable to provide spare pipes in order to avoid having to dig up the road if further cables are
to be laid. Ducts which are not used at once should be plugged. The cables should not rest on the sharp
edges 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 opening
shall be removed prior to pulling in the pulling in the cable in order to prevent stones or coarse soil from
getting into the duct.
Fig. 8 Surface soil cleared at the entry to a duct or pipe

2.4 Laying cables indoor
Cables which must be protected mechanically or against electrical disturbances should be laid in steel
ducts, trays or pipes.
13 cables may be clamped directly onto walls, foundations and structures in the building, if the distance
is not more than 1020 mm.
2.5 Cable channel
The 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.
58
Fig. 9 Cable
channels outdoor
Fig. 10 Cable channel in outdoor switchboard

plant.
Fig. 11 Cable channel in concrete floor.
59
2.6 Cable ladder

Definition of cable ladders specifies that the distance between the rungs may be a maximum of 300 mm. If
the rungs have a flat top surface they should be at least15 mm wide and round rungs should have a diameter 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 ladders

fitted on ceiling pendant
Fig. 13 Wrapping a
1-phase cable
At bends or where a cable leaves the cable ladder, the cable should be secured with plastic straps or
lashing wire. In the case of vertical assembly, the cable is aslo fixed to every second rung. Cable over
40 mm should however, be secured with brackets type KSV, if the vertical run is more than 10 m.
A maximum of five cables may be located under the same attachment device.
In most cases the cable ladder offers the best solution when building cable ways. In case of great
mechanical load, high short-circuiting currents and high ambient temperature cable ladders are particularly
suitable due to their great mechanical strength and good cooling properties.
60
2.7 Section trays

Various 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
61
2.8 Conduits
Conduits are protective pipes which may be of plastic or metal, rigid or flexible.
The conduits have to be secured to structures, machinery, building or equivalent.
In harsh environments when the cable sheath gives insufficient protection, conduits should be used to
protect the cable. Steel pipes also offer an excellent protection against electrical disturbances.
Flexible conduits may be used to mechanically protect flexible cables connecting electrical units.
Fig. 16 Steel conduit
FIg. 17 Flexible metal conduit with plastic sheath
Fig. 18 Hot dipped galvanized steel conduits
62
2.9 Cable table

The cable table constitutes a list of the cables in the cable network. The following are specified for each
cable:
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
63
3. Various fastening material

The following selection of material is only indicative. When ordering fastening material it is of utmost
importance 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 bar
The ASEA standard supporting bar is hot dipped galvanzied and form pressed in order to provide space for
the cable straps between the iron and the base on which it is installed.
SUPPORTING BAR
Material: 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
64
Fig. 22 Cable drawing on strip iron in transformer

assembly
Fig. 23 Cable drawing on strip iron along concrete

wall
3.2 Profiled bars

The section of the profiled bar is designed to act as a holder for special types of cable clamps. The bar
should 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 for
embedment in concrete.
The distance between bars used to support cables should be approximately 500 mm. Cables may be
fixed with clamps or with cable straps together with a special support.
The cable clamps shall not be re-tightened, since this can cause cold floating damaging the cable
insulation.
65
3.3 Suspension wire

The 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 Illumination
assembly with suspension
wire. The cable is fastened
to the wire with plastic straps
66
Fig. 27 Suspension wire

with turnbuckle
3.4 Free suspension

When parts of machinery are moving in relation to each other one method to solve the interconnection is to
use freely suspended flexible cables.
The cables should be fastened in their ends by means of special supporting clamps releasing the strain
from the conductors.
A multi cable loop may be kept together by brackets or terylene string where mechanical forces can occur
due to short-circuit.
Fig. 28 Freely suspended cables in a furnace

assembly
67
3.5 Clamps for cable and conduits

There are a lot of both metal and plastic clamps for cables available on the market. The cable is mostly
screwed onto the base, but it may also be pressed or hooked to various flanges and profiled bars. Sometimes 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 straps

Clips 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
68
Stainless steel
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
69
3.8 Lashing wire

The lashing wire consists of a plastic coated galvanized steel wire. The wire is basically used to secure the
cables to cable ladder rungs in bends and when the cable is leaving the ladder.
Diameter
Braking load
Weight/100 m
Lashing wire white PVC
Lashing wire black PVC
1.5 mm
1.5 mm
25 kp
25 kp
1.8 kg
1.8 kg
Fig. 36 Lashing wire
3.9 Expansion bolts and plugs

The 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
70
4. Marking of Cables
There are a great variety of cable marking systems available on the market. ABB have choosen to work with
the two following suppliers:
Partex
Fleximark.
Each of these two systems is divided into two different marking systems:
Preprinted cable markings
Computerized cable markings
These markings are produced by the use of computerized printer. The technical data are taken directly from
the cable and core lists.
4.1 Standard marking
All cables shall be provided with durable markers at both ends.
Each cable shall be marked with cable number
Each core shall be marked with: Core number and Cable number.
Fig. 40 Core marking
Fig. 41 Marking of a cable and consisting of 3 cores and protective earth conductor
4.2 Cable marking
Yellow markings with black characters shall be used.
Fig. 42 Cable marking standard
Fig. 43 Holder for cable markings type Partex, which are used when extra many characters are required
71
4.3 Core marking

White markings with black characters shall be used.
Fig. 44
4.4 Cable numbers
The marking sleeves are to be fixed on the steath of the cable close to the stripped end, see fig. 45. When
cables are terminated in a connection box, the markings are to be fixed to the cables outside the box. The
markers are threaded onto a plastic strap, which is fastened around the cable (fig. 42).
4.5 Core numbers
The markings are to be placed near to the points of connections.
The cable core marking should state in the following order from the left to the right or from bottom to the
top:
Core number
Cable number
See fig. 45.
4.6 Partex
Please contact Partex Fabriksaktiebolag for further information.
Address:
Box 80
S-547 02 Gullspng, SWEDEN
Telephone +46-551-20560
Fig. 45
72
4.7 Flexipart
Please contact Miltronic AB for further information.
Address:
Box 1022
S-611 29 Nykping, SWEDEN
Telephone +46-155-87000
4.8 Other standards
Outside Sweden various customers may require special marking system. The design office will then
coordinate the material needed and issue the necessary installation instructions.
4.9 Open type markers
Partex can also deliver an open marker, with which already terminated wires can be marked. See fig. 46.
Fig. 46
5. Terminations
5.1 Length of cable ends
It is of utmost importance that both cable ends are measured to the correct length before cutting the cable.
Enough is sufficient.
Fig. 47 Cable ends to various equipment

The 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 the
furthest terminal in the main terminal group.
73
5.2 Cable termination sheet

The 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
74
See fig. 49 Termination details for cable Nr 94106 at destination point =AL-AK. A21.
6. Sensitive Cables
Cables that are designed to provide a high level of interference immunity are considered to be sensitive
cables.
The most common interfaces are;
low frequency magnetic fields (from large currents in power cables)
electrical radiation (overvoltages caused by short circuit in power cables)
cross talk between cores/cores and between twisted pairs/twisted pairs.
These cables can be constructed as follows;
twisted pairs
screen of aluminium foil
screened by steel, aluminium or copper tape
screened by copper wire braid (90 %)
individual screened pairs
By combining different kinds of screens one can achieve a desired protection level.
Sensitive signals;
analog signals (010V)
digital signals
thyristor firing pulses
75
7. Fireproof Cables
The fire behaviour of cables is assessed and classified in terms of:
Flame propagation
flame protected cables
Smoke generation
low smoke cables
Function during a fire fire resistant cables
When cables are buried in the ground, fire behaviour has no significance.
Where cables are terminated indoors, there is a need for flame protection.
Where cables are laid openly indoors, flame protected cables must be used.
Flame protected cables
Resulting from test as recommended in IEC 332-1. Cat. A, B, C. (Tests on electrical cables under fire
conditions). Cables are classified as follows;
Cable propagates flame, this type of cable shall only be used in buried installations.
Self extinguisher after ignition with a small flame
Difficult to ignite and low flame propagation
Very difficult to ignite and very low flame propagation.
Low smoke cables

Low smoke cables give off less smoke than conventional plastic and rubber cables. Low smoke cables are
also difficult to ignite and show little flame propagation during testing. There are two kinds of low smoke
cables. 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 cables
Fire resistant cables fulfil several important demands. Besides being operationally dependable in fires, they
are also difficult to ignite, and limit the spread of fire. The fire resistant cables have good electrical and
mechanical strength properties, load capacity and flexibility.
Fire resistant cables meet the demands of fire test class B30, in which the cables must retain its electrical
function while being heated in an oven for 30 minutes from room temperature to 821 C. During this time the
cable 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 to
an open gas flame for 3 hours at 750 C, during which time the cable must retain its electrical function. The
cable shall withstand its rated voltage for 12 hours after the fire.
76
000. Examples of Typical Installations

001 Table for selection of material
= Preferred standard
= Standard
= Not recommended
Material for securing Terylene Wooden

cord
bracket
KSVbracket
Installation
bracket
Plastic
straps
Lash
wire
Method of laying
Stainless
steel
straps
Clamp
bracket
No means
of
securing
Laying in
Cable channel
Laying in
Cable duct
Laying on
Cable ladder
Section rails/trays
installation
Conduits
Supporting
bar
Profile bar
Installation
Suspension line
Installation
Free
Suspension
Bracket
Installation
) Cable strap support must be used, see page 29, Fig. 49.
77
002 Table for selection of installation method
SWITCHGEAR and TRANSFORMER

Cable channel
Anchor
rail
Ladder
SWITCHGEAR and DISTRIBUTION BOARD

Ladder
Cable channel
Ladder or cable channel
CONTROL ROOM
Ladder
Cable channel
Section beam
Strip iron
TERMINAL BOX
Section beam
Direct
laying
Conduit
Motors /
apparatus
78
Motors /
apparatus
Strip iron
Motors /
apparatus
Motors /
apparatus
Fig. 50 Typical installation
79
80
81
82
83
84
85
86
SITEMAN 14 - 94
1WAT 910033-14
Laying, termination and

jointing of high voltage
cables <80 kV
87
List of contents
1.
General .............................................................................................. 89
2.
Laying of high voltage cables <80 kV ............................................ 89
2.1 Cable drums ....................................................................................... 89
2.2 Handling of cable drums at site .......................................................... 89
2.3 Rotation of cable drums ..................................................................... 90
2.4 Braking of cable drums ...................................................................... 90
3.
Methods of laying ............................................................................ 91
3.1 General rules when laying of cables .................................................. 91
3.1.1 Stretch force ....................................................................................... 91
3.1.2 Bending radius ................................................................................... 91
3.1.3 Distance between cable planes ......................................................... 91
3.1.4 Interrelations and location of different classes of cables .................... 91
3.1.5 Distance between cables at rated data .............................................. 91
3.1.6 Cable table ......................................................................................... 92
3.1.7 Cable laying card ............................................................................... 92
3.2 Laying from a trailer ........................................................................... 92
3.3 Laying by hand ................................................................................... 92
3.4 Laying by motor-driven equipment, general ....................................... 94
3.4.1 Laying by motor-driven rollers ............................................................ 95
3.4.2 Laying by winches and cable pushers ............................................... 96
3.5 Laying in ground ................................................................................ 99
3.6 Crossing of roads ............................................................................... 99
3.7 Laying indoors .................................................................................... 99
3.8 Temporary marking ............................................................................ 99
3.9 Length of cable ends ........................................................................ 100
4.
Description of cable ways ............................................................. 100
4.1 Cable channel .................................................................................. 100
4.2 Cable duct ........................................................................................ 101
4.3 Cable ladder .....................................................................................103
4.4 Section rails/trays ............................................................................. 106
5.
Termination and jointing of high voltage cables <80 kV ............ 107
5.1 Termination and jointing ...................................................................107
5.2 Crimping of conductors .................................................................... 107
5.2.1 General ............................................................................................107
5.2.2 Points to bear in mind when crimping .............................................. 107
5.2.3 Cu-terminals .................................................................................... 108
5.2.4 Al and Al/Cu-terminals ..................................................................... 109
5.2.5 Marking of terminals ........................................................................ 110
5.2.6 Dimension checking .........................................................................111
5.3 Tools ................................................................................................. 112

prosecuted.
88
1. General
The intention with this document is to give site personnel a guide-line regarding methods when handling
and laying of high voltage cables from 1 kV up to 80 kV.
Regarding termination and jointing it is impossible to give universal information because it is a difference
between the different suppliers. Consequently, it is of utmost importance to follow the manufacturers
instruction when terminating and jointing of high voltage cables
2. Laying of high voltage cables

2.1 Cable drums
Cables are normally supplied on wooden drums. Short lengths may be supplied in rings or on other types of
drums.
The drum required depends on the length, the weight and the outer diameter of the cable.
2.2 Handling of cable drums at site
Cable drums are transported overland on railway, trucks or lorries. They are wedged tightly in order to
prevent them from moving during transport. The drums must be inspected for damage before unloading and
any complaints should be covered by a factual statement from the carrier in order to be able to claim damages.
A ramp, crane or forklift may be used for unloading cable drums. If neither of these is available a
provisional ramp of square timbers of beams should be erected. The angle of inclination should not exceed
1 in 4. The timber and beams must be strong enough to support the weight of the drum. While rolling down
the ramp the drum must be guided by ropes with the aid of winches or block and tackle. It is advisable to
pile sand approximately 20 cm high at the end of the run to act as a stop.
Note: Neither coils nor drums, even if they are small and not heavy, should be thrown onto the ground
when unloading them, as the cable is likely to be damaged.
A suitable trailer or tractor with forks should be used for transporting the cable drums within the site area.
The drums should never be rolled over longer distances.
After removing the planking from the drum the cable should be inspected for visible damage which may
have been caused by improper rolling of the drum. The labour who are going to carry out the cable laying
should be clearly informed that they are about to handle valuable and very easily damaged material. The
cable should not be pulled over hard and pointed obstacles, which could damage the insulation, nor should
it be bent too sharply.
At site a record on all cable drums should be kept stating type and length of cable for each drum arriving
or leaving the storage area. This in order to always know the quantities in stock and quantities being
installed.
Fig. 1 Lifting with crane.
89
2.3 Rotation of cable drums

Some cable drums have a painted arrow on the side. This arrow is showing the direction for rolling the drum
on the ground during transportation in order not to loose 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 the
opposite direction to the pull.
Fig. 2 The drum must be rolled in the direction of the arrow.

2.4 Braking the cable drum
When pulling off the cable, drum stands with hydraulic jacks and mechanical brakes are preferably used. If
the stand is not equipped with a brake, a plank can be used for braking.
It must be possible to brake the drum at any time if there is a sudden stop in order to prevent further
unrolling and consequent kinking of the cable, especially the latter must be prevented by all means.
Fig. 3 Hydraulic jack with mechanical brakes.
90
Fig. 4 Braking of drums. Please note:

The arrow shows direction of rolling
on the ground, not pulling.
3 Methods of laying
It is of utmost importance to follow instructions regarding bending radius, ambient temperature, stretch
force, etc. given by the manufacturer when laying of power cables.
The following methods and recommendations may be a guide-line for laying of high voltage cables.
3.1 General rules when laying of cable
3.1.1 Stretch force
In general, the maximum stretch force when laying cable may be:
with copper cables 5 Kp/mm2 (50 N) lead area
with aluminium cables 3 Kp/mm2 (30 N) lead area
3.1.2 Temperature
If the ambient temperature is below 10 C the cable must be heated before laying. Otherwise it will be too
stiff to handle and the insulation could be damaged during bending.
Preheat the cable in a store at a minimum of 15 C for 24 hours.
Temperature fluctuation result in length variations in the cables and they must therefore be laid in gentle
curves if the cables are long.
3.1.3 Bending radius
The bending radius of the cable shall be minimum:
Type of cable
For laying
When installed
Three-core
Single-core
PEX
15 diameter
15 diameter
20 diameter
10 diameter
10 diameter
15 diameter
3.1.4 Distance between cable planes

The vertical distance between cable planes and the distance to the ceiling should not be less than 300 mm.
3.1.5 Distance between cables at rated data
Power cables shall be laid as stated in the installation drawings. In general spacing between 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.
91
3.1.6 Cable table

The cable table constitutes a list of the cables in the cable network. The following are specified for each
cable
type of cable
number of core and their areas
an individual cable number
the plant parts to be connected by the cable
routing of cables (option)
3.1.7 Cable laying card
The card has the following functions:
to specify the information given in the cable table, one card for each cable
to act as a work order to the cable laying team
to record work progress. By using one cardbox for unlaid cables and one box for laid, the progress of
work can easily be measured at any time
3.2 Laying from a trailer
Cables may be laid out directly from a trailer if there are no obstacles in the trench or in its vicinity. Care has
to be taken that the drum is rotated carefully and braked, if necessary, in order to prevent excessive tensile
stresses or kinking of the cable.
3.3 Laying by hand
Rollers placed at distances of 3 to 4 m will facilitate laying. Corner rollers or similar devices should be
provided where there are bends in the route, always maintaining the minimum bending radius of the cables,
see fig. 6 and 7.
The cable is to be carried in hand, if not supported by rollers, with the men standing 4 to 6 m apart along
the route.
If there is not sufficient labour to lay long lengths in one sequence, the drum may be jacked up in the
centre of the section and the required length pulled off from the top of the drum in the direction A (see fig.
5). The drum is then further rotated and a vertical loop 3 to 4 m long pulled off in the direction B. The cable
is lifted sideways over the drum towards the trench and the remaining cable pulled off from the bottom of
the drum in a loop. The twist in the cable has to be spread over a length of 4 to 6 m.
Fig. 5 Pulling off a cable in a loop.
92
Fig. 6 Laying by hand by the use of cable rollers.
Fig. 7 Corner rollers.
93
If obstacles in the trench prevent laying of the second half of the cable, it should be laid out in a configuration of 8 on the side of the drum towards direction A. It should be noted that the cable can only be
pulled off again in the direction from which it was first looped.
Fig. 8 Pulling off a cable in a

configuration of 8.
3.4 Laying by motor-driven equipment, general

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 a
guide:
The cable volume, i.e. the number and volume of cables, has to be of such a proportion that the time
gained by using the equipment is not lost in transport and handling of the same.
The cable diameter should not be less than 30 mm, if not more than one cable can simultaneously be
pulled.
The length of the cables should in average be over 50 m, since manual handling of both ends is
inevitable.
The cable routes shall be designed in a manner making it possible to position 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 in order not to damage the
cable and for simplifying the pull. The permissible pull is much higher with a pulling eye provided that all
conductor strands are evenly stressed, see fig. 9 and 10.
A continuous check on the stretch force by means of strain gauge or a dynamometer attached to the rope
holding the winch, with the latter resting on rollers.
A shearing pin or a friction coupling, which will interrupt the pulling if the maximum stretch force is
exceeded, must be provided at the winch.
Cable and pulling rope should be guided by rollers, especially at the bends, see fig. 1921.
The stretch force may be still higher if the cable is pulled into a steel or plastic pipe, even if the pipes are
greased. They may reach 100 % of the weight of the cable if the bends total about 300. Steel pipes may be
greased with a special lubricant and plastic pipes with boiled-down soap of low alkali content.
All cables and especially single-sore cables should not be straightened completely after laying, but left
slightly meandering, in order to allow for the longitudinal expansion caused by changes in the temperature.
94
Fig. 9 Cable stocking.
Fig. 10 Cable pulling eye.
3.4.1 Laying by motor-driven rollers

The cable is pulled off the jacked-up drum by electrically driven rollers set up in the trench 20 to 30 m apart.
If heavy cables are to be pulled around a sharp bend, it may be necessary to set up one motor driven
roller before and one after the bend. All rollers are connected to the main switch box via smaller distribution
boxes and are switched on and off jointly. At the head of the cable 3 to 4 men or an auxiliary winch, which
must run synchronously with the rollers, will be sufficient for guiding it.
Fig. 11 Laying by motor-driven rollers.
95
Fig. 12 Motor-driven Roller.
3.4.2 Laying by winches and cable pushers

Electrical or petrol engine operated cable pulling machines both pulling and pushing are mostly operated
in groups and synchronized by the use of walkie-talkies, see fig. 13.
Fig. 13 Laying by winches and

cable pushers.
1.
23
4.
Motor-driven drum stands with dynamometer

Cable pushers
Cable laying machine with winch
Accessories:
1 pc
1 pc
50 pcs
12 pcs
Cable stocking
Roller for pulling cables in pipes
Cable rollers
Corner rollers
Work sequence (fig 13).

The wire is pulled out from machine 4 with the winch and is then run through machines 2 and 3 on a route
prepared with rollers. The wire is fixed to the cable end by means of a cable stocking. Each machine is then
manned and communication is established with walkie-talkies. Machine 4 pulls the cable and machines 2
and 3 assist by pushing the cable around corners and difficult passages.
96
Fig. 14
Cable winch.
Fig. 15 Cable pusher.
Fig. 16 Cable
stocking.
Fig. 17 Pulling eye.
97
Fig. 18 Glass fibre rod for drawing guide lines

and cables through piping.
Fig. 19 Cable roller.
Fig. 20 Corner roller.
Fig. 21 Roller for pulling cables

into concrete pipes.
98
3.5 Laying in ground

Earth cables shall be laid directly in the ground in according to the installation drawings applicable to each
project.
Note: If a cable channel is used, cheaper and simpler cables may be used. It is also much easier to add
and replace cables.
3.6 Crossing of roads
For the crossing of roads the cables must be drawn into pipes.
It is always advisable to provide spare pipes in order to avoid having to dig up the road if further cables
are to be laid. Ducts which are not used at once should be plugged. The cables should not rest on the sharp
edges 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, a deepening should be made immediately
before the opening prior to pulling in the cable in order to prevent stones or coarse soil from getting into the
duct and clogging it up, the pulled-in cable should be cushioned so that it is nearly in contact with the top of
the duct at both ends, fig 23.
The inner diameter of the duct shall be at least 1.5 times the outer diameter of the cable.
Fig. 22 Deepening in the trench bed at the entry to a duct or pipe.
Fig. 23 Protecting the cable at the end of a duct.

3.7 Laying cables indoors
Cable which must be protected mechanically or against electrical disturbances should be laid in steel ducts,
trays or pipes.
If the disturbances do not effect more than 10 m of the cable run and if the number of cables is less than
10, then the cables may be strapped to a strip iron. When support of the cable way or mechanical protection
is necessary, section beams can be used.
13 cables may be clamped directly onto walls, foundations and structures in building if the distance is
not more than 1020 m.
3.8 Temporary marking
When the cable is laid and cut off, both ends shall be temporarily marked in order to enable the
identification of the cable prior to termination and final marking. This is best done by the use of a suitable
tape and a water-proof marking pen with a point of approximately 2 mms thickness.
Fig. 24 Mark with cable No. and with cubicle, box No. etc.
99
3.9 Length of cable ends

It is of utmost importance that both cable ends are adjusted to the right length. Too long cables create waste
and too short ones mostly mean that a new cable has to be pulled, since jointing often is not allowed.
The following calculations may act as a guide, see fig 25.
Fig. 25 Cable ends to various equipment.
4. Description of cable ways

The following section describes the cable ways recommended by ABB.
4.1 Cable channel
Description
The cable channels in outdoor switchyards are mostly made of concrete and covered with concrete slaps or
wooden covers.
Indoor the channels are often integrated in the floors of the building and covered with channelled plates.
Installation
The cables can either be placed directly in the bottom of the channel or on racks.
No means of securing the cables are necessary.
Application
The main advantage of using cable channels is that cables may easily be replaced, added or inspected.
Cable channels make it possible to use not reinforced cables, since the channel itself offers the sufficient
mechanical protection.
Fig. 26 Cable channels

outdoors.
100
Fig. 27 Cable channel in outdoor switchboard

plant.
Fig. 28 Cable channel in concrete floor.
4.2 Cable duct

Description
Different types of ducts are
used. One type of ducts is in
a building embedded pipe
made of galvanized steel or plastic. Another type is channel with one side detachable, such as a lid, made
of metal (generally galvanized sheet metal) or plastic. The duct may be entirely enclosed or perforated. A
covered cable ladder should be considered as a duct.
Installation
The cable should lie loosely except in the case of vertical assembly. in this case the distance between the
attachment points should be max. 500 mm.
No means of securing are necessary in horizontal ducts.
Plastic straps or lashing wire are used to fasten the cable to vertical perforated ducts.
Application
Ducts may be used when special protection for mechanical or electrical disturbance is required.
Steel ducts may also be used as a thermal protection.
Ducts of plastic or stainless steel should be used in strong corrosive condition.
Small channels of plastic are being used in cubicles for protecting and supporting a bundle of single
leaders.
101
Fig. 29 Cable duct bank.
Fig. 30 PVC ducts in concrete.
102
4.3 Cable ladder

Description
E1-AMAs *) definition of cable ladders specifies that the distance between the rungs may be a maximum of
300 mm. If the rungs have a flat top surface they should be at least 15 mm wide and round rungs should
have a diameter of at least 19 mm.
Ladders are available in widths of 200, 300, 400, 500, 600 and 1000 mm.
*) E1-AMA Rules for Swedish design on electrical equipment.
At bends or where a cable leaves the cable ladder, the cable should be secured with plastic straps or
lashing wire. In the case of vertical assembly, the cables are also fixed to every second rung. Cables over
40 mm should, however, be secured with brackets type KSV, if the vertical run is more than 10 m.
A maximum of five cables may be located under the same attachment device.
Application
In most cases the cable ladder offers the best solution when building cable ways. In cases of great
mechanical load, high short-circuiting currents and high ambient temperature cable ladders are particularly
suitable due to their great mechanical strength and good cooling properties.
Fig. 31 Wrapping a
1-phase cable.
Fig. 32 Cable ladders

fitted on ceiling pendant.
103
Fig. 33 Typical installation.
104
Fig. 34 Typical installation.
105
4.4 Section rails/trays

Description
Various 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 they may be painted or electro-plated
with zinc.
See fig 31and 37.
Installation
Section rails/trays may be installed directly onto foundations and walls in order to provide mounting holes for
straps and as protection for cables. They can also be mounted between two points providing a support for
the cables.
When the cable is secured to the rails/trays, the fixing points should not be spaced more than 500 mm.
The cables should be secured with plastic straps or lashing wire.
Section rails may be used for a small number of cables (120 depending on the size) to separate units as
a protection and support for the cables.
Trays can be used as above, but can carry more cables depending on the width of the tray.
Fig. 35 Cable
protection.
Fig. 36 Section rail with L and U shape.
106
A, mm
49
87
124
162
236
311
461
Fig. 37 Tray.
5. Termination and jointing of high voltage cables < 80 kV.

5.1 Termination and jointing.
Since the design of termination and jointing components varies a lot between the different manufacturers, it
is important to follow the manufacturers instructions in order to safeguard a correct cable work. Redoing the
termination or jointing is always very costful and time consuming.
Note:
Read carefully through the instruction before commencing work.
Cross out those sections which do not apply for the work in question.
5.2 Crimping of conductors
5.2.1 General
The Elpress system is the most common system used by ABB and covers the following areas:
Cu-terminations up to 1000 mm2
Al-terminations up to 1200 mm2
C-sleeves up to 300 mm2
However, this instruction describes the most frequently used components covering the following areas:
Cu-terminations up to 400 mm2
Al-terminations up to 630 mm2
C-sleeves up to 150 mm2
Full information on material and tools shall always be submitted to site prior to erection start.
5.2.2 Points to bear in mind when crimping
Terminals and connectors
The terminals (cable lug, splice, etc) must suit the cross-sectional area and construction of the conductor
(number of strands, degree of compression, shape, hardness).
Crimping tool
The crimping tool must be correct for termination and must be designed so that the crimping operation
cannot be interrupted until the crimping cycle is complete, except by performing a special operation.
107
Markings
In order to avoid mistakes, both tools and terminations must carry unique and permanent markings,
which must also appear on the packaging. On crimping, the identification mark of the tool must be
impressed automatically on the termination.
Dimension checking
The quality of the crimped connection and the condition (wear) of the crimping tool is checked by
measuring the dimensions of the termnation at the completed crimp.
A supplier of terminations and crimping tools should be able to provide details of nominal dimensions and
tolerances for the terminations before and after crimping, and to supply special measuring equipment for
this, where needed.
Cu-terminations
Take great care not to damage any of the strands when stripping the copper cable.
Strip about 5 mm more of the insulation than the depth of the barrel of the cable lug or splice (i.e. up to
the inspection hole or cable stop).
Check carefully that the type number of the die corresponds to the marking of the cable lug or splice.
Normally one crimp is needed up to 400 mm2. For round compressed conductors 185 mm2 and above,
two adjacent crimps are needed.
Al-terminations
Take great care not to damage any of the strands when stripping the aluminium cable.
The stripped length must be 5 mm more than the depth of the socket in the termination.
Circular performing with the appropriate tool may be necessary if stranded or sector-shaped cable is
used.
Two crimps with a punch are always made in the aluminium termination barrel.
The barrel of the aluminium terminations is serrated internally and protected against corrosion by a thin
layer of vaseline.
No preparation such as cleaning or application of compound is needed. There is no need to wire-brush
the stripped cable end.
5.2.3 Cu-terminals
Copper type terminals type KR/KRF:
Used mainly to terminate cables at copper busbars and equipment terminals.
The same terminal is used for both flexible and stranded or sector-shaped
conductors.
Spliced type KS/KSF:
Used primarily to splice copper conductors in underground cable systems.
The same splice is used for both flexible and stranded or sector-shaped
conductors. These splices can also be used for straight jointing of earthing lines.
Branch connectors type C

(C-sleeves):
This pattern up to 120 mm2.
This pattern from 1500 mm2 up to 300 mm2.
The terminals are made of electrolytic copper.
108
5.2.4 Al and Al/Cu terminals

Splice sleeve type AS:
Used mainly for jointing aluminium conductors in underground
cable systems, but also at the transition between overhead lines
and underground cables.
Cable lug type AK:
Used to terminate aluminium conductors at busbars and
aluminium terminals on apparatuses.
Aluminium/Copper Terminals:
The Al/Cu terminals are manufactured by friction-welding the two component parts together, a method in
which the aluminium and copper are bonded together by the heat produced as one metal rotates against
the other under pressure. The result is a totally hermetic joint, immune to corrosion and galvanic action
even under outdoor conditions.
Al/Cu splice sleeve type AKS:

For jointing Al to Cu conductors.
Al/Cu pin sleeve type AKP:

To connect Al conductors to
equipment and junction boxes.
Al/Cu cable lug type AKK:

Used to terminate an Al
conductor at a Cu busbar.
Terminals for Al cables are made of solid pure aluminium.

The system may be used for both stranded and solid aluminium conductors.
Note that there is a difference of one area step between stranded and solid conductors.
Example: Barrels for 120 mm2 stranded wire, fit 150 mm2 solid conductors.
The punch identification number is automatically imprinted on the terminal. Comparison of the imprints
with the barrel marking provides a check that the correct tool has been used. The number of the punch and
matrix also coincides with the outside diameter of the barrel.
109
5.2.5 Marking of terminals

As well as showing cable area, the marking system indicates which tools should be used.
Copper terminals
Cu conductor
Area in mm2
Bolt size mm
Type No. of
hexagonal die
Cu conductor
120150 mm2
Cu conductor
7095 mm2
Die identification
number
Max. diameter
of conductors
Aluminium terminals
Number for circular

preforming punch
and matrix
Stranded Al
conductor
in mm2
110
Number for compression

punch and matrix
Solid Al
conductor
in mm2
Bolt size
M12
5.2.6 Dimension checking

Aluminium terminals:
The result of crimping can be measured after a period of use.
If dimension T is exceeded, the tools must be adjusted or replaced.
The number of the punch is imprinted at the bottom of the crimp. This number is the same as the outside
diameter of the terminal barrel. The number also appears in the marking of the barrel, making it easy to
check that the correct tool has been used.
Measuring points
Al conductor, mm2
Stranded
Solid
D = 52
D = 52
Tool
Matrix
Punch
T
mm
16
25
35
25
35
50
P13M
P13M
P20M
P13D
P13D
P20D
6.8
6.8
10.8
50
70
95
70
95
120
P20M
P20M
P25M
P20D
P20D
P25D
10.8
10.8
13.5
120
150
185
150
185
240
P25M
P25M
P32M
P25D
P25D
P32D
13.5
13.5
18.4
P32M
P36M
P40M
P40M
P52M
P52M
P32D
P36D
P40D
P40D
P52D
P52D
18.4
21.0
22.8
22.8
31.0
31.0
240
300
400
500
500 A
630 A
Copper terminals:
The dimension N is checked on the hexagon faces that have the impression of the dies. Measure with a
calliper on one or both sides of the impression.
Types KR and KS
Area mm2
N mm
10
16
25
6.4
7.6
8.8
35
50
70
10.3
12.1
13.9
95
120
150
16.5
16.3
20.3
185
240
300
400
20.6
23.4
24.6
27.4
Measurement surfaces
111
C-sleeves
For C-sleeves, the dimension h is checked, preferably with a calliper, on maximum height of the crimped
oval.
C-sleeve
h max. mm
C4
C5
C6
10.6
13.7
15.8
C8-6, C8, C9-8 and C9

C11-8, C11-9 and C11
C13.8, C13-9, C13-11 and C13
22.0
23.2
27.0
C15-8, C15-9, C15-13 and C15

C16-9, C16-13 and C16
34.5
38.5
5.3 Tools
In order to guarantee a good quality of cable work it is important to follow the general information or guidelines from the actual supplier.
It is also very important to point out that some tools must be checked periodically. Regarding tools for
crimped connections, the tools must be checked periodically according to ABB Quality System Guide-lines
chapters No. 4.11 and 4.12 respectively.
Note: It is the responsibility of the user to ensure this is done.
Regarding tools for crimping connectors, see ABB Corporate Standard book C8.
112
SITEMAN 16 - 94
1WAT 910033-16
Cubicles in
electrical rooms
Touch-up painting
113
List of contents
A.
1.
2.
2.1
2.2
2.3
2.4
2.5
2.6
3.
3.1
3.2
3.3
3.4
4.
4.1
4.2
4.3
4.4
Cubicles in electrical rooms

General .............................................................................................. 3
Handling of cubicles ......................................................................... 3
Packing ............................................................................................... 3
Unloading .......................................................................................... 4
Checking ............................................................................................. 5
Lifting and indoor transport of cubicles ............................................... 5
Storage ............................................................................................... 6
Temporary marking ............................................................................. 7
Control ............................................................................................... 7
Access roads ...................................................................................... 7
Floors .................................................................................................. 7
Suspended floors ................................................................................ 8
Depending points ................................................................................ 9
Installation ....................................................................................... 10
Cubicles ............................................................................................ 10
Busbars ............................................................................................. 13
Clearance to walls and ceilings......................................................... 15
Cleaning ............................................................................................ 15
B.
5.
5.1
5.2
5.3
5.4
5.5
5.6
5.7
5.8
5.9
5.10
5.11
5.12
6.
6.1
6.2
6.3
Touch-up painting........................................................................... 17
General ............................................................................................ 17
Definitions ......................................................................................... 17
Cleaning prior to grinding .................................................................. 17
Grinding of damaged surfaces .......................................................... 18
Application of filler ............................................................................. 18
Grinding after stopping up ................................................................ 18
Primer coating ................................................................................... 18
Cleaning and masking prior areosol spray painting .......................... 18
Finishing coat .................................................................................... 19
Finishing coating with areosol paint .................................................. 19
Finishing coating brush painting .................................................... 19
Choice of fillers and paints ................................................................ 19
Tools, accessories, etc. .................................................................... 19
Touch-up painting of galvanized steel with zinc-rich paint ........ 20
General ............................................................................................. 20
Work steps general ........................................................................ 20
Choice of galvanopaste .................................................................... 20

prosecuted.
114
A. Cubicles in electrical rooms

1. General
The intention with this instruction is to give a brief introduction of the methods used by
ABB when installing relay, control and distribution boards in electrical rooms.
It is of utmost importance, however, to penetrate all layout and installation drawings
together with installation manuals for the delivered cubicles and equipment prior to start
of installation.
2. Handling of cubicles
2.1 Packing
The cubicles may be delivered in the following manner:
Individual cubicles fitted with apparatus.
Several cubicles mounted together as one unit.
Accessories.
The cubicles are normally delivered standing on a transport pallet covered with a plastic
cover and firmly attached to the pallet.
Loose accessories are delivered in wooden boxes.
When the cubicles are shipped overseas, a more durable packing is needed, such as:
Cases of wood.
Cases of plywood.
Steel containers with open roof.
Note that ABB-deliveries normally are covered with sealed air tight plastic bags before
they are packed into the cases. Bags with moisture absorbing material are placed inside
the cubicles to keep them dry.
Packing list is packed together with the cubicles.
Fig. 1 Standard packing.
115
2.2 Unloading
Handle the cubicle carefully when unloading or moving them.
The easiest way to unload from a truck is to use a forklift truck. Note that the forklift
must be equipped with wheels big enough to make the handling of cases safe and
steady. The roads at site are often of poor quality during the erection period.
If possible, unload and transport the cubicles directly to their final position in their
packings, see figure 2.
Fig. 2
To unload the cubicle from the pallet, move it forward or backwards on the pallet until the
cubicle can be tilted. While holding the cubicle in a tilted position, pull away the pallet and
set the cubicle down on the floor carefully, see figure 3.
Fig. 3
Fig. 4
2.3 Checking
Check the consignment against the accompanying packing list to ensure that the correct
items have been delivered. Any complaints are to be remitted as soon as possible to ABB
in order to avoid delay in the installation work. Do not forget to make a check-up on
separately packed apparatus.
116
2.4 Lifting and indoor transport of cubicles

Cubicles are normally provided with lifting devices. However, the method of lifting varies
from type to type. It is therefore important to follow the lifting instruction given i the
enclosed information in order not to damage the cubicles by applying the lifting slings
wrongly. Figure 5 shows some typical lifting arrangements.
Indoor transport of Safesix switchgear. The cubicle should be lifted from the pallet with
the use of a fork lift. The cubicle can be transported indoors with a pallet lifter. Two lifting
tackle are placed in the cubicle as shown in figure 4.
The lower door of the cubicle must be removed and put somewhere safe, before the
fork lift is used to lift the cubicle, and kept safely during assembly period.
If the cubicle cannot be transported in the upright position because of for example low
doors, it can be laid on its back on a pallet and moved with the use of a fork lift to its
erection position.
To remove the connecting apparatus choose the selector to door position. The
connecting apparatus can now be pulled out on the door extension rail. This can be done
with the cubicle mounted on the pallet. The trolley moves most safely on a low position.
The busbar and the roofing plate are delivered separately packed in each cubicle.
Check that parts specified in the enclosed packing list are present. Any parts missing or
damaged must be claimed as soon as possible.
Fig. 5
117
2.5 Storage
Sometimes the cubicles, due to various reasons, cannot be installed immediately upon
their arrival to site, but have to be stored.
The cubicles delivered on transport pallets covered with plastic wrapping are to be
stored in clean, dry and dust-free premises. When the cubicles are equipped with heating
elements, these should be temporarily connected during storage in order to avoid
corrosion.
The cubicles delivered in wooden cases with sealed air tight plastic bags and moisture
absorbing material should be stored indoor or under cover. Do not open these cases if
they are stored oudoor. The check of the content should then be carried out when the
cubicles are installed.
Always use timber to space the cases from the ground.
The equipment may be stored for a couple of months in unopened cases. If longer
storing periods should occur, the manufacturer should be contacted for advice.
2.6 Temporary marking
Temporary marking of the cubicles can be necessary sometimes. Be careful when using
labels or tapes on painted surfaces. A special marking tape can be ordered from your
ABB-supplier.
3. Control
3.1 Access roads It is always very important to check the transport ways in order to
ensure that no obstacles can cause hinderance. The following check points can act as a
guide:
Can the road be used by our transport vehicle?
Are there any electrical wires or pipes crossing the road?
Is it necessary to build temporary unloading platforms?
Are door openings large enough?
Hoisting wells?
Staircases?
3.2 Floors
The cubicles are designed to be erected on an even and thoroughly levelled base to
enable the interjoining of cubicles without any extra measures. See figure 6.
Experience proves that above tolerances are hard to obtain. ABB therefore recommend
that steel profiles are embedded in the concrete in a manner as shown in figures 7 and 8.
The civil work drawings have to show in detail the foundation design for all cubicles and
to specify the tolerances required for each project.
If the floor is not in level, it will be difficult to open and close the doors. Cubicles with
drawable circuit breaker may be more sensitive. Here the contact function between
breaker and the fixed contact can be jeopardized.
Check that the floor is even and in level, and that iron profiles are correctly embedded
as stated in the civil drawings. Holes for cable entries in the floor have to be carefully
checked regarding size and location.
118
Description
Measured
length (m)
Allowed
deviation (mm)
Class 2
Warpage
2.0
4.0
L
3
5
E
Declivity
Fig. 6 Tolerances for floors.

3.3 Suspended floor
Suspended floors are used mainly for the following reasons:
Flexible installation of cubicles. The final layout can be decided at a late stage.
Open space under cubicles means no problem to install cables.
Easy to adjust the floor to correct level.
Easy to extend and re-position the panels.
The floor should be fire resistant and can be of electrically insulating or semiconducting
design.
The insulating floor is used mostly in switchgear rooms or similar.
The semiconducting floor is intended for computer rooms and other areas where static
electricity may cause damage, injury or inconvenience.
The floors are built up of floor scaffold and fire resistant slabs. It can be completed with
stairs and banisters and can also be reinforced for higher loadings, see figure 9.
Fig. 7 Embedded steel profiles in concrete.
119
Fig. 8 Typical foundation

for cubicles.
The floor is built up from tubular legs,

beams and fire-resistant slabs.
The legs are adjustable vertically.

The shape of the base-plate ensures
that the leg stands securely even on
rough surfaces.
The beams are tensioned between

the walls with the aid of a special
tensioning device.
Fig. 9
120
3.4 Depending points

When ABB is given access to electrical rooms, the depending points stated in our
contract and erection plans shall be completed. The following list may act as an example:
Access roads ready.
All civil work ready.
Doors and windows installed.
Room painted, cleaned.
Lighting installed, ready.
Power outlets ready.
Room lockable.
Roof sealed, ready.
Air conditioner installed, ready.
4. Installation
4.1 Cubicles
Note that a cubicle having a number of apparatus fitted on the door or on the hinged
frame, will fall forward if the door or frame is accidentally opened before the cubicle has
been secured to a nearby cubicle or to the floor, alternatively the wall.
The erection of cubicles starts preferrably at the highest point of the floor.
Cubicles with adjustable screws must not rest on these after alignment. Shims have to
be inserted to take up the load.
The cubicles are bolted or welded to the base, see figures 10 17.
Note! No welding is allowed on cubicles with electronic equipment.
When drilling in concrete floors, remember always to take measures preventing dust to
enter into the apparatus of the cubicles.
For further information do always read the installation manual for the actual equipment
carefully before the start of installation.
1) Note that the loose floor slabs under the cubicles have to be secured
to the beams as well as the cubicles.
Fig. 10 Fastening of cubicles to suspended floors.
121
Fig. 11 Cubicles fastened with expansionshell bolt in concrete.
Fig. 12 Cubicle fastened with clamp and

expansion-shell bolt.
Fig. 13 Cubicle welded to embedded

L-profile.
Fig. 14 Cubicle fastened with clamp

either with expansion-shell bolt in
concrete or welded T-bolt to steel beam.
Fig. 15 S0ecuring Safesix cubicle on concrete flooring.
122
Fig. 16 Attachment of Safesix

cubicle on frame
flooring.
Fig. 17 Cubicle fastened to pre-aligned profile
bar with T-bolt and clamp.
4.2 Busbars
For series-manufactured switchgear, apparatus, etc., special assembly instructions are
normally provided and these apply to the complete installation including the bolted joints
in the busbars.
For joints in other equipment, where special measures must be taken, e.g. control of
tightening torque, special locking facilities etc., instructions are either given on the
assembly drawing or are supplied separately for the joints in question.
If modifications are necessary during the on-site installation, it is of utmost importance
that the joints are made in accordance with the applicable standard to ensure satisfactory
performance. See figures 18 and 19.
Switchgear type Center
Joining is carried out from the front of the
cubicle. The same method applies for both
horizontal busbars, N and PE busbars.
1. Dismantle the protective cover in front of
the busbars so the joints are accessible.
2. Loosen the bolts to the joint pieces.
3. Slide the joint pieces towards the right
cubicle.
4. Tighten all bolts with a torque wrench,
20 Nm.
5. Replace the protective cover.
Fig. 18Joining of busbars.
Note In the case of double joint pieces,

both should be placed on the front
side!
123
Switchgear type Safesix
Fig. 19a Assembly of busbars.
Fig. 19b Assembly of busbars, view from above.
124
4.3 Clearance to walls and ceilings

Minimum clearance to ceilings and walls varies a lot between different types of cubicles
depending on demands regarding cooling and required installation space for the busbars, opening of doors, etc.
Install the cubicle according to drawings from the design office and check that the
minimum clearance according to the manufacturers installation manuals are kept.
See figures 20 21.
4.4 Clearing
Remove cable waste and other litter. Clean off grease and dirt, especially from the
insulators. Finally, vacuum-clean the cubicles. See figure 21.
Checking free space around cubicles
Fig. 20 Space required for switchgear

type Center.
Above
There must be at least 150 mm free space above
the cubicle. Where cables run in from above, the
distance also depends on the cable type and the
way in which it is laid.
Against walls
The minimum distance between the rear of the
cubicle and the wall behind, as well as between the
end panels and wall at the side, should be at least
40 mm.
Cubicles with handles in the doors should have at
least 150 mm between the left end panel and the
wall to allow the doors to open more than 90.
125
Fig. 21 Space required for switchgear type Safesix.
126
B. Touch- up painting
5. General
This document is a guide-line for touch-up painting of products delivered to sites. It is
based on ABB:s quality requirements of today and the painting methods used by the
manufacturers.
In ABB we have both normal wet painted products and powder painted products. Since
powder spraying cannot be used on site, a one-component, alkyd based paint system is
utilized for touch-up painting. As far as possible, however, touch-up painting should
achieve the same quality and finish as the original and adjacent surface.
Surfaces with no particular requirements regarding finish may be brush painted. In
more exacting cases repair painting should be done by arerosol spraying. Examples of
such surfaces are the outsides of control cabinets, desks, connection boxes, etc.
In cases where there are considerable damages, a local contractor, with suitable equipment, should be engaged. Do not forget to ask for a fixed price and check wether it
should be cheaper to order a spare part.
If touching up the paint yourself, do so in a room suitable for this, well ventilated and
free of dust.
Before applying the filler and painting, carefully straighten the damaged steel sheet so
that the layer of filler can be kept as thin as possible.
5.1 Definitions
Alkyd paint has a binding agent composed of an acid and alcohol (synthetic resin),
also called alkyd.
Two-component filler a filler containing hardener. The advantage of this type of filler is
that it is stronger and more elastic and hardens more rapidly than a one-component filler.
It does not crackle so readily, is easy to rub down and gives a good finish.
White spirit has various commercial names, e.g. petroleum spirits or mineral spirits. It
is the most common and least toxic medium for degreasing, diluting and cleaning.
Xylene or dimethylbenzene is an extremely flammable solvent, mainly used as a paint
diluent.
Diluent reducer a general term for white spirits, xylene, etc.
5.2 Cleaning prior to grinding
Both the damaged and the adjacent surfaces must be cleaned so that all grease, dust
and other dirt are removed. Otherwise impurities can be trapped in the abrasive paper
and rubbed into the surface.
Clean with an organic solvent such as xylene or white spirit, using a non-fluffing rag
dipped in the solvent.
5.3 Grinding of damaged surfaces
Large damaged areas, which are to be stopped up, should preferably be machine grinded
(drilling machine with a wire brush or rubbed disc or an oscillating grinder).
Damages which are limited to the paint should carefully be grinded so that no marks
are visual, thus avoiding the necessity of stopping. Start with a relatively coarse rubbing
paper No 100. Then rub the area around the damaged part with a finer paper, e.g. No.
150 or 180.
All grinding should be done so that the transition becomes less and less visible towards
the adjacent surface.
127
5.4 Application of filler

Damage should be stopped up with a generally accepted filler system.
If a two-component filler is used, it is important to mix filler and hardener in the right
proportions. Too much hardener speeds up hardening and too less slows it down. Follow
the instructions. Do not mix more than will be needed.
Use a spatula that is suitable in size for the damaged area. Spread the filler as evenly
as possible in order to obtain a flat and even surface. When dry, check with a straight
edge that there is no unevenness. If the surface is uneven, stop up such areas again.
There should be sufficient filler to allow it to be grinded down.
Note 1: Use as little filler as possible. Too much entails unnecessary grinding.
Note 2: Careful preparation is essential if a good surface is to be obtained.
5.5 Grinding after stopping up
The stopped up area must be grinded to be even with the adjacent surfaces.
Start with abrasive paper No. 100. As the area becomes even change to a finer grade,
e.g. No. 150, and finish with No. 180 to ensure that there are no visible scores. Check the
surface with the straight edge from time to time.
5.6 Primer coating
If the original coating has been damaged or grinded through to the metal, a primer must
be applied and rubbed down to an even surface.
Primer coating can be obtained as areosol spray or other types of cans.
After primer coating, finish smoothly with abrasive paper No. 180.
5.7 Cleaning and masking prior areosol spray painting
Properly grinded surfaces should be cleaned with a non-fluffing rag dipped in white spirit.
Before spraying, the area to be painted must be masked off from adjacent areas, which
must be well covered. Use masking tape and paper. Remove the tape as soon as the
painting has been completed, otherwise it may stick and damage the paint.
5.8 Finishing coat
Before applying the finishing coat, all surfaces must be either primed or smoothly grinded,
in some cases both. Choose the colour according to the manufacturers information.
5.9 Finishing coating with areosol paint
Before starting painting check that the room is well ventilated and free of dust.
Read carefully the instructions on the areosol spray can.
Shake the areosol spray can well. Hold the can about 20 cm (8 ins) from the surface to
be painted. Check first on a separate test piece.
When you have finished painting, turn the can upside down, push the button and empty
the nozzle in order to avoid that it is getting clogged with dried paint.
5.10 Finishing coating - brush painting
Use a brush of good quality which does not loose hair.
Stir the paint in the can to an even consistency. Regarding diluent, see the instructions for the paint being used.
Brush the paint in four directions (vertically and horizontically) to obtain a good surface
finish.
128
5.11 Chioce of fillers and paints

Project delivery contains products from many manufacturers. Consequently it is
impossible to write a list regarding colours, article numbers, etc.
The main goal for touch-up paint is to get the same quality and finish as the original
adjacent surface. Choose the filler and paint according to the manufacturers instructions
(or product pamphlets) to avoid mistakes during the touch-up painting work.
5.12 Tools, accessories, etc.
1. Drilling machine with a wire brush.
2. Drilling machine with rubber disc and abrasive paper.
3. Oscillating grinder with abrasive paper (alternative to No. 2).
4. Abrasive paper, medium,
grain size 100
5. Abrasive paper, fine,
grain size 150
6. Abrasive paper, extra fine, grain size 180
7. Abrasive paper for machine
8. Spatulas.
6. Touch-up painting of galvanized steel with zinc-rich paint

6.1 General
This information is intended for the repair of the corrosion protection on galvanized steel.
Damages on galvanized parts, caused by, for example welding, drilling, cutting, etc.,
must be repaired with a zinc-rich paint (galvanopaste zinc content 93 to 95 %). The
paint is applied with a brush or areosol spray. Brush painting is preferable since the areosol gas contains toxic products
6.2 Work steps general
Remove all burr, welding slag and rust. Use a wire brush, file and countersink bit or
other suitable tool.
Clean all surfaces from grease, old paint, etc.
Stir repeatedly so that the zinc powder keeps well mixed in the can.
Allow to dry for four hours before applying a second coat.
6.3 Choice of galvanopaste
It is important to have a zinc content of 9395 % in the paint you have planned to use.
If it is impossible to purchase it locally, please contact your homeoffice for delivery to
site in order to reach the right quality.
129
130
SITEMAN 18 - 94
Earthing
1WAT 910033-18
131
List of Contents
1.
1.1
1.2
1.3
2.
2.1
2.2
2.3
2.4
2.5
2.6
3.
4.
4.1
4.2
4.3
4.4
4.5
5.
General ...................................................................................................... 133

System earthing ......................................................................................... 133
Protective earthing ..................................................................................... 133
Electrical hazard ........................................................................................ 133
Earthing outdoor ...................................................................................... 134
Earth grid, earthing rods, pits etc ............................................................... 134
Steel structure ............................................................................................ 135
Transformers and high voltage apparatus .................................................. 135
Overhead earth screen .............................................................................. 136
Surge arresters .......................................................................................... 136
Fences ....................................................................................................... 137
Earthing indoor ........................................................................................ 138
Installation ................................................................................................ 149
Precautions and planning .......................................................................... 149
Materia ....................................................................................................... 149
Installation .................................................................................................. 149
Tools ........................................................................................................... 149
Tempoprary earthing .................................................................................. 149
Principal arrangement for earthing of structures and apparatus ....... 140
Appendix 1 .......................................................................................................... 156

prosecuted.
132
1. General
n order to promote the understanding of earthing it is usual to divide the term under two general headings,
namely system earthing and protective earthing.
1.1 System earthing
Primarily systems earthing is considered as the permanent connection of a system or part of a system
which would normally be under tension to earth. Normally it is the system or part of the systems zero point
which is connected to earth, direct or via a neutral earthing equipment.
The fact that a point in the system is earthed, means that any part of system which is galvanically
connected is also earthed. A system earthing does not effect parts of the system which are magnetically
coupled, e.g. via a transformer to an earthed net.
In a power network there can be found several system earths e.g. each voltage level can have its own
earthing.
The primary reasons for bonding the network potential to earth are to protect people and equipment.
1.2 Protective earthing
The level of protection from high voltage for personnel that can be achieved by the selection of good
insulation and thoughtful plant design is inadequate. The require-ments of high current instructions are that
exposed details shall be protective earthed in a way that ensures complete safety.
An exposed detail is understood to be one which can be touched, accessed or is of a prominent nature,
but which under normal conditions is not under tension. However due to its material nature or coating could
under insulation failure conditions come under tension.
Examples of exposed details could be frames, covers and supports for machinery, transformer and
equipment, mountings for insulators and bushings, lead sheating, reinforcement bar, screening and termination boxes for cables, metal transformer housing, fencing and other such like plant details.
The purpose and requirement of protective earthing of exposed details is that during earth fault
conditions it will direct the flow of current to earth in such a manner that voltage that:
a) could be dangerous to personnel on the plant or for people in general are prevented
b) could create fire are prevented.
It is particularly important that the protective earthing is effective against the onset of fire when the exposed
details are flammable, particularly wood. Metal poles with stays should normally be earthed, whereas stayed wooden poles are generally not earthed. The necessary protection is achieved via the fact that the stays
are mounted sufficiently long from the insulator pins or they are fastened to the pole via a stay insulator.
1.3 Electrical hazard
An estimate of level of danger from an electrical hazard can not be achieved solely by evaluating the voltage the person will be exposed to, the magnitude and duration of the current the body could be exposed to
has great significance as well as the current path through the body.
The magnitude of the current flowing through a body is in part determined by the voltage and current
path resistance. The bodies resistance drops normally to some value under 5000 ohms with the onset of
perspiration. This obviously means that the risk for electrocution is proportionally greater in humid and wet
areas as opposed to dry areas.
Fig. 1 shows example of step and touch voltages in the vicinity of an earthing electrode in the overload
on-state during an earth fault.
Fig. 1
133
2. Earthing outdoor
2.1 Earth grid, earthing rods, pits etc.
The earth grid normally consists of some form of symmetrical grid net in order to achieve an even
dissipation of voltage across the net.
The number of squares in an earth network for a station which is to have a direct earthed high voltage
net should be in the order of 25, for a small station 16 squares should be sufficient. An increase in the
number of squares gives at best a marginal reduction in the station earth resistance.
Even a short vertically placed earth rod provides excellent earthing capability.
Fig. 2
The above drawing gives an

example of an earth grid for
small switchyards. The grid
itself in this case is made of
120 mm2 copper wires, buried
to a depth of 0.5 m. If the earth
resistance has to be further
decreased the earth grid may
be connected to a number of
rods forming earthing pits. Fig.
3 gives an example of such
design. See also fig. 24.
Test link chamber

Fig. 3
134
Earthing pit
The earthing pits are usually composed of 14 earthing rods connected together via test link to the main
earth grid. The rods are copper clad steel rods of 12 meter length, which may be extended with other rods
by threaded joints.
The test links can be utilized for resistance measurement both of the earth grid and of the earthing pit.
Earthing pits can be added, if needed.
2.2 Steel structures
Gantry steelwork and high voltage equipment supports are earthed by connecting at least one of the legs
to the grid. Structures standing on more than one foundation have an earth connection at each foundation if
the earth fault current path through the steel is >10 m.
Fig. 4 Earthing of tower and overhead earth screen.

2.3 Transformer and high voltage apparatus
Power transformer neutral are directly connected to the earth grid by duplicate conductors each
dimensioned for the max fault current.
The earth wire from the transformer tank shall be connected directly to the grid.
High voltage equipment normally earthed via the steel structures. Exceptions to this rule are items of
equipment with a neutral outlet e.g. surge arresters and potential transformers, which are earthed
separately, Also separately earthed are earthing switches and separately mounted operating mechanism as
well as terminal boxes for control cable, for example on current and potential transformers and marshalling
boxes for multi-core cables.
In some countries it is established practice to earth all equipment to the grid with separate earth wires,
forming a parallell path with the steel of the supporting structure.
Fig. 5
135
2.4 Overhead earth screen

The primary reason for erecting a protective overhead earth in a switchyard is to provide protection against
a direct lightning strike.
Protection against direct lightning strikes is achieved by erecting a lightning trap over the phase lines, see
fig. 6. Arcing horns on insulator chains are also considered as line protection, even though their primary
function is to protect against an overvoltage across the insulator elements tracking and carbonising the
elements, see fig. 7. A radical alternative to protect against lightning strike would be to install the high
voltage cables in the ground. Unfortunately this is not economically practical, as underground cable is
appreciably more expensive than overhead cable.
Fig. 6
Fig. 7
Fig 8
Fig. 9
1) This wire is only included if required by the project specification. Normally the
overhead wire is terminated directly to the mast. To be installed if shown on the
erection drawings for the project.
2.5 Surge arresters
For overvoltage protection of high voltage equipment surge arresters are used.
Modern surge arresters have contributed towards better protection of transformer stations not to mention
substantial economic savings.
Connection of the surge arrester to the earth grid shall be as direct as possible.
WARNING! The surge arrester must never be separately earthed as it then may cancel the
protection of the transformer.
136
Fig. 10
Surge arresters can be designed with a counter that registers the number of times the arrester strikes. The
counter does not need to be mounted above touch height protection level. The recommended mounting
height is approximately 1.8 metres above ground level. The connection between the counter and the surge
arresters foot should be insulated for 3 kV (air insulated or cable). The cable shall have as a minimum a
25 square millimetre.
2.6 Fences
Fences of metallic material shall be earthed by connecting a number of the fence posts at about 50 m
intervals to the main earth grid. In some instances separate earthing of fences is specified.
If the substation belongs to a solidly earthed high voltage system, an earthing conductor shall be buried
about 0.3 0.5 m one metre outside the fence. All gate posts and earthed fence posts must be connected
to this conductor.
Fig 11
137
Fig 12
3. Earthing indoor
3.1 General
The basic objectives of an equipment-grounding system are the following:
To reduce the risk of electric shock to personnel.
To provide adequate current carrying capability, both in magnitude and duration, to accept the ground
fault current permitted by the overcurrent protection system without creating a fire or explosive hazard to
buildings or contents.
To provide a low impedance return path for ground fault current necessary for the timely operation of the
overcurrent protection system.
Wherever a grounding conductor crosses cable trenches, underground service ducts, pipes, tunnels,
railway tracks, etc., it shall be laid at least 300 mm below them and shall be rerouted around equipment /
structure foundations.
Grounding conductor around the building shall be buried in the ground at a minimum distance of
1500 mm from the outer boundary of the building. If high temperature is encountered at any location, the
grounding conductor shall be laid at least 1500 mm away from such location.
Grounding conductors embedded in concrete shall have approximately 50 mm concrete cover. If grounding conductor is required to be embedded in major foundations, then it shall be laid in a sleeve.
All steel columns and metallic stairs shall be connected to the nearest grounding conductor by two
grounding leads. Electrical continuity shall be ensured by bonding the different sections of hand-rails and
metallic stairs.
Metallic pipes, conduits and cable tray sections for cable installation shall be bonded to ensure electrical
continuity and connected to grounding conductor at not more than 10 m intervals. Apart from intermediate
connections, both ends shall also be connected to the grounding system.
Metal conduits and lattice structures shall not be used as ground continuity conductor.
A separated grounding conductor shall be provided for grounding lightning fixtures, receptacles, switches,
junction boxes, lightning conduits, etc.
Wherever grounding conductors cross or run along metallic structures such as gas, water or steam
conduit or pipes, steel reinforcement in concrete etc. it shall be bonded to the same.
138
Fig. 13 Building Grounding General.
Fig 14 Suite of Control Panels.
139
Fig. 15 Single Control Panel.
Fig 4 Battery Charger.
140
Fig 16 Motor Control Centre.
Fig 17 Low Voltage Switchgear.
141
Fig 18 Auxiliary Transformers.
Fig 19 Computer Floor.
142
Fig 20 HF Grounding.
Fig 21 Pipe Joint.
143
Fig 22 Pipe Work.
144
Fig 23
145
Fig 24 Cable Support Ladders.
146
Fig 25 Cable Support Ladder.
147
Fig 26 Connection Boxes.
Fig 27 Cooling Apparatus.
148
4 Installation
4.1 Precautions and planning
The installation of the earth grid is one of the jobs which needs planning, not to come into conflict with the
other jobs, i.e. erection of steel structures, cable ducts, etc.
Too much excavation at the same time may make the area too rough for achieving an efficient workflow.
It is often convenient to excavate for laying the earth grid after erecting the steel structures and before
mounting insulators, busbars and other conductors.
4.2 Material
The earth grid is usually made of copper wires clamped, brazed or thermic-welded together. See fig. 3638.
The conductor for the earth grid should be supplied in sufficient lengths to minimize the number of joints.
Annealed copper wires are softer to handle than standard wire and therefore recommended.
4.3 Installation
The earth grid with its numerous connection must be installed with utmost care. The following points are
emphasized:
the grid is of vital importance for personal safety
the material is buried and not available for inspection and repair after installation
certain corrosion may take place
short-circuit and earth-fault currents usually increase with time which means increased stress on the
grid.
Also parts of the earth grid above ground must be made safe. Follow carefully the instructions given by
the design office for:
earthing of steel structure
earthing of towers (masts) with earth wires
earthing of apparatus and boxes
earthing switches
disconnecting earthing switches
maintenance earthing
transformer tanks
surge diverters and counters
cable screens
4.4 Tools
Brazing
Welding and heating equipment of right capacity. High quality of right grade of brazing material shall be
available. Ref. to Siteman 94-11.
Compression
Hydraulic compression tools of sufficient capacity fitting the actual compression clamps. Ref. to Siteman
94-12.
Thermic welding
Welding moulds. Disc-grinder. Ref. to Siteman 94-11.
Cleaning
A good selection of steel brushes, separate ones for each type of metal.
4.5 Temporary earthing
To carry out work in a switchyard in service or with the system outside in service it is not sufficient to open
and lock the disconnectors in question. To be safe the phase conductors must be effectively grounded on
the work-side.
Due to increasing earth-fault currents and higher demand on portable earthing equipment, the
introduction of fixed earthing switches is becoming more and more frequent. However, portable earthing is
still the most commonly used method. See Appendix 1.
149
5. Principal arrangements for earthing of structures and apparatus
Fig. 28 Earthing of power transformer
Fig. 29 Earthing of circuit breaker
150
Fig. 30 Practical earthing layouts
Fig. 31
151
Fig. 32 Temporary earthing terminal
Fig. 33 Earthing on steel pole
Fig. 34. Principal arrangement for earthing of fence and gate
152
Fig. 35 Earthing of structure and apparatuses.
153
Fig. 36 Compression clamp (C-sleeve)
Fig.37. Brazing of bars
Fig. 38 Thermic-welding
154
Fig. 39
Earthing rods are used to reach deep earth levels where invariable low earth resistance can be obtained.
See diagram above.
155
Appendix 1
156
SITEMAN 20 - 94
1WAT 910033-20
Air insulated
switchgear
157
List of Contents
1.
General .......................................................................................... 159
1.1 Design characteristics ..................................................................... 159
1.2 The single-line diagram ................................................................... 159
1.3 Modifications, extensions .. ..............................................................160
1.4 Insulation ......................................................................................... 160
1.5 Pollution .......................................................................................... 160
2.
Civil Work ....................................................................................... 160
2.1 Drawings ......................................................................................... 160
2.2 Foundations .................................................................................... 160
3.
Heavy loads, such as transformers, reactors, etc ...................... 162
3.1 Transport, roads, access roads and surveys .................................. 162
4.
Insulators ....................................................................................... 162
4.1 Types of insulators .......................................................................... 162
4.2 Pollution .......................................................................................... 164
5.
Busbars and wires ........................................................................ 165
5.1 Types of busbars ............................................................................. 165
5.2 Materials ......................................................................................... 165
5.3 Rigid and flexible conductors .......................................................... 166
5.4 Mechanical strength ........................................................................ 166
5.5 Corona ............................................................................................167
6.
Clamps ........................................................................................... 167
6.1 Types of clamps .............................................................................. 167
6.2 Design ............................................................................................. 169
6.3 Material ........................................................................................... 170
7.
Erection .......................................................................................... 170
7.1 Access and work start ..................................................................... 170
7.2 Steel structure ................................................................................. 170
7.3 Outdoor earthing ............................................................................. 172
7.4 Insulators ........................................................................................ 172
7.5 Busbars and wires .......................................................................... 173
7.6 Clamps ............................................................................................176
7.7 High voltage apparatus ................................................................... 179
8.
Inspection, quality control ........................................................... 181
9.
Testing and commissioning ......................................................... 181
Appendices 1 2 ............................................................................ 182183

prosecuted.
158
1. General
This document will, in principle, be a guideline for the installation of Air Insulated Switchgear and shall be
followed if no other information is given on the drawings.
1.1 Design characteristics
When projecting a switchyard the main points to consider are:
System security
Future extensions
Costs
Flexibility of operation
Maintenance
Environment
Available space
There are two major types of high voltage switchyards:
Line switching stations
Transformer stations
When designing steel structures and foundations, the stress calculations are based on the maximum force
which any part of the equipment can be expected to withstand in its lifetime.
The mechanical forces acting on the electrical equipment and supporting structures are:
Dead weight
Normal loads from conductors
Ice load
Wind load
Short-circuit forces
Mechanical operation forces
Earthquake forces
When designing the busbar the following main factors have to be considered:
Maximum load current
Maximum withstand impulse voltage
Mechanical strength to withstand dynamic forces
Atmospheric contamination
1.2 The single-line diagram
The design of an outdoor substation is
based on the single-line diagram. This
diagram should show the connection
arrangements of all electrical equipment,
i.e. busbars, overhead lines, power
cables, connection points, power transformers, high voltage apparatuses, AC/
DC converters, reactive power
compensation equipment etc.
When designing the single-line diagram
the bus switching arrangements and the
degree of service flexibility and reliability
must be considered.
The most frequent bus arrangements
are shown in Appendix 1.
Fig. 1 Single-line Diagram

230/66 kV switchyard
159
1.3 Modifications, extensions

Almost every switchyard will sooner or later be subject to modifications and/or extensions. Clarity and
flexibility therefore have high priority in the design. Furthermore, access roads with safety clearances for
moving equipment must be considered.
1.4 Insulation
Electrical clearances are fundamental for the design. For safety and reliability it is essential that adequate
clearances are provided to live parts.
1.5 Pollutions
In recent years contamination has been a growing problem in transmission sys-tems. The contamination is
mainly of two kinds; coastal and industrial. See clause 4.2.
2. Civil Work
2.1 Drawings
For outdoor switchyards the civil engineering design represents a large portion of the total design work.
Drawing for levelling of the ground, dimensioning of the foundations, layout of cable ducts etc., have to be
produced.
The foundation drawings from an ABB design office shall show the foundation tops on which towers,
apparatus structures etc. shall be fixed.
2.2 Foundations
It is important that our site construction manager works in close cooperation with the site civil contractor in
order to guarantee a successful foundation work.
Normally the foundation bolts are embedded in the foundations from the begin-ning.
However, pockets are sometimes left in the foundations and the bolts are casted in under our supervision.
Note that approved expansion concrete must be used.
Templates
Templates are used for fixing the foundation bolts. For small foundations up to 0.5 0.5 m and in large
quantities, steel templates as shown in fig. 2 are suitable.
Fig. 2.
For larger foundations steel templates will be too heavy. A suitable material, which is usually easily
obtainable, is plywood (1/2 to 3/4 thick). The plywood template design can be similar to that of the steel
version. For really large foundations, the wooden template may be split into two parts as shown in fig. 3.
Fig. 3
160
Checking
It is often the responsibility of ABB, as the switchgear contractor, to check the location and the allignment of
the foundation bolts, independently of who has done the civil works. When measuring the distance between
bolts within large foundation, a long steel tape-measure may be used. The same method can also be used
for measuring between foundations when distances are not too long.
A levelling instrument is required for levelling of the foundations. A transparent plastic hose filled with
water or a spirit-level can also be used for shorter distances.
The client shall allocate a bench mark, i.e. a fix point to which all our measurements shall refer, when
checking the foundations.
Note that all concrete has to cure 23 weeks before load can be applied.
Special care is to be taken to check that the foundation bolts are reliably fixed at the bottom end so that
they will not move during the filling and vibration of the con-crete.
The bolts shall be available 23 weeks before they are embedded in the foundations.
No erection shall be carried out on the foundation before a letter of access is issued by the civil
contractor.
All alterations regarding the foundations must be entered into the drawings in red and sent to the design
office for updating.
Check for thread damage and that sufficent threads are over the top of the foundation.
Grouting (option)
After the steel structures have been erected, the distance between the steel and the concrete may be filled
up with concrete (=grouting).
Fig. 4 Typical foundation
Fig. 5
Foundations and
cable ducts
161
3. Heavy loads, such as transformers, reactors, etc.

3.1 Transports, roads, access roads and surveys
The transport of transformers has to be carefully planned. The roads from the harbour or the railway station
where the transformers are landed up to site have to be investigated. Allowed loads for roads, bridges,
heights to viaducts and other hindrances have to be checked.
The local authorities have to be contacted so they can issue a permission for extra heavy, long and wide
transport.
A local transport company has to be engaged, insurance checked etc.
The above can all either be included in the total transport, ex works, or partly organized from site.
The location of the access roads in relation to power transformer foundations is an essential factor in the
switchyard layout. They have to be planned so that the transformer can easily be shifted or replaced in case
of emergency, preferably with a mobile crane.
Note! The safety clearance to live parts must be checked.
The installation of transformers is always carried out under supervision of an expert from the manufacturer.
4. Insulators
4.1 Types of insulators
Insulators in outdoor switchyards are used for supporting conductors and for providing insulation between
phases and to earth. Sheds on the insulators provide the necessary creepage distance.
Insulators used are basically of two types:
support insulators for static arrangements
chain insulators for flexible buswires.
In addition to electrical requirements insulators must withstand the mechanical forces caused by short
circuit and earthquakes. This is especially important for support insulators.
Also environmental conditions, such as pollution and salt have to be considered.
Support insulators
There are two types of support insulators, solid core and pin and cap.
Fig.6 Solid core
Fig. 7 Pin and cap
For the lower voltage range the support insulators are made as one unit. For higher voltage ranges,
however, the insulators (insulator stacks) are made up of several units bolted together.
Chain Insulators
The strings are composed of insulator elements with non-rigid connecting details.
Fig. 8
Fig. 9
Insulator strings are used as tension and suspension insulators for overhead wires.
162
Tension strings
Fig. 10 Suspension strings
Fig. 11 V-string
In order to protect the insulators against damage due to flash-over the insulator string is fitted with arcing
horns or rings.
Connecting fittings must be able to carry the rated short time current without serious damage. When the
short-circuit current is higher than the fittings can withstand, these must be by-passed by flexible conductors
dimensioned for the rated value.
Insulator strings in outdoor switchyards are used for stringing flexible conductors between gantries.
Single, duplicate or even triplicate strings may be used depending on conductor tensions etc.
An assembly with more than two insulator strings must satisfy the following conditions:
Equal tension sharing between insulator strings.
If one of the insulator strings is broken the remaining ones must be undamaged.
Tension clamps of either bolted or compression type hold the wire to the insulator. A turnbuckle is also
provided for adjusting the sag.
Fig. 12 Tension insulator string

V-strings can be used to reduce the swing of the buswires due to
the wind .
Suspension strings are used on gantry beams to guide and
control line droppers.
Fig. 13 Suspension insulator string
163
Fig. 14 Switchyard with string insulators
FIg. 15 Switchyard with support insulators

4.2 Pollution
Pollution is, in some installations, a major maintenance problem. One basically distinguish between
industrial pollution with deposited layers and salt pollution in coastal areas.
Experiments have verified that the individual effect of either contamination or humidity is not very severe,
but combined contamination and humidity severely affect insulation performance.
Flash-over in case of industrial pollution evolves slowly. Salt deposits are dissolved and dry band formation develops gradually. On the other hand flash-over in case of coastal salt evolves rapidly since the salt is
already dissolved and the whole surface suddenly starts conducting.
Tests and experiences gained in the field have shown that the effect of pollution can be minimized by
following design and maintenance precautions, i.e.:
1) Increasing the creepage distances
2) Washing the insulators
3) Applying silicone grease as a protective coating
4) Using a suitable insulator shape.
164
5. Busbars and Wires

5.1 Types of busbars
In outdoor switchyards the two most commonly used types of busbars are strain busbar of stranded wires
and the supported tubular busbar, see fig. 16 and 17. In addition to these, two types of rods and other
sections are used for special purposes.
5.2 Material
Copper and aluminium are the metals which are used for busbars.
Compared with most other metals, both copper and aluminium have good electrical conductivity. Of these
two metals, copper has the better. The conductivity of aluminium is about 60% of that of copper. This means
that aluminium conductors require 60% larger area to achieve the same conductivity as copper. Comparing
the weights of the two metals, the main technical advantage of aluminium will appear. It is namely only 1/3
of that of copper. Aluminium can be operated at a somewhat higher temperature than copper which gives
an extra advantage.
For the same current conducting capacity, the weight of the aluminium conductor will in general be
considerably less.
Fig. 16 Outdoor switchyard with strain busbar
Fig. 17 Outdoor switchyard with supported tubular busbar
165
5.3 Rigid and flexible conductors

For more moderate short-circuit currents and normal rated currents stranded wires are the most economical
alternative.
Tubes are used for high short-circuit currents and high rated currents.
Bars are mostly used only for shorter connections, especially for current ratings on power transformer
secondaries.
Aluminium iron-wires are used as overhead earth wires.
More and more switchyards are built with aluminium tubes because of the increasing rated and shortcircuit currents. Tube diameter and thickness are determined by mechanical strength rather than service
currents.
F = flexible L = Bay length

R = rigid
W = Bay width
Fig. 18 Rigid and flexible conductors
5.4 Mechanical strength
The mechanical forces acting on electrical equipment and supporting structures are: dead weight, normal
loads from conductors, ice load, wind load, short-circuit loading, mechanical operation and forces due to
earthquake. The worst case for the electrical equipment and the supporting structures results from a
combination of these factors.
Snatch forces
The bundle conductor arrangement of strung (wires) type busbars constitute a special calculation and
evaluation problem due to the snatch forces caused by short-circuit currents (parallel conductors forcibly
pulled together by magnetic attraction forces. These are causing high axial forces in the conductors).
See fig. 19.
Fig. 19 Bundle conductors
166
Vibrations
A special problem with tubular conductors is their sensitivity to vibrations. Vibrations often occur at moderate wind velocities, when the wind initiates a frequency which coincides with the systems own frequency,
perhaps only 13 Hz.
Vibrations could possibly cause the following defects:
Fatigue failure of the busbar
Fatigue (or impact) failure of the end fixings
Incorrect functioning of pantograph isolators
Damage to support insulators
Therefore the following methods for damping of tubular conductors are used.
Loose wire inside the tube
Clamps with damping effects
Auxiliary mass dampers.
5.5 Corona
On extremely high voltage installations corona rings and large radius bends are used and care is taken to
achieve a low value of electric stress on the conductor surface.
6. Clamps
6.1 Types of clamps
There are principally two types of clamps
Mechanical pressure
compressed
bolted
Welded
The mechanical pressure clamps (compressed or bolted) are the most commonly used in outdoor
switchyards designed by ABB. Of the two types the bolted design is almost exclusively used for connection
above ground.
Fig. 20
167
Bolted clamps
There are fundamentally four different groups of bolted clamps depending on the principle of connection to
the conductor i.e.:
Fixed clamps
See fig. 21
Sliding clamps
See fig. 22
Flexible clamps
See fig. 23
Support clamps
(as conductor support only) See fig. 22
Fig. 21 Fixed clamp
Fig.22 Bus support slide/fixed
Fig. 23 Flexible clamps

Welded clamps
Welded clamps are sometimes used in large switchyards having aluminium type conductors of high current
rating.
Welding gives very good contact properties but has the disadvantage of being more complicated,
requiring high dimension accuracy and being less flexible when it comes to modifications etc.
Fig. 24 Welded clamps
168
Fig. 25 Welded connection
Welded methods
The welding seam must be protected by an inert shielding gas flow such as argon (MIG or TIG-welding).
Fig. 26
Weld type straight coupler. Chamfered ends for easy insertion. Center
stop for accurate centering of coupler.
Fig. 27
Streamlined, weld type T-connector.
Tap element socket deep enough to
allow for error in cut-off
We have only mentioned the welding methods here. In case it will be applied, see SITEMAN 08-94 (Welding
rules) and SITEMAN 17-94 (Aluminium welding).
Compression clamps
The use of compression clamps is most common when connecting the earth wires both under and above
ground.
Fig. 28 Compression clamps
For more details see SITEMAN 12-94. However, other frequent methods are brazing using bronz-alloy and
thermic welding process described in SITEMAN 11-94.
When rectangular earth bars are used they are mostly brazed together.
6.2 Design
Electrical connections must be made so that maintenance never will be required. This is indeed a stringent
requirement.
Clamps used for connection of conductors in outdoor switchyards must be designed and dimensioned to
guarantee uninterrupted current supply and also not yield to mechanical forces between conductors due to
short-circuit or other severe stresses.
Contact resistance
One extremely important characteristic is the contact resistance which is responsible for the temperature
rise and which must be kept as low as possible. The resistance must not increase significantly during the
switchyards lifetime.
Some important design characteristics are:
compression bolts placed as close as possible to the conductor
compression bolts placed opposite to one another
bolts must exert the required pressure
the cast section must have sufficiently large cross
section to be able to conduct the rated current.
Fig. 29
169
High voltage and current clamps

Special attention must be paid to the clamp design when used for very high voltages (corona) and high
currents. Such information is available in the manufacturers catalogues and from the design office.
Fig. 30
6.3 Material
Clamps for copper conductors
Connection clamps for copper conductors are manufactured exclusively of copper or of corrosion resistant
bronze. Bronze is the more common material. Brass must not be used due to risk of stress corrosion.
Copper and bronze connectings cause less problems than the aluminium ones, since the oxides are more
easily removed.
Clamps for aluminium conductors
Connection clamps for aluminium conductors are manufactured of corrosion resistant copper-free aluminium alloy.
The corrosion resistance of aluminium depends to a large extent on the difficulty to reduce oxides which
develop on its surface. These oxides are electrically insulating and must therefore be removed as effectively
as possible from the contact surfaces.
Bolts
Generally, three types of material are used.
high alloyed, high strength aluminium (sensitive to corrosion). Used by EDF, France
hot dipped galvanized steel. Used in Germany
high alloyed Swedish stainless steel (expensive). Used by the Swedish State Power Board.
7. Erection
7.1 Access and work start
When a co-contractor is responsible for the civil work the engineer in charge (customer or representative)
shall grant access to site in writing and in due time.
If allowed by the time schedule, the erection of high-voltage apparatuses shall not commence until the
erection material such as steelwork, support and string insulators, conductors etc., have been erected and
the ground refilled and levelled. This applies also to the concrete cable ducts, which shall be ready at the
same time.
7.2 Steel structures
High towers
In order to facilitate more than one team to work with steel structures, it is recommended to start with the
towers. If the crane does not have sufficient height lifting capacity, the tower may be erected in two parts.
The lower part is hoisted with a crane. The upper part is then erected manually, piece by piece, as
illustrated in fig. 31. It is not necessary to fasten the hook of the crane at the top of the tower. If it is fastened
above the center of gravity, it is safe enough.
170
When the crane has insufficient height lifting capacity, the upper parts can be erected piece by piece.
Fig. 31.
Tightening of bolts
When the towers, the cross-beams or apparatus structures are assembled, the bolts must not be
completely tightened. The final tightening shall be done after adjustment in straight position.
Adjustment
The adjustment to straight position is most conveniently controlled with a teodolite. The measurements are
taken from two directions at 90 angle as shown in figure 32. The levelling could be done by shims or
levelling nuts. If levelling nuts are used grouting may be required.
Fig. 32
For security reasons should the towers be grounded immediatly after erected.
171
Fig. 33
Cross beams
Cross beams are to be erected on the ground and hoisted up by means of a derrick or, more convenient, a
mobile crane.
Apparatus structures
Before the erection of Apparatus structures the Overhead lines and the Overhead ligtning protection wires
should be installed for security reasons and the convenience of having more space. The erection of
Apparatus structures will usually not involve any lifting problems.
7.3 Outdoor earthing
For the erection of the outdoor earthing refer to SITEMAN 18-94.
7.4 Insulators
Handling, checking and storing
Of all the components going into the material handling process of a project the insulators are the most
easily damaged. Only in case of minor damages on the surface there is a chance of acceptance. The
design office must be contacted for further instructions.
Furthermore insulators are expensive items and they are also expensive to air freight due to their heavy
weight. This called for keen precautions and care during the whole handling process.
When ordering it is always advisable to include some spare insulators of each type (up to 5 %).
Checking must be done immediately upon arrival, especially if the packing is damaged or there is the
slightest suspicion of careless handling.
Installation
Assembly
Arrange a protected and controllable assembly area in the switchyard.
Assemble all the components, insulator elements and fittings, to composite units at ground level.
Fit the insulator assembly into place.
Follow a sequential plan which will give good control.
Tighten the bolts to right torque.
A torque wrench is recommended, manual or electric.
Use tools with care not to knock off porcelain chips.
172
Lifting
Most insulators are erected at high levels. The lowest part of a support insulator is normally 2.5 metres
above ground. Suspension insulators may be more than 10 metres above ground and of considerable
weight.
If possible, a mobile crane with suitable soft slings should be used.
Some maintenance questions
During maintenance work including transport in the switchyard care shall be taken to protect the insulators.
Switchyard steelwork may have to be painted or re-painted after some years. If sand blasting of the
steelwork is proposed as part of the painting process, it should generally be refused due to the
extraordinary difficulties in protecting insulator surfaces. For minor repair of scratches galvanization may be
used.
Tools
The tools requirement is modest, except for the lifting devices. Good soft slinging devices and a torque
wrench are needed.
7.5 Busbars and Wires
Conductor material, such as wire drums and tubes, will usually be stored outdoor because of size and
weight. It is important that they do not come into contact with earth and sand which may jeopardize contact
properties and increase corona in case of surface scratches.
Furthermore, it may be necessary to build wooden platforms or similar to keep the material above water
level. This is perhaps also the best protection against earth and sand influences as above.
Usual checking and handling routines shall apply.
Installation
After erection of steel structures and insulators follow the installation of conductors, which must be done
with care not to damage the insulator.
It is important that the material is kept clean. Parts to be connected together by means of clamps shall be
subject to the same careful cleaning and protection as described for the clamps. See Clause 7.6.
WARNING! Never use the same steelbrush for copper and aluminium as it will accelerate corrosion.
Wire busbars
Stringing of wires must be done according to the sag and tension chart.
Great care should be taken to avoid caging i.e. bending the wire so the strands go apart.
When cutting the wire always remember to tape the ends or use a special tool before cutting in order to
keep the strands in place.
Below follow some methods to measure the length of buswire including the sag, both on the ground and
between gantries.
a) The distance between the gantries is measured as illustrated in fig. 34. To this
length is added a figure for the sag as stated in the sag and tension chart. Note that
this figure is temperature dependent. If compression clamps are used, their extension also has to be added.
The complete buswire including string insulators with hardware are assembled on the
ground.
Note! Always use cover and wood as protection against earth and sand.
b) The buswire is assembled with a string insulator in one end on the ground. This end
is pulled up. A wire puller is fitted in the other end and connected to a rope, see
fig. 35. Two measuring boards are fitted so that the sag can be measured. The
second end is pulled up to the right sag and a tape marking is applied to the rope.
The buswire is taken down and the total length is recorded and the second string
insulator is fitted. The complete buswire is then finally installed as shown in fig. 36.
173
A=
B=
C=
Distance between gantries

Sag plus compression clamp extension
Total length of buswire including insulator arrangements
Fig. 34 Measuring of span on ground.
Fig. 35 Measuring of span between gantries
174
Fig. 36 Final installation of span

c) Another method is to use a rope as a measurement and position it so that sag is correctly recorded,
see fig. 35.
Tubular conductors
Tubes can either be erected in straight pieces or formed to different shapes by bending or by using various
preformed tubular elements which are welded together to obtain the necessary shape. Bending and welding
create both special problems regarding tools and special trained staff, which have to be thoroughly
penetrated from case to case.
Hoisting
The hoisting of the buswires/bars can be done manually or with various motor drive hoisting gears. Be sure
to have sufficient lifting points in order not to bend the busbars.
If flexible connectors (expansion joints) have been welded on the ground in between sections make sure
that they are reinforced temporarily.
Fig. 37 Welding of
tubular connectors
175
Fig. 38 Erection of tubular connectors

Tools
The following list of tools is only indicative:
Pulley block
Soft slings
Rope
Wire puller
Measuring board
Theodolite
Wire drum stands
Different types of hoisting gears:
Winch for wire rope (type Tirfor)
Motor winch
Winch mounted on car
Mobile crane
Torque wrenches
7.6 Clamps
The connection clamps must be handled with care. Scratches on the surface as even slight damaging of the
outer surface can create corona.
Connections must be placed on a clean surface. Sand or other contaminants would cause damage to the
threads of the bolts and nuts. In case the connectors are delivered coated with contact paste the wrapping
should not be opened until the connectors are installed.
It is highly recommended to check the number and type of the clamps against the shipping and the
PLANA documents or similar. The clamps are installed rather late in the erection period. Faulty deliveries
may cause delays and extra costs at the end.
Installation
Treatment
The brushing is carried out in two steps. First dry and then with contact paste.
Cleaning
The contact surface of the connector as well as the conductor shall be thoroughly cleaned with a steel
brush, in order to remove the oxide layer. Different brushes must be used for copper and aluminium.
As already mentioned the oxides are electrically insulating and aluminium has the thickest layer.
176
Contact paste
Immediately (within 5 min.) after cleaning, the contact surface shall be coated with the delivered contact
paste which shall be brushed through with a steel brush all over the surface. For cable conductors, ensure
that the paste penetrates as deeply as possible between the strands of the cable.
The grease will help to seal the surface from renewed oxidation, although not completely effective. Ample
used it will also seal off contact surfaces from water penetration.
WARNING! Never use the same steel brush for copper and aluminium as it will accelerate corrosion.
Installation of rigid connections
Make sure that the conductor completely fills the groove. At the end of the groove there is cavity to keep
the conductor end free, a space shall be left between the conductor and the end of the conductor groove,
see fig. 39.
Fig. 39
When installing the cap on the body make sure that approximately the same gap is left on both sides
between cap and body of the connector, see fig. 40.
Fig. 40
Installation of expansion connectors
When mounting an expansion connector the positioning of the bus relative to the connector must take
ambient temperature into account.
Measure the total travel (L) of the bus. The distance (P) from the minimum temperature end position can
be taken from the diagram in fig. 51 by following the vertical line from L to the curve for actual ambient
temperature and then read P horizontally from the point of intersection. The meanings of L and P are indicated in figure 41 43.
Example: Ambient temperature 40 C
Maximum travel (L): 80 mm
P = 56 mm
Fig. 41
Fig. 42
Fig.43
177
Connections to apparatus pad terminals

The terminal is to be cleaned according to clause 8.6. The jointing shall be carried out with stainless steel
bolts with double springwashers and washers as shown in fig. 44.
Fig. 44
Tightening torque
Every clamp manufacturer specifies a recommended tightening pressure i.e. the required torque for tightening the bolts. It is of utmost importance that the correct torque is applied.
The tightening torque for M12 is 6085 Nm for dry or slightly oiled screws.
Pre-tighten the bolts in the sequence shown in fig. 45 and 46 to 60 % of the recommended torque. Retighten all bolts to their recommended torque following the same sequence.
It may be needed to check the torque before handing over to commissioning.
Fig. 45
Fig. 46
Connection between copper and aluminium

This type of connection is tricky, since copper and aluminium are 1.8 V apart in the electrochemical series.
One method is to use bi-metallic spacers or to get the copper part tin plated. Another method is forming the
connection as a so-called Mass-Anode-System, which means that the volume and surface area of aluminium dominate over copper, eliminating the need of bi-metal. In this case it is important to orientate the
connection so that the aluminium is above the copper and thereby covers it so that rain water runs from the
aluminium to the copper and not vice versa. See fig. 4750.
Fig. 47
Fig. 48
Fig. 49
Fig. 50
Aluminium cold flow

The penetration of the oxide layer is partly a result of pressure applied. The higher the pressure, the more
effective penetration. The difficulty, however, is that aluminium is cold floating, i.e. it becomes deformed
under pressure. The pressure therefore must be limited to about 20 N/mm2.
To summarize:
Thorough brushing, ample greasing followed by immediate installation and tightening with correct
pressure will guarantee long and problemfree contact life.
178
Tools
The following tools are required:
For all types of clamps:
Use suitable steel brushes, separate ones for copper and aluminium respectively.
For bolted clamps:

A torque wrench and a lifting device for heavier clamps are required.
For compression clamps:
Both hand-operated, hydraulic or electrical/hydraulic operated compression tools are used. It is important
that the tools are approved by the manufacturer of the clamps. See SITEMAN 12-94.
For thermic welding process:
A set of specific moulds is required. See SITEMAN 11-94.
Fig. 51
7.7 High voltage apparatus

Erection sequence
Apparatus should be erected and adjusted before connection of the primary conductors. If place is
available, the apparatus may be erected indoors and later transported to the switchyard.
In parallel with the erection of apparatuses the laying of cables, erection of support insulators, busbars
etc., are carried out.
Testing
Re-tightening of bolts and checking of steel structures etc. should be finalized before carrying out the
operational tests on the equipment. The tests are performed first as local tests on the equipment itself and
thereafter from the control room (remote) for checking of signals, interlocking etc.
179
Circuit breakers
Erection of circuit breakers is a comprehensive work and must be carried out according to the erection
instructions.
Precaution: If the equipment is stored outdoor, which often is the case, it must be positioned so that it,
during rainy periods, is not exposed to water. For longer storage periods the equipment must be covered
and the anti-condensation heaters be connected.
Lifting devices with sufficient capacity (check with dimension print) must be available.
The flexible connectors between the breaker and the current transformers are included in the delivery.
Fig. 52 Erected circuit breakers

Disconnecting switches
The comments under
item circuit-breakers
above are in many
respects valid also for
disconnecting switches.
Regarding switches with
build-on earthing
switches it should be
realized that there are a
lot of variations when
erecting the operating
mechanism.
Fig. 53 Erected disconnecting switches and

voltage transformers
180
Earthing switches
Connections to earthing switches shall be made with shortest possible route to the earth grid.
8. Inspection, quality control

It is of utmost importance to carry out an erection that comply with standards stated in the contract between
ABB and the customer and between ABB and subcontractor. Make sure that the contract is understood
even in this respect.
During the progress of erection a Remaining list has to be kept updated. The list shall state all work that
has to be re-done or is unclear.
Before Taking over the list has to be finalized.
Note that all drawings have to be up-dated as built in red and one copy submitted to the design office.
9. Testing and Commissioning

Even if testing and commissioning are usually not the ultimate responsibility of the erection engineer, he is
intimately involved.
Erection and commissioning goes hand in hand and require close cooperation.
181
Duplicate busbars
Main and transfer busbars
Duplicate and transfer busbars
1 12 breaker sysytem
Double circuit-breaker
182
183
184
185
Book No. 14
Version 0
Erection
ABB Transmission and Distribution Management Ltd

BA THS / BU Transmission Systems and Substations
P. O. Box 8131
CH - 8050 Zrich
Switzerland
ReklamCenter AB (50-99078)
Printed in Sweden, ABB Support 1999-04
BU TS / Global LEC Support

C/o ABB Switchgear AB
SE - 721 58 Vsters
Sweden

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BA THS / BU Transmission Systems and Substations LEC Support Programme

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BA THS / BU Transmission Systems and Substations LEC Support Programme

BA THS / BU Transmission Systems and Substations LEC Support Programme

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

Site mobilization ............................................................. 7

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

This document and parts thereof must not be

BA THS / BU Transmission Systems and Substations LEC Support Programme

2. Checklist - arrival to the country site

3.3 Temporary power supply

BA THS / BU Transmission Systems and Substations LEC Support Programme

3.4 Offices and indoor store

Figure 3. Typical site office.

BA THS / BU Transmission Systems and Substations LEC Support Programme

Figure 4. Container store.

BA THS / BU Transmission Systems and Substations LEC Support Programme

Figure 6. View of an outdoor storage area.

Figure 7. Section view outdoor storage area.

3.5 Outdoor store

BA THS / BU Transmission Systems and Substations LEC Support Programme

The ground shall be level and, if possible, covered with gravel.

4. Checklist for civil work

BA THS / BU Transmission Systems and Substations LEC Support Programme

Arrival to the country site

Transportation from airport?

Landing card. How to be

Other comments regarding

BA THS / BU Transmission Systems and Substations LEC Support Programme

Arrival to the country site

Personal belongings preferable to be brought from home

Customs regulations for

Arrival to the country site

LIVING CONDITIONS (cont.)

2.11 Address, residence?

2.12 Telephone, residence?

2.13 Possibilities for recreation?

2.14 Contact Swedish embassy,

2.15 Other comments regarding

Arrival to the country site

Private doctors available?

Medicine, antibiotica, serum,

Risk of deseases like malaria,

Other comments regarding

Address to SOS international

Arrival to the country site

Address for company mail?

Telephone number during

Work permit / permit to stay?

Visit local ABB, contact man?

Visit customer, contact man?

Visit consultant, contact man?

Visit subcontractor, contact

4.10 Visit transport company, contact man?

Arrival to the country site

WORKING CONDITIONS (cont.)

4.13 Local purchasing of erection

4.14 Workshop for minor repairs

4.15 Plant for hot dip galvanizing

4.16 Bank opening account