RAUFOSS EXPLOSIVE COMPRESSION FITTINGS

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1 INSTRUCTION MANUAL FOR RAUFOSS EXPLOSIVE COMPRESSION FITTINGS Box Raufoss Norway Tlf.: Fax: January 2013, rev 2 Available on Page 1

2 CONTENTS GENERAL INFORMATION ON EXPLOSIVE AND SAFETY PROCEDURES Explosive... 3 Initiators... 3 Safety distance... 3 INSTRUCTION MANUAL FOR RAUFOSS EXPLOSIVE COMPRESSION FITTINGS General instruction..4 Installation in rainy weather..4 Evaluation of an old conductor Cleaning the conductor before installation..5 Tools..6 Joints for ACSR conductors...6 Dead ends for ACSR conductors..8 Joints for conductor without steel core.. 10 Dead ends for conductor without steel core..11 Dead ends for EHS steel wire..12 Jumper Terminals January 2013, rev 2 Available on Page 2

3 GENERAL INFORMATION ON EXPLOSIVE AND SAFETY PROCEDURES The Raufoss Fittings are compressed by means of explosives. The User must comply with local laws and regulations pertaining to transportation, handling, storage and use of explosives. A responsible person must ensure that all safety regulations are adhered to and that the site of detonation is properly secured. EXPLOSIVE The explosive is a detonating cord. It is very stable and may be stored for an extended period of time, if stored in a dry room. The fittings may be fired at temperatures between -30 C and +60 C. INITIATORS a) Time Fuse The time fuse must be dry and without kinks or bends and must not be damaged. The fuse length should be a minimum of 100 cm with a burn rate of 105 sec./m to 130 sec./m, which should give the personnel involved ample time to reach safety. The burn rate should be verified for new and different types of time fuse. b) Non electric igniton A NONEL igniter is the most common. c) Blasting Cap No. 8 The blasting cap is sensitive to impact and heat and must be handled with care. Follow suppliers recommendations. For special application, other methods for initiating the explosive may be used. Please contact VP metall AS for information. See contact information on page 1. SAFETY DISTANCE No personnel should be closer than 50 meters to the fitting at the time of detonation. 25 January 2013, rev 2 Available on Page 3

4 INSTRUCTION MANUAL FOR RAUFOSS EXPLOSIVE COMPRESSION FITTINGS This instruction manual covers typical compression fittings such as joints, dead-ends and jumper terminals. Special instruction manuals will be issued as required for other type compression fittings. GENERAL INSTRUCTION 1. Check that the correct fitting is used. 2. Check that all fittings components are clean and dry before installation. 3. The conductor ends must be cleaned before installation. Water, ice, snow and dirt must be removed. The part of the conductor end which goes into the joint must always be brushed before installation. On a 1-shot steel-aluminium conductor with a greased steel core, the outside of the steel core must be dried with a dry rag or twist. If more than the steel core is greased, the special instruction manual must be used. 4. Check that the explosive is tight around the main sleeve. 5. Detonate the fitting approximately 1 m above ground. A simple wooden rack will do the job. See fig. A and B. Fig. A: Firing rack for joints Fig. B: Firing rack for dead-ends 6. Under extremely dry conditions the development of hot gasses and remnants of the time fuse may at the moment of detonation ignite grass or dry vegetation under the firing rack. The site should be secured against fire hazard by removal of dry grass or vegetation or by soaking the site with water. The safety fuse should be tied to the firing rack so the remnants of the glowing fuse may easily be located. A fire extinguisher should be readily available at the site. 7. It is of utmost importance that the conductor ends are prepared and marked correctly and that the fitting is mounted precisely as specified in this manual. Inaccurate work may result in reduced gripping length and therefore reduced holding power. INSTALLATION IN RAINY WEATHER A sloping conductor may provide a path for water both on the outside and between the strands. Therefore, always elevate the joints and tilt the dead-ends such that water will run away from the fitting during installation. See fig. A and B. Water must not under any circumstance be allowed to collect inside the fitting during installation! 25 January 2013, rev 2 Available on Page 4

5 EVALUATION OF THE STATE OF AN OLD CONDUCTOR 1. When cutting out an old fitting, always cut the conductor at least 10 cms from the end of the aluminim tube. 2. After having removed the aluminium strands, check the conductor visually: For any sign of corrosion on the aluminium strands (white powder between the strands), more conductor has to be cut away, or this powder must be removed, and the al.strands must be brushed in the area that will fit into the fitting. For any sign of corrosion on the visible steel (red/brown spots), more conductor needs to be cut away. There must be no signs of corrosion on the steel that will fit into the fitting. If the old fitting was sloped, the end that points upwards, is most disposed to corrosion. For obvious signs of overheating in the old fitting more conductor needs to be cut out. Signs of considerable overheating may be e.g. dark colour on the conductor, signs of sliding or burnt strands. If the conductor contains old filling compound from the old joint, this part has to be cut away. On old conductors where the steel core is greased, this grease may spread to the aluminium strands. If so, contact the constructor 3. If the part that needs to be cut out is so long, that a repair joint may not be used, at least 30 mtr of new conductor has to be used, centric to the old joint. 4. If any corrosion further out on the conductor, consider changing the whole section of conductor instead of just the joints. Contact the constructor in any case of doubt. CLEANING THE CONDUCTOR BEFORE INSTALLATION 1. Every conductor with an outer layer of aluminium will have an oxide coating. The thickness and insulating property of this layer is dependant of how old the conductor is, and the climate it has been exposed to. 2. The conductor ends must always be brushed before installation of implosive fittings on an old conductor (not necessary on a conductor recently delivered from factory). All the length that is to go into the connector must be brushed. 3. It is important that the brushing is done in a dry environment. 4. The brush must be rust proof. 5. The brushing must be done along the strands. In that way a larger part of the strand surface is cleaned, and no particles will be left between the strands. 25 January 2013, rev 2 Available on Page 5

6 TOOLS The following tools are required to install the fittings: 1. File for trimming the aluminium and steel strands 2. A pair of pliers for applying the serving wires 3. Fuse plier for cutting the fuse 4. Electric tape 5. Knife 6. Cable cutter 7. Marking pen 8. Detonator No. 8 with 100 cm safety fuse / or similar systems 9. Firing rack. Can be made from available pieces of lumber of approx. 2 m length 10. Matches JOINTS FOR ACSR-CONDUCTORS 1. Components: a) Main sleeve with PVC hose and explosive. b) Galvanized Steel Sleeve with or without filler tube. c) For some conductor types filler tubes may be required between the main sleeve and the aluminium strands. 2. Installation: a) Serve the conductor a distance from the ends equal to half the length of steel sleeve plus approx. 15 mm. Remove the aluminium strands a distance from the ends equal to half the length of steel sleeve less 2-3 mm. Serve the steel core approx. 10 mm from the end. See fig. 1. b) Mark both ends of the conductor a distance from the ends equal to half the length of the main sleeve. See fig January 2013, rev 2 Available on Page 6

7 c) Slide the main sleeve over the conductor and off to one side. Install filler tubes if required. See fig. 3A and 3. d) Slide the steel sleeve over one of the steel cores while removing the serving wire. Insert the steel core from the other conductor end into the free end of the steel sleeve while removing the serving wire. Check that both core ends are completely inserted into the steel sleeve. See fig. 4 and 5. e) Slide the main sleeve over the steel sleeve to the marks on the conductor. If filler tubes are required, check that both tubes butts up against the steel sleeve. See fig. 4, 5 and January 2013, rev 2 Available on Page 7

8 3. Detonation: a) Tape a detonator No. 8 with safety fuse (min. length of 100 cm) to the centre of the explosive charge. Check that the detonator is oriented parallel to the conductor as shown on the joint and on the drawing. Make sure that it is taped tight against the explosive. See fig. 6 b) Light the fuse and walk a minimum of 50 m away from the fitting. c) After detonation remove remains of PVC hose and the joint is finished. Check the marks to make sure that the conductor did not slide out. DEAD-ENDS FOR ACSR CONDUCTOR 1. Components: a) Main sleeve with PVC hose, explosive and including pad for connecting to jumper terminal. b) Forged and galvanized steel eyebolt with or without filler tube. c) For smaller conductors the drilled portion of the eyebolt is a separate unit (steel sleeve). See fig. 9A. d) For some conductor types, filler tubes may be required between the main sleeve and aluminium strands. 2. Installation: a) Serve the conductor a distance from the ends equal to the bore depth of the eye bolt plus approx. 15 mm. Remove the aluminium strands a distance from the end equal to bore depth of eyebolt less 2 3 mm. If separate steel sleeve is used (see paragraph 1c above), remove aluminium strands a distance equal to the length of the sleeve less 2 3 mm. Serve the steel core approx. 10 mm from the end. See fig. 7. b) Slide the main sleeve over the conductor end. Install filler tube if required. 25 January 2013, rev 2 Available on Page 8

9 See fig. 8. c) Slide the eyebolt over the steel core while removing the serving wire. Check that the steel core butts against the bottom of the borehole in the eyebolt. Mark the conductor as shown in fig. 9. If a separate steel sleeve is provided for the steel core, slide the sleeve over the core and mark the conductor as shown in fig. 9A. d) Slide the main sleeve towards and against the flange of the eyebolt. Filler tube, if required, is mounted as shown. Check that the mark on the conductor is at the mouth of the main sleeve and that the eyebolt is rotated to its correct position relative to the jumper pad. Place the assembled dead-end on the firing rig. 3. Detonation: a) Tape detonator No. 8 with safety fuse (min. 100 cm length) to the explosive a distance of approx. 60 mm from the jumper pad. Check that the detonator is oriented parallel to the conductor and is taped tight against the explosive. See fig January 2013, rev 2 Available on Page 9

10 b) Light the fuse and walk a minimum of 50 m away from the fitting. d) After detonation, remove remains of PVC hose and the joint is finished. Check the marks to make sure that the conductor did not slide out. JOINTS FOR HOMOGENEOUS (NO STEEL CORE) CONDUCTORS AND STEEL WIRE 1. Components: Main sleeve with PVC hose and explosive. 2. Installation: b) Serve the conductor a distance of mm from the ends. Mark both ends a distance from the end equal to half the length of the main sleeve. See fig. 11. c) Slide the main sleeve over the conductor ends while removing the serving wire. Check that the conductor ends butt up against each other at the centre of the main sleeve using the marks on the conductor. See fig January 2013, rev 2 Available on Page 10

11 3. Detonation: a) Tape detonator No. 8 with safety fuse (min. length of 100 cm) to the centre of the explosive charge. Check that the detonator is oriented parallel to the conductor, as shown on the joint and on the drawing. Make sure that it is taped tight against the explosive. See fig. 13. b) Check that the conductor ends are correctly positioned inside the main sleeve. c) Light the fuse and walk a minimum of 50 m away from the fitting. d) After detonation, remove remains of PVC hose and the joint is finished. Check the marks to make sure that the conductor did not slide out. DEAD-ENDS FOR HOMOGENEOUS (NO STEEL CORE) CONDUCTOR 1. Components: a) Main sleeve with PVC hose, explosive and including pad for connecting to jumper terminal. b) Forged and galvanized steel eyebolt. 2. Installation: a) Serve the conductor a distance of mm from the end. Mark the conductor a distance from the end equal to the length of the main sleeve less the root length of the eyebolt. See fig. 14. b) Slide the main sleeve over the conductor to the mark while removing the serving wire. Slide the eyebolt inside the main sleeve until its flange touches the end of the sleeve and until the conductor end butts up against the eyebolt. Check that eyebolt is rotated to its correct position relative to the jumper pad. Place the assembled dead-end on the firing rig. See fig January 2013, rev 2 Available on Page 11

12 3. Detonation: a) Tape detonator No. 8 with safety fuse (min. 100 cm length) to the explosive a distance of approx. 60 mm from the jumper pad. Check that the detonator is oriented parallel to the conductor as shown on the joint and on the drawing. Make sure that it is taped tight against the explosive. See fig mm b) Check that the conductor is correctly positioned inside the main sleeve. c) Light the fuse and walk a minimum distance of 50 meters away from the fitting. d) After detonation, remove remains of PVC hose and the joint is finished. Check the marks to make sure that the conductor did not slide out. DEAD-ENDS FOR EHS STEEL WIRE 1. Components: Forged and galvanized steel eyebolt with PVC hose and explosive. 2. Installation: a) Mark the wire as shown in fig. 17. Serve the wire a distance of mm from the end. b) Slide the wire end inside the eyebolt while removing the serving wire until it butts up against the bottom of the bored hole. Place the assembled dead-end on the firing rig. 25 January 2013, rev 2 Available on Page 12

13 3. Detonation: a) Tape detonator No. 8 with safety fuse (min. length of 100 cm) to the explosive as shown in fig. 17. Check that the detonator is oriented parallel to the wire, as shown on the joint and on the drawing. Make sure that it is taped tight against the explosive. See fig. 17. b) Check that the wire is correctly positioned inside the eyebolt. c) Light the fuse and walk a minimum distance of 50 meters away from the fitting. d) After detonation, remove remains of the PVC hose and the joint is finished. Check the marks to make sure that the conductor did not slide out. JUMPER TERMINALS 1. Components: a) Main sleeve with PVC hose and explosive, and with contact area for attachment to deadend pad. b) Bolts for attachment to dead-end. 2. Installation: Mark the condutor as shown in fig. 18, A + 10 mm Slide the conductor end inside the main sleeve until it butts against the bottom of the sleeve. Check that the conductor is correctly positioned; that the marking reaches the opening of the sleeve. Place the assembled jumper teminal on the firing rig. 25 January 2013, rev 2 Available on Page 13

14 3. Detonation: a) Tape detonator No. 8 with time fuse (min. length of 100 cm) to the explosive as shown on fig. 19. Check that the detonator is oriented parallel (not perpendicular) to the wire, as shown on the joint and on the drawing. Make sure that it is taped tight against the explosive. See fig. 19. b) Check that the conductor is correctly positioned inside the main sleeve. c) Light the fuse and walk a minimum distance of 50 meters away from the fitting. e) After detonation, remove remains of PVC hose and the jumper terminal is finished. Check the marks to make sure that the conductor did not slide out. 4. Attachment to the dead-end: The contact surface on the dead-end pad the jumper terminal is protected during transport and storage with a thin layer of grease and plastic bag. Remove the plastic bag on both contact surfaces and wipe both areas with a clean cloth etc. such that only a film of grease remains. Attach the jumper terminal immediately to the dead-end pad using the enclosed bolts, washers and lock washers. See fig. 20. Recommended torque on the bolts are as follows: SIZE TORQUE M Nm ( 7.4 kpm) ½ UNC 80 Nm ( 7.8 kpm) 5/8 UNC 150 Nm (14.7 kpm) Use torque wrench! 25 January 2013, rev 2 Available on Page 14

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