Ieee STD 404 IEEE Standard For Extruded and Laminated Dielectric Shielded Cable Joints Rated 2500 V To 500 000 V PDF

IEEE Standard for Extruded and
Laminated Dielectric Shielded Cable

Joints Rated 2500 V to 500 000 V
IEEE Power Engineering Society

Sponsored by the
Insulated Conductors Committee
IEEE
3 Park Avenue IEEE Std 404™-2006
New York, NY 10016-5997, USA (Revision of
IEEE Std 404-2000)
15 March 2007
IEEE Std 404™-2006
(Revision of
IEEE Std 404-2000)

Sponsor
Insulated Conductors Committee

of the
IEEE Power Engineering Society
Approved 6 December 2006

IEEE-SA Standards Board
Abstract: Electrical ratings and test requirements of cable joints used with extruded and
laminated dielectric shielded cable rated in preferred voltage steps from 2500 V to 500 000 V are
established in this standard. In addition, test requirements for cable jacket and cable shield
restoration devices are defined. A variety of common joint constructions are also defined. This
standard has been designed to provide uniform testing procedures that can be used by
manufacturers and users to evaluate the ability of underground power cable joints, and
associated cable shield and cable jacket restoration components, to perform reliably in service.
Keywords: cable joints, dielectric integrity tests, extruded dielectric cable, impulse withstand
voltage (BIL), laminated dielectric cable, sheath/shield sectionalizers, transition joints, withstand
voltage
_________________________
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Copyright © 2007 by the Institute of Electrical and Electronics Engineers, Inc.

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Introduction
This introduction is not part of IEEE Std 404-2006, IEEE Standard for Extruded and Laminated Dielectric Shielded
Cable Joints Rated 2500 V to 500 000 V.
This revision of IEEE Std 404™-2000 now includes fingerprint tests to establish and subsequently confirm
the properties of materials or components used in certain cable joints, such as heat-shrinkable, hand-taped,
and certain multi-component cold-shrink joints that cannot be subjected to the 100% electrical production
tests of premolded and single-component cold-shrink joint designs.
This revision of the standard has now harmonized the requirements between the cable accessory standards
for joints and terminations, making it easier to perform qualification tests on a complete cable system.
In addition, test requirements for cable jacket and cable shield restoration devices have been added, which
were not present in previous editions of the standard.
Joints that connect more than two cables or connect cables with two different conductor sizes are not
covered by this standard. However, manufacturers and users are encouraged to use appropriate parts of this
standard to evaluate these types of joints.
Notice to users
Errata
Errata, if any, for this and all other standards can be accessed at the following URL: http://
standards.ieee.org/reading/ieee/updates/errata/index.html. Users are encouraged to check this URL for
errata periodically.
Interpretations
Current interpretations can be accessed at the following URL: http://standards.ieee.org/reading/ieee/interp/
index.html.
Patents
Attention is called to the possibility that implementation of this standard may require use of subject matter
covered by patent rights. By publication of this standard, no position is taken with respect to the existence
or validity of any patent rights in connection therewith. The IEEE shall not be responsible for identifying
patents or patent applications for which a license may be required to implement an IEEE standard or for
conducting inquiries into the legal validity or scope of those patents that are brought to its attention.
iv
Copyright © 2007 IEEE. All rights reserved.
Participants
At the time this standard was completed, the Revision of IEEE Cable Joint Standard 404 Working Group
had the following membership:
Glenn J. Luzzi, Chair

Frank DiGugliemo, Vice Chair
Andre Bellemare Paul Hann Allen MacPhail

Bob Benn Rick Hartlein John M. Makal
Jim Braun Wolfgang Haverkamp Mike Malia
Thomas C. Champion, III Mike Jackson Michael Smalley
Jack Cherry Ed Jankowich Gregory Stano
Philip Cox Roy Jazowski Frank Stepniak
David Crotty Sherif Kamel Bill Taylor
John P. DuPont Carlos Katz Milan Uzelac
Robert D. Fulcomer Gael Kennedy Carl Wentzel
Robert Gear, Jr. Albert Kong Harry Yaworski
Frank Kuchta
The following members of the individual balloting committee voted on this standard. Balloters may have
voted for approval, disapproval, or abstention.
Roy W. Alexander R. B. Gear, Jr. Michael S. Newman

Earle C. Bascom, III Randall C. Groves Joe W. Nims
Michael G. Bayer Frank DiGuglielmo Ralph E. Patterson
Harvey L. Bowles Richard L. Harp Iulian E. Profir
Chris Brooks Dennis Horwitz Bartien Sayogo
Kent W. Brown David W. Jackson Michael J. Smalley
Vern L. Buchholz Edward M. Jankowich Nagu N. Srinivas
Weijen Chen A. S. Jones Gregory J. Stano
Robert A. Christman Gael Kennedy S. Thamilarasan
Mark S. Clark Jim Kulchisky James R. Tomaseski
John H. Cooper William E. Larzelere, Jr. Martin J. Von Herrmann
Tommy P. Cooper William E. Lockley John N. Ware, Jr.
Russ C. Dantzler G. L. Luri Joe D. Watson
Gary L. Donner Glenn J. Luzzi Lee E. Welch
Donald G. Dunn William M. McDermid William D. Wilkens
Gary R. Engmann Gary L. Michel James W. Wilson, Jr.
Robert D. Fulcomer Rachel I. Mosier Tiebin Zhao
Shantanu Nandi
v
When the IEEE-SA Standards Board approved this standard on 6 December 2006, it had the following
membership:
Steve M. Mills, Chair

Richard H. Hulett, Vice Chair
Don Wright, Past Chair
Judith Gorman, Secretary
Mark D. Bowman Kenneth S. Hanus Greg Ratta

Dennis B. Brophy William B. Hopf Robby Robson
William R. Goldbach Joseph L. Koepfinger* Anne-Marie Sahazizian
Arnold M. Greenspan David J. Law Virginia Sulzberger
Robert M. Grow Daleep C. Mohla Malcolm V. Thaden
Joanna N. Guenin T. W. Olsen Richard L. Townsend
Julian Forster* Glenn Parsons Walter Weigel
Mark S. Halpin Ronald C. Petersen Howard L. Wolfman
Tom A. Prevost
*Member Emeritus
Also included are the following nonvoting IEEE-SA Standards Board liaisons:
Satish K. Aggarwal, NRC Representative

Richard DeBlasio, DOE Representative
Alan H. Cookson, NIST Representative
Don Messina
IEEE Standards Program Manager, Document Development
William Ash
IEEE Standards Program Manager, Technical Program Development
vi
Copyright ©2007 IEEE. All rights reserved.
Contents
1. Scope .......................................................................................................................................................... 1
2. Normative references.................................................................................................................................. 1
3. Definitions .................................................................................................................................................. 3
3.1 Cable joint categories .......................................................................................................................... 3

3.2 Joint constructions ............................................................................................................................... 3
3.3 Other terms .......................................................................................................................................... 4
4. Service conditions ...................................................................................................................................... 4
5. Ratings........................................................................................................................................................ 4
5.1 Voltage ................................................................................................................................................ 4

5.2 Current and temperature ...................................................................................................................... 4
6. Construction ............................................................................................................................................... 7
6.1 Identification........................................................................................................................................ 7
6.2 Shielding.............................................................................................................................................. 8
6.3 Sheath/shield sectionalizers ................................................................................................................. 8
7. Testing........................................................................................................................................................ 8
7.1 Production tests for premolded and single-component cold-shrink joints........................................... 8

7.2 Fingerprint tests for heat-shrink and multi-component cold-shrink joint components ........................ 9
7.3 Fingerprint tests for elastomeric taped joint components .................................................................. 10
7.4 Design tests and testing sequence for all joint types.......................................................................... 11
7.5 Design test conditions........................................................................................................................ 12
7.6 Dielectric integrity tests..................................................................................................................... 12
7.7 Voltage withstand tests ...................................................................................................................... 15
7.8 Short-time current test ....................................................................................................................... 17
7.9 Cyclic aging test for extruded dielectric and transition joints............................................................ 17
7.10 High-voltage time test...................................................................................................................... 20
7.11 Sectionalizer tests ............................................................................................................................ 20
7.12 Semiconducting shielding test ......................................................................................................... 21
7.13 Cable metallic-shield restoration and cable jacket restoration components..................................... 21
7.14 Connector thermal and mechanical tests.......................................................................................... 24
Annex A (informative) Typical values of heat-shrinkable and multi-component cold-shrink joint

component tests and sampling rates ............................................................................................................. 25
Annex B (informative) Typical values of elastomeric taped joint component tests and sampling rates ...... 26
Annex C (informative) Bibliography............................................................................................................ 27
vii
1. Scope
This standard establishes electrical ratings and test requirements of cable joints used with extruded and
laminated dielectric shielded cables rated in preferred voltage steps from 2500 V to 500 000 V. In addition,
it defines test requirements for cable jacket and cable shield restoration devices.
This standard also defines a variety of common joint constructions.
Joints that connect more than two cables or connect cables with two different conductor sizes are not
covered by this standard. However, manufacturers and users are encouraged to use appropriate parts of this
standard to evaluate these joints.
2. Normative references
The following referenced documents are indispensable for the application of this document. For dated
references, only the edition cited applies. For undated references, the latest edition of the referenced
document (including any amendments or corrigenda) applies.
AEIC CS1, Specifications for Impregnated Paper-Insulated Metallic-Sheathed Cable, Solid Type.1
AEIC CS2, Specification for Impregnated Paper and Laminated Paper Polypropylene Insulated Cable, High
Pressure Pipe Type.
AEIC CS3, Specifications for Impregnated-Paper-Insulated Metallic Sheathed Cable, Low Pressure Gas-
Filled Type.
AEIC CS4, Specifications for Impregnated-Paper-Insulated Low and Medium Pressure Self-Contained
Liquid Filled Cable.
1
AEIC publications are available from the Association of Edison Illuminating Companies, 600 N. 18th Street, P.O. Box 2641,
Birmingham, AL 35291-0992, USA (http://www.aeic.org/). AEIC publications are also available from Global Engineering
Documents, 15 Inverness Way East, Englewood, CO 80112-5704, USA (http://global.ihs.com/).
1
IEEE Std 404-2006
IEEE Standard for Extruded and Laminated Dielectric Shielded Cable Joints Rated 2500 V to 500 000 V
AEIC CS6, Specifications for Ethylene Propylene Rubber Insulated Shielded Power Cables Rated
5 Through 69 kV.
AEIC CS7, Specifications for Crosslinked Polyethylene Insulated Shielded Power Cables Rated
69 Through 138 kV.
AEIC CS8, Specification for Extruded Dielectric Shielded Power Cables Rated 5 Through 46 kV.
ANSI C119.4, Electric Connectors—Connectors for Use Between Aluminum-to-Aluminum or Aluminum-

to-Copper Bare Overhead Connectors.2
ASTM D149-97a, Standard Test Method for Dielectric Breakdown Voltage and Dielectric Strength of
Solid Electrical Insulating Materials at Commercial Power Frequencies.3
ASTM D412-98, Standard Test Methods for Vulcanized Rubber and Thermoplastic Elastomers.
ASTM D991-89, Standard Test Method for Rubber Property-Volume Resistivity of Electrically Conductive
and Antistatic Products.
ASTM D4325-02, Standard Test Methods for Nonmetallic Semi-Conducting and Electrically Insulating
Rubber Tapes.
ASTM D4496-04, Standard Test Method for DC Resistance or Conductance of Moderately Conductive
Materials.
ICEA P-32-382, Short-Circuit Characteristics of Insulated Cable.4
ICEA P-45-482, Short-Circuit Performance of Metallic Shields and Sheaths on Insulated Cable.
IEEE Std 4™, IEEE Standard Techniques for High-Voltage Testing.5, 6
IEEE Std 82™, IEEE Standard Test Procedure for Impulse Voltage Tests on Insulated Conductors.
IEEE Std 575™-1988, IEEE Guide for the Application of Sheath-Bonding Methods for Single-Conductor
Cables and the Calculation of Induced Voltages and Currents in Cable Sheaths.7
IEEE Std 592™, IEEE Standard for Exposed Semiconducting Shields on High-Voltage Cable Joints and
Separable Insulated Connectors.
IEEE Std C37.09™, IEEE Standard Test Procedure for AC High-Voltage Circuit Breakers Rated on a
Symmetrical Current Basis.
NEMA WC4/ICEA S-65-375, Varnished-Cloth-Insulated Wire and Cable for the Transmission and
Distribution of Electrical Energy.8
2
ANSI publications are available from the Sales Department, American National Standards Institute, 25 West 43rd Street, 4th Floor,
New York, NY 10036, USA (http://www.ansi.org/).
3
ASTM publications are available from the American Society for Testing and Materials, 100 Barr Harbor Drive, West Conshohocken,
PA 19428-2959, USA (http://www.astm.org/).
4
ICEA publications are available from the Insulated Cable Engineers Association, P.O. Box 20048, Minneapolis, MN 55420, USA
(http://www.icea.net/).
5
IEEE publications are available from the Institute of Electrical and Electronics Engineers, 445 Hoes Lane, Piscataway, NJ 08855-
1331, USA (http://standards.ieee.org/).
6
The IEEE standards or products referred to in this clause are trademarks of the Institute of Electrical and Electronics Engineers, Inc.
7
IEEE Std 575-1988 has been withdrawn; however, copies can be obtained from Global Engineering, 15 Inverness Way East,
Englewood, CO 80112-5704, USA, tel. (303) 792-2181 (http://global.ihs.com/).
8
NEMA publications are available from Global Engineering Documents, 15 Inverness Way East, Englewood, CO 80112, USA
(http://global.ihs.com/).
2
IEEE Std 404-2006
3. Definitions
For the purposes of this standard, the following terms and definitions apply. The Authoritative Dictionary
of IEEE Standards Terms [B7]9 should be referenced for terms not defined in this clause.
3.1 Cable joint categories
Cable joints are generally described by one of the categories that follow. These descriptive categories are
provided only for convenience. They are not intended to cover all possible joint constructions. Some joint
constructions may incorporate characteristics of two or more of the design categories listed.
3.1.1 extruded: A joint in which both cables are insulated with extruded dielectric materials rated 2.5 kV
to 500 kV.
3.1.2 laminated: A joint in which both cables have a dielectric that consists of fluid-impregnated paper or
paper/synthetic laminated tape, or varnished cloth.
3.1.3 transition: A joint that connects an extruded dielectric cable to a laminated dielectric cable.
3.2 Joint constructions
3.2.1 field vulcanized: A joint constructed in the field using externally applied heat and pressure to cross-
link the joint dielectric.
3.2.2 filled: A joint consisting of an outer shell that is filled with an insulating material to occupy the space
around the individual insulated conductor(s).
3.2.3 heat-shrink: A joint consisting of one or more expanded polymeric extruded tubes or molded parts
that undergo thermally activated recovery when heated to an appropriate temperature.
3.2.4 multi-component cold-shrink: A joint provided to the end user as two or more individual
components, excluding the metallic splice, and the cable shield and jacket restoration components, that are
applied over a prepared cable and reduced in diameter without the use of heat.
3.2.5 premolded: A joint that is factory molded in the shape that it will take when installed. Installation is
performed by sliding the joint over a prepared cable. The use of heat is not a part of the installation
procedure.
3.2.6 single-component cold-shrink: A joint provided to the end user as a single component device,
excluding the metallic splice, and the cable shield and jacket restoration components, that is applied over a
prepared cable and reduced in diameter without the use of heat.
3.2.7 taped: A joint constructed in the field with the use of one or more tapes that are applied over the
cable layers. Heat may or may not be applied as part of the installation procedure.
9
The numbers in brackets correspond to those of the bibliography in Annex C.
3
IEEE Std 404-2006
3.3 Other terms
3.3.1 fingerprinting: Tests made to establish and subsequently confirm the properties of materials or
components used in cable accessories. The samples used for the initial tests shall be from the same batch as
those used in the accessory design tests. For the purposes of this standard, this only applies to field-
fabricated joint constructions such as heat shrinkable, multi-component cold-shrink joints, field vulcanized,
and taped joints.
3.3.2 sectionalizer: A sectionalizer is used to minimize induced current in the cable sheath/shield by
electrically interrupting the semiconducting shield and conducting metallic sheath or shield of the two cable
lengths that are joined together. Sectionalizers are primarily used on cable systems operating at 60 kV and
above as described in IEEE Std 575.10
4. Service conditions
Current cable joint designs are considered suitable for use under the following service conditions.
However, it must be understood that this list was compiled based more on user and manufacturer
experience than on actual design testing. It is not meant, in any way, to imply that any or all of these
conditions are fully verified in this standard. For specific questions regarding these or other service
conditions, the manufacturer should be consulted.
a) In-air, including exposure to direct sunlight

b) Buried in earth
c) Intermittently or continuously submerged in water at a depth not exceeding 7 m (23 ft)
d) Environmental temperatures within the range of −30 °C to +50 °C
e) In underground chambers, tunnels, and vaults
f) Approximately horizontal installation of laminated dielectric joints rated 69 kV to 500 kV
5. Ratings
5.1 Voltage
The voltage ratings and test levels of cable joints shall be in accordance with Table 1 through Table 4.
5.2 Current and temperature
The current and temperature ratings of the cable joint shall be equal to or greater than those of the cable for
which it is designed as verified in 7.8, 7.9, 7.14, and the emergency operating temperature test of 7.7.3. For
transition joints, the maximum temperature rating is based on the cable with the lower temperature limit.
10
For information on references, see Clause 2.
4
IEEE Std 404-2006
Table 1 —Voltage ratings and test levels for extruded dielectric cable joints rated 2.5 kV to 46 kV
AC voltage design tests Minimum

Voltage rating Basic insulation Column D partial
Voltage rating DC withstand
phase-to- level (BIL) Column A 1 min AC discharge
phase-to-phase, Column B Column C voltage
a ground, and full wave cyclic aging withstand voltage level,
U (kV rms) 5 min at 4.5 U0 5 h at 3.5 U0 15 min (kV)
U0 (kV rms) b (kV crest) voltage voltage (kV) 1.5 U0
(kV rms) (kV rms)
(kV rms) (kV rms) c
2.5 1.4 60 4 6 5 9 2 30
5 2.9 75 9 13 10 18 5 35
8 4.6 95 14 21 16 23 7 45
15 8.7 110 26 39 31 35 13 75
25 14.4 150 43 65 50 52 22 105
35 20.2 200 61 91 71 69 30 140
d d d
46 26.6 250 67 100 80 80 40 172
a
For use with 100% insulation level cable as defined in the applicable AEIC CS6 or AEIC CS8. To obtain test values for voltage classes that are not listed, use linear interpolation between the next
higher and lower listed values and round off to the nearest whole kilovolt.
b
For grounded systems.
c
Based on a sensitivity of 5 pC.
d
Values interpolated between 35 kV and 69 kV class.
5
IEEE Std 404-2006
Table 2 —Voltage ratings and test levels for extruded dielectric cable joints rated 69 kV to 500 kV
AC voltage tests Minimum

Voltage Voltage DC
partial
rating rating BIL and Column A Column B withstand
discharge
phase-to- phase-to- full wave 15 min 6 h HV voltage
voltage
phase, U ground, U0 (kV crest) withstand time test 15 min
a level, 1.5 U0
(kV rms) (kV rms) b test at 3 U0 at 2.5 U0 (kV)
(kV rms) c
(kV rms) (kV rms)
69 39.8 350 120 100 240 60

115 66.4 550 200 166 300 100
138 79.7 650 240 200 315 120
161 93.0 750 280 232 375 140
230 132.8 1050 400 332 525 200
345 199.2 1300 600 500 650 300
500 288.7 1550 870 725 775 435
a
For use with 100% insulation level cable as defined in the applicable AEIC CS6 or AEIC CS7. To obtain test values for
voltage classes that are not listed, use linear interpolation between the next higher and lower listed values and round off to
the nearest whole kilvolt.
b
c
Based on a sensitivity of 5 pC.
Table 3 —Voltage ratings and test levels for transition cable joints
Voltage Voltage AC withstand test AC HV time test DC

rating BIL and withstand
rating phase-
phase-to- full wave Time Voltage Time Voltage voltage
to-phase, U
ground, U0 (kV crest) (min) (kV Rms) (h) (kV rms) 15 min
(kV rms) a
(kV rms) b (kV)
c
2.5 1.4 60 1 8 6 8 30
5.0 2.9 75 1 16 6 16 38
8.7 5.0 95 1 20 6 20 48
15 8.7 110 1 35 6 35 55
25 14.4 150 1 58 6 58 75
35 20.2 200 1 80 6 80 100
46 26.6 250 1 100 6 100 125
69 39.8 350 1 100 24 100 175
115 66.4 450 1 170 24 170 225
120 69.3 550 1 170 24 170 275
138 79.7 650 1 200 24 200 325
161 93.0 750 1 230 24 230 375
230 132.8 1050 1 330 24 330 525
345 199.2 1300 1 500 24 500 650
500 288.7 1550 1 720 24 720 775
a
For use with 100% insulation level cable as defined in the applicable AEIC CS1, AEIC CS2, AEIC CS3, or AEIC CS4. To
obtain test values for voltage classes that are not listed, use linear interpolation between the next higher and lower listed values
and round off to the nearest whole kilovolt.
b
c
Voltages represent 0.5 times the BIL.
6
IEEE Std 404-2006
Table 4 —Voltage ratings and test levels for laminated cable joints
Voltage Voltage AC withstand test c DC

rating BIL and withstand
rating phase-
phase-to- full wave Time Voltage voltage
to-phase, U
ground, U0 (kV crest) (h) (kV Rms) 15 min
(kV rms) a
(kV rms) b (kV
)d
2.5 1.4 60 6 8 30
5.0 2.9 75 6 16 38
8.7 5.0 95 6 20 48
15 8.7 110 6 35 55
25 14.4 150 6 58 75
35 20.2 200 6 80 100
46 26.6 250 6 110 125
69 39.8 350 24 100 175
115 66.4 450 24 170 225
120 69.3 550 24 170 275
138 79.7 650 24 200 325
161 93.0 750 24 230 375
230 132.8 1050 24 330 525
345 199.2 1300 24 500 650
500 288.7 1550 24 720 775
a
For use with 100% insulation level cable as defined in the applicable AEIC CS1, AEIC CS2, AEIC
CS3, or AEIC CS4. To obtain test values for voltage classes that are not listed, use linear
interpolation between the next higher and lower listed values and round off to the nearest whole
kilovolt.
b
c
Where this test voltage or test procedure differs from the applicable AEIC specification, the latter
shall apply.
d
Voltages represent 0.5 times the BIL.
6. Construction
6.1 Identification
Cable joints shall be permanently and legibly identified with the following information:
a) Company name or logo

b) Part identification
c) Date of manufacture (month and year)
Joints that cannot accommodate this information shall be supplied with a label that contains this
information. The manufacturer shall also provide a method of securely attaching the label to the outside of
the joint after it is assembled in the field unless otherwise specified by the user. In all cases, the
identification shall be legible for the life of the joint.
7
IEEE Std 404-2006
In addition, the following information shall be contained on either the joint, joint components, or the
packaging material:
d) “Use before” date and storage conditions, if applicable

e) Maximum phase-to-phase or phase-to-ground voltage rating
f) Cable insulation diameter range
If the joint consists of a kit that contains a variety of materials manufactured at different times, then the
date of manufacture shall be the date that the kit is packaged.
6.2 Shielding
Cable joints shall have a shielding system that is capable of maintaining the outer surface of the joint
effectively at ground potential. The shielding shall comply with the requirements of IEEE Std 592.
6.3 Sheath/shield sectionalizers
The sheath/shield sectionalizer must meet the requirements of 7.11 to ensure they are capable of
withstanding ac and lightning conditions.
Sectionalizers must also be impervious to moisture entry to be functional. The requirements of 7.13.2 may
be used to verify the moisture integrity of a sectionalizer design.
Sectionalizers shall also be mechanically rugged.
7. Testing
To claim conformance to this standard, a cable joint manufacturer shall qualify the particular joint design,
including material and construction details, according to the design tests of 7.4, and also perform the
production tests according to the requirements of 7.1, 7.2, or 7.3 for that particular design category.
Production tests shall be performed on 100% of all premolded joints produced and also 100% of all single-
component cold-shrink joints produced.
The production electrical tests of 7.1 cannot be performed on field fabricated joints, such as heat-
shrinkable, hand-taped, or certain multi-component cold-shrinkable joints. To assure the reliability of these
field-fabricated joints, the manufacturer shall perform a series of physical and electrical tests on the
materials that make up the joint according to 7.2 for heat-shrink or multi-component cold-shrink joint
components and 7.3 for taped joint components.
7.1 Production tests for premolded and single-component cold-shrink joints
The following production tests shall be performed by the manufacturer on 100% of all premolded and
single-component cold-shrink joints produced:
a) Partial discharge voltage level (see 7.6.1)

b) AC withstand or full-wave impulse withstand voltage (see 7.7.1 and 7.7.3)
8
IEEE Std 404-2006
7.2 Fingerprint tests for heat-shrink and multi-component cold-shrink joint

components
The following fingerprint tests shall be performed by the manufacturer according to the sampling rate
shown in Table A.2. These tests shall be performed on stress control, conductive, insulating and protective
tubes whether extruded or molded. The tests are performed after these components have completed all
manufacturing processes, such as molding, extruding, cross-linking and expansion, i.e., in the as-supplied
forms. The required tests are summarized in Table A.1 along with typical values.
7.2.1 Visual examination
Expanded tubes shall be free from splits, pinholes, inclusions, or other visible defects. Tubing edges shall
be straight and smooth.
7.2.2 Dimensions
The wall thickness of expanded tubes shall be measured at four equally-spaced positions around the
sample. The length of the expanded tubes shall also be measured.
The same tubes shall then be fully recovered and cooled (if applicable). The above measurements shall then
be repeated. Calculate the ratio of minimum thickness to maximum thickness expanded and the ratio of
minimum thickness to maximum thickness recovered. Calculate the change in length after recovery.
See Table A.1 for typical values of expanded wall thickness ratio, recovered wall thickness ratio, and
length change.
7.2.3 Tensile strength and ultimate elongation
Specimens shall be prepared from fully-recovered tubing or molded components. Specimen thickness shall
be between 2 mm and 4 mm (0.079 in and 0.157 in). From each of the samples in the lot, five specimens of
each material shall be prepared in accordance with ASTM D412-98. Tubing specimens shall be cut along
the length of the tubing.
The test shall be performed at a cross-head speed of 500 mm/min ± 50 mm/min (20 in/min ± 2 in/min).
The tensile strength is determined using the maximum applied load and the initial specimen cross-sectional
area.
Ultimate elongation is the increase in length at the point of break over the initial length expressed as a
percentage.
See Table A.1 for typical values of tensile strength and elongation.
7.2.4 Volume resistivity of conductive tubes
From each of the samples in the lot, five specimens shall be prepared from tubing or molded components
and tested in accordance with ASTM D991-89.
See Table A.1 for typical values.
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IEEE Std 404-2006
7.2.5 Dielectric strength of insulating tubes
The dielectric strength of tubing or molded components shall be determined at room temperature in
accordance with ASTM D149-97a.
From each sample of the lot, five specimens of tubing or molded components shall be recovered onto a
cylindrical mandrel of diameter equal to the fully recovered specimen inside diameter plus 10%.
See Table A.1 for typical values of dielectric strength.
7.2.6 Sampling rate
Unless otherwise required by customer or manufacturer specifications, the component sampling

requirements after each manufacturing step, including molding, extrusion, cross-linking, and expansion,
shall be according to the sampling rate shown in Table A.2.
7.3 Fingerprint tests for elastomeric taped joint components
The following fingerprint tests for taped joint components shall be performed by the manufacturer
according to the sampling rate shown in Table B.2. These tests shall be performed on non metallic and
electrically insulating rubber tapes according to 7.3.1, 7.3.2, 7.3.3, and 7.3.5 and on semiconducting rubber
tapes according to 7.3.1, 7.3.2, 7.3.3 and 7.3.4. The required tests for each type of tape, along with the
corresponding ASTM tape classification, are summarized in Table B.1 along with typical values.
All tests are performed on the sample rolls after removing and discarding at least 610 mm (24 in) of the
outer layer.
All sample rolls shall be subjected to 23 ºC ± 2 ºC and 50% ± 2% relative humidity for a minimum of 16 h
before specimens are removed.
All samples are then removed from the rolls at a slow, uniform rate without jerking. The individual samples
shall be left for a minimum period of 1 h at 23 ºC ± 2 ºC and 50% ± 2% relative humidity. All tests are then
conducted at these same standard conditions.
7.3.1 Fusion
Remove three specimens, 280 mm in length, from each roll of the sample lot. Using the winding fixture and
procedure described in Clause 8 and Clause 9 of ASTM D4325-02, wind the specimens using 300%
elongation. After wrapping, condition the specimens at 23 ºC ± 2 ºC and 50% ± 2% relative humidity for
24 h. Following the conditioning, the maximum flag for any specimen shall meet the requirements of
Table B.1.
7.3.2 Dimensions
7.3.2.1 Length
Unwind the tape and separator from each roll of the sample lot. After the conditioning in 7.3, place each
tape/separator sample on a hard smooth surface and measure their length. The length shall meet the
requirements of Table B.1.
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IEEE Std 404-2006
7.3.2.2 Width
Unwind the tape and separator from each roll of the sample lot. After the conditioning in 7.3, place each
tape/separator sample on a hard smooth surface and measure their width. The width shall meet the
requirements of Table B.1.
7.3.2.3 Thickness
Unwind the tape and separator from each roll of the sample lot. Measure the tape/separator sample
thickness at five locations uniformly distributed over the length of the test specimen using the procedure of
Clause 12, Clause 13, and Clause 14 of ASTM D4325. The average of the five measurements shall meet
the requirements of Table B.1.
7.3.3 Tensile strength and ultimate elongation
For each roll in the sample lot, cut five specimens, 610 mm in length, from a single ply of tape (rubber and
separator) that is free from visible defects using the ASTM standard die, as shown in Figure 1 (die A) of
ASTM D412-98, except that the ends of the specimens cut from 19 mm tape need not be full width. Place
bench marks on the specimens as directed in ASTM D412-98. Measure the thickness in accordance with
14.2 of ASTM D4325-02, removing the separator where it is not an integral part of the tape. The average
breaking strength and average percent elongation shall meet the requirements of Table B.1. When
specimens break at the jaws, discard the results and retest.
7.3.4 Volume resistivity
This test is applicable only to semiconducting tapes. For each roll in the sample lot, test five specimens.
Condition the tapes at 90 ºC ± 2 ºC for 168 h. Remove the specimens from the oven, assemble in
electrodes, and test within 2 min. Use strip electrodes for tape as shown in Figure 2 of ASTM D4496-04.
Apply direct voltage of 5 V ± 0.5 V for the time specified in ASTM D4496-04. The average volume
resistivity shall meet the requirements of Table B.1.
7.3.5 Dielectric strength
This test is applicable only to insulating tapes. Make five breakdown tests on each roll of the sample lot.
Use type-3 electrodes as described in Table 1 of ASTM D149-97a. To prevent flashover of the sample,
insulating fluid may be used, or the tape width can be increased by attaching additional tape strips to each
edge of the test sample. Measure and calculate the dielectric strength in kilvolts per millimeter (kV/mm) in
accordance with ASTM D149-97a using the short-time test by increasing the voltage at a uniform rate of
500 V/s. The average dielectric strength in kilovolts per millimeter shall meet the requirements of
Table B.1.
7.3.6 Sampling
Unless otherwise required by customer or manufacturer specifications, the tape sampling requirements shall
be according to the sampling rate shown in Table B.2.
7.4 Design tests and testing sequence for all joint types
Table 5, Table 6, and Table 7 list the sequences of design tests required by this standard. Each column in each
of the tables represents one test sequence. These design tests shall be performed on extruded, transition, and
laminated dielectric cable joints, respectively. All design tests shall be performed on production units (or
production materials if the joints are fabricated in the field) to demonstrate compliance of the design with this
standard. The results of these tests shall be recorded in the form of a report certifying that a joint design meets
the requirements of this standard. The report shall be available from the manufacturer upon request.
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IEEE Std 404-2006
7.5 Design test conditions
The following design test conditions shall apply unless otherwise specified:
a) Cable joints shall be properly assembled with actual production components according to the
manufacturer’s instructions. All parts that are normally grounded shall be connected to the
ground of the test circuit.
b) Ambient air temperature shall be between 10 °C and 40 °C.
c) All ac voltages shall have a frequency of 60 Hz ± 5% or 50 Hz ± 5%, and a sine wave shape of
acceptable commercial standards as defined in IEEE Std 4.
d) Voltages shall be measured in accordance with IEEE Std 4.
e) The cable used in these tests should conform to the applicable AEIC specification. Insulation
thickness shall be in accordance with AEIC specification for the 100% insulation level. Unless
otherwise stated, the smallest nominal diameter cable for which the cable joint is designed
should be used, if practical. The exception to this is the short-time current test (see 7.8), in
which case the largest nominal conductor for which the cable joint is designed should be used, if
practical. If testing is performed on cable not conforming to AEIC specification, it is incumbent
on the manufacturer to ensure that the tests are at least as severe on the joint as would be the
case on the appropriate AEIC cable. In this case, the cable construction and corresponding cable
specification shall be referenced in the joint test report.
f) If a cable failure occurs during a design test, the failed cable may be reterminated provided that
the minimum specified distance between the joint and the termination is met. The test shall be
resumed by repeating the step during which the cable failed. If the minimum length cannot be
met, the joint on the failed cable or a new joint shall be assembled on a new cable, and the
design test shall be repeated.
g) If a joint failure occurs during a design test, all qualification tests in that column sequence of
Table 5, Table 6, or Table 7 shall be repeated for the number of samples specified for that
column. Any joint samples that passed the original tests may be used to repeat that column of
testing if desired.
7.6 Dielectric integrity tests
7.6.1 Partial discharge voltage level test
This procedure is used as a production test for premolded and single-component cold-shrink joints. It is
also part of the design test sequence for all joints intended for use on extruded dielectric cables. The
purpose of this test is to verify that the partial discharge voltage level of the test specimen is not less than
the value given in Table 1 or Table 2. The test voltage shall be raised to 20% above the partial discharge
voltage level specified in Table 1 or Table 2. If partial discharge exceeds 5 pC, the test voltage shall be
lowered to the partial discharge voltage level specified in Table 1 or Table 2 and shall be maintained at this
level for at least 3 s but not more than 1 min. If partial discharge readings still exceed 5 pC, the joint design
does not meet the requirements of this standard.
7.6.2 Ionization test
This test is applicable only for transition joints. The purpose of this test is to verify that the ionization factor
of transition joints remains within the limits specified in Table 8. The ionization factor is the difference, at
50 Hz or 60 Hz, between the dissipation factor measured at an average stress in the cable of 4000 V/mm
and the dissipation factor measured at an average stress of 800 V/mm. The measurement voltage is based
on the insulation thickness of the laminated cable.
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IEEE Std 404-2006
Table 5 —Design tests and sequence for extruded dielectric cable joints
Minimum number of samples required in each sequence

Design test Reference
3(2) a 3(2) b 3(1) c 3 7e
Partial discharge voltage level 7.6.1 X X

AC withstand voltage 7.7.1 X X
DC withstand voltage 7.7.2 X X
Impulse withstand voltage at 25 °C 7.7.3 X X
Impulse withstand voltage at
7.7.3 X X
emergency temperature
Cyclic aging in-air, 30 cycles
(shield and jacket restoration devices, 7.9.1
d
if applicable) or 7.9.2 X
7.9.1
Cyclic aging in water, 30 cycles X
or 7.9.2
High-voltage time 7.10 X X
Sectionalizer test (if applicable) 7.11 X X
Shield restoration: two short-time
d
current tests (if applicable) 7.13.1 X
Jacket restoration: cyclic aging in
water, 10 cycles (if applicable) d 7.13.2 X
Short-time current 7.8 X
AC withstand voltage 7.7.1 X
Shielding 7.12 X
Connector thermal and mechanical 7.14 X
a
For cyclic aging in-air, three samples are required for 2.5 kV to 46 kV joints according to 7.9.1 and two samples are required for
69 kV to 500 kV joints according to 7.9.2. Shield and jacket restoration components should be assembled on these in-air samples if
applicable.
b
For cyclic aging in water, three samples are required for 2.5 kV to 46 kV joints according to 7.9.1 and two samples are required for
69 kV to 500 kV joints according to 7.9.2. For 69 kV to 500 kV, the two samples in water are not required if the joint design
incorporates a solid metal housing that is welded or soldered to a solid cable sheath or pipe.
c
Three samples are required for 2.5 kV to 46 kV joints. One sample is required for 69 kV to 500 kV joints.
d
Shield and jacket restoration component testing shall be performed in the sequence shown if tested in conjunction with design tests
of a completed joint. If testing either or both of these components independent of a joint design test, it is not necessary to perform the
previous dielectric tests in this sequence.
e
Four samples are required for thermal tests, and three samples are required for mechanical tests.
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IEEE Std 404-2006
Table 6 —Design tests and sequence for transition joints
Minimum number of samples required in

each sequence
2a 2b 2 7d
AC withstand voltage 7.7.1 X X

DC withstand voltage 7.7.2 X X
7.7.3 X X
emergency temperature
Ionization 7.6.2 X X
Cyclic aging in-air
(shield and jacket restoration devices,
c
if applicable) 7.9.2 X
Cyclic aging in water 7.9.2 X
Ionization 7.6.2 X X
High-voltage time 7.10 X X
Sectionalizer (if applicable) 7.11 X X
Shield restoration: two short-time
current tests (if applicable) c 7.13.1 X
Jacket restoration: cyclic aging in
water, 10 cycles (if applicable) c 7.13.2 X
Shielding 7.12 X
a
For cyclic aging in-air, two samples are required. Shield and jacket restoration components should be assembled on
these in-air samples if applicable.
b
For cyclic aging in water, two samples are required. For 69 kV to 500 kV, the two samples in water are not required if
the joint design incorporates a solid metal housing that is welded or soldered to a solid cable sheath or pipe.
c
Shield and jacket restoration component testing shall be performed in the sequence shown if tested in conjunction with
design tests of a completed joint. If testing either or both of these components independent of a joint design test, it is not
necessary to perform the previous dielectric tests in this sequence.
d
Four samples are required for thermal tests, and three samples are required for mechanical tests.
Table 7 —Design tests and sequence for laminated dielectric cable joints
Minimum number of
samples required
3(1) a 7b
AC withstand voltage 7.7.1 X

DC withstand voltage 7.7.2 X
emergency temperature 7.7.3 X
a
Three samples are required for 2.5 kV to 35 kV joints and one sample is required for
46 kV to 500 kV joints.
b
Four samples are required for thermal tests, and three samples are required for mechanical
tests.
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IEEE Std 404-2006
Table 8 —Maximum allowable ionization factor values for transition joints
Joints connecting paper-insulated Joints connecting self-contained and

lead-covered (PILC) cable high-pressure pipe-type cables
Maximum Maximum
Rated voltage Rated voltage
ionization factor ionization factor
(kV) (kV)
(%) (%)
10–20 0.60 ≤ 161 0.10

21–35 0.40 > 161 0.05
36–69 0.20
The measurement shall be made at ambient temperature.
For transition joints on self-contained or pipe-type cables, the ionization factor is defined as the difference,
at 60 Hz, between the dissipation factor measured at 1.2 U0 and the dissipation factor measured at 0.125 U0.
U0, the phase-to-ground voltage, shall be that of the cable with the lower rating.
If the measured value is outside the limits specified in Table 8, the joint design does not meet the
requirements of this standard.
This test is not required for joints that employ nonlinear, high dielectric constant or impedance layer
materials. However, the manufacturer shall demonstrate that the nonlinear material is stable and will
perform effectively over the life of the joint.
7.7 Voltage withstand tests
The purpose of these tests is to verify that the insulation of the test specimen is not defective and will
withstand the voltages shown in Table 1 through Table 4. Some of the tests are used as both production and
design tests.
These tests are applicable for all joint types. The test voltage shall be applied to the parts of the cable joint
that are energized in service.
For transition cable joints, all electrical test values are based on the cable with the lower test requirements.
For pressurized cables, the gas or liquid pressure shall be within the operating limits specified by the
appropriate AEIC cable standard.
7.7.1 AC voltage
This test is applicable as a design test for all joint types. It is also one of the production test options for
premolded and single-component cold-shrink joints.
The test voltage shall be raised, at a rate of 5 kV/s ± 3 kV/s, to the value specified in one of the following:
⎯ Table 1, Column D, for extruded dielectric cable joints 2.5 kV kV to 46 kV
⎯ Table 2, Column A, for extruded dielectric cable joints 69 kV to 500 kV
⎯ Table 3 for ac withstand test for transition cable joints
⎯ Table 4 for ac withstand test for laminated dielectric cable joints
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IEEE Std 404-2006
The cable joints shall withstand the specified test voltage for the time specified in the tables.
7.7.2 DC voltage
This test is applicable as a design test for all joint types.
The test voltage shall have a negative polarity (the negative terminal is connected to the conductor of the
test specimen) and shall be raised to the value specified in Table 1, Table 2, Table 3, or Table 4. The cable
joints shall withstand the specified test voltage for 15 min.
7.7.3 Impulse voltage (BIL)
This test is applicable as a design test for all joint types. It is also one of the production test options for
premolded and single-component cold-shrink joints.
The test voltage wave shape shall be as specified in IEEE Std 4, having the BIL specified in Table 1,
Table 2, Table 3, or Table 4 of this standard. The test procedure (including sample conditioning) shall be as
specified in IEEE Std 82.
The cable joint shall withstand ten positive and ten negative full-wave impulses with a magnitude equal to
the BIL value specified in Table 1, Table 2, Table 3, or Table 4.
Tests at emergency operating temperature shall correspond to the impulse temperature requirements
outlined in the applicable standard (see Table 9). The cable manufacturer should be consulted in the case of
special-use cables.
Table 9 —Reference cable standards for temperature requirements
Cable type Standard
1.0 kV to 69 kV paper-insulated metallic- AEIC CS1

sheathed
69 kV to 500 kV high-pressure pipe-type AEIC CS2
8 kV to 46 kV low-pressure gas-filled AEIC CS3
15 kV to 500 kV self-contained AEIC CS4
5 kV to 69 kV EPR AEIC CS6
69 kV to 138 kV XLPE AEIC CS7
5 kV to 46 kV extruded dielectrics AEIC CS8
600 V to 28 kV varnished cloth NEMA WC4
For extruded dielectric cable joints, the test shall be performed first with the conductor at ambient
temperature, and then again with the conductor at the maximum emergency operating temperature of the
cable +0 °C/−5 °C.
For transition joints, the test shall be performed first with the conductor temperature of both cables at
ambient temperature, and then again with the cables at elevated temperature, +0/−5 °C. The elevated
temperature is based on the maximum emergency operating conductor temperature of the cable with the
lower temperature rating.
For laminated dielectric cable joints, the test shall be performed only at the maximum emergency operating
conductor temperature of the cable, +0 °C/−5 °C.
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IEEE Std 404-2006
Elevated conductor temperatures are primarily obtained by circulating ac current in the conductor of the
cable. There shall be no current in the metallic shields of the cable or joint. The reference location for all
conductor temperature requirements is midway between the end of the joint and the base of the termination.
In all cases, the test temperature shall be reported in the test report. Elevated conductor temperatures
produced by means other than by circulating current in the conductor of the cable is permissible only by
mutual agreement between the supplier and the end user. Such alternate methods must ensure that the
conductor temperature is at the maximum emergency operating temperature of the cable +0 °C/−5 °C.
When the impulse voltage withstand test is used as a production test, the cable joint shall withstand one full-wave
impulse at each polarity with a magnitude equal to the BIL value specified in Table 1, Table 2, or Table 3.
7.8 Short-time current test
The purpose of this test is to verify that the extruded dielectric cable joint is capable of withstanding short-
time, short-circuit currents. The magnitude shall be equal to the short-circuit rating (in rms symmetrical
amperes) of the largest size conductor for which the joint is designed for a duration of 0.17 s. The 50 Hz or
60 Hz current magnitude shall be sufficient to raise the cable conductor temperature from ambient to its
rated short-circuit temperature. The current magnitude used for this test shall not exceed 35 kA and may be
determined by using ICEA P-32-382 and utilizing the formulas given to correct the curves to the
appropriate ambient temperature condition.
The current magnitude shall be measured in accordance with IEEE Std C37.09.
Following the short-time current test, the cable joint shall be tested in accordance with the ac voltage test of
7.7.1 to further verify its integrity.
7.9 Cyclic aging test for extruded dielectric and transition joints
The purpose of this test is to verify that cyclic loading will not adversely affect the ability of the cable joint to
operate in-air or submerged in water. If a joint design or construction specifically requires an integral jacket
restoration kit or environmental seal for proper operation, and the manufacturer only provides the joint with
this device as a complete kit, then 7.9.1 or 7.9.2 shall be performed with this cover or seal installed.
If desired, cable metallic-shield restoration components and/or cable jacket restoration components may be
qualified simultaneously with a cable joint qualification. In this case, either or both of these restoration
components shall be assembled only on the in-air samples as described in 7.13.
7.9.1 Extruded cable joints rated 2.5 kV to 46 kV
If cable restoration components are to be qualified simultaneously with a specific joint design, the
appropriate restoration components should be assembled on the in-air joints. The joint samples in water are
cycled without jacket restoration components to ensure that these devices do not influence potentially
marginal joint electrical interfaces.
The test may be conducted on each joint individually or with two or more joints connected in series.
The cable joints shall be assembled on a cable that has an insulation outside diameter that is at or near the
minimum diameter for which the cable joint is designed, and shall be subjected to the continuous ac voltage
shown in Table 1, column A, for 30 d. The test shall be performed on a minimum of three cable joints in-air
and a minimum of three cable joints in tap water, on the same type and size cable. The same six joints are
to be used on all cyclic aging tests. The cable joints in water shall be submerged at a minimum depth of 0.3
m (1 ft), measured from the top surface of the joints. The water shall neither be heated nor cooled during
this test, but shall be left to follow the load cycling unconstrained.
17
IEEE Std 404-2006
A minimum length of 2 m (6.5 ft) of cable is required between joint ends and the base of each termination.
The six joints shall be subjected to 30 load cycles. Each load cycle is defined as a 24 h time span with a
current-on period and a current-off period. During the current-on period, sufficient ac current shall be passed
through the conductor to achieve a cable conductor temperature within +0 °C/−5 °C of the cable rated
emergency operating temperature for a period of at least 6 h. There shall be no current in the cable metallic
shield. The cable emergency operating temperature shall be determined by reference to the applicable standard
(see Table 9). The cable manufacturer should be consulted in the case of special-use cables.
The reference location for all conductor temperature requirements is midway between the water surface and
the base of the end terminations for joints tested in water or midway between the joint end and the base of
the end terminations for joints tested in-air. The temperature at this location shall not be influenced by the
joint, water, or end terminations.
The following information shall be recorded in the test report:
a) The maximum temperature of the outside of the joint housings in water

b) The maximum temperature of the outside of the joint housings in-air
c) The temperature of the outside surface of the cables in-air
d) The cable rated emergency operating temperature used to qualify the joint
During the current-off period, the reference cable conductor temperature should drop to within 5 °C of the
ambient air temperature. If this condition cannot be met, the test shall be interrupted at the end of the 5th,
10th, 15th, 20th, and 25th cycles. During these interruptions, the voltage, current, and any supplemental
heat source shall remain off for a period of 24 h to allow the joints to cool as close to room temperature as
possible. The load cycle (current and voltage) and supplemental heat source (if used) shall be resumed at
the end of the interruption period. This procedure may be followed even if the temperature condition during
the current-off period can be met.
The test specimens shall complete 30 load cycles. The 24 h interruption periods are not considered part of a
load cycle.
If, for any reason, the voltage or conductor temperature falls below the specified level at any time during
any given load cycle, then that load cycle shall be repeated. Load cycles may be contiguous, or there may
be periods with no voltage and no current between load cycles to accommodate schedule variations or
equipment failures.
7.9.2 Extruded cable joints rated 69 kV to 500 kV and transition joints rated 2.5 kV to
500 kV
If cable restoration components are to be qualified simultaneously with a specific joint design the
appropriate restoration components should be assembled on the in-air joints. The joint samples in water are
cycled without jacket restoration components to ensure that these devices do not influence potentially
marginal joint electrical interfaces.
The test may be conducted on each joint individually or with two or more joints connected in series. The
conductors of multi-conductor joints shall be connected in series.
The cable joints shall be assembled on cables that have an insulation outside diameter that is at or near the
minimum diameter for which the cable joint is designed. Sheath/shield sectionalizers shall be incorporated
if they are part of the joint design. They shall remain shorted until the tests in 7.11 are performed.
Testing shall be performed on four cable joints. The same four joints are to be used for all cyclic aging
tests. Multi-conductor joints in a common housing are considered one joint. Two joints are suspended in-air
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IEEE Std 404-2006
and two are submerged in tap water to a depth of 1 m (3.3 ft). The two samples in water are not required if
the joint design incorporates a solid metal housing that is welded or soldered to a solid cable sheath or pipe.
Conduit may be used for the in-water portion of this test and may be made of any appropriate material. The
conduit (or enclosure) shall be longitudinally centered on the joints and shall extend a minimum of 300 mm
(12 in) beyond each joint end. A vertical tube having a minimum inside diameter of 50 mm (2 in) shall be
attached to the conduit. It shall be of sufficient length to provide the specimen with a head of tap water
measuring a minimum of 1 m from the top surface of the joint. The water shall neither be heated nor cooled
during this test, but shall be left to follow the load cycling unconstrained.
A minimum length of 2 m (6.5 ft) of cable is required between the conduit or water tank and the base of
each end termination for joints tested in water or between the joint ends and the base of each termination
for joints tested in-air.
The four joints shall be subjected to 30 load cycles. Each load cycle is defined as a 24 h time span with a
current-on period and a current-off period. During the current-on period, sufficient ac current shall be
passed through the cable conductor to achieve a conductor temperature within +0 °C/−5 °C of its rated
emergency operating temperature for a period of at least 6 h. For transition joints, the emergency operating
temperature of the cable with the lower rating shall be used. The cable emergency operating temperature
shall be determined by reference to the applicable standard (see Table 9). The cable manufacturer should be
consulted in the case of special-use cables.
Two times the rated phase-to-ground ac voltage shall be applied continuously for the 30 cycles. For
transition joints, two times the rated phase-to-ground ac voltage of the cable with the lower rating shall be
used. There shall be no current in the cable metallic shield.
The reference location for all conductor temperature requirements is midway between the end of the
conduit and the base of the end terminations for joints tested in water or midway between the joint ends and
the base of the end terminations for joints tested in-air. For transition joints, this measurement is made on
the cable with the lower temperature rating. The temperature at this location shall not be influenced by the
joint, water-filled conduit, or end terminations.
The following information shall be recorded in the test report:
a) The maximum temperature of the outside of the joint housings in water

b) The maximum temperature of the outside of the joint housing in-air
c) The temperature of the outside surface of the cables in-air
d) The cable rated emergency operating temperature used to qualify the joint
During the current-off period, the reference cable conductor temperature should drop to within 5 °C of the
ambient air temperature. If this condition cannot be met, the test shall be interrupted at the end of the 5th,
10th, 15th, 20th, and 25th cycles. During these interruptions, the voltage and current shall remain off for a
period of at least 24h to allow the joints to cool as close to room temperature as possible. The load cycle
(current and voltage) shall be resumed at the end of the interruption period. This procedure may be
followed even if the temperature requirement during the current-off period can be met.
The test specimen shall complete 30 load cycles. The 24 h interruption periods are not considered part of a
load cycle.
If, for any reason, the voltage or conductor temperature falls below the specified level at any time during
any given load cycle, then that load cycle shall be repeated. Load cycles may be contiguous or there may be
periods with no voltage and no current between load cycles to accommodate schedule variations or
equipment failures.
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IEEE Std 404-2006
For transition joints, the ionization factor shall be measured as specified in 7.6.2 at the beginning of the test
period and at the end of the load cycle test (the completion of 30 cycles). The ionization factor shall be in
accordance with Table 8.
For transition joints, the internal pressure of the pressurized and laminated dielectric cable shall be
maintained at normal operating pressure throughout this test, except for solid-type laminated dielectric
cables, which shall have a maximum pressure during the test of 103 kPa (14.9 psi) gauge.
7.10 High-voltage time test
The purpose of this test is to verify the electrical integrity of extruded dielectric and transition joints.
Table 5 and Table 6 specify the design test sequence. Test voltage is applied as follows:
For extruded dielectric cable joints rated 2.5 kV to 46 kV:

⎯ Test voltage specified in Table 1, column C, for 5 h followed by:
⎯ Test voltage specified in Table 1, column B, for 5 min.
For extruded dielectric cable joints rated 69 kV to 500 kV:

⎯ Test voltage specified in Table 2, column B, for 6 h.
For transition joints rated 2.5 kV to 500 kV:

⎯ Test voltage and time as specified in the ac HV time test column of Table 3.
All joints subjected to this test shall be completely submerged in ambient temperature tap water. The
submersion depth is a minimum of 0.3 m (1 ft) for 2.5 kV to 46 kV extruded dielectric cable joints and a
minimum of 1 m (3.3 ft) for 69 kV to 500 kV extruded dielectric cable joints and all transition joints. These
submersion depths correspond to the submersion depths required during the load cycle tests for each joint
construction. They are measured from the top surface of the joint.
The joint shall be submerged for at least 1 h before the test voltage is applied. Samples previously tested in
a water-filled conduit may be left in the conduit. Samples previously tested in-air shall be submerged in tap
water using any convenient method.
7.11 Sectionalizer tests
Cable joints with sectionalizers shall be tested in accordance with the following procedures. All joints
subjected to this test shall be completely submerged in ambient temperature tap water. The minimum
submersion depth shall be 0.3 m (1 ft) for extruded cable joints rated 2.5 kV to 46 kV and 1 m (3.3 ft) for
all other joints. This depth corresponds to the submersion depth required during the load cycle test, 7.9.1
and 7.9.2, for each joint construction and is measured from the top surface of the joint.
The joints containing sectionalizers shall remain submerged in the water following the high-voltage time test.
7.11.1 AC voltage withstand tests
CAUTION
A voltage of 20 kV ac shall be applied across each sectionalizer for a minimum of 1 min. During this test,
the water should be grounded for safety.
20
IEEE Std 404-2006
The sectionalizer shall then be shorted and 20 kV ac shall be applied between the sectionalizer and the
grounded water for a minimum of 1 min. The sectionalizer shall withstand both tests without arcing across
or to ground.
7.11.2 Impulse voltage withstand tests
CAUTION
The impulse test voltage shall be a 1.2 µs × 50 µs wave that meets the requirements of IEEE Std 4.
Ten 60 kV crest, positive impulses followed by ten 60 kV crest, negative impulses shall be applied
across the sectionalizer. During this test, the water should be grounded for safety.
The sectionalizer shall then be shorted and ten 30 kV crest, positive impulses followed by ten 30 kV crest,
negative impulses shall be applied between the sectionalizer leads (cable shields) and the grounded water.
The sectionalizers are considered satisfactory if the impulse voltage is withstood without any physical
damage to the joint, cable, or sectionalizer.
7.12 Semiconducting shielding test
The purpose of this test is to verify that the cable joint insulation shield will maintain the outer surface
effectively at ground potential under normal operating conditions, and initiate fault current arcing if the
cable joint insulation system should fail.
The insulation shield of all joint types shall meet the resistivity stability requirement of IEEE Std 592. All
joints with exposed semiconducting shields for use on extruded dielectric cables rated 15 kV to 35 kV shall
meet the short-circuit requirements of IEEE Std 592.
7.13 Cable metallic-shield restoration and cable jacket restoration components
Virtually all modern cable designs require jacketing materials over the cable metallic shielding. Therefore,
when cables are joined, it is necessary to replace or restore these cable components with appropriate
devices that will provide the same current carrying capability and environmental protection as the non-
spliced portions of the cable.
Metallic-shield restoration components are available in various configurations and in many cases are
provided along with an environmental sealing device. The following test sequence encompasses both the
metallic-shield restoration and environmental seal restoration components. They may be tested on joints
that are undergoing design testing or they may be tested on separate samples. If they are tested on separate
samples, these samples shall be assembled in the same manner as they would be installed in service. If a
device is being tested independently as a shield restoration or a jacket restoration device, it is only
necessary to perform the tests in the appropriate subclause (7.13.1 or 7.13.2). If these tests are being
performed on the restoration components only, and not as part of a joint qualification test, it is not
necessary to apply the continuous, ac phase-to-ground voltage of 7.9 or any of the dielectric tests in the
sequence.
The cable metallic-shield restoration and/or cable jacket restoration components are installed on three
complete joint assemblies for 2.5 kV to 46 kV joint ratings or two complete joint assemblies for 69 kV to
500 kV joint ratings. It is not possible to perform a dielectric test of the integrity of the environmental seal
in certain situations without altering the design of the device. An example is when either bare metallic-
shield materials emerge from the jacket restoration devices or when the cable jackets are semiconductive.
Therefore, the integrity of the seal device shall be determined using moisture sensitive tape. Prior to
installing the jacket restoration component, apply a moisture sensitive tape within 25 mm (1 in) of the inner
moisture barrier of the jacket restoration component on each side of the joint. A sufficient length of this
tape shall be used to go completely around the circumference of the cable.
21
IEEE Std 404-2006
The metallic-shield restoration and cable jacket restoration components are only installed on cable joints
that will be cyclically aged in-air according to the requirements of 7.9.1 or 7.9.2, cyclic aging test, for
30 load cycles. The joint samples in water are cycled without jacket restoration components to ensure that
these devices do not influence potentially marginal joint electrical interfaces.
7.13.1 Cable metallic-shield restoration components
Load cycle the cable joints, shield restoration components, and/or the jacket restoration components, as
applicable, in-air only according to 7.9.1 for joint ratings of 2.5 kV to 46 kV or 7.9.2 for joint ratings of
69 kV to 500 kV.
Following the load cycling, and, if applicable, the partial discharge, high-voltage time, impulse, and
sectionalizer tests, it is necessary to verify that the metallic-shield restoration components are capable of
withstanding two, short-time, short-circuit currents. The 50 Hz or 60 Hz current magnitude (in rms
symmetrical amperes) and duration (in seconds) shall be determined by Equation (1). The current
magnitude shall be sufficient to raise the cable shield temperature from ambient to its rated short-circuit
temperature, either 350 °C if all cable materials in direct contact with the metallic shield are thermosetting
(e.g., XLPE or EPR) or 200 °C if any cable materials in direct contact with the metallic shield are
thermoplastic or laminated dielectric material. For example, as stated in ICEA P-45-482, a cable having a
cross-linked semiconducting shield under the metallic shield and a cross-linked jacket over the metallic
shield would have a maximum allowable shield temperature of 350 °C. Or, if the cable sheath is lead, the
short-circuit temperature shall be limited to 200 °C regardless of the other cable materials. The 350 °C or
200 °C short-circuit temperatures are calculated values only and need not be measured during the test.
The current source shall be connected between the cable conductor and the cable shield at one end of the
cable. The conductor and shield shall be connected together at the other end of the sample. The test may be
performed on several joints simultaneously if connected in series. If the shielding components exit the jacket
restoration components on each end of the joint, then a jumper of appropriate cross section shall be used to
join them across each joint. The current magnitude shall be measured in accordance with IEEE Std C37.09.
In accordance with ICEA P-45-482, the required short-circuit test current magnitude for the shield may be
calculated by the following equation:
(I/A)2*t = K* log10 [(T2 + λ) / (T1 + λ)] (1)
where
I is the short-circuit current in amperes
A is the cable shield cross-sectional area in circular mils (calculated from Table 11)
t is the duration of short circuit in seconds (shall be ≤ 1 s)
T1 is the starting ambient temperature in degrees Celsius
T2 is equal to 350 °C if all cable materials in direct contact with the metallic shield are thermosetting
(e.g., XLPE or EPR) or 200 °C if any cable materials in direct contact with the metallic shield are
thermoplastic or laminated. This temperature is a calculated value only. It is not necessary to
measure the shield temperature during the test.
λ, K are determined from Table 10
22
IEEE Std 404-2006
Table 10 —Values for λ or K
Cable shielding material Value of λ Value of K
Aluminum a 228 0.0125

b
Bronze 564 0.0297
Copper c 234 0.0297
d
Lead 236 0.0010
Steel e 180 0.0036
Zinc f 219 0.0080
Cupro-nickel alloy g 1800 0.0140
a
¾ hard, 1350 aluminum.
b
Commercial bronze, 90% copper, 10% zinc.
c
Annealed, 100% conductivity copper.
d
Pure lead, 99.99%.
e
Mild or low carbon steel.
f
Commercial rolled zinc, 0.08% lead.
g
80% copper, 20% nickel.
Table 11 —Calculation of cross-sectional area [the symbol A in Equation (1)]
Formula for calculating A

Type of shield or sheath
(See Note 2)
Wires applied either helically, as a braid or serving; or
longitudinally with corrugations nds2 (a)
Helically applied tape, not overlapped 1.27 nwb (b)
Helically applied flat tape, overlapped (See Note 3) 4bdm × (100 / [2 (100 − L)])−1/2 (c)
Corrugated tape, longitudinally applied 1.27 [π (dis + 50) + B] b (d)
Tubular sheath 4bdm (e)
NOTE 1—
A is the effective cross-sectional area, shield, or sheath
B is the tape overlap (in mils) (usually 375)
b is the thickness of tape (in mils)
dis is the diameter over semiconducting insulation shield (in mils)
dm is the mean diameter of shield or sheath (in mils)
ds is the diameter of wires (in mils)
w is the width of tape (in mils)
n is the number of serving or braid wires or tapes
L is the overlap of tape (in percentage)
NOTE 2—The effective area of composite shields is the sum of the effective areas of the components. For
example, the effective area of a composite shield consisting of a helically applied, not overlapped tape and a
wire serving would be the sum of the areas calculated from Equation (b) of Table 11 and Equation (a) of
Table 11.
NOTE 3—The effective area of thin, helically applied overlapped tapes depends, also, on the degree of
electrical contact resistance of the overlaps. Equation (c) of Table 11 may be used to calculate the cross-
sectional area of the shield of new cable. An increase in contact resistance may occur after cable installation
or during service involving exposure to moisture and heat. Under these conditions the contact resistance may
approach infinity, where Equation (b) of Table 11 could apply.
23
IEEE Std 404-2006
If practical, the test should be conducted using a duration of 0.17 s (10 cycles at 60 Hz). If the calculated
fault current cannot be achieved due to equipment limitations, then an alternate current and time
combination may be used to conduct the test as long as the alternate time and current have the same I2t
value as the originally calculated values and the alternate time (t) is not longer than 1 s. The test samples
may be allowed to cool to ambient after the first short-time current test.
All shield restoration components shall withstand two, full short-time current tests without signs of arcing
of the metallic components, and without catching on fire. All metallic-shield restoration components must
also remain intact. Slight melting of polymeric components is allowed as long as no material leaves the
cable.
7.13.2 Cable jacket restoration seal integrity
The following procedure is used to qualify cable jacket restoration components for seal integrity.
If this test is being performed in conjunction with the metallic-shield restoration component test of 7.13.1,
the following procedure would be performed following the two short-time current tests of that subclause.
If this test is being performed to qualify a cable jacket restoration seal design exclusive of any metallic-
shield components, the following procedure would be performed following the partial discharge test and, if
applicable, the sectionalizer test.
The cable jacket restoration assemblies that were cyclically aged in-air for 30 cycles shall be completely
submerged in ambient temperature tap water for 24 h. The minimum depth of water shall be 0.3 m (1 ft) for
extruded cable joints rated 2.5 kV to 46 kV and 1 m (3 ft) for all other joints. This depth corresponds to the
submersion depth required during the load cycle test of 7.9.1 and 7.9.2 for each joint construction and is
measured from the top surface of the joint. The assemblies shall then be subjected to an additional ten
thermal cycles with current of magnitude equal to the cyclic aging current requirements used for 7.9.1 or
7.9.2. It is not necessary to apply the continuous, ac phase-to-ground voltage of 7.9.1 or 7.9.2. Afterward,
the assemblies shall be removed from the water and the external surfaces fully dried. Within 2 h of removal
from the water, the environmental seals shall be removed and the moisture sensitive tape examined. The
cable jacket restoration/environmental seal component design is acceptable if there is no evidence of water
migration beyond the water block area as determined by the color of the moisture sensitive tape.
7.14 Connector thermal and mechanical tests
Connectors used in cable joints used to join two aluminum conductors or an aluminum conductor to a
copper conductor, shall meet all Class-A current cycle requirements given in ANSI C119.4.
In addition, connectors to join two aluminum conductors or an aluminum conductor to a copper conductor,
for use in any cable joint excluding pipe-type, laminated dielectric cable joints, shall meet all Class-2
partial tension requirements given in ANSI C119.4. The tensile strength requirements for connectors used
in pipe-type laminated dielectric cable joints must be established between the supplier and the end user.
The manufacturer should follow a similar test protocol to verify that connectors used between copper
conductors will perform reliably in service.
24
IEEE Std 404-2006
Annex A
(informative)
Typical values of heat-shrinkable and multi-component cold-shrink joint

component tests and sampling rates
Table A.1—Heat-shrink and multi-component cold-shrink joint component tests

and requirements
Shrinkable tubing or Stress

Reference Conductive Insulating Protective
molded component control
Visual examination 7.2.1 No splits, pinholes, inclusions, or other defects

Dimensions (%)
Expanded (min/max wall
thickness ratio) 7.2.2 ≥ 60 ≥ 60 ≥ 60 ≥ 60
Recovered (min/max wall
thickness ratio) 7.2.2 ≥ 80 ≥ 80 ≥ 80 ≥ 80
Length change after recovery 7.2.2 ≤ 15 ≤ 15 ≤ 15 ≤ 15
Tensile strength (MPa) 7.2.3 ≥ 10 ≥ 10 ≥ 10 ≥ 10
Elongation at break (%) 7.2.3 ≥ 200 ≥ 200 ≥ 200 ≥ 200
Volume resistivity (Ω-cm) 7.2.4 — ≤ 50k — —
Dielectric strength (kV/mm) 7.2.5 N/A N/A ≥ 10 —
Table A.2—Heat-shrink and multi-component cold-shrink joint component sampling rates
Length of lot size Sampling size

(m) (pieces)
1 to 500 2
501 to 2 000 4
2 001 to 5 000 7
5 001 to 10 000 10
> 10 000 15
25
IEEE Std 404-2006
Annex B
(informative)
Typical values of elastomeric taped joint component tests and sampling

rates
Table B.1—Taped joint component tests and requirements
Up to Up to Up to
Voltage class of tape Reference Semiconductive
35 kV 138 kV 325 kV
ASTM tape classification II III V IV
Fusion (max flag) 7.3.1 2 mm 2 mm 2 mm 2 mm
Dimensions (acceptable
variations from nominal)
Length 7.3.2.1 ≥ nominal ≥ nominal ≥ nominal ≥ nominal
Width 7.3.2.2 ± 0.76 mm ± 0.76 mm ± 0.76 mm ± 0.76 mm
Thickness (avg) 7.3.2.3 ± 0.076 mm ± 0.076 mm ± 0.076 mm ± 0.076 mm
Tensile strength (MPa, min) 7.3.3 1.7 1.7 2.4 0.69
Elongation at break (min %) 7.3.3 500 700 700 300
Volume resistivity (Ω-cm, min) 7.3.4 — — — 103
Dielectric strength for 0.76 mm
thickness (kV/mm, min) 7.3.5 20 24 28 N/A
Table B.2—Taped joint component sampling rates
Number of rolls in Number of sample

shipment rolls
50 to 200 2
201 to 500 3
501 to 1000 4
1001 to 5000 50
26
IEEE Std 404-2006
Annex C
(informative)
Bibliography
[B1] ASTM D4388-02, Standard Specification for Nonmetallic Semi-Conducting and Electrically
Insulating Rubber Tapes.11
[B2] CEI/IEC 60502-4, Power Cables with Extruded Insulation and Their Accessories for Rated Voltages
from 1 kV up to 30 kV.12
[B3] CEI/IEC 60840, Power Cables with Extruded Insulation and Their Accessories for Rated Voltages
above 30 kV up to 150 kV.
[B4] ICEA S-94-649, Standard for Concentric Neutral Cables Rated 5,000–46,000 Volts.13
[B5] ICEA S-97-682, Standard for Utility Shielded Power Cables Rated 5 Through 46 kV.
[B6] ICEA S-108-720, Standard for Extruded Insulation Power Cables Rated Above 46 kV Through
345 kV.
[B7] IEEE 100™, The Authoritative Dictionary of IEEE Standard Terms, Seventh Edition.14, 15
[B8] NEMA WC 3/ICEA S-19-81 (Reaff 1992), Rubber-Insulated Wire and Cable for the Transmission
and Distribution of Electrical Energy.16
[B9] NEMA WC 5/ICEA S-61-402, Thermoplastic-Insulated Wire and Cable for the Transmission and
Distribution of Electrical Energy.
[B10] NEMA WC 7/ICEA S-61-524, Cross-Linked Thermosetting-Polyethylene-Insulated Wire and Cable

for the Transmission and Distribution of Electrical Energy.
[B11] NEMA WC 8/ICEA S-68-516, Ethylene-Propylene-Rubber-Insulated Wire and Cable for the
Transmission and Distribution of Electrical Energy.
11
ASTM publications are available from the American Society for Testing and Materials, 100 Barr Harbor Drive, West
Conshohocken, PA 19428-2959, USA (http://www.astm.org/).
12
CEI/IEC publications are available from the Sales Department of the International Electrotechnical Commission, Case Postale 131,
3, rue de Varembé, CH-1211, Genève 20, Switzerland/Suisse (http://www.iec.ch/). IEC publications are also available in the United
States from the Sales Department, American National Standards Institute, 11 West 42nd Street, 13th Floor, New York, NY 10036,
USA.
13
ICEA publications are available from ICEA, P.O. Box 20048, Minneapolis, MN 55420, USA (http://www.icea.org/).
14
IEEE publications are available from the Institute of Electrical and Electronics Engineers, 445 Hoes Lane, Piscataway, NJ 08855-
1331, USA (http://standards.ieee.org/).
15
The IEEE standards or products referred to in this clause are trademarks of the Institute of Electrical and Electronics Engineers, Inc.
16
NEMA publications are available from Global Engineering Documents, 15 Inverness Way East, Englewood, CO 80112, USA
(http://global.ihs.com/).
27

Ieee STD 404 IEEE Standard For Extruded and Laminated Dielectric Shielded Cable Joints Rated 2500 V To 500 000 V PDF

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IEEE Standard for Extruded and

Laminated Dielectric Shielded Cable

IEEE Power Engineering Society

IEEE Standard for Extruded and

Insulated Conductors Committee

Approved 6 December 2006

The Institute of Electrical and Electronics Engineers, Inc.

Copyright © 2007 by the Institute of Electrical and Electronics Engineers, Inc.

Print: ISBN 0-7381-5294-3 SH95603

Secretary, IEEE-SA Standards Board

Glenn J. Luzzi, Chair

Andre Bellemare Paul Hann Allen MacPhail

Roy W. Alexander R. B. Gear, Jr. Michael S. Newman

Steve M. Mills, Chair

Mark D. Bowman Kenneth S. Hanus Greg Ratta

Satish K. Aggarwal, NRC Representative

3.1 Cable joint categories .......................................................................................................................... 3

4. Service conditions ...................................................................................................................................... 4

5.1 Voltage ................................................................................................................................................ 4

7.1 Production tests for premolded and single-component cold-shrink joints........................................... 8

Annex A (informative) Typical values of heat-shrinkable and multi-component cold-shrink joint

Annex C (informative) Bibliography............................................................................................................ 27

This standard also defines a variety of common joint constructions.

ANSI C119.4, Electric Connectors—Connectors for Use Between Aluminum-to-Aluminum or Aluminum-

ICEA P-32-382, Short-Circuit Characteristics of Insulated Cable.4

IEEE Std 4™, IEEE Standard Techniques for High-Voltage Testing.5, 6

3.1 Cable joint categories

3.2 Joint constructions

3.3 Other terms

a) In-air, including exposure to direct sunlight

5.2 Current and temperature

AC voltage design tests Minimum

AC voltage tests Minimum

69 39.8 350 120 100 240 60

Voltage Voltage AC withstand test AC HV time test DC

Voltage Voltage AC withstand test c DC

a) Company name or logo

d) “Use before” date and storage conditions, if applicable

6.3 Sheath/shield sectionalizers

Sectionalizers shall also be mechanically rugged.

7.1 Production tests for premolded and single-component cold-shrink joints

a) Partial discharge voltage level (see 7.6.1)

7.2 Fingerprint tests for heat-shrink and multi-component cold-shrink joint

7.2.1 Visual examination

7.2.3 Tensile strength and ultimate elongation

7.2.4 Volume resistivity of conductive tubes

See Table A.1 for typical values.

7.2.5 Dielectric strength of insulating tubes

See Table A.1 for typical values of dielectric strength.

7.2.6 Sampling rate

Unless otherwise required by customer or manufacturer specifications, the component sampling

7.3 Fingerprint tests for elastomeric taped joint components

7.3.3 Tensile strength and ultimate elongation

7.3.4 Volume resistivity

7.3.5 Dielectric strength

7.5 Design test conditions

7.6 Dielectric integrity tests

7.6.1 Partial discharge voltage level test

7.6.2 Ionization test

Minimum number of samples required in each sequence

Partial discharge voltage level 7.6.1 X X

Table 6 —Design tests and sequence for transition joints

Minimum number of samples required in

(I/A)2t = K log10 [(T2 + λ) / (T1 + λ)] (1)