New Energy Busines-Training Module for HT & LT Cable Termination

1
 CABLE TERMINATION PROCEDURE

OBJECTIVE :-

To train the construction staff about standard cable termination process of all
equipment's in the solar PV plant. It makes electrical connections between the
cable to cable and cable to equipment.

COMPOSITION OF CABLES:-

1. Conductor
2. Conductor Screen
3. Insulation
4. Inner Sheath
5. Armouring
6. Metallic Screen
7. Outer Sheath

Metallic Screen

2
 CABLE TERMINATION FLOW CHART

Measuring & Placement Removal of Metallic Screen Inner insulation removed

of armor clamping ring according to the length of lug
on Cable

Crimping of lug by Heat shrinkable sleeve Terminate cables at bus bar

hydraulic crimping tools applied on cable

3
 CABLE TERMINATION PROCEDURE

WORKING PROCEDURE FOR TERMINATION:-

1. At cable terminating end sufficient length of spare cable shall be left in the ground
and at cable tray for future needs.
2. The rise of the cable immediately from the ground shall be enclosed in PVC/PE
pipe of suitable diameter to protect against direct exposure to the sun.
3. The insulation resistance value of the cable should be measured before
commencing the termination and jointing process.
4. The phase sequence/polarity at both ends of the cable must be confirmed to
prevent any phase mismatch.
5. The termination/jointing work will be performed by certified technicians following
the procedures outlined in the jointing OEM manual.
6. For HT Termination/Joints, it is essential to verify that the jointer holds a valid
certificate matching the voltage rating of the cable.
7. The cable shall be properly fastened using non-metallic clamps.
8. Use appropriate Nut, bolt, washer and spring washer to terminate the
terminal/cable points.
9. Appropriate labels shall be fixed identifying the phase circuit, voltage and date of
commissioning etc., on the cable supporting structure.
10. Provide proper earthing, reference IS-3043:1987 (Code of practice for earthing).

4
 CABLE TERMINATION PROCEDURE
WORKING PROCEDURE FOR JOINTING:-
1. The cable jointing personnel and his crew shall have good experience in the type of
jointing and terminations that are used. The jointing works shall commence as soon
as two or three lengths of cable have been laid. All care should be taken to protect
the caps/seals on the cable ends and the cable.
2. Comprehensive jointing instructions should be obtained from the manufacture of
jointing kits and meticulously followed.
3. The materials used in the joints like sleeve, ferrules, screen/sheath continuity bonds,
paste, lugs etc. shall be as per the recommended manufacturer or as per the
technical team.
4. Sufficient overlap of cables shall be allowed for making the joints as per OEM
guideline.
5. The joint bay should be of sufficient dimensions to allow the jointers to work with as
much freedom of movement and comfort as possible. Sufficient space should be
kept below the cable to be jointed.
6. The jointing tools kit shall be as per the recommended manufacturer and technical
team.
7. Before cable entry into any equipment the provision of holes in the gland plate to
be checked ; if not the plates are to be removed necessary cable entry holes to be
made in the plate and post drilling remove any sharp edges in the hole to prevent
damage to the cables.
8. Fix the gland and verify its tightness.
9. Ensure the cable enters the cable chamber in the panel box properly, without
causing any damage.
5
 CABLE TERMINATION PROCEDURE
10. Measure and mark the length of the cable for the removal of outer insulation to
ensure proper fitting of the heat sleeve.
11. Create adequate space above the conductor to allow for proper crimping of the lug. Heat Sleeve
12. Apply anti-corrosion paste on the conductor where the outer sheath has been
removed.
13. Crimp the lug onto the conductor using appropriate crimping tools.
14. Ensure that the edges are filed properly to eliminate any sharp edges after crimping.
15. Apply heat sleeve of the required rating onto the lug barrel and conductor, apply Lug
heat to secure it in place.
16. Before connecting the cable to the busbar/terminal, recheck the insulation resistance
value and continuity of the cable. Then, connect it to the busbar using the
appropriate size of bolt and required torque value.

Dressing of Cable:-
1. Use cable supports, such as clamps, tie or brackets, to secure the cable along its
route.
2. Ensure that the supports are spaced appropriately to prevent sagging or excessive
tension on the cable.
3. Ensuring that its securely fastened to cable supports and free from any sharp edges or
obstructions.
4. Use cable ties or straps to bundle and organize multiple cables if necessary.
5. Label the Cable with relevant information, such as cable type, voltage rating, and
termination points, this helps to identify the cable and facilitate the maintenance or
troubleshooting in the future.
6
 REQUIRED TOOLS & TACKLES

HYDRAULIC CRIMPING HAND CRIMPING TOOLS FOR HT CABLE

Sleeves
Tape

Knife Nose Plier

It is used for Crimping the lugs It is used for HT Cable Termination
It is used for Crimping the Lugs

7
Inspection Checklist
HT End kit and Termination

Client:
Job & Draw ing No.:
Date:
Equipment :- INVERT ER PAD No: Sub Contractor:
Observation
Sl No. HT End kit & T ermination REMARKS IF ANY
Execution QC

1 Check the license/Certification of the jointer

2 Installation manual,SOP & checklist followed or not .

3 Check WA card issued by admin

4 Check the availability of tools & tackles as per the SOP

Check the approved make and voltage level,size and
5
components of the kit as per the BOM
Check the meggeer value/ continuity/ healthiness of cable
6
before kit

7 Check for the following parts (before putting sleeves)

Creepage distance (from Bottom of Lug to till end of removal

a
of Semicon layer)

b Proper length of semicon layer

c Position of breakout

Smooth polishing of XLPE insulation outer surface after

d
removal of Semicon layer
After polishing,application of Silicon Grease from end of
e removal of semicon layer to start of stress control tube (
applicable for Raychem kits)
After polishing,application of Silicon Grease from end of
f removal of semicon layer to end of lug
( applicable for 3M kits)

g Position of lekage collector above semicon layer

h Proper crimping of lug ( min 4 times )

i Position of braided wire

j Length of braided wire

k Support ring below armour wires

l Position of armour clamp

m Tightness of armour clamp

8 Check for the following (after putting sleeves)

a Mastic tape application near lug

b Position of lug

c Proper shrinking of sleeve

Check the cable loopping properly palced and its sand

9
bed(if applicable)
10 Check the megger value after end kit

11 Check the cable armour earthing done properly

Check the cable terminated without stress on bushing with
12
touque
Check rain sheds provided as per manufacture
13
requirements for Indoor/Outdoor

8
Contractor EPC Engineer EPC QC Engineer RIL/Consultanat