FAILURE OF CABLE

TERMINATION
A COMMON CAUSE VOLTAGE DIP
IN SINGAPORE

By
LEE WAI MENG
J.M. PANG & SEAH (PTE) LTD

J.M.PANG & SEAH (PTE) LTD

 CONTENTS

• FUNDAMENTAL OF CABLE TERMINATION

• SITE TESTING OF CABLE TERMINATION

• PARTIAL DISCHARGE MEASUREMENT IN

CABLE TERMINATION

• CASE HISTORY OF PREMATURE FAILURE

OF CABLE TERMINATION

JMPS J.M.PANG & SEAH (PTE) LTD CONTENTS

 FUNDAMENTAL OF
CABLE TERMINATION

JMPS J.M.PANG & SEAH (PTE) LTD FUNDAMENTAL OF CABLE TERMINATION

 Armour PVC Copper Semi XLPE copper
PVC outer sheath Screen conducting
screen

CONSTRUCTION OF CABLE

JMPS J.M.PANG & SEAH (PTE) LTD FUNDAMENTAL OF CABLE TERMINATION - 1

 Copper
pp Screen

Cable Insulation

C bl C
Cable Conductor
d t (E (Energized)
i d)

Electric Field
Flux Lines

Uniform distribution of electric field Non uniform distribution of electric field

for screened cable for un-screened cable

JMPS J.M.PANG & SEAH (PTE) LTD FUNDAMENTAL OF CABLE TERMINATION - 2

 LINES OF ELECTRICAL STRESS WITHOUT STRESS CONTROL

30%

80%
40%

50%

90%
60%

70%
20%
Copper Screen

10%
Copper
XLPE
Semi-conducting Screen

LINES OF ELECTRICAL STRESS WITH STRESS CONTROL

20%
30%
40%

60%
10%

50%

70%

80%
Copper Screen

90%
Copper

XLPE
Semi-conducting Screen Stress Control
S C
Tube

JMPS J.M.PANG & SEAH (PTE) LTD FUNDAMENTAL OF CABLE TERMINATION - 3

 30%
50%
70%
10%

90%
Insulator 90% Line

Conductor

Electric field in the

shape of a funnel

Copper Screen
30%
50%
70%
10%
connected to earth

90%

LINES OF ELECTRIC FIELD

JMPS J.M.PANG & SEAH (PTE) LTD FUNDAMENTAL OF CABLE TERMINATION – 4

 deep cut

Armour PVC Copper Semi XLPE copper

PVC outer sheath Screen conducting
screen

Deep Cut At XLPE

JMPS J.M.PANG & SEAH (PTE) LTD FUNDAMENTAL OF CABLE TERMINATION - 5

 Guideline for Stress Control Tube

Length of Stress Control Tube (mm)

Operating Voltage (kV) Single Core Cable Multi-Core Cable

22 190 250

11 130 190

6.6 100 130

JMPS J.M.PANG & SEAH (PTE) LTD FUNDAMENTAL OF CABLE TERMINATION - 6

 SECTION 3: DESIGN & CONSTRUCTION (22kV & 6.6kV TERMINATION KITS)
Design 3.1 The heat shrink, cold shrink or slip over type of Semi-Conductive 3.4 Semi-conductive stress control mastic
t
termination
i ti kits
kit and
d accessoriesi offered
ff d shall
h ll b
be d
designed
i d M ti
Mastic shall
h ll be
b provided
id d ffor th
the iinsulation
l ti semi-
i
for both 185mm² and 300mm² cables described in conducting screen cutback.
Clause 1.1, Section 1 of this specification.

Termination 3.2 To suit the various cable termination heights found in Anti-Track 3.5 The insulation shall be a heat-shrinkable
Height the Company
Company’s s different switchgear and transformer cable Insulation flexible polymeric tubing, easily distinguished
boxes/compartments, the supplier shall provide insulation Sleeve/Tubing by colour from non anti-track material and
sleeves of 800mm and 700mm standard length for the 22kV shall not be coloured black, possessing anti-
and 6.6kV termination kits respectively. track and erosion resistant properties for use
as an external covering of the insulation cable
It shall be possible to cross the cable cores with the
cores.
termination kit installed and for the kit to function normallyy in
this manner. Three-Legged 3.6 Three legged semi-rigid mould glove
Mould Glove shall be provided.

Stress Control 3.3 For heat shrink type of termination, the stress control Earth Braids 3.7 Three lengths of 1000mm tinned copper
g
Tubing tubing
g shall be a flexible p
polymeric
y tubing,
g, p
permanentlyy braids shall be pprovided with each termination
colour black, possessing properties to provide electrical kit for earthing of the metallic tape screen of
stress control over the insulated cable cores. Stress control the cable. The minimum cross-sectional area
tubing incorporating paste like stress-relief compound of each braid shall be 25mm². A copper lug
coated on the inner wall of the tubing will not be accepted. shall be crimped at one end of each braid.
The length of stress control tubing shall not be less than The lug shall be suitable for a bolt size of
250mm and 130mm for 22kV and 6 6.6kV
6kV respectively
respectively. The 12mm
12mm.
stress control tubing shall have the words “Stress Control”
in white printed on it to distinguish it from black coloured LV
heat-shrink tubing.

JMPS J.M.PANG & SEAH (PTE) LTD FUNDAMENTAL OF CABLE TERMINATION - 7

 Breakdown Strength of Insulation

Type of Insulation kV/mn

Oil - paper 40

XLPE 70

Air 3

JMPS J.M.PANG & SEAH (PTE) LTD FUNDAMENTAL OF CABLE TERMINATION - 8

 Method of Air Void Elimination

The following methods can be used to eliminate the air voids

t
tapped
d beneath
b th the
th stress
t control
t l tube
t b att the
th interface
i t f
between the semi conducting screen and the insulation :

• By using mastic tape (new method)

• By using paint (old method)

JMPS J.M.PANG & SEAH (PTE) LTD FUNDAMENTAL OF CABLE TERMINATION - 9

 Types of Cable Termination

• Heat Shrink Type

• Cold Shrink Type

• Slip Over Type

JMPS J.M.PANG & SEAH (PTE) LTD FUNDAMENTAL OF CABLE TERMINATION - 10

 Heat Shrink Type Termination

Vendor:Tyco

JMPS J.M.PANG & SEAH (PTE) LTD FUNDAMENTAL OF CABLE TERMINATION - 11

 Prepare the cable to the required length and
remove the oversheath. The armouring should
be removed according to the dimensions given
or according to the types of glands being used.
used
Remove both the innersheath 75 mm above
armouring or according to the gland type, and
the metal tape shield according to the
dimensions. Then remove the conductive core
screen to 20 mm above the metal tape shield.
The core insulation should be kept clean and
smooth any irregularities should be smoothed
smooth,
out using non-conductive abrasive paper.
Earthing - Fasten the earth braid to the copper
tape screen with one turn of the constant force
spring Fold back the earth braid and wrap the
remaining constant force spring over the earth
braid. Wrap Red HV-adhesive tape SMVA (50%
overlap) for a distance of 90 mm around the
cable jacket and lay the earth tails on top of the
Red HV-adhesive tape SMVA.

JMPS J.M.PANG & SEAH (PTE) LTD FUNDAMENTAL OF CABLE TERMINATION - 12

 Remove any binders from the end of screen and
remove the release paper from the Stress
control mastic SMCM. Place the point of the
tape at the conductive screen cutback, then
stretching the tape to ½ its original width, tightly
wrap 3 - 4 layers to fill the conductive screen
step and create a smooth transition. The tape
should overlap the screen and insulation by 10
mm on either side.

Slide the Stress control tubing SMCT over

each core with a 50mm overlap onto the
screen. Shrink down the tubing using a torch
working from the bottom upwards.

JMPS J.M.PANG & SEAH (PTE) LTD FUNDAMENTAL OF CABLE TERMINATION - 13

 Slide the Breakout SMBH over the cores and
remove any release paper which may be in the
breakout. Pull the breakout out well down into
the crutch and shrink the breakout into place
starting at the centre. First shrink down towards
to the skirt (1), then finally upwards toward the
end of the fingers (2).
(2)

With the cores in the correct position, fit the

connectors
t or lugs.
l Th using
Then i a slight
li ht tension,
t i
wrap the Red H.V. adhesive tape SMVA (50%
overlap) on the lug barrel. Build up the barrel
diameter
d a ete aand
d ooverlap
e ap tthe
e co
core
e insulation
su at o by 20 0
mm.

JMPS J.M.PANG & SEAH (PTE) LTD FUNDAMENTAL OF CABLE TERMINATION - 14

 Wrap one layer of the Red Adhesive SMVA over
each of the breakout turrets.
Slide the Non-tracking g SMVT onto each
g tubing
core. Start shrinking in an upward direction.
The core tubes can thus be trimmed off on the
cable lugs or connectors.

Up to indoor terminations are now complete.

JMPS J.M.PANG & SEAH (PTE) LTD FUNDAMENTAL OF CABLE TERMINATION - 15

 Position the Sheds SMVS according to the
specified dimensions and shrink into position.
Hold the edge of the Shed with a pair of pliers and
brush with flame. Only the collar will shrink.

Outdoor and indoor terminations are now

complete.

JMPS J.M.PANG & SEAH (PTE) LTD FUNDAMENTAL OF CABLE TERMINATION - 16

 Cold Shrink Type Termination

Vendor: 3M

JMPS J.M.PANG & SEAH (PTE) LTD FUNDAMENTAL OF CABLE TERMINATION - 17

 P
Preparation
i for
f Cable
C bl Termination
T i i
Prepare cable using dimension shown in below figure, be sure to allow for depth of terminal lug

Wrap 2 highly stretched half-lapped layers of semi-conducting tape① over the tape shield and
semi-con extending ½″ (13mm) on to cable insulation. Start and end tapping ¾″(19mm) onto tape
shield. Provide a smooth, even leading edge over cable insulation as shown②. Select one of two
Mastic seal strips, provided in kit and remove white liners. Using light tension , wrap a band of
mastic around the cable jacket ½″(13mm) from cut edge③. Cut off excess

JMPS J.M.PANG & SEAH (PTE) LTD FUNDAMENTAL OF CABLE TERMINATION - 18

 Position pre-formed Ground Braids④ along opposite sides of cable jacket and secure in place
with binding wire on vinyl tape as shown in below. Ground Braid Legs⑤ over cable tape shield
should be position ¼″ from jacket cut edge. Lay each Ground Braid Legs⑤ around the cable
shield and trim its length to prevent overlap as needed⑥.
needed⑥

Secure Ground Braid Legs to cable

shield using supplied Constant-Force
spring⑦. Start the spring on one braid
folded section⑧ and wrap p Ground Braid
Legs and spring together in a common
direction. Capture both Ground Braid
Legs while wrapping and cinch the
spring after wrapping the final winding

JMPS J.M.PANG & SEAH (PTE) LTD FUNDAMENTAL OF CABLE TERMINATION - 19

 Select second Mastic Seal Strip from kit and remove white liners. Using light tension, wrap a
band of mastic over the Ground Braids covering the Solder-Blocks and the previously
i t ll d Mastic
installed M ti Seal St i ⑨ Apply
S l Strip⑨. A l one highly-stretched,
hi hl t t h d half-lapped
h lf l d layer
l vinyl
i l tape
t over
Constant Force Spring⑩ and Mastic Seal Strip ⑨. Start tapping ¼″ (½″ Max) over applied
13 Tape⑪, extend over Mastic Seal Strip and finish by covering binding wire or vinyl tape
band⑫ applied in step 1

JMPS J.M.PANG & SEAH (PTE) LTD FUNDAMENTAL OF CABLE TERMINATION - 20

 Position Jacket Seal PST Assembly① over cable jacket with loose core tab② Direct
away from prepared cable end.

Install Jacket Seal PST by pulling loose core pull tab while unwinding counter-
clockwise②. Silicone rubber tube (not the core) should be align with ridge formed by
previously applied 13 tape③.
tape③

JMPS J.M.PANG & SEAH (PTE) LTD FUNDAMENTAL OF CABLE TERMINATION - 21

 Cover the edge of the 13 Tape with a liberal coating of Silicone Grease④.

Slide 8-Skirt Termination Body on to the cable and remove core. Pull while unwinding
counter-clockwise
counter clockwise,⑤ ⑤ starting with the loose end.
end Make sure the termination body
(not the core) is aligned as shown⑥ below.

JMPS J.M.PANG & SEAH (PTE) LTD FUNDAMENTAL OF CABLE TERMINATION - 22

 Position Silicone 4-Skirt Insulator over cable end and install by pulling loose core end
while unwinding counter-clockwise. Align 4-Skirt Insulator (not the core) to overlap
previously installed 8-Skirt
8 Skirt Termination by ¾
¾″(19mm)
(19mm) as shown⑦ below

Install terminal lug per manufacturer’s direction. Wrap 4 half-lapped layers of Silicone
Rubber Tape over the lug and onto the insulator for 1″(25mm)①. If lug is not used,
solder block conductor and wrap 4 half-lapped layers of 70 Tape from the solder block
to 1″(25mm) on to the insulator using “Tapping Hint”

JMPS J.M.PANG & SEAH (PTE) LTD FUNDAMENTAL OF CABLE TERMINATION - 23

 Slip Over Type Termination

Vendor: ABB

JMPS J.M.PANG & SEAH (PTE) LTD FUNDAMENTAL OF CABLE TERMINATION - 24

 Single Core Cable with Copper Tape Screen

• Remove the oversheath,

oversheath according
to dimension A+X below
• Cut of excess length of the core

Size mm2 A

Cu<70 205

Others 185

JMPS J.M.PANG & SEAH (PTE) LTD FUNDAMENTAL OF CABLE TERMINATION - 25

 Remove the copper tape until dimension B+X mm from the edge of the
oversheath
Size mm2 B
Cu<70 175
Others 155

St i back
Strip b k the
th insulation
i l ti and
d XLPE-insulation
XLPE i l ti according
di tot dimensions
di i C+X

Size mm2 C
Cu<70 135
Others 115

JMPS J.M.PANG & SEAH (PTE) LTD FUNDAMENTAL OF CABLE TERMINATION - 26

 • Cut the earth braid in three pieces 0.5m each
• Fasten the earth braid to the copper
pp tape
p screen with one turn of the
constant force spring

• Fold back the earth braid and wrap the remaining constant force spring
over the earth braid

JMPS J.M.PANG & SEAH (PTE) LTD FUNDAMENTAL OF CABLE TERMINATION - 27

 • Apply one layer of filling tape (FT) on the
edge
d off the
h over sheath
h h
• Put the earth braid over and wind remaining
FT tape over all

• Apply two layer of Electrical tape (ET) with

50% over lap
p
• Start 10mm below the FT tape, continue
over the edge of the copper tape screen
and
d 10mm
10 up on the
h insulation
i l i screen off
the cable and back again

JMPS J.M.PANG & SEAH (PTE) LTD FUNDAMENTAL OF CABLE TERMINATION - 28

 • Confirm 30mm
• Make a tape mark 75 mm from the end of the insulation screen
• Apply one of FT tape at the center of the taping

• Wind one layer of ET tape

• Start on the insulation and wind
towards the end of the conductor

JMPS J.M.PANG & SEAH (PTE) LTD FUNDAMENTAL OF CABLE TERMINATION - 29

 • Apply grease over the insulation and spread it by means of the
brush included.
• Use half the g
grease content in tube

• Apply remaining grease on the black

layer inside the bottom end of the
termination.
• Spread the grease by squeezing the
termination

JMPS J.M.PANG & SEAH (PTE) LTD FUNDAMENTAL OF CABLE TERMINATION - 30

 • Push and twist the termination over the cable and the FT tape down
to the tape marking

JMPS J.M.PANG & SEAH (PTE) LTD FUNDAMENTAL OF CABLE TERMINATION - 31

 • Fold
F ld down
d th end
the d off the
th termination
t i ti andd remove the
th tape
t
• Crimp the cable lug on the cable
• M
Make
k a seall by
b wrapping
i a few
f t
turns off the
th FT tape
t over the
th
cable lug

• Fold
F ld back
b k the
h end
d off the
h termination
i i

JMPS J.M.PANG & SEAH (PTE) LTD FUNDAMENTAL OF CABLE TERMINATION - 32