INSTALLATION

& OPERATION MANUAL

POWER CABLES AND WIRES

www.alfanar.com
2
TABLE OF CONTENTS
1. Pre-Installation.................................................................................................................................................... 3
1.1 Introduction.............................................................................................................................................. 3
1.2 Pre-installation.......................................................................................................................................... 3
1.2.1 Cable Inspection.................................................................................................................................... 3
1.2.2 Cable Storage........................................................................................................................................ 3
1.2.3 Drum Handling...................................................................................................................................... 4
1.2.4 Prevention of Moisture Ingress............................................................................................................. 5
1.2.5 Pre-Installation Check List.................................................................................................................... 5
1.2.5.1 Code review........................................................................................................................................ 5
1.2.5.2 Cable inspection................................................................................................................................. 5
1.2.5.3 Cable storage...................................................................................................................................... 5
1.2.5.4 Cable handling.................................................................................................................................... 5
1.2.6 Route Survey......................................................................................................................................... 5

2 Installation........................................................................................................................................................... 6
2.1 Installation Temperature........................................................................................................................... 6
2.2 Equipment................................................................................................................................................ 7
2.2.1 Equipment check list............................................................................................................................. 7
2.2.2 Cable feed-in setups.............................................................................................................................. 8
2.3 Physical Limitations of Cables................................................................................................................. 9
2.3.1 Minimum installation radius................................................................................................................. 10
2.3.2 Maximum pulling tension..................................................................................................................... 10
2.3.2.1 Pulling eye attached to the conductor................................................................................................. 10
2.3.2.2 Cable grip over lead sheath................................................................................................................ 11
2.3.2.3 Cable grip over non-leaded cable....................................................................................................... 11
2.3.2.4 Check list prior to pulling cable......................................................................................................... 11
2.3.3 Sidewall pressure................................................................................................................................... 11
2.4 Laying Methods........................................................................................................................................ 12
2.4.1 Direct in the ground............................................................................................................................... 12
2.4.2 Underground tunnels or ducts............................................................................................................... 12
2.4.3 Cable tray.............................................................................................................................................. 13
2.4.3.1 Tray design......................................................................................................................................... 13
2.4.3.2 Tray system design............................................................................................................................. 13
2.4.3.3 Tray application.................................................................................................................................. 13
2.4.3.4 Tray load capacity.............................................................................................................................. 14
2.4.3.5 Cable tray installation......................................................................................................................... 14
2.4.4 Special laying........................................................................................................................................ 15

3 Splicing................................................................................................................................................................ 15
3.1 Solid Dielectric Insulated Cable............................................................................................................... 15
3.1.1 Removal of cable jacket and shield....................................................................................................... 15
3.1.2 Placing connectors................................................................................................................................. 16
3.1.3 Preparation of joint for insulation......................................................................................................... 16
3.1.4 Insulating the joint................................................................................................................................. 16
3.1.5 Shielding of the insulated joint.............................................................................................................. 17
3.1.6 Protective covering................................................................................................................................ 17
3.2 Lead Sheathed Cable................................................................................................................................ 17
3.2.1 Removal of the sheath........................................................................................................................... 17
3.2.2 Making the lead joint............................................................................................................................. 17

4 Terminating.......................................................................................................................................................... 18
4.1 Cable Preparation..................................................................................................................................... 18
4.2 Installation of Terminations...................................................................................................................... 18
 Pre-Installation

4
1
1 - PRE-INSTALLATION

1.1 Introduction
This manual provides installation methods commonly encountered in industrial, commercial and electric power utility
applications and should be used in conjunction with the engineer’s installation specifications and all applicable codes.
These methods are recommended for all types of power and control cables. This manual is intended for use by the design
engineer and the installer in the field. The information provided is concise and should be adequate for the majority of
installations.

1.2 Pre-installation
To ensure safety during cable installation and reliability once the cable is installed, you should confirm the following
prior to installation.

• The cable selected is proper for your application.

• The cable has not been damaged in transit or storage.

Review all applicable local, state, provincial, and national codes to verify that the cable selected is appropriate for the
installation job.

Any existing cable damage must be identified and any further damage prevented from occurring. This is done through
proper cable inspection, handling and storage.

1.2.1 Cable Inspection

Inspect every reel of cable for damage before accepting the shipment. Be particularly alert for cable damage if:
• A reel is laying flat on its flange side.
• Several reels are stacked on top of each other.
• Other freight is stacked on top of a reel.
• Nails have been driven into reel flanges to secure shipping blocks.
• A reel flange is damaged.
• A reel has been dropped (hidden damage likely).
• A cable covering has been removed, or is stained or damaged.
• A cable end seal has been removed or is damaged.

1.2.2 Cable Storage

Cables should be stored on hard surfaces so that reel flanges cannot sink. Small reels may weigh several hundred kilograms
while large reels can exceed several thousand kilograms.

Impact damage can be prevented by the following precautions:

• Aligning reels flange to flange.

• Using guards across flanges when different reel sizes are stored together.
• Maintaining adequate aisles and barricades to prevent equipment from hitting the cable.
1 - PRE-INSTALLATION

1.2.3 Drum Handling

YES NO

Cradle both reel flanges between forks Do not lift by top flange. Cable
or reel will be damaged

Reels can be hoisted with a shaft Use a spreader bar to prevent bending
extended through both flanges the reel flanges and mashing the cable

Place spacers under the bottom flange and Upended heavy reels will often
between reels to create a space to insert the forks arrive damaged. Refuse or receive subject
to inspection for hidden damage

Lower reels from truck using hydraulic gate, Never allow forks to touch cable
hoist or fork lift. LOWER CAREFULLY. surface or reel wrap

Always load with flanges on edge Never drop reels

and chock and block securely

6
1.2.4 Prevention of Moisture Ingress
Care should be exercised during installation to avoid any damage to cable coverings. This is important in wet or other
harsh environments. The protective end cap should not be removed from the ends of the cable until immediately prior
to termination or jointing, especially for cables that do not have extruded bedding. When the caps have been removed,
the unprotected ends of the cable should not be exposed to moisture.

1.2.5 Pre-Installation Check List

1.2.5.1 Code review
• Review all applicable local, state, provincial, and national codes relating to cable installation
• Consult local inspection authority

1.2.5.2 Cable inspection

• Check for shipping damage before accepting shipment. Record any damage on the way bill
• Confirm that the cable specified was received
• Verify that the cable end seals are intact

1.2.5.3 Cable storage

• Provide firm support for reels
• Protect cable from mechanical damage and from liquid spills
• Check cable end seals periodically
• Advise all splicers, installers and handlers of all special instructions

1.2.5.4 Cable handling

• Remove nails and staples from reel flanges
• Calculate and comply with recommended bending radii
• Use swivels, and avoid overruns when unreeling by utilizing a reel brake or back tension

1.2.6 Route Survey

Route survey of the cable route is very important in planning for a direct buried cable project. Each section of the route
from splice location to splice location must be prepared properly before cable installation begins. It is very important
to identify all conflicts and obstructions along the route before installation is underway.

One of the objectives of the pre-survey is to determine where each reel of fiber optic cable is to be placed. Slack locations
and cable storage requirements must also be considered along with splice locations. The pre-survey will verify construction
methods, special tools required, or possibly require a revision of preliminary splice locations.

The characteristic of the ground along the route needs to be investigated. If a subsurface investigation seems to be required,
it should be conducted. This will clear up any concerns about underground conditions that may be encountered during
installation.

All road crossings, creek crossings, etc. need to be addressed so that preparatory work can begin before cable laying.
This will identify what type of preparatory work will be required to negotiate these crossing points. A good pre-survey
and proper planning will preclude reel ends falling too close to roads, creeks, or any other undesirable locations.
 Installation

8
2
2 - INSTALLATION

A high percentage of cable failures are due to mechanical damage, which typically occurs during transportation, handling
and installation.

In fact, most cables are subjected to more mechanical stress during installation than they ever experience in actual
operation. Needless to say, handling and installing the cable according to the manufacturer’s recommendations is extremely
important.

When cables are installed in a raceway, underground electrical duct or cable tray, the following factors must be considered:
• Conductor configuration
• Raceway or cable tray fill
• Physical limitations of cables
• Installation equipment
• Ambient temperature and conditions

Similarly, when cable is installed as exposed wiring or as messenger-supported wiring, all of the above factors except
raceway or cable tray fill must be considered as well as the requirements for securing and supporting the cables.

2.1 Installation Temperature

It is recommended that the cables should be installed only when both the cable and ambient temperature are above 0 °C
and have been so for the previous 24 hours, or where special precautions have been taken to maintain the cable above
this temperature.
Cable should be pulled more slowly and trained in place the same day it is removed from storage. Do not impact, drop,
kink or bend cable sharply in low temperatures.

2.2. Equipment
The proper use of appropriate equipment is crucial to a successful cable installation. The equipment recommended for
a variety of installations is listed in the following checklist and the appropriate equipment should be selected for the
particular installation requirements.

2.2.1 Equipment check list

• 0-1/5/10 Kip Dynamometer • Make-Up Air Blower & Hose
• Basket Grip Pullers • Manhole Edge Sheave
• Cable Cutter • Measuring Tape
• Cable End Seals • Personal Protection Equipment (PPE)
• Cable Pulling Lubricant • Plywood Sheets
• Cable Tray Bend Sheaves • Portable Electric Generator
• Cable Tray Rollers • Pre-Lubing Devices
• Capstan-Type Puller • Pulling Rope
• Diameter Tape • Pump, Diaphragm
• Duct Cleaning Mandrels • Radios or Telephones
• Electric Safety Blankets And Clamps • Reel Arbor
• Extension Cords With GFCI Protection • Reel Brakes
• Fish Tape or String Blower/Vacuum • Reel Jacks
• Floodlights • Several Wire Rope Slings of Various Lengths
• Gang Rollers: With At Least 4 Ft Effective Radius • Shackles/Clevis
• Guide-In Flexible Tubing (Elephant Trunks) • Short Ropes For Temp Tie-Offs
• Hand Winches (Come-A-Long) • Cable End Seals
• Hipot Tester • Swivels
• Lint-Free Rags • Warning Flags, Signs
2 - INSTALLATION

2.2.2 Cable feed-in setups

The following diagrams illustrate various cable feed-in setups:

Guide-in Tube

Setup for reel on truck

Setup for duct close to floor

Setup for overhead, into tray

PROPER IMPROPER

The feed-in setup should unreel the

cable with a natural curvature

10
 Single Sheave Sheave Assembly

Single sheaves should only be used for GUIDING cables. Arrange multiple blocks to maintain bending radii whenever cable
changes direction or elevation. For pulling around bends, use conveyor sheave assemblies of the appropriate radius series.

The pulleys must be positioned to ensure that the effective curvature is smooth and changes direction or elevation
evenly at each pulley. Never allow a polygon curvature to occur as shown in the below figure.

The fit of the pulley around the cable is also important when pulling heavy weights (e.g. pulleys at the top of a vertical drop).

NEVER ALLOW
Radius
Remember to use the radius of the surface over which the cable is bent, not the outside flange diameter of the pulley.
A “10 inch” cable sheave typically has a 10 in. outside flange diameter with a 6 in. inside diameter that provides an
inside (bending) radius of 3 in.

2.3 Physical Limitations of Cables

Another major consideration in any cable installation is the physical limitations of the cable as it is being pulled into position.
The cable is subjected to extreme stress during pulling and, if not done properly, can distort or displace cable components
and affect its integrity and performance. Therefore, it is very important that the following guidelines be observed:

• Calculate and do not exceed the maximum pulling tension, maximum sidewall bearing pressure or the minimum
bending radius.
• Verify that the raceway or cable tray system is completely installed prior to cable installation and that the wiring
space is adequate.
• Train the cable to avoid dragging it on the edge of the raceway or cable tray.
• When using a basket grip, it must be securely fastened to the cable. Once the cable is installed, cut the cable behind
the location of the basket grip.
• The elongation characteristics of the pull rope should provide a constant and smooth pulling tension.
• Pull no faster than 40 ft (12 m) per minute.
• Pull with a capstan, whenever possible.
• Do not stop a pull unless absolutely necessary.
• Never pull the middle of the cable.
• Seal the cable ends of cable with an end seal with mastic coating inside.
2.3.1 Minimum installation radius

Cable Type L.V Cables M.V Cables

Single-Core Cables
15 Ø 20 Ø
- Unarmoured
15 Ø 15 Ø
- Armoured

Multi-Core Cables
12 Ø 20 Ø
- Unarmoured
12 Ø 15 Ø
- Armoured

Where Ø is the overall diameter of the cable.

Wherever possible, larger installation radius should be used, except that the minimum bending radius where the cables
are placed in position adjacent to joints and terminations may be reduced to that given in the below table, provided that
the bending is carefully controlled, e.g. by the use of a former.

Cable Type L.V Cables M.V Cables

Single-Core Cables
8Ø 15 Ø
- Unarmoured
8Ø 12 Ø
- Armoured

Multi-Core Cables
6Ø 12 Ø
- Unarmoured
6Ø 10 Ø
- Armoured

Where Ø is the overall diameter of the cable.

2.3.2 Maximum pulling tension

The maximum pulling tension is dependent on the cable design, the mechanical limitations, the conductor material,
and the method of laying and pulling the cables. The maximum permissible pulling force can be calculated based on
the method of pulling as follows:

2.3.2.1 Pulling eye attached to the conductor

With pulling eye attached to copper conductors, the maximum pulling tension should not exceed 0.036 times circu-
lar-mil area of conductor (Cm). With pulling eye attached to aluminum conductors, the maximum pulling tension
should not exceed 0.027 times circular-mil area of conductor (Cm). Or in other words

Tm = 0.036 x n x Cm (Copper)

Tm = 0.027 x n x Cm (Aluminum), Where

Tm : Maximum pulling tension in N

n : The number of conductors
Cm : Circular mil area of each conductor

The maximum limitation for this calculation is 22240 N (2268 kgf) for single conductor (1/C) cables, and 44480 N
(4536 kgf) for multi core cables. This limitation is due to unequal distribution of tension forces when pulling multiple
conductors.

When the calculated pulling tension is close to (or within 10 % of) the maximum pulling tension, the use of a tension
gauge during the pulling is recommended.

12
2.3.2.2 Cable grip over lead sheath
The maximum pulling tension on the lead sheath should not exceed 10.33 N/mm2 (1500 lbf/in2).

2.3.2.3 Cable grip over non-leaded cable

The maximum pulling tension on the cable should not exceed 4400 N (1000 lbf).

2.3.2.4 Check list prior to pulling cable

a. Be sure there is adequate clearance between duct or conduit diameter and cable diameter.
b. Use adequate lubrication of the proper type to reduce friction in conduit and duct pulls.
c. After installation, check to determine that end seals are still intact and have not been damaged to the point where
water could enter. Apply suitable end seals to help protect against damage if the cable will be subjected to immersion
or rain. This is particularly important if there will be a delay of sometime between the pulling operation and splicing
and terminating.
d. Be sure to check the maximum tension limits of the cable pulling accessories (cable grips, pulling eyes, swivels, pull
rope, etc.). They should have a capacity equal to or greater than the tension limits that are required to pull the cable.

2.3.3 Sidewall pressure

One of the limitations to be considered in the installation of electrical cables is sidewall pressure. The sidewall pressure
is the force exerted on the insulation and sheath of the cable at a bend point when the cable is under tension, and is
normally the limiting factor in an installation where cable bends are involved. The sidewall pressure in general is ex-
pressed as the tension out of a bend expressed in newtons divided by the inside radius of the bend expressed in meters.

Where

P : Sidewall pressure in N/m (lbf/ft)

To : Tension leaving the bend in N (lbf)
r : Inside radius of conduit in m (ft)

The normal maximum sidewall pressure per meter (foot) of radius is as given below. However, in order to minimize
cable damage because of excessive sidewall pressure, the installer should check the proper recommendations for each
type of cables to be installed.

Maximum sidewall pressure

Cable Type
( N/m ) ( lbf/ft )
Non-shielded multi-core cables 7300 500
Single core cables 7300 500
6 to 15 kV Power cables 7300 500
20 and 30 kV Power cables 4400 300
Armoured cables (all voltage grades) 4400 300
Instrumentation cable – single pair 4400 300
Instrumentation cable – multi-pair 7300 500

2.4 Laying Methods

The best method of laying a cable depends on the type of cable and working conditions. The followings are generally
applied as the most common cable laying methods.

2.4.1 Direct in the ground

This method is shown in Fig. 1 below, and is employed in following cases:
1. Where the road is narrow so the construction of conduit under the road is not permitted.
2. Where the number of cables is few and no future increase is expected.
3. Where the road digging is easy.
 Fig. 1 Direct Burial
telephone cable drum
tension meter
caterpillar

operator

pulling wire

pulling eye
roller or caterpillar
telephone cable drum
telephone tension meter cable drum
caterpillar
tension meter
power cable for caterpillar
caterpillar
operator
operator
pulling wire
pulling wire
pulling eye
trough, if necessary
pulling eye roller or caterpillar
roller or caterpillar

power cable for caterpillar

power cable for caterpillar
2.4.2 Underground tunnels or ducts
This method is showntrough,
in Fig. 2, 3 below, and is employed in following cases:
if necessary

1. The casetelephone
of main underground transmission
trough, if necessary
cable drum line where the number of cables is many or expected to be increased in
the near future.
control panel caterpillar

2. The case of hard pavement or where hard pavement will be constructed in future.
3. Where digging is difficult due to heavy traffic.
operator

telephone cable drum

telephone
control panel caterpillar
cable drum Fig. 2 Cable Layig at Duct Manhole
Tunnel roller or caterpillar
Manhole control panel caterpillar cable
pulling eye
operator

operator

pulling wire

power cable for caterpillar Manhole

Tunnel roller or caterpillar Manhole
Manhole cable
roller or caterpillar pulling eye
Tunnel
Manhole cable
pulling eye

pulling wire

pulling wire
power cable for caterpillar

power cable for caterpillar

telephone cable drum
caterpillar
control panel winch car

operator

Fig. 3 Cable Layig at Tunnel

Manhole cable drum Duct
telephone Manhole
caterpillar cable
telephone
control panel cable drum tension meter
caterpillar winch car

control panel winch car

pulling wire
operator pulling eye

operator

Manhole Duct
cable Manhole
Manhole Duct
cable Manhole tension meter

tension meter

pulling wire
pulling eye
pulling wire
pulling eye

14
2.4.3 Cable tray
2.4.3.1 Tray design
a. Cable tray design should be based upon the required loading and the maximum spacing between supports. Loading
calculations should include the static weight of cables and a concentrated load of 890 N (200 lb) at midspan. The
tray load factor (safety factor) should be at least 1.5 based on collapse of the tray when supported as a simple beam.
b. When the ladder-type tray is specified, rung spacing should be a nominal 22.9 cm (9 in). For horizontal elbows, rung
spacing should be maintained at the center line.
c. Design should minimize the possibility of the accumulation of fluids and debris on covers or in trays.

2.4.3.2 Tray system design

a. In general, vertical spacing for cable trays should be 30.5 cm (12 in), measured from the bottom of the upper tray to
the top of the lower tray. A min. clearance of 22.9 cm (9 in) should be maintained between the top of a tray and
beams, piping, etc., to facilitate installation of cables in the tray.
b. Cables installed in stacked cable trays should be arranged by descending voltage levels, with the higher voltage at the top.
c. When stacking trays, the structural integrity of components and the pullout values of support anchors and attachments
should be verified.

2.4.3.3 Tray application

The usual materials from which the tray is fabricated are aluminum, galvanized steel, and fiberglass. In selecting ma-
terial for trays, the following should be considered:
a. A galvanized tray installed outdoors will corrode in locations such as near the ocean or immediately adjacent to a cooling
tower where the tray is continuously wetted by chemically treated water. If an aluminum tray is used for such applications,
a corrosive-resistant type should be specified. Special coatings for a steel tray may also serve as satisfactory protection
against corrosion. The use of a non-metallic tray should also be considered for such applications.
b. For cable trays and tray supports located outdoors, the effect of the elements on both the structure and the trays should
be considered. Aluminum alloys 6061-T6, 6063-T6, and 5052-M34 are acceptable, with careful recognition of the
differences in strength. Mill-galvanized steel should normally be used only for indoor applications in non-cor rosive
environments. Hot-dipped galvanized-after-fabrication steel should be used for outdoor and damp locations.
c. Consideration should be given to the relative structural integrity of Al vs. steel tray during a fire.
d. When the galvanized surface on the steel tray is broken, the area should be coated to protect against corrosion.

2.4.3.4 Tray load capacity

a. The quantity of cable installed in any tray may be limited by the structural capacity of the tray and its supports. Tray
load capacity is defined as the allowable weight of wires and cables carried by the tray. This value is independent of
the dead load of the tray system. In addition to and concurrent with the tray load capacity and the dead load of the tray
system, any tray should neither fail nor be permanently distorted by a concentrated load of 890 N (200 lb) at midspan
at the center line of the tray or on either side rail.
b. A percentage fill limit is needed for randomly filled trays because cables are not laid in neat rows and secured in
place. This results in cable crossing and void areas, which take up much of the tray cross sectional area. Generally, a
30% to 40% fill for power and control cables and a 40% to 50% fill for instrumentation cables is suggested. This will
result in a tray loading in which no cables will be installed above the top of the side rails of the cable tray, except as
necessary at intersections and where cables enter or exit the cable tray systems.
c. The quantity of cables in any tray may be limited by the capacity of the cables at the bottom of the tray in order to
withstand the bearing load imposed by cables located adjacent and above. This restraint is generally applicable to
instrumentation cables, but may also apply to power cables.
2.4.3.5 Cable tray installation

• Dropouts
a. Drop-out fittings should be provided when it is required to maintain the minimum cable bending radius.
b. Where conduit is attached to the tray to carry exiting cable, the conduit should be rigidly clamped to the side rail.
When conduit is rigidly clamped, consideration should be given to the forces at the connection during dynamic (seismic)
loading of the tray and conduit system. Conduit connections through the tray bottom or side rail should be avoided.

• Covers
a. Horizontal trays exposed to falling objects or to the accumulation of debris should have covers.
b. Covers should be provided on exposed vertical tray risers at floor levels and other locations where possible physical
damage to the cables could occur.
c. Where covers are used on trays containing power cables, consideration should be given to ventilation requirements and
cable Ampacity derating.

• Grounding
Cable tray systems should be electrically continuous and solidly grounded. When cable trays are used as raceways for
solidly grounded or low-impedance grounded power systems, consideration should be given to the tray system Ampa-
city as a conductor. Inadequate Ampacity or discontinuities in the tray system may require that a ground conductor be
attached to and run parallel with the tray, or that a ground strap be added across the discontinuities or expansion fittings.
The ground conductor may be either bare, coated, or insulated, depending upon metallic compatibility.

• Identification
Cable tray sections should be permanently identified with the tray section number as required by the drawings or construction
specifications.

• Supports
The type and spacing of cable tray supports will depend on the loads. Tray sections should be supported near section
ends and at fittings such as tees, crosses, and elbows.

• Location
Trays should not be installed in proximity to heating pipes and other heat sources.

2.4.4 Special laying

In case cables are installed in special places where there are bridges or railways, special laying methods are employed
as follows:
1. When a cable crosses a river or canal, cables are attached to the bridge. If there is no suitable bridge in the neighborhood,
an exclusive bridge should be built or a method of submarine laying should be adopted. As long as the strength and
space of the bridge permits, it is best to attach the cables to the bridge. Whether it is better to build an exclusive
bridge or to lay submarine cable depends on the cost and difficulty of construction.
2. In case of crossing a railway, there are two methods; one is digging through the railway bed, and the other is piercing
from the side of the railway by using an excavator, when the cable crosses many tracks like a surface from railroad
or suburban railway, digging the railway bed is usually adopted. Except for the above case, piercing by using an
excavator is adopted.

16
Splicing

3
3 - SPLICING
These general guidelines are offered for splicing cables 6 kV and higher. However, because of the variety of cables
and methods of splicing, they are not intended as a detailed set of instructions. Most contracting companies have in-
structions for specific cable constructions and the type of splice being used, and these instructions are to be followed.
There are many different splices available, such as: pre-molded rubber, heat shrink, cold shrink, resin, and tape. This
section will cover the basic requirements for splicing insulated copper or aluminum conductors up to 69 kV (using
any of the above methods): shielded and non-shielded; single and three conductor; thermoset, thermoplastic, or paper
insulated; lead, thermoset, or thermoplastic covered and/or jacketed.
The objective is to make a joint in a power cable that is electrically equivalent to the cable. To achieve this objective,
the following conditions are necessary to properly prepare the cable and install the joint:
a. Tools should be in first class condition—clean, dry and sharp.
b. Strict adherence to instructions, dimensions, cleanliness, and freedom from contamination are to be followed.
c. The materials used in the fabrication of the joint must be compatible with the cable materials and be new and clean.
d. The materials used for re-jacketing the splice should be suitable for the environment.

3.1 Solid Dielectric Insulated Cable

3.1.1 Removal of cable jacket and shield
a. The non-metallic jacket should be removed by ring cutting and slitting. In this case, it will be necessary to cut further than halfway
through the jacket. Extreme care must be exercised in sheath and jacket removal not to damage the underlying layers. Also,
extreme caution on removing the extruded semiconducting material from the cable should be exercised. The ring cutting should
not go into the insulation.
b. The length of the jacket removed should be in accordance with the manufacturer’s instructions for the splice being used.
c. The metallic shield and semiconducting layer of the cable should be removed in accordance with the manufacturer’s instructions
for the splice being used. It is very important to remove all of the semiconducting material from the cable insulation and do not
leave any cuts or gouges in the exposed cable insulation. Sometimes an abrasive cloth is required to remove all of the semiconducting
material from the cable insulation. The abrasive cloth must contain no conductive particles and should have a fine grit of between
100 and 150, with 120 normally being used. The exposed cable insulation surface should be cleaned with a cable cleaner
approved by the cable manufacturer.

3.1.2 Placing connectors

a. Connectors are available in several types, among which are welded, soldered, compression, and indent. Most types
are suitable for copper conductor with thermosetting insulation. When compression or indent type connectors are
used with aluminum conductors, the connectors should contain an oxide inhibitor compound.
b. Remove the cable insulation from each cable end a distance as specified in the manufacturer’s instructions. The
distance will typically be half the connector length plus an additional length for growth of the connector. Copper
connectors will grow very little, but aluminum connectors will grow more.

3.1.3 Preparation of joint for insulation

a. If a pre-molded rubber, heat shrink, or cold shrink splice is being used, the components must be slid over the conductor
on the cable before the connector is compressed on the conductor.
b. For most tape splices and some other splices, it is necessary to ‘‘pencil’’ the factory-applied cable insulation. The pencil
length should be approximately six times the thickness of the cable insulation. The pencil can be applied with either a
penciling tool or a knife and abrasive cloth. The pencil surface should be as smooth as possible without gouges or cuts.
The pencil and the exposed cable insulation should then be cleaned with a cleaner approved by the cable manufacturer.
c. Once the cable has been prepared to the splice manufacturer’s specifications, the connector should be crimped or
otherwise connected to the cable. Any sharp burrs occurring on the connector should be removed. If oxide inhibitor
is used all residual inhibitor compound must be removed.

3.1.4 Insulating the joint

a. If a pre-molded rubber splice is being used, it can now be properly positioned on the cable. This shields the connector,
insulates the joint, and continues the cable insulation shield across the splice. Silicone grease provided with the splices
must be liberally used.
b. If a heat shrink resin or cold shrink splice is being used, it can now be positioned and installed as per manufacturer’s
instructions to shield the connector, insulate the joint and continue the splice insulation shield to the cable insulation
shield on both sides of the splice.

18
c. If a tape method is used to insulate the joint, the manufacturer’s instructions should be followed. The conductor
shield will be installed over the connector and slightly onto the pencil, using semiconducting tape. Apply the
semiconducting tape as smoothly as possible so there are no abrupt dimensional changes. Over this use high-voltage
insulating rubber tape. Stretch the tape to a minimum of 80% of its original width while wrapping with smooth half-lapped
layers. Continue installing the tape to the dimensions as specified by the manufacturer.

3.1.5 Shielding of the insulated joint

a. Pre-molded, heat shrink and cold shrink joints typically have a semiconducting layer on the outside of the splice.
This layer overlaps the cable semiconducting layer on both sides and shields the joint.
b. Resin and tape splices for shielded cable joints typically require a layer of semiconducting tape installed with a 2.5 cm
(1 in) overlap onto the cable semiconducting layer on both sides of the splice.
c. The cable metallic shield is then continued over the joint. The joint metallic shielding should match the fault current
capacity of the cable shield. If an external ground is to be attached to the cable shield at this joint, care must be taken to
keep water out of the splice. Where the ground exits the splice and the protective covering, mastic or some similar
material must be used to keep moisture from running down the ground into the splice. If the ground leaving the splice
is not a solid strap or solid bare conductor, the ground must be solder blocked either at the factory or in the field to
prevent moisture ingress through the strands of the external ground.

3.1.6 Protective covering

The cable and splice metallic shield should be insulated and protected from cable jacket to cable jacket with a covering suitable
for the environment. The covering of a joint should be of a material similar to the cable jacket. All sharp points should be remo-
ved before any jacket is installed. For cold shrink and heat shrink jackets, they should be positioned to overlap the cable jacket
and installed as per manufacturer’s instructions. For a tape cover, the covering tape should be applied in half-lapped layers to a
thickness equal to or slightly greater than the cable jacket and onto the existing cable jacket for approximately 3.7 cm (1.5 in) on
each end. For cables with a moisture-impervious layer, re-jacketing should employ a moisture-impervious layer also.

3.2 Lead Sheathed Cable

There are several types of lead sheathed cables. Some cables with extruded insulation have lead sheaths. These cables
will not be discussed here. This section will refer specifically to oil impregnated paper insulated cables with a lead
sheath. Special consideration must be given to these cables in removal of the lead sheath and making of the joint.
Environmental and health considerations must be taken into account when dealing with these cables.

3.2.1 Removal of the sheath

The joint manufacturer’s installation instructions should be followed to determine the amount of lead sheath to remove.
The lead sheath is then ring cut at this location, about halfway through the lead. Typically the lead is then removed by
using a ‘‘chipping knife’’ and a hammer. The chipping operation is begun at the cable end and worked toward the ring
cut. The chipping knife is held parallel to the paper insulation and shield and does not damage or nick the papers. The
lead is then torn off at the cutback point, leaving the end of the remaining lead slightly ‘‘belled’’. For most splices, the
lead is ideally not belled, but they can handle whatever belling occurs during removal of the lead sheath.

3.2.2 Making the lead joint

The joint can be insulated by any one of several different methods.
a. The joint can be taped or insulated with a poured hot compound. In either of these cases, a lead sleeve is typically
slid over the joint, centered, and the ends of the sleeve beaten down snugly against the cable sheath. Scrape all wiping
surfaces clean, and apply stearine flux to the wiping surfaces and paper pasters to limit the wiping area. Make the
wipes by pouring molten lead onto the wipe area. As the solder becomes plastic on cooling, the solder is worked by
wiping with a cloth pad. This process is continued until a leak free, tight joint is affected at each end of the lead
sleeve. Tape is applied before this lead sleeve is installed. The hot compound is poured after the sleeve is installed, by
cutting two notches into one end of the sleeve. The hot compound is poured into the lower notch, while the upper one
is used as a vent. Once the compound is poured, the notches must be soldered back closed.
b. Pre-molded, heat shrink and cold shrink joints can also be used on PILC cable, after a means of stopping the oil is
applied. By stopping the oil from leaking out of the cable, the cable is effectively transformed into a polymeric
equivalent cable and can then be treated as such. The same basic components associated with each means of insulating
a joint on a shielded polymeric cable can now also be used on this PILC cable with the oil stop system on it. In all
cases, follow manufacturer’s instructions.
 Terminating

20
4
4 - TERMINATING
Cable terminations are required when connecting insulated shielded power cables to other conductors such as a bus
bar or un-insulated overhead lines. When a shielded power cable is ended or terminated, and the outer cable shield is
stopped on the cable insulation, there is a very high concentration of stress at this point. These terminations must contain
a method of controlling this high stress (stress cone or stress grading material), an outer non-tracking surface, and
a means of providing an environmental seal to prevent moisture ingress. There are many different types of terminations
available, such as pre-molded rubber, heat shrink, cold shrink, and tape.
For non-shielded cable, environmental sealing of the connector to the jacket is advantageous to keep out water, and an
outer insulating non-tracking covering will minimize the possibility of a failure due to surface discharge.

These general guidelines are offered for terminating cables. However, because of the variety of cables and methods of
terminating, they are not intended as a detailed set of instructions. Most manufacturers have instructions for specific
cable constructions and the type of termination being used, and these instructions are to be followed.

The objective is to make a termination in a power cable that is electrically equivalent to the cable. To achieve this
objective, the following conditions are necessary to properly install the cable and the termination:
a. Tools are to be in first class condition clean, dry and sharp.
b. Strict adherence to instructions, dimensions, cleanliness, and freedom from contamination are to be followed.
c. The materials used in the fabrication of the termination must be compatible with the cable materials and be new and clean.

4.1 Cable Preparation

The removal of the cable jacket and shield, the preparation of the cable end for the termination, and the installation
of the lug are all the same operations as for splices. The guidelines for preparing the cable as outlined in 4.1.1, 4.1.2,
and 4.1.3 should be followed. For exact removal and installation dimensions, the manufacturer’s instructions should
be followed for the type of termination selected and the cable being used. Again, note that it is extremely important to
remove the entire black semiconducting layer from the actual cable insulation before installing the termination.

4.2 Installation of Terminations

a. If a pre-molded rubber termination is being used, it can now be properly positioned on the cable. Follow manufacturer’s
instructions for installation and environmental sealing of the termination.
b. If a cold shrink or heat shrink termination is being used, it can now be positioned and installed as per manufacturer’s
instructions. Also, follow the instructions to make sure that the termination is environmentally sealed.
c. If tape is used to make a termination, the manufacturer’s instructions should be followed and similar practices should
be followed that were outlined in 4.1.4.
d. For methods of terminating shielded cable, some form of stress relief is used, either a stress cone or stress grading
material. Proper positioning of these is critical for the termination to perform properly. The high stresses occur where
the cable insulation shield ends, and the positioning of the termination is critical relative to the end of the insulation
shield. If the termination contains stress grading material, it must be in contact with the insulation shield and extend
onto the cable insulation. If the stress grading material is not in contact with the cable shield semiconductor, then the
termination will fail.
e. For cable terminations installed within enclosures, it is important that the required minimum air clearances are maintained
between phases and ground.
f. Sufficient space should be allowed to properly train cables without exceeding appropriate bending radius.
g. When connecting terminations to insulated bus bar, it is recommended that the exposed metallic connections be
reinsulated.
h. The connection from the shield to ground at the cable termination should be of sufficient size to match the shield
fault current capability.
NOTES

22
For catalogue soft copy scan QR code MKT_120342_Cables Instl_Oct19_01

www.alfanar.com