TRANSMISSION & DISTRIBUTION Centre RUD Splicing 1 Book 2/20. RUD... · 2005. 3. 30. · It is...

�T R A I N I N G

M A N U A L1 2 / 1 7 / 9 8

RUDSplicing

Training Development Centre

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RR U D S P L I C I N G

OBJECTIVE:Given an underground cable termination,

instruction sheet, cable preparation toolsand #2 primary cable, you will be able toperform one of the three terminationsshown in this module.

WHY?As a lineman, it is important to know the

proper use of all tools and equipment used inthe line trade for your safety and that of othersaround you.

LEARNING OBJECTIVES:1. Identify the parts of an underground

cable.

2. Recall the minimum bending radius of #2solid 25kV XLPE cable.

3. Prepare a #2 underground primary cablefor one of the three terminations usingthe underground cable preparation tools.

4. Install the Elastimold 25kV elbow.

5. Install the 25kV 3-M Quick-Splice.

6. Install the 25kV Elastimold termination.

PREStart Here

EMDROC UOM

ELEREV

ESR LOSPEC

PARSER

Bonding and

GroundingINT

LINFRM

CSMVEC

UGCSTK

SUR

SPL

DES

RUBCLB

CRPAMP

DEC

PTR

SMN

LADRES

HOTROP HND

CADTEN

Digger Derrick

Basic Electricity

Safety

Line Design & Construction

Tools

RUD

Copyright © 1997 by the Training and Development Centre, SaskPower. All rights reserved. 1 2 / 1 7 / 9 8

IN THIS MODULE:1. Tools and Cable Preparation

2. Installation of Elastimold LoadbreakElbow

3. Installation of 3-M Quick-Splice Kit

4. Installation of Elastimold Terminator

RESOURCES:• Instruction sheet for each splice

ESTIMATED TIME:1 day

PREREQUISITES:• Conductor Splicing and Insulator Ties

module

LEARNING STEPS:1. Cover the module.

2. Complete the Review Questions.

3. Clarify any questions you may have.

4. Complete the Skills Practice.

Copyright © 1997 by the Training and Development Centre, SaskPower. All rights reserved.1 2 / 1 7 / 9 8

Tools and Cable Preparation

Rural Underground CableThe most common underground cable used on 25kV undergroundapplications is #2 solid aluminum conductor, cross-linkedpolyethylene insulation (XLPE), unjacketed concentric neutral.

As illustrated in the above graphic, this cable is made up of:

• Conductor — high voltage current carrying aluminum wire.

• Conductor Shield — semi-conductive material applied to theconductor to produce a complete uniformly sized and smoothsurface.

• Insulation — cross-linked polyethylene used to insulate thehigh voltage conductor from the grounded shield.

• Insulation Shield — semi-conductive material applied to theinsulation conductor to produce a complete uniformly sizedand smooth surface.

• Concentric Neutral — used to ground the semi-conductiveinsulation shield, protect the cable from damage and providereturn path for the circuit.

4 T R A I N I N G M A N U A L .

1 2 / 1 7 / 9 8Copyright © 1997 by the Training and Development Centre, SaskPower. All rights reserved.

Cable Termination FailureOccasionally, cable terminations fail. Some common causes ofcable termination failure are:

• Improper measurements

• Cause improper installation of components leading tonon-uniform electric stress relief.

• Improper cleaning of the insulation

• Causes conductive contaminants to be left on theinsulation.

• Improper removal of semi-conductive insulation shield

• Will leave traces of conductive material on theinsulation.

• Nicking conductor or leaving sharp projections onconnectors

• Causes high stress points. Sharp points cause arcing,which produces corona, which deteriorates the spliceor termination.

• Improper removal of insulation

• (i.e. square cut) can cause high electrical stress points.

• Improper or improperly installed connectors

• Damaged semi-conductive insulation

• Cuts or nicks in the shield or insulation duringinstallation.

• Bending Radius

• Damage caused by bending the cable too sharply, thusflattening the cable. This type of damage could alsobe caused by driving over the cable.

Follow manufacturer’s minimum bending radius: #2 solid ALXLPE cable has a minimum bending radius of 300mm.

R U D S P L I C I N G 5 .

1 2 / 1 7 / 9 8 Copyright © 1997 by the Training and Development Centre, SaskPower. All rights reserved.

ToolsThe following tools are suggested to perform underground cablesplicing:

• Hacksaw

• Insulation remover (speed stripper)

• Measuring tape

• Needle nose pliers

• Preparation/cleaning kits

• Rags

• Semi-conductor remover

• Silicon Lubricant

• Skinning knife

• Small tarp

Insulation Removing Tool (Speed Stripper)



This tool is used to strip cross-linked polyethylene insulation fromprimary cable up to 2 inches in diameter.

• Place the tool on the cable with the cable end toward theblade. Slide the saddle up until it is snug and tighten thelock screw.

• The square cut/spiral cut adjusting screw must be set at the“Square Cut” position on the scale.

• Extend the knife blade to the proper depth of cut by turningthe depth adjusting knob counterclockwise. It is notnecessary to set the blade closer than 1/64 inch to theconductor.

• The spiral cut scale is only relative. The setting of theadjusting screw will vary depending on size, manufacturer,age, and temperature of the cable. Set the adjusting screwfor a spiral cut.

• When the desired amount of insulation has been cut, reducethe blade angle. To do this, back up the speed stripper aboutone-eighth turn. Loosen the adjusting screw and move it tothe “Square Cut” position. Keep pressure on the tool towardthe unstripped cable and turn until the insulation is cut clean.

• Remove the tool from the cable by loosening the saddle lockscrew and opening the saddle.

Remember that the width or thickness of the spiral cut should bebetween 1/16 and 1/8 of an inch to aid in making a clean, squarecut.

It is absolutely vital not to score the conductor usingthis tool.!



Semi-conductor Removing Tool

This tool is used to remove the black semi-conductive insulation.

• Mark the cable at the point to which you wish to remove thesemi-conductor.

• Turn the depth adjusting wheel until the blade is set at theproper depth of cut. The proper depth for each cable shouldbe determined on a piece of scrap cable before doing thefinal cut.

• Set square/spiral lever at “Square Cut.”

• Open the jaws of the tool by turning opening/closing knob sotool can be slipped over the cable.

• With the blade at the point you marked on the cable, turn theopening/closing knob in the reverse direction until the toolfits snugly on the cable. At this point, the tension will be offthe opening/closing knob and it will turn freely.

• Turn the tool around the cable several times to complete theinitial square cut.



• Move square/spiral cut lever to the “Spiral Cut” position.Turn tool around cable until semi-conductor is cut to the endof the cable. Remove the tool. Pry up on the semi-conductor from the end of the cable and peel it from thecable.

Pencilling Tool

• Each tool body handles only one conductor size; but, by useof interchangeable bushings, each body will accept a varietyof insulation thicknesses.

The pencilled edge should be maximum 1/8 inch and even.

When using the semi-conductor removing tool, besure not to score the polyethylene insulation.!



• Penciling is accomplished by rotating the body of the tool(with the blade in place) on the cable until the desired pencilis obtained.

• Apply tool to the cable, turning the tool until the desiredinsulation has been removed. Use minimum pressure on thefinal revolution to obtain the smoothest pencil.

• Smooth any unevenness on the pencil or insulation surfacewith an abrasive cloth.

Insulation/Semi-Conductor PreparationOnce you have removed the proper amounts of semi-conductor andinsulation, you must perform the final step before installing thetermination — and that is cleaning the cable end.

• The insulation can be sanded lightly to remove any particlesof semi-conductor still stuck in the insulation or small nicksor cuts in the insulation. Sanding should not be used toremove large nicks or cuts.

• The next step is to clean the insulation with the cleaningcloth supplied in the preparation kit. Care must be taken notto wipe over the semi-conductor onto the insulation as thiswill bring conductive particles onto the insulation.

• To clean the semi-conductor wipe lightly with a damp clothtoward the unstripped end. Do not wipe too vigorously asthis will remove the conductive particles from the semi-conductor.

• The last step is to apply the silicon lubricant supplied withthe termination kit. Apply according to the instructionssupplied with the termination kit.



Installation of Elastimold Loadbreak Elbow

The loadbreak elbows are used as a loadbreak termination. Theseelbows will break up to 200A of resistive load. The elbow is to beused with an approved hotstick.

Check Contents of Kit• Elbow connector housing

• Compression lug

• Probe

• Probe wrench

• Lubricant (do not substitute)

• Installation/operation instructions

Ensure Correct Elbow Size• The #2 aluminum 25kV elbow should have .760 - .950

stamped on the side of the elbow housing. This indicates theinsulation diameter in inches.



Train the Cable Into Position• In the transformer, train the cable so it is located in the final

assembled position with enough slack to provide adequateclearance for operating. Cut off excess cable.

Cable Preparation

• Unwrap and bind concentric neutral wires 8-1/2 inches backfrom end of cable.

• Remove shield and insulation 1-15/16 inches from the cableend. Cut squarely, taking care not to nick conductor.

The cable should be wound in a clockwise direction in the vault.



• Wire brush conductor and immediately install compressionlug.

• Remove insulation shield a distance of 6-7/8 inches from theend of the compression lug. Bevel the insulation end 1/8inch maximum.

• Position compression lug so the contact threaded hole alignswith the bushing bore. Using an MD-6 and BG dies, startcrimping at the crimp line mark. Make 5 or 6 crimps makingsure not to overlap the crimps. Rotate 180 degrees eachsuccessive crimp. Carefully wipe excessive inhibitor fromthe outside of the lug and cable.

• Thoroughly clean insulation to remove all traces ofconductive residue.



Elbow Assembly

• Lubricate the cable insulation and inside the elbow housingwith the lubricant supplied. Do not substitute. Otherlubricants may be harmful to this product or its matingproduct(s). Keep insulation clean of dirt and grime.

• Slide the elbow housing onto the cable with a back and forthtwisting motion. Wipe off all excess grease.

• Align elbow with compression lug’s threaded hole.

• Remove protective cap from probe. Thread probe into lugby hand, taking care not to cross-thread. Tighten withwrench until wrench bends.



Concentric Neutral Connection

• Insert one end of a No. 14 AWG (2.5mm) copper concentricwire through the grounding eye on the elbow. Twist tight,taking care not to damage eye.

• Twist concentric neutral wires and connect to ground usingappropriate connector. Provide adequate slack in wires forelbow operation.



Install Elbow Onto Bushing

• Lubricate the receptacle portion of the elbow connector andthe mating bushing with the lubricant supplied.

Do not operate by hand.!

Lubricate only if the transformer and elbow are known to be de-energized.



Installation of 3-M Quick-Splice Kit

Occasionally, primary underground cable will be damaged, andthere is a need for a method of repair in the middle of a cable. Suchrepairs require a splice, such as the 3-M Quick-Splice.

Check Installation KitThis installation kit should contain the following:

• 1 - Quick-splice body

• 2 - End caps

• 1 - Splice (conductor contact)

• 1 - Lubricant (Do not substitute)

• 1 - Installation instruction

Check the Quick-Splice body. It should read .795 inch to .940inch (outside insulation diameter).



Cut Cable to Length

• Overlap both cables and cut to 24 inches from centre line ofjoint. This procedure will insure sufficient length ofconcentric neutral wires to be able to rejoin over joint.

• Fix the concentric neutral on one cable at 10 inches from thecentre line of the splice. Unwind the concentric neutral onthe other cable a distance of 17 inches from the centre line ofthe splice. Take care not to bend the wires, as this will makeit difficult to replace them when the splice is completed.

• Cut both cables at centre line of joint.

Prepare Cable• Remove insulation 1-5/8 inches from the end of each cable.

Bevel the end of the insulation to a maximum of 1/8 inch onboth cables. This will make installation of the housingeasier.



• Carefully remove the cable semi-conductive shield a distanceof 5-1/8 inches from the ends of each conductor. Do notnick or cut the insulation or conductor. This could result infailure of the assembly.

• Clean cables.

Install Quick-Splice Body

• In order to facilitate the splice installation, wrap a smallamount of vinyl tape around the edge of the jacket on cableX to form a ramp. This tape must be removed later.

• Lubricate the insulation of both cables with silicone greasesupplied with kit.

• Slide end caps onto their respective cables.



• Lubricate and slide the Quick-Splice body onto cable X.

• Aluminum conductors must be wire brushed andimmediately inserted into the connector. Make crimps usingthe BG die with the MD-6, rotating crimps 180 degrees.

• Remove tape which was installed for a ramp. Relubricatecables.

• Centre splice body over connector.

The space between each end of the Quick-Splice body and thesemi-conductive shield, as shown above, must be a minimum1/16 inch and maximum 1/2 inch. This ensures correct positionof the Quick-Splice body. If the space is outside these figures,the splice must be redone.



Install End Caps

• Firmly seat one end cap against splice body and twist ontosplice body. Two locking grooves exist on the splice body.The workman should feel two snaps.

• Check for correct spacing of the Quick-Splice body, andtemporarily mark the location of the installed end cap.Install the remaining end cap, check for location of theQuick-Splice body, and remove the tape.

Ground the Splice

• Reshape shield wires and secure to ends of joint as shown.

• Insert one of the shield wires from the cable through the jointgrounding eye. Repeat for the other cable.

• Connect joint grounding wires and remaining shield wires,using a YC2C2.



Installation of Elastimold Terminator

Underground cable requires a termination to attach the cable to anoverhead source of energy. The Elastimold terminator is a goodexample of this.

Check Contents of KitThis installation kit should contain the following:

• Terminator housing

• Rod connector

• Two (2) strips of mastic tape

• Lubricant

• Silicone tape

• Installation instructions



Prepare Cable

• Prepare concentric wires for termination.

• Train cable into position, leaving approximately .5metres of cable past the termination point so there willbe enough concentric neutral to use for grounding ofthe termination. Unwrap concentric neutral wires backapproximately .5m. At this point, place a couple ofwraps of PVC tape over the concentric wires to holdthem in place on the cable. Wrap one of the masticstrips over the PVC tape on the concentric wires.

• Separate the unwrapped concentric wires one by one.Once separated, fold them back over the mastic,pressing the wires into the mastic.

• Place the other strip of mastic over the top of thefolded back concentric wires, directly over the firstmastic strip, and squeeze tightly.

• Secure concentric wires at a point, approximately 2inches below the mastic by using one strand andwrapping it around the wires tightly a few times. Twistthe loose concentric wires together to form a groundlead.

• Cut excess cable off 9 inches up from the top of theconcentric wires.

• Remove cable insulation from end of conductor for distanceof 1-7/8 inches.



• Remove semi-con for a distance of 5-7/8 inches from the endof the insulation.

• Bevel the insulation end for approximately 1/4 inches.

Install Connector

• Wire brush the conductor and immediately install the #2 solstem connector. Using an MD-6 with the BG dies, install asmany crimps as possible, starting at the crimp line andworking towards the cable insulation. Rotate the tool 180degrees between crimps.

• Sand burrs or sharp edges off the connector with sandpaper,and clean excess penatrox from conductor and cable.

Clean Cable• Prepare cable using approved methods. Small nicks or cuts

may be sanded out of the insulation if necessary. Cleaninsulation with solvent, ensuring not to drag semi-conparticles onto the insulation.

• Clean connector.

• Lubricate connector and cable with the silicone lubricantprovided.

• Lubricate cable entrance to the terminator housing.



Install Termination

• Grip the terminator housing in the indicated area and slowlyslide it onto the cable.

• Hold the rod connector and pull the bleed tab in the directionshown to release internal air pressure.

• Check to make sure that exposed conductive stress cone isstill flush with the neutral wires. If not, repeat Steps 1 and 2.

Be careful not to puncture a hole in the terminatorhousing as the connector rod enters the sealing ringarea.

!



Complete Termination Installation

• Holding the tabs at the base of the housing, pull the hoodover the sealed area the cable.

• Install the mounting bracket below the bundled concentricwires.



SummaryTo summarize this module, you have learned:

• Parts and characteristics of #2 primary underground cable.

• How to prepare underground cable for the three majorterminations.

• How to perform each of the three major terminations.

Now...

• Complete the Review Questions.

• Clarify any questions or concerns you may have.

• Complete the Skills Practice.



REVIEW QUESTIONS

RUD Splicing

Identify the parts of an underground cable.

1. Using the following list of cable parts as a guide, indicate theparts of an underground 25kV XLPE cable on the followingdiagram.

(a) Conductor

(b) Insulation

(c) Semi-conductive insulation shield

(d) Concentric neutral

(e) Semi-conductive conductor shield

2. State three common causes of underground cable terminationfailure.

This section is a review for your Power Line Apprenticeshipwritten exams. Complete the questions, and verify your answerswith the Review Question Solutions located at the end of thismodule.



3. Match the term in the left column with the description in the rightcolumn.

Recall the minimum bending radius of #2solid 25kV XLPE cable.

4. The minimum bending radius of #2 solid AL XLPE cable is____________ mm.

___ Cross linked polyethylene used to

insulate the high voltage conductor

from the grounded shield.

___ Semi-conductive material applied to

the conductor to produce a complete,

uniformly sized, and smooth surface.

___ Used to ground the semi-conductive

insulation shield, protect the cable

from damage, and provide return path

for the circuit.

___ High voltage, current carrying

aluminum wire.

___ Semi-conductive material applied to

the insulation to produce a complete,

uniformly sized, and smooth surface.

(a) Insulation

(b) Insulation

shield

(c) Conductor

shield

(d) Concentric

neutral

(e) Conductor



SKILLS PRACTICE

RUD Splicing

Prepare a #2 underground primary cable forone of the three terminations using theunderground cable preparation tools.

1. Prepare cable and tools.

___ Measure cable(s) as per instruction sheet.

___ Use insulation stripper to remove insulation and semi-conductor to proper measurements.

___ Use semi-conductor removing tool to remove semi-conductorto proper measurements.

___ Clean and lubricate the insulation and splice or terminationusing proper work methods.

Install the Elastimold 25kV elbow.

2. Install Elastimold elbow.

___ Prepare cable as per instruction sheet.

___ Install conductor connector.

___ Install elbow housing for proper location of threadedconnector.

___ Install male contact using supplied wrench.

___ Secure and prepare concentric neutral.

___ Lubricate elbow.

This section is intended as a practice for your Power LineApprenticeship practical exams. Perform each task, asdescribed, under the direction and observation of a competentperson. They should complete the checklist and give youappropriate feedback.



Install the 25kV 3-M Quick-Splice

3. Install 3-M splice.


___ Install splice housing over cable.

___ Install connector.

___ Centre splice.

___ Ground the splice using concentric neutral and YC2C2.

Install the 25kV Elastimold termination.

4. Install Elastimold terminator.


___ Install #2 sol stem connector.

___ Clean cable in preparation for terminator.

___ Install silicone tape over stem connector.

___ Install silicone grease provided over semi-con cutoff.

___ Install terminator by removing centre strand for core removal.

___ Install silicone tape over lug barrel.

___ Ground terminator and bracket.



1.

2. Any 3 of the following:

Improper measurements.Improper cleaning of the insulation.Improper removal of semi-conductive insulation shield.Nicking conductor or leaving sharp projections on connectors.Improper removal of insulation.Improper or improperly installed connectors.Damaged semi-conductive insulation.Bending radius.

3. a, c, d, e, b

4. 300

REVIEW QUESTION SOLUTIONS

RUD Splicing


Copyright © 1997 by the Training and Development Centre, SaskPower. All rights reserved. 1 2 / 1 7 / 9 8

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