IEEE Standard for Power Cable Joints

March 18, 1977 SH06171

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 IEEE
Std 4 0 4 - 1 9 7 7

IEEE Standard for Power Cable Joints

Sponsor

Insulated Conductors Committee of the

IEEE Power Engineering Society

© Copyright 1977 b y

The Institute of Electrical and Electronics Engineers, Inc

No part of this publication may be reproduced in any form,

in an electronic retrieval system or otherwise,
without the prior written permission of the publisher.

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 Approved December 1 2 , 1 9 7 5

I E E E Standards Board

Joseph L . Koepfinger, Chairman Warren H. C o o k , Vice Chairman

Sava I. Sherr, Secretary

Jean J a c q u e s A r c h a m b a u l t Stuart P. J a c k s o n William J. N e i s w e n d e r

R o b e r t D . Briskman Irving K o l o d n y
Dale R . C o c h r a n William R . Kruesi
L o u i s Costrell Benjamin J. L e o n
Frank D a v i d o f f A n t h o n y C. L o r d i
Jay Forster Donald T. Michael
Irvin N. H o w e l l , Jr. Voss A. Moore
William S. M o r g a n
Gustave Shapiro
R a l p h M. S h o w e r s
Robert A. Soderman
Leonard Thomas
Charles L. Wagner
William T. W i n t r i n g h a m f

fDeceased

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 Foreword

(This f o r e w o r d is n o t a part o f IEEE Std 4 0 4 - 1 9 7 7 , IEEE Standard f o r P o w e r Cable J o i n t s . )

This standard has been written to fill a need for standardization of terminology and test require­
ments for A C power cable joints.
Because most types of joint are field assembled by personnel with different levels of skill and
experience, the joint is the component of a cable system with the widest range of quality, and,
therefore, the most difficult to categorize. S o m e of the tests, specified for other materials, are not
only inapplicable for joints, but are often impossible to perform.
The test values, listed in this standard, are compatible with levels for other system components,
such as terminations. They are, in general, minimum values. Higher test values have been recom­
mended by some users. Before these higher values are used, however, specific agreement should be
obtained from the designers and manufacturers of all system components.
One of the aims of the authors of this standard has been to eliminate the confusion of terminol­
ogy connected with this subject. Beginning with the definition of "splice" as the basic conductor
connection, and "joint" as the complete, insulated and protected component, it is hoped that
standardized terms will become specific and unambiguous. The IEEE Dictionary of Electrical and
Electronics Terms, IEEE Std 1 0 0 - 1 9 7 2 (ANSI C 4 2 . 1 0 0 - 1 9 7 2 ) has never covered terms applicable
to power cable usage. The definitions used in this standard will be included in the revision of the
IEEE Dictionary of Electrical and Electronics Terms.
The work of preparing this standard was carried out by the Accessories Subcommittee on In­
sulated Conductors of the IEEE Power Engineering Society. The membership of the Subcommittee
was as follows:

Ν. E. Piccione, Chairman

B" W Λ Μ R
- Ε
· L E U C H

R
-W A l l e n
J. J. L o w e
T. A . Balaska G. Ludasi
F. J. Bender M M a l i a

O. I. Berkhan F. M. M c A v o y
° R B e s t
L. B. M c C l u n g
R. A . Burkhardt A . McKean
L

J. W. B r o w n j MedekD

E. C. B u r n u p R. p. M o t t
D . J. Carrigan j Mulligan
A

J. F. Castles ρ Neuger
Η
· c h u
P. L. Pearson
D . R. Clarke ρ ρ Pugh
F. V. C u n n i n g h a m Ε. S. Raila
F
- D e S i o
D . M. R i g n e y
L. J. D y l e w s k i A. Rios
J. D . Freed N. R . Sacks
G. B. Garibay E. L. S a n k e y
R B G e a r
A . Sansores
A. Godoshian p . g Schullerts
A. Gruenwald E. L. S h e l t o n
G. Hamburger R. Sheridan
H. C. Hervig L. H. Spangler
C. H o o g e r h y d e N. R. Spencer
R. R. H o w a r d VV. T. Starr
R. F. H u b e r D R Stevens
C. H. Hunter F. R . S t o c k u m
A . Hvizd, Jr. WK. Switzer
A. R. J a c k s o n Η. N. T a c h i c k
H. J o h n s o n j Tramontano
R. S. Keith ρ Tuttle D

D . W. Kissinger j . R Tuzinski
S
- Kozak R . . Ward A

J. H. L a w s o n A . C. W e s t r o m
R . H. L e e O W i l l i s

A t the time this document was approved the members of the working group were:

A. Gruenwald, Chairman

T. A . Balaska J. Nicholas
D . Clarke W. Richard
A . L. M c K e a n H. O . T h o m p s o n
R . C. Waldron

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 Contents
SECTION P A G E

1. Scope 7

2 . Service Conditions 7
2.1 Usual Service Conditions 7

2.2 Unusual Service Conditions 7

3 . Definitions 7

4. Terminology 8
5 . Basic Components for Cable Joints 8
5.1 Connector &
5.2 Insulation 9
5 . 3 Shielding (Screening) 9

5.4 Filling C o m p o u n d 9

5.5 Housing 9

5.6 Protective Covering 9

6. Joint Rating and Design Criteria 9

6.1 Rated Voltage 9

6.2 Temperature Limitations 9

6.3 Rated Internal Pressure 9

6.4 Cable Information Required 9

6.5 Service Environment 9

7. Design Tests 9

7.1 Dielectric Tests 9

7.2 Thermal and Mechanical Tests 9

7.3 Tightness Test on Cable Joint 1 1

8. Field Tests 1 1

TABLES
Table 1 Design Test for Joints on Cables with Laminated Dielectrics 10
Table 2 Design Tests for Joints on Cables with Extruded Dielectrics 10
Table 3 Pressure Tightness Tests 1 0

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 IEEE Standard for Power Cable Joints

1. Scope joint design and application, they should be

brought to the attentions of those responsible
The purpose of this standard is to outline defi­ for the design requirements so that special con­
nitions, terminology, voltage ratings, and test sideration may be given to such conditions. Ex­
requirements for cable joints for all types of in­ amples of such unusual conditions include the
sulated ac power cable rated in preferred volt­ following:
age steps from 2 . 5 to 5 0 0 k V .
N o attempt is made in this standard to cover (a) Concentration of fumes or vapors, abra­
design details, dimensional data, or installation sive dust, steam, salt spray, alkalinity,
instructions normally supplied by the designer. acidity, and organic liquids.
Cable joints are made or assembled on the job- (b) Vibrations, shocks, or mounting require­
site with the components supplied, and there­ ments.
fore, it is essential that all drawings and instruc­ (c) High or low ambient temperatures above
tions be followed carefully by trained person­ 5 0 ° C or below - 1 0 ° C .
nel in order that the actual field joints develop (d) Space limitations.
the characteristics established by design tests (e) Maintenance problems, special installa­
on similar joints. tion requirements, or operating duty.
(f) Physical strain or internal forces which
may develop because of magnetic forces
2 . Service Conditions
associated with high momentary or
short-circuit current, or from mechanical
2.1 Usual Service Conditions. Joints conform­
forces such as tension, twisting, or bend­
ing to this standard shall be suitable for opera­
ing.
tion at both the standard and emergency tem­
perature rating of the cables being joined. (g) Internal or external pressure.
Joints may be subjected to the same service en­ (h) Storage conditions or extended storage
vironment as the cables being joined; therefore, of joint components.
the physical and corrosion protection of the
3. Definitions
joint is an important factor which must be de­ 7
termined by the user and included with the in­ 3.1 splice. The physical connection of two or
formation specifying the type of joint required. more conductors to provide electrical continu­
ity.
2.2 Unusual Service Conditions. Where unusu­
al service conditions exist which may affect the 3 . 2 insulated splice. A splice with a dielectric

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 IEEE
Std 4 0 4 - 1 9 7 7 IEEE S T A N D A R D F O R

medium applied over the connected conductors 4. Terminology

and adjacent cable insulation.
Some of the special terms in c o m m o n use to
3 . 2 . 1 nonshield insulated splice. A n insu­
identify special features of cable joints are
lated splice in which no conducting material is
employed over the insulation for electric stress listed here and defined.
control. 4 . 1 normal joint. A joint which is designed
3 . 2 . 2 partially shielded insulated splice. A n not to restrict movement of dielectric fluid be­
insulated splice in which a conducting material tween cables being joined.
is employed over a portion of the insulation for
4 . 2 semistop joint. A joint which is designed
electric stress control.
to restrict movement of the dielectric fluid be­
3 . 2 . 3 shielded insulated splice. A n insulated
tween cables being joined.
splice in which a conducting material is em­
ployed over the full length of the insulation for 4 . 3 stop joint. A joint which is designed to
electric stress control. prevent any transfer of dielectric fluid between
the cables being joined.
3 . 3 cable joint. A complete insulated splice, or
group of insulated splices, contained within a 4 . 4 fluid filled joints. Joints in which the
single protective covering or housing. In some joint housing is filled with an insulating materi­
designs, the insulating material may also serve al that is fluid at all operating temperatures.
as the protective covering. Insulated end caps
4 . 5 gas filled joint. Joints in which the fluid
are considered joints in this context.
filling the joint housing is in the form of a gas.
3 . 3 . 1 straight joint. A cable joint used for
connecting two lengths of cable, each of which 4 . 6 compound filled joints. Joints in which
consists of one or more conductors. the joint housing is filled with an insulating
3 . 3 . 2 branch joint. A cable joint used for compound that is nonfluid at normal operating
connecting one or more cables to a main cable. temperatures.

4.7 taped joint. A joint with hand-applied

N O T E : A branch j o i n t m a y be further designated b y tape insulation.
naming the cables b e t w e e n w h i c h it is m a d e , eg, single
c o n d u c t o r cable, t h r e e - c o n d u c t o r cable, t h r e e - c o n d u c ­ 4 . 8 poured joint. A joint insulated by the
tor main c a b l e t o s i n g l e - c o n d u c t o r branch, etc. It is means of a hot or cold poured insulating medi­
c u s t o m a r y t o designate the various kinds as Y j o i n t , Τ
um which solidifies.
j o i n t , / / j o i n t , cross j o i n t , e t c .
4 . 9 premolded joint. A joint made of pre-
molded components assembled in the field.
3 . 3 . 3 insulating (isolating) joint. A cable
joint which mechanically couples and electric­ 4 . 1 0 Field Molded Joint. A joint in which the
ally separates the sheath, shield, and armor on solid-dielectric joint insulation is fused and
contiguous lengths of cable. curved thermally at the j o b site.
3 . 3 . 4 transition joint. A cable joint which
connects two different types of cable. 5. Basic Components for Cable Joints

3 . 4 design tests. Tests made on typical joint 5.1 Connector. A metallic device of suitable
designs to obtain data to substantiate the de­ electric conductance and mechanical strength,
sign. These tests are of such nature that after used to splice the ends of two or more cable
they have once been made, they need not be conductors, or as a terminal connector on a
repeated unless significant changes are made in single conductor. Connectors usually fall into
the material or design which may change the one of the following types:
performance of the joint.
solder
3 . 5 production (routine) tests. Tests made on welded
joint components or subassemblies during pro­ mechanical
duction for the purpose of quality control. compression or indent.

3 . 6 field tests. Tests which may be made on Conductors are sometimes spliced without con­
the cable and accessories after installation. nectors, by soldering, brazing, or welding.

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 IEEE
POWER CABLE JOINTS Std 4 0 4 - 1 9 7 7

5 . 2 Insulation. A material of suitable dielec­ 6 . 4 Cable Information Required (including di­

tric properties, capable of being field-applied, mensional tolerances).
and used to provide and maintain continuity of ( 1 ) T y p e of cable.
insulation across the splice. The material need ( 2 ) Conductor information including the
not be identical to the cable insulation, but number of conductors, type of construc­
should be electrically and physically compati­ tion, type of material, size, and shape.
ble, including factory-molded insulating compo­ (3) The type and thickness of insulation.
nents that are field-installed. (4) Type, or types, of shielding.
(5) Protective covering.
5.3 Shielding (screening). A conducting layer,
(6) The voltage and ampacity rating of the
applied to control the dielectric stresses within
cable.
tolerable limits and minimize voids. It may be
( 7 ) The number of cables to be joined and
applied over the entire joint insulation, on the
a complete description of their configu­
tapered insulation ends only, or over irregular
ration in the joint.
conductor or connector surfaces.
( 8 ) Diameters over insulation shielding and
5 . 4 Filling Compound. A dielectric material jacket, for premolded joints.
poured or otherwise injected into the joint
housing. Filling compounds may require heat­ 6 . 5 Service Environment.
ing or mixing prior to filling. S o m e filling com­ ( 1 ) aerial
pounds may also serve as the insulation. ( 2 ) direct burial
( 3 ) duct
5 . 5 Housing. A metallic or other enclosure for
( 4 ) cable tray
the insulated splice.
( 5 ) submarine
5.6 Protective Covering. A field-applied ma­ ( 6 ) unusual service condition (see Section
terial to provide environmental protection over 2.2)
the joint or housing, or both. ( 7 ) manhole.

7. Design Tests

6. Joint Rating and Design Criteria
The joint rating and the governing design con­
ditions include the following:
6 . 1 Rated Volage. The rated voltage of a joint
is the voltage at which it is designed to operate
under usual service conditions.
N O T E : Unless o t h e r w i s e specified, the voltage rating is
assigned with the understanding that the j o i n t will b e
applied o n three-phase circuits w h o s e n o m i n a l phase-
to-phase voltage rating d o e s n o t e x c e e d that o f the
joint.
6 . 2 Temperature Limitations. The joint shall
be capable of operating with the conductor and
connector within the joint at the same maxi­
m u m temperature limitations as those of the
conductors of the cable being joined.
6 . 3 Rated Internal Pressure. The rated internal
pressure of a joint is the nominal internal op­
erating pressure. This will depend on the types
of cable being joined and the service condi­
tions.
The design tests shall include the following:
(Separate joint samples may be required for
different design tests.)
7.1 Dielectric Tests. 6 0 hertz, impulse, and di­
rect current withstand tests in accordance with
appropriate values listed in either Table 1 or Ta­
ble 2 dependent upon cable type.
7.2 Thermal and Mechanical Tests. The con­
nector-conductor assembly shall meet all appli­
cable tests as covered by:
(a) T D 1 6 1 1 9 5 8 EEI Specification for
Straight Compression Type Connectors
for Insulated Copper Conductors.
(b) T D 1 6 0 EEI Specifications for Solder
Sweated Split Tinned Copper Connec­
tors.
(c) T D J 1 6 2 (EEI) or 1 4 . 1 0 - 1 9 6 2 ( N E M A )
Standards for Overhead Distribution
Connectors for Aluminum Conductors.
N O T E : Class A Heat C y c l e Test and Class 2 Partial
T e n s i o n Test shall b e used.

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 IEEE
Std 4 0 4 - 1 9 7 7 IEEE S T A N D A R D F O R

Table 1
Design Test for Joints on Cables with Laminated Dielectrics

Test Values in k V
Rated k V L o w Frequency Impulse D i r e c t Current
φ to φ 6hr(l) Crest ( 1 ) 15 m i n ( 2 )

2.5 10 60 15
5.0 15 75 25
8.7 23 95 35
15.0 36 110 55
25 53 150 75
35 77 200 100
46 102 250 125
69 118 350 175
92 139 450 225
115 163 550 275
138 191 650 325
161 221 750 375
196 268 900 450
*230 268 900 450
230 315 1050 525
287 335 1300 650
*345 360 1300 650
345 400 1550 775
500 470 1800 990

* R e d u c e d B I L values w h i c h have general a c c e p t a n c e , where particular

c o n s i d e r a t i o n has been given t o effective g r o u n d i n g and arrestor p r o t e c ­
tion.

Table 2
Design Tests for Joints on Cables with Extruded Dielectrics

Test Values in k V Maximum Apparent

Rated k V L o w Frequency Impulse D i r e c t Current Discharge ( 3 )
0 to 0 6hr(l) Crest ( 1 ) 15 min ( 2 ) (picocoulombs)

5 15 75 25 5
8 23 95 35 5
15 36 110 55 5
25 53 150 75 5
35 77 200 100 5

N O T E S : ( 1 ) Test levels, waveshapes, and p r o c e d u r e s a c c o r d i n g t o IEEE Std 4 8 - 1 9 7 5 ,

High V o l t a g e A C Cable T e r m i n a t i o n s ; and IEEE Std 8 2 - 1 9 6 3 , Test P r o c e d u r e for Im­
pulse V o l t a g e Tests o n Insulated C o n d u c t o r s . ( 2 ) D C test values based o n 50 p e r c e n t B I L ,
and values b e l o w 1 5 k V rating adjusted in a c c o r d with limits i m p o s e d b y IEEE Std 4 8 -
1 9 7 5 , latest revision. ( 3 ) T e s t at 1 5 0 p e r c e n t o f rated voltage t o g r o u n d (refer t o A E I C
S p e c i f i c a t i o n f o r P o l y e t h y l e n e and Cross-linked P o l y e t h y l e n e Insulated Shielded P o w e r
Cables N o . 5-69, latest e d i t i o n ) . ( 4 ) F o r voltages higher than are s h o w n in T a b l e 1 o r 2 ,
c o n s u l t c a b l e and a c c e s s o r y manufacturers.

Table 3
Pressure Tightness Tests

N o m i n a l Pressure Withstand Pressure f M a x i m u m Field Test

(psi) (psi) (psi)

Solid type cable 20 15

15 40 28
40 100 70
100 250 175
200 500 350

f N o t t o e x c e e d capabilities o f cables being j o i n e d .

10

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POWER CABLE JOINTS
7.3 Tightness Test on Cable Joint. The cover­
ing or housing of a joint shall withstand the
applicable liquid or gas pressure test for one
hour, as determined from Table 3 . Pressure
tests, where applicable, shall be based on values
agreed on by manufacturer and user.
8. Field Tests
Acceptance tests or proof tests or both, as
defined here and under the provisions outlined,
may be made on completed cable systems as a
check on workmanship in cable joining and for
possible mechanical damage during installation.
Field tests are tests which may be made on the
completely installed cable system b y the user
as an installation acceptance or proof test. The
acceptance tests and field tests are not intend­
ed to preclude the testing of the cable system
on a periodic basis after having been placed in
service.
Pressure tightness tests may be made in the
field as indicated in Table 3 or at 7 0 percent
of the design test for joints with a rated pres­
sure not included in Table 3 .
The values listed in Tables 1 and 2 are not to
11
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IEEE
Std 4 0 4 - 1 9 7 7
be used as the test voltages for a given rated
voltage cable system, but are intended only as
a guide for voltage which the joint should be
expected to withstand without affecting its di­
electric characteristics.
T h e magnitude of the actual test voltage to be
used for the installed cable system shall be de­
termined by reference to applicable IEEE,
A E I C , or IPCEA cable test specifications. The
joint supplier shall be consulted before con­
ducting any field tests which exceed the values
listed in Table 1 or 2 .
N O T E S : ( 1 ) Transformers, regulators, and o t h e r equip­
m e n t w h i c h c a n n o t b e d i s c o n n e c t e d from the cable
s y s t e m while c o n d u c t i n g the field test s h o u l d be inves­
tigated t o be sure the withstand strength o f this equip­
m e n t is n o t e x c e e d e d . ( 2 ) All values are withstand test
voltages w i t h o u t negative tolerance. ( 3 ) O n assembled
multiple c o n d u c t o r j o i n t s o f n o n s h i e l d e d cables, the
design test voltage shall be applied b e t w e e n each c o n ­
d u c t o r and g r o u n d with the terminals o n adjacent c o n ­
d u c t o r s g r o u n d e d . O n shielded cable, the test voltage
shall be applied b e t w e e n the c o n d u c t o r and the
g r o u n d e d shielding. ( 4 ) T h e values in these Tables are
for general use. It is r e c o g n i z e d that j o i n t s with a high­
er o r l o w e r voltage rating than the c a b l e m a y be used
w h e r e different insulation levels are required o r are
acceptable.