How to Control Electric Stress in Cable Joints & Terminations?

Table of Contents
 Introduction
 Electrical Stress & Stress Control
 Causes
 Methods of Stress Control
 Stress Cone Method
 Heat Shrinkable Stress Control Tubing Method
 Other Methods to Control Stress

Introduction
Power cables are of great importance in power transmission and distribution systems.
Terminations and joints are the basic accessories of the power cables and they are
required to make connections between lines or to an electrical apparatus.
The various aspects are considered while designing the cable terminations and
joints because they must possess the same integrity as their associated cables while
making the connection both all indoor and outdoor applications.

The most critical aspect of high voltage cable jointing and termination is control of

the dielectric stress originated at the point of screen termination–electric stress
control.
Electrical Stress & Stress Control
Terminals and joints of high and medium voltage cables must manage the electric
fields at the ends. When the insulation shield is removed from a cable, high potential
gradients are concentrated at the cutback point, as show in the Figure 1.
 Figure 1 – Distribution
of electric field
 Also Read: Different Types of Wiring Systems and Methods of Electrical Wiring &
Cables
In this figure it can be seen that the earth shield of a cable (0%) is cut off,
the equipotential lines (from 20% to 80%) concentrate at the edge of the earth
electrode, causing high electrical stress.
Electric field enhancement at these points can produce local discharges that could
lead to either flash over along the insulation surface or dielectric breakdown
causing cable failure.
In cable installation, shielded power cables require electrical stress control when
terminated.
Cable terminations and jointing are designed to eliminate the stress concentration at the
screen termination to avoid the break-down of the cable– electrical field has to
be controlled in a cable termination and jointing.
The stress distribution at the conductor joint varies considerably due to changes in
the profile introduced by the use of a ferrule .
Sharp edges and protrusions  at the joint, if left unrelieved also result in abrupt
change of the stress gradient.
It is therefore essential for the conductor to have a smooth profile so that there is
no undue concentration of stresses.
However, the more important aspect of  stress control  applies to the location where the
insulation screen is terminated.
It shall be noted that not only the dielectric stress increases in termination region, but
also a potential gradient is set up along the interface between the dielectric and the
surrounding medium.
The stress in the dielectric at the screen termination will be well above the design
stress and may lead to premature failure.
 Related post: Cables Feeder Protection, Faults Types, Causes & Differential
Protection
In addition if the surrounding medium is air, or there is a void between the dielectric
and the filling medium, then the stress in the area may cause the air to permit
discharge even at the working voltage.
Paper is somewhat resistant to these discharges, but for polymeric insulation,
like XLPE ( Cross-linked polyethylene ), such discharges will rapidly erode the dielectric
and eventually result in failure.
Without application of stress control, discharges would occur, adversely affecting
the life of the joint and termination.
Figure 2 show the distribution of electric field without and with stress control.

Figure 2 – Distribution
of electric field without stress control (up) and with stress control (down)
 Also Read: Choice Of Wiring System & Types Of Cables Used In Internal Wiring
Causes
Major weaknesses in the area of termination and joints of high and medium voltage
cables requiring stress control are:
 Compression lugs allowing moisture to penetrate the conductor cores
 Failure to eliminate air pockets
 Core crossing resulting in partial discharge
 Poor cable preparation
 Moisture penetration
 Inadequate phase-to-phase and phase-to-earth clearance
 Tracking
 Poor jointing instructions
Related post Submarine Cables – Construction, Characteristics, Cables Laying & Joints
Methods of Stress Control
There is no universal termination or joint. There is a variety of different types of
termination and joints each with advantages and disadvantages.
The optimization of cable terminations is achieved by investigating various
constructions.
The proper termination method should provide good electrical and mechanical integrity.
To design a proper termination, an electric field distribution analysis should be done in
the critical regions.
 Related post: Cable Size Calculation for LT & HT Motors
Stress Cone Method

The common method employed for stress control is the use of a stress cone that is
shown in Figure 3.

Figure 3 – Stress cone

 Also Read: Insulating And Dielectric Materials – Types, Properties & Applications
The stress cone is a mean of controlling the capacitance in the area of screen
termination, thereby reducing the dielectric stress along a gradient to tolerable limits
at the point of termination.
The stress cone is extended beyond the screen termination, so that the potential
gradient at the dielectric surface is reduced to a level where discharges will not occur.
In joints of high and medium voltage paper cables, the stress cone is usually built to a
predetermined contour by hand application of insulating paper tapes, while in
terminations the stress cone is either hand-applied or performed. With the
development of polymeric and elastomeric cables, premoulded stress cones have also
been introduced.
 Related post: How To Locate Faults In Cables? Cable Faults, Types &  Causes
Before the stress cone is applied, it is necessary to reduce the electrical stress at
the conductor joint, arising out of reasons explained earlier.
The concept is to provide a smooth profile so that the stress is evened out. This is
obtained by ‘stepping’ of cable papers, which is achieved by removing the paper
insulation in a set of steps, having risers and treads from the inner conductor surface
to the outer insulation surface.
With the two cable ends so treated and joined together, hand applied impregnated
paper tapes are applied over the assembly to form the joint dielectric.
 Related article: Wire & Cable Size Calculator in AWG
Heat Shrinkable Stress Control Tubing Method
Another common method is heat shrinkable stress control tubing that is used
to control high electrical stresses at insulation screen terminating point in medium
voltage plastic and paper insulated cable joints and terminations up to 36 kV.

Figure 4 – Stress
control tubing
They also control the high stresses over the connectors in joints.
Stress control tubing is made from thermally stabilized cross linked high permittivity
and high resistivity polymeric material.
 Also Read: Insulation Resistance of a Cable | Why Cables are insulated?
Other Methods to Control Stress

Other methods are:

 High-resistance tapes or coatings, and materials with non-linear resistance
layers, the material being of constant surface resistivity passes a small current and
thereby sets up a linear voltage gradient along its length. A better stress distribution
is achieved by using materials of non-linear resistivity, which also allows small
current in the layer increase, the resistance of the material drop, and a smooth linear
voltage gradient is achieved along the applied length.
 Materials having relative permittivity significance higher than the cable dielectric.
The method is based on the principle that when materials of dissimilar permittivity are
subject to a potential gradient across their combined thickness, the highest stress is
experienced by the material having the lowest permittivity. It can be seen from the
schematic diagram that the equipotential lines emerge gradually from the dielectric,
thus producing a smooth gradient at the dielectric surface.
Related Articles:
 Why Power Transmission Cables & Lines are Loose on Electric Poles
& Transmission Towers?
 What are Tiny Cylinder in Power Cords & Cable & Why?
 Why Coaxial Cables are Highly Insulated?

About the Author: Manuel Bolotinha

-Licentiate Degree in Electrical Engineering – Energy and Power Systems (1974 –

Instituto Superior Técnico/University of Lisbon)
– Master Degree in Electrical and Computers Engineering (2017 – Faculdade de
Ciências e Tecnologia/Nova University of Lisbon)
– Senior Consultant in Substations and Power Systems; Professional Instructor
 Tags
Distribution of electric fieldElectric Stress ControlElectrical StressStress ConeStress control tubing
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