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Wednesday, June 26, 2013

How do I Splice a Medium Voltage Cable?

     How Do I Splice a Medium Voltage Cable?

     Boy, you would really think this was a simple question to answer.  It's not.  The first problem is that there are a number of different types of 'medium voltage' cable; and each can have different components (and thus different splicing requirements).  Let's look through a few of those.

  1. Cable can be 'jacketed' or 'non-jacketed' (explanation here).
  2. Cable can be 1/C or 3/C (explanation here).
  3. Cable can be Armored (or not - explanation here).
  4. Cable can contain 'concentric neutral cables' or 'copper tape shield' (explanation here).
  5. Cable can be designed for anything between 5kV and 35kV.
     There may even be other different cable configurations.  The key though, is that when making a cable splice, the goal is to recreate the structure of the cable in the splice.  So, if your cable is 3/C Armored - then you need to be sure you are purchasing a splice kit which will be able to splice three conductors and be armored.

     As an example here in this post, I will look at the installation steps for splicing a 1/C, jacketed, concentric neutral cable at 25 kV. 

  1. Make sure the HVS Medium Voltage Splice Kit you've purchased is correctly sized for your cable!
  2. Remove the cable jacket to the dimensions shown on the installation sheet.
  3. Fold back the neutral wires on 'side 1' and trim the neutral wires on the other side.
  4. Use a tie wrap to keep unneeded concentric wires out of the way (to avoid damaging them)
  5. Abrade insulation (abrading the PE improves the bond of the HVS)
  6. Place heat shrink tube over cable and then install connector.
  7. Apply SRM at semi conductor cutback (Stress Relief Material)
  8. Apply SRM over connector
  9. Apply Silicone Grease (SG)
  10. Put black stress control tube in place and shrink with a gas torch.
  11. Apply red sealant butted up against the black stress control tube on the semi-con.
  12. Position black/red triple layer tube in place and shrink.  Begin shrinking in the middle and move toward one end of tube.  Then come back to middle and work toward other end.
  13. Connect and splice neutral wires and bend them to splice.
  14. Install shielding mesh by spiral wrapping.
  15. Position the wrap around shrink sleeve and secure the channel (to hold it in place).
  16. Shrink the sleeve.
  17. Congratulations, you've done it! 

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