MEDIUM VOLTAGE POWER CABLE

TERMINATION AND SPLICING

CH Asia World of Electric Inc.

By:
Carlo N. Candelaria, REE
 Voltage Classification
(IEC 60038)
 Low Voltage
 Up to 1000V

 Medium Voltage
 1000V to 35kV

 High Voltage
 35kV to 230kV

 Extra High Voltage

 Above 230kV
Power Cables
- an assembly of one or more
electrical conductors, usually held together
with an overall sheath. The assembly is used
for transmission of electrical power. Power
cables may be installed as
permanent wiring within buildings, buried in
the ground, run overhead, or exposed.
General Construction of Power Cables
Conductor Screen or Strand Shield
SEMI-CONDUCTING LAYER
Act as “Faraday Cage” to shield the insulation from
air surrounding the conductors strands
The definition of a semiconductor is a material
that is neither a good conductor or a good
insulator but that conducts more electricity when
heat, light or voltage is added.

Strand Shield (semiconductor)

a.) prevent partial discharge
between conductor air gaps.
b.) Serve as a transition
between conductive and non-
conductive material
 Insulation
Intended to contain the voltage

 PILC – Paper Insulated Lead Covered

 XLPE – Cross-Linked, Poly Ethylene

 EPR – Ethylene Propylene Rubber

 Insulation Shield
(Semi-conducting Layer)
 Eliminates the problem of air voids between
the insulation and metallic components

“ Short-outs the air that undelies metallic shield,

preventing corona effect and its resultant ozone
damage.”
 Insulation Shield
(Metallic Shield)

FUNCTION
 To confine the dielectric field within the cable
 To obtain symmetrical radial distribution of Voltage
Stress within the dielectric
 To limit radio interference
 To reduce the hazard of shock
 To provide return for short circuit current in the event
of a cable failure
 For concentric neutral cables, to provide a neutral
return path
Insulation Shield

Copper Tape or
Copper Wire
(Metallic Shield)

Semi-conducting layer
- Act as transition from non-
conductive to conductive layer
 Non-shielded Cable
(High Stress Concentration)

Electric Flux
Lines

Metallic
Conduit
Shielded Cable (Even
Stress Distribution)

Electric Flux Lines

 Jacket
(Sheath)
 Intended to provide • Rubber (e.g. Neoprene)
physical protection • Jacket
Thermoplastic (e.g.
and keep moisture PVC)
out of the cable • Lead

Common Types
 QUESTION???
Regarding POWER CABLES?
TERMINATION
 To terminate a shielded power cable means to
discontinue; or putting an end to an insulation
shield.

Class of Termination
1. Class 3 – Stress Control
2. Class 2 – Stress Control, insulator for tracking protection
3. Class 1 – Stress Control, insulation for tracking
protection, seal to external environment
(IEEE Standard 48)
1. Stress Control
Electrical Stresses Generated Inside a
Cable
 Types of Stress Control
 Geometric Stress Control (Stress Cone)
 Capacitive Stress Control (Dielectric High-K)

High-K (high dielectric constant)

material is used
to reduce stress at the shield
discontinuity by
field refraction due to different K
values of
two adjacent dielectric layers.
 Hi – K Stress Control
TRADITIONAL HIGH-K
STRESS CONE (CAPACITIVE)
TERMINATION STRESS CONTROL
TERMINATION
 Example: (ATI Manila – Thermal Scanning)
Before
After
 2. External Leakage Insulation
(Between Conductor & Ground)
FLASHOVER PROTECTION TRACKING PROTECTION

BIL per (IEEE 48)

THE
INSULATOR
 TRACKING

Three Conditions Must Exist:

• CONTAMINATION • MOISTURE
- Dust - Humidity
- Chemicals - Fog
- Salt - Condensation
- Other Airborne Particles - Mist
- Snow
• VOLTAGE - Rain
- Surface Stress (V/mil)
DISCHARGE
FORMATION Surface Resistance
Reduced When Wet

DRY BANDS
(Areas of Higher
Surface Resistance)
ELECTRICAL
&
DISCHARGES
Concentrated
Voltage Gradient (Generated in
Dry Band Areas)
 Ways To
CONTROL TRACKING

1. Increase Distance from HV to Ground

2. Rain Shed (Insulator Skirts)

3. Track Resistant Materials

- Porcelain
- Inorganic Fillers in Rubber
- Inorganic Fillers in EVA
Ethylene-vinyl acetate(Heat Shrink)

- Silicone Rubber
Advantages of Silicone Rubber as
INSULATOR MATERIAL

1. Silicone is Hydrophobic

2. Silicone Can Recover Its Hydrophobicity

3. Silicone is Inherently UV-Stable

4. Silicone is Mostly Inorganic --

(No Conducting Carbon Path)

5. Silicone Has a Smooth Surface

 Examples
HYDROPHOBIC & HYDROPHILIC
SILICONE RUBBER PORCELAIN

Hydrophobic Hydrophilic
(Water “Balls-up”) (Surface “Wets”)
 HYDROPHOBIC
VS
HYDROPHILIC

HYDROPHOBIC HYDROPHILIC

Contact Angle

Water “balls” up Surface “wets” out

Energy from leakage current can cause
insulator surfaces to become hydrophilic
SILICONE RUBBER INSULATOR
Coated with ASTM D-2132 Contaminant

Surface remains “Hydrophobic”

 EPDM INSULATOR

UV Damage

Ethylene Propylene Diene Monomer (EPDM)

 SUMMARY and CONCLUSIONS
• Silicone Insulators are superior to EPDM, EVA and
porcelain insulators
• Silicone is more hydrophobic than other polymers or
porcelain
• Silicone has the ability to regenerate its hydrophobicity
in the event that high-leakage current changes its state
• Silicone Insulators are inherently stable to UV due to
its high backbone bond energy
• Silicone Rubber Terminations - In use 30+ years
with excellent results
3. Seal to the External Environtment

Top Seal Potting

(Conductor Seal) Compound

Bottom Seal
(Jacket Seal)
SEALING
with
TAPE
POTTING
with
RESIN
 SEALING
with
HEAT SHRINK
 SEALING
with
COLD SHRINK
 Types of Termination
 Live Front Termination –
Expose live parts of
termination

 Dead Front Termination

– Seals live parts of
termination
 Termination Technologies
 Tape Termination

 Porcelain (Forced Fit) Termination

 Cold Shrink Termination

 Heat Shrink Termination

 Tape Termination

 Electrical Semi-conducting tape

 Scotch No. 13 Tape

 Liner less Rubber Splicing Tape

 Scotch 130C Tape

 Vinyl Electrical Tape

 Scotch Super 33+ ™

 Electrical Stress Control Tape

 Scotch 2220 Tape
 Porcelain (Forced Fit) Termination
Other Types
COLD SHRINK TERMINATION
 Examples of Silicone Rubber
COLD SHRINK TERMINATIONS
Joslyn JPT & 3M™ QT-II Termination 3M™ QT-III Termination
Plymouth/Bishop ColdTerm Integrated 1-Piece
Plymouth Joslyn
Silicone Silicone
Tape Tape
Top Seal Top Seal

Silicone
Silicone
Grease
Grease

Pull Tabs
 Examples of Silicone Rubber
COLD APPLIED (Shrink) TERMINATIONS
Raychem TFT
“Holdout” Tube

VITAL STEP: Loosen

termination by twisting
until it moves on holdout

Twist & slide off of

holdout tube onto cable

Adjust into final

position if necessary

Use pull tabs to

position over jacket
Typical Cold Shrink Termination
INSTALLATION

Apply mastic
seal around jacket
& neutral wires

Apply silicone
grease to fill
semi-con step
Install termination
by removing
supporting core

Complete top seal

with application
of silicone rubber
tape
 COMPLETED
TERMINATION(S)

Outdoor Termination
(With Skirts)

Indoor Termination
(Tubular, without Skirts)
HEAT SHRINK TERMINATION
 Example of
HEAT SHRINK TERMINATION

Raychem HVT
Heat Shrink Termination
INSTALLATION

(1)
Stress Relief
Material
(Semi-con Step
Filler)

(2)
Stress Control
Tube
(Special Torch,
“Bushy” Flame)
 (3)
Top Seal

(4)
Jacket
Seal
 (5)
Separate
Insulator
Tube
Allow Tube
To Cool (6)
Before Separate Shrink
Proceeding Insulator Evenly
Skirts With no
Tilt or Sag
 COMPLETED
TERMINATION(S)

Outdoor Termination
(with skirts)

Indoor Termination
(same, but without skirts)
 INVERTED
Outdoor Termination
BUILT-IN COMPOUNDS:

• HI-K SEALING COMPOUND

Eliminates silicone grease at
semi-con cut-back step

• SILICONE SEALING COMPOUND

No (inverted) bottom seal taping required
 BENEFITS of COLD SHRINK

• No Tools for Installation

• Low Installation Force

• Good Interfacial Pressure
• Live Seal

• Broad Application Range

• Environmentally Stable Materials

SPLICING
 DEFINITION

A Splice can be defined as two or more

conductors joined with a suitable
connector, reinsulated, reshielded and
rejacketed with compatible materials
applied to a properly prepared surface.
ELECTRICAL STRESS
 Functions of
MEDIUM VOLTAGE SPLICES
• Control Electrical Stress in Connector Area

• Insulate Between Voltage and Ground

• Maintain Metallic Shield Continuity
• Provide Protection from Impact and Moisture
• Provide for a 30-40+ Year Service Life
• Provide Resistance to Acidic & Alkaline Soil
 Common Steps for
POWER CABLE SPLICING

1. Properly Prepare Surface

2. Join Conductors with a Connector
3. Reinsulate
4. Reshield
5. Rejacket
 Common Methods of
SPLICING
TAPE

PUSH
ON
MOLDED PUSH-ON
HEAT
SHRINK
HEAT
SHRINK

COLD
SHRINK
 Common Methods of
SHIELDING THE CONNECTOR AREA
SEMI-CON “GRADING”
TAPE
EXAMPLE SPLICE

CAPACITIVE (HI-K) “GRADING”

HEAT SHRINK
EXAMPLE SPLICE

CONDUCTIVE “ELECTRODE”

EXAMPLE

(“Faraday Cage” Effect) MOLDED SPLICE

Common Methods & Materials for
RE-INSULATING
EPDM
EPR MOLDED
RUBBER PUSH-ON
SPLICING
TAPE

EVA
HEAT SHRINK

SILICONE RUBBER
COLD SHRINK
 Common Methods of Semi-Con
RE-SHIELDING
HEAT SHRINK
SPLICE
INSULATION
SHIELD

Semi-Conducting H.S. Tube

TAPE SPLICE
MOLDED RUBBER SPLICE

Semi-Conducting
Tape
Integral Molded
Semi-Conducting Jacket
 Common Methods of Metallic
RE-SHIELDING

Braided Shielding Sleeve

Shielding Tape (or Shielding Sock)

Ground Strap Jumper

Concentric Neutral Wires

(from Original Cables)
 Common Methods of
RE-JACKETING
Rubber & Vinyl Tapes Heat Shrink
Resin

Molded
Armorcast™
Semi-Conducting Rubber
Mechanical Protection
Cold Shrink
 GROUNDING

?
• The shielded cable system must be grounded!
• There are many engineering & safety considerations
for determining where & how many times to ground.
• A splice does not necessarily have to be a grounding
location.
• Splice manufacturers generally provide a method for
grounding (for use if the splice is to be grounded).
Molded Rubber
Push-on Splice
 Typical
MOLDED RUBBER SPLICE
SEMI-CONDUCTIVE EPDM
ELECTRODE INSULATING RUBBER
(Replaces Cable Strand Shielding) (Replaces Cable Insulation)

SEMI-CONDUCTING
JACKET
(Replaces Cable Insulation Shield & Jacket)
 Examples of
PUSH-ON MOLDED SPLICES

Cooper EZ II

Elastimold PCJ

3M QS-II
 PUSH-ON EPDM RUBBER SPLICE

+ Less Installation Time than Tape Splice

+ Production Tested Splice Body

- Installation Force to Push on Splice

- Parking Position on Prepared Cable (Non-symmetrical cutbacks)
- Limited Application Range
- Special Connector Required
- EPDM - Rigid in Cold Weather
- Must Know Cable Details
Heat Shrink Splice
 Typical
HEAT SHRINK SPLICE
Stress Relief
Material

Splice Tube
Insulation
Sealant &
Insulation Shield
Semi-con
 Example of
HEAT SHRINK SPLICE

Raychem HVS
 Heat Shrink Splice
INSTALLATION
Step 1 Step 2

Park Tubes on Cable Connect

Step 3 Step 4

Stress Relief Material Stress Relief Material

Step 5 Step 6

Black Stress Control Tube Red Insulating Tube

Step 7 Step 8

Red Sealant Black/red Dual Layer Tube

Step 9 Step 10

Ground Braid Shielding Mesh

Step 11 Completed Sp
lice

Rejacketing
Tube
 HEAT SHRINK SPLICE

+ Less Installation Effort and Time than Tape Splice

+ Wide Application Range (Easy Size Transitions)

+ Symmetrical Cutbacks

- Parking Position on Cable Jacket

- Torch Required (Permit required or Torch not allowed)
- Applying Heat Properly
- Must Know Cable Details
Cold Shrink Splice
 Typical
COLD SHRINK SPLICE
SEMI-CONDUCTIVE SILICONE
ELECTRODE INSULATING RUBBER
(Replaces Cable Strand Shielding) (Replaces Cable Insulation)

SEMI-CONDUCTING
INSULATION SHIELD
(Replaces Cable Insulation Shield)
 Example of
Cold Shrink “EPDM RUBBER” Splice
Pirelli Elaspeed
Cold Shrink Jacket
Spiral Core Pull Straps

Installed

Cut & Remove

Straps
Cold Shrink “EPDM RUBBER” Splice

+ Less Installation Effort

+ Wide Application Range (Easy Size Transitions)
+ Symmetrical Cutbacks
+ Constant Pressure on cables/connector

- Parking Position on Cable Jacket

- EPDM does not shrink well in Cold Weather
- Possibility for Core Hang-up
- Must Know Cable Details
 Example of
Cold Shrink “SILICONE RUBBER” Splice

Installed

(With Cold Shrink Jacketing)

 Cold Shrink Silicone Rubber Splice
INSTALLATION
Park Jacketing Tube(s) Park Splice Body

Step 1 Step 1 Continued)

Connect Apply
Red Compound

Step 2 Steps 3 & 4

 Install Splice Body Connect Neutrals
(not shown)

(Shield Sleeve
for shielded cable
Step 5 Shown) Step 6

Rubber Mastic Position

Jacketing Tube

Step 7 Step 8
 Install
Jacketing Tube

Step 9 Completed Splice

 Cold Shrink “SILICONE RUBBER” Splice

+ Less Installation Effort

+ Wide Application Range (Easy Size Transitions)
+ Symmetrical Cutbacks
+ Constant Pressure on cables/connector
+ Silicone Material shrinks well in all weather and is flexible
+ Production Tested Splice Body

- Parking Position on Cable Jacket

- Possibility for Core Hang-up
- Must Know Cable Details
 SPLICING SUMMARY
• A “splice” may be considered as the reconstruction of a short
section of cable - For proper splice selection, “match the cable”!
• Good cable preparation is critical for a reliable splice installation !

• For most installations where the cable details are known, modern
molded and shrink type splices may be used for reliability,
simplicity and fast installation.
THE END
Thank You for Listening!

QUESTIONS???