ORIGINAL DOCUMENT APPROVED December 16, 2006

June 19, 2012

June 19, 2012

TRANSMISSION ENGINEERING STANDARD TES-P-104.04, Rev. 01

TABLE OF CONTENTS

1.0 SCOPE

2.0 CABLE SPLICES

2.1 Definitions
2.2 General Requirements
2.3 Routing Cables
2.4 Connectors
2.5 Conductor Connections
2.6 Heat Shrinkable Sleeve
2.7 Phasing of Cable Splices
2.8 Cable End Caps
2.9 Partial Discharge Test

3.0 CABLE TERMINATIONS

3.1 Definitions
3.2 General Requirements
3.3 Precautions in Making Cable Terminations
3.4 Locating Cable Terminations
3.5 Grounding of Cable Terminations
3.6 Partial Discharge Measurement
3.7 Elbow Terminations

4.0 STRESS CONE (FOR JOINTS/SPLICES & TERMINATIONS)

4.1 Definition
4.2 General Requirements
4.3 Locating Stress Cone

5.0 BIBLIOGRAPHY

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TRANSMISSION ENGINEERING STANDARD TES-P-104.04, Rev. 01

1.0 SCOPE

This standard has been prepared as a guide for the splicing & termination of electric
power cables with copper or aluminum conductor that will be used for 0.6/1, 11, 13.8,
33, 34.5, 69, 110, 115, 132, 230 and 380 kV underground cables circuits in the
transmission system of Saudi Electricity Company (SEC) Saudi Arabia.

1.1 General Requirements

1.1.1 All splices & terminations shall meet the requirements of applicable
Saudi Electricity Company Material Standard Specification 12-
TMSS-10, 12-SDMS-01 (latest revision), IEEE-48, IEEE-404 and in
strict compliance with manufacturer’s instructions.

1.1.2 The cable joints & terminations shall also meet the standards of
SASO, AEIC, ICEA, IEC and/or any other internationally recognized
organizations.

1.1.3 All cable joints & terminations shall be installed in a professional

manner with acceptable workmanship by manufacturer certified
jointer/terminator. Before commencement of work all cable splicing
and terminating personnel shall obtain certification (from
manufacturer or SEC) valid for a period of not more than one year
from the date of issue stating that the person has been trained and is
capable of accomplishing the task.

1.1.4 All GIS terminations shall be done under manufacturer’s supervision

and instruction, based on GIS termination drawings and installation
instructions which shall be submitted to SEC for review and
acceptance prior to starting the termination work. Personnel carrying
out the terminations shall posses certificate from mother company
and/or by an independent agency valid for a period of not more than
one year from the date of issue.

1.1.5 The cables splicing and terminating operation shall be performed in a

manner to mitigate the adverse effects of the environmental
conditions specified in 01-TMSS-01 latest revision.

1.1.6. Quality certificate (check list sheet) for each cable joint & termination
shall be filled and signed by the jointer/terminator and shall be
submitted to SEC as part of “final as built record”.

1.1.7 The Manufacturer written confirmation must be provided during the

base design that all cable terminations and joints shall be performed
under direct strict supervision of terminations and joints
manufacturer.

1.1.8 The contractor must insure in writing to Project Department that the
Cable Accessories stored (for manufacturer’s specifed period) are as
per the manufacturer recommendation.
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TRANSMISSION ENGINEERING STANDARD TES-P-104.04, Rev. 01

2.0 CABLE SPLICES

This section covers various types of cable splices for all types and sizes of electric
power cables commonly used by SEC for high and low voltage power transmission.

Cable splices, not covered here shall be made according to the cable manufacturer's
recommendations and design.

2.1 Definitions

The term "Cable Splice" as used in the specifications refers to all splices, solid
taps and branches in electric power power cable as may be made in man holes,
hand holes, splice boxes, vaults, tunnels, etc. This term does not apply to
splices for pulling into ducts.

The various types of cable splices referred to in this section are defined as
follows:

Straight Splice:- A splice between two cables having the same number of
conductors.

"Y" Splice:- A splice for connecting one cable to two cables, all of which have
the same number of conductors.

2.2 General Requirements

In making cable splices, the splicer and/or terminator must be certified by

manufacturer or SEC or an independent agency and shall specifically follow
this section and the manufacturer's recommendations for the particular splice
and type of cable being installed.

Splicing power cables requires great care in the assimilation of manufacturer's

instructions, utilizing prescribed materials with proper tools and above all,
observing extreme cleanliness in all phases of the splicing operation. The
cutting of the cable for splices also requires the observance of exact
dimensions (length and depth) in the preparation of the cable for the splicing
procedure. The operation should be carried out in a proper dust free tent where
humidity and temperature are controlled as per manufacturer's
recommendations.

The removal of the semi-conducting layers over the conductor and the
insulation should be executed in a manner prescribed in the manufacturer's
instructions for each splice.

Similar recognition should be applied in the removal of the conductor,

insulation and jacket.

Unless otherwise permitted by SEC, all splicing operations shall be conducted

in a double walled tent equipped with a positive pressure type air conditioning
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TRANSMISSION ENGINEERING STANDARD TES-P-104.04, Rev. 01

unit. The air conditioning unit shall be capable of maintaining the relative
humidity below 40%.

2.3 Routing Cables

Route the cables into their final positions, avoiding sharp bends and allowing
the ends to overlap. The overlap for splicing power cable should equal the
length of the completed splice. Also, it is desirable to have at least 15mm of
straight cable beyond ends of finished splice.

2.4 Connectors

Connectors for use in splicing shall be either compression or thermite welded

types in accordance with the manufacturer's specific recommendations.

2.4.1 Compression connectors shall be suitable for aluminum or copper

conductors. All connectors 35 mm2 and above shall have tapered ends
and metal barriers. Tapered ends will ease tape splicing and alleviate
stress points on high voltage splices.

2.4.2 Solder type connectors shall not be used with solid dielectric cables.

2.4.3 When splicing copper to copper conductors, only copper connector

shall be used.

2.4.4 When splicing aluminum to aluminum conductors, only aluminum

connectors shall be used.

2.4.5 When splicing copper to aluminum conductors, only suitable

bimetallic connectors shall be used.

2.5 Conductor Connections

2.5.1 Preparation of Conductors

The normal procedure for cleaning exposed bare conductor ends prior
to installing connectors is brushing the surface of the conductor with
a steel brush until it is clean and bright. When cleaning aluminum
conductor for compression connections, it is necessary to apply an
SEC approved inhibitor compound to the exposed conductors
immediately after the wire brushings. The inhibitor compound will
prevent the formation of a non-conductive film of oxide on the
conductor surface, which would otherwise form as a result of the
chemical reaction between the aluminum surface and air.

2.5.2 Application of Compression Connectors

Care shall be taken always to select the recommended compression

die for pressing the joint connector. It shall be installed in strict

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TRANSMISSION ENGINEERING STANDARD TES-P-104.04, Rev. 01

compliance with manufacturer's instructions for applying

compression connectors.

2.5.3 Preparation of Cable Joint Surfaces

After the cable joint connector is installed and prior to applying the
insulation tape, or heat shrink material, the surfaces of the insulation
and insulation shield must be thoroughly cleaned with a SEC
approved cable cleaning fluid. The use of benzine, or gasoline, for
this purpose, is not permitted.

2.6 Heat Shrinkable Sleeve

Heat shrinkable polyethylene provides a recommended method for insulating

underground splices for XLPE cables (600V to 34.5kV). If the manufacturer's
splice kit does not include a heat shrinkable sleeve to protect the concentric
neutral wires against corrosion, then one shall be installed.

2.7 Phasing of Cable Splices

When the cable splices are installed for the purpose of circuit expansion or
repair, the cables to be spliced shall be identified and labeled to correspond
with phase identification at the source side of the cable termination. Splicing of
the cables in accordance with proper phase identification will eliminate the
possibility of the splice introducing an out-of-phase condition in the circuit.

2.8 Cable End Caps

During the period that cables have been placed in ducts or trenches, and are to
be spliced at a later time, the cable ends are to be sealed to eliminate moisture
entering and corroding the cable conductor.

Heat shrinkable caps shall be utilized and installed on open ends of the cables
in order to maintain the integrity of the cable.

2.9 Partial Discharge Test

Partial discharge measurements shall be carried out for extra high voltage cable
230kV & 380kV at site after completion of splicing/jointing of the cable to
detect the weak points. The tests shall be carried out preferably during the HV
test or immediately thereafter.

3.0 CABLE TERMINATIONS

3.1 Definitions

The term "Cable Termination" as used in this Section refers to all terminations
of electric power cable in order to effect an electrical connection to the cable
conductor.
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TRANSMISSION ENGINEERING STANDARD TES-P-104.04, Rev. 01

In its simplest form, a cable termination may be formed by attaching a suitable

terminal lug to the end of a cable conductor. For insulated power cable,
however, it is necessary to remove a section of the outer jacket and shielding
(if applicable), to seal the cable end against the entrance of moisture, as well as
to provide a suitable stress cone to shield the electrical field. The method of
sealing the cable end varies with the type of cable termination.

3.2 General Requirements

3.2.1 Taped Termination

A taped cable termination is one in which the cable end is sealed by

the application of suitable insulating tape. Taped terminations of
power cables over 5kV shall require the construction of a stress cone
by building up the proper shape through consecutive layers of tape.

3.2.2 Premolded and Molded Terminations

A premolded termination may be one of several types of slip on

terminations constructed of rubber like synthetic materials or a
combination of plastics and polymers. Terminations in this category
include skirted one-piece terminations with varying creep distances,
or elbow type of separable connections.

The application of premolded and molded terminations shall be

performed in strict compliance with the manufacturer's installation
procedures.

3.2.3 Heat Shrink Terminations

Heat shrink irradiated polyethylene is used to control terminal stress

and provide a means of terminating 11kV, 13.8kV, 33kV, 34.5kV,
69kV, 110kV, 115kV, 132kV, 230kV and 380kV cables, indoor and
outdoor.

The application of heat shrink irradiated polyethylene shall be

performed in strict compliance with the manufacturer's installation
procedures.

3.2.4 Porcelain Terminations

Indoor and outdoor porcelain terminations are used for 69kV to

380kV rated cables, and shall be installed in strict compliance with
the manufacturer's procedures.

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TRANSMISSION ENGINEERING STANDARD TES-P-104.04, Rev. 01

3.2.5 SF6 Gas-Immersed Terminations

SF6 Gas-Immersed terminations are used up to 380kV rated cables,

and shall be installed in strict compliance with the manufacturer's
procedures.

3.2.6 Terminal Lugs

Terminal lugs used for all cable terminations must be selected to

insure the compatibility of the metal to metal contact. Where cables
with aluminum conductors are to be terminated on copper bus, such
as transformers or switchgear etc, the terminal lug shall be rated
copper-aluminum. An oxide inhibitor shall be applied to the
aluminum conductor prior to compressing the terminal lug.

3.2.7 Leakage Distance

For outdoor terminations, the leakage distance shall be 40mm/kV

line-to-line (minimum). In case of coastal areas the leakage distance
shall be 50mm/kV, preferably with High Voltage Insulator Coating
(RTV Coating for coastal/polluted areas) as per specification # 15-
TMSS-07.

3.2 Precautions in Making Cable Terminations

In making cable terminations, the splicer and/or terminator must be certified by

an independent agency and shall specifically follow the specifications, details
and dimensions given on the manufacturer's drawings for the particular
termination and type of cable being installed.

Extreme care shall be taken in every step from start to finish to keep the cable
termination free from moisture, dirt, particles of metal and air pockets. To
accomplish this, the technician's hands, tools, containers and supplies must be
kept clean, dry and free from foreign matter at all times.

Do not expose unpacked premolded insulating materials to the atmosphere for

more time than absolutely necessary (as suggested by the manufacturer).

After the cable insulation has been exposed by removal of any section of the
outer covering, operations should be continued without interruption until the
cable termination is complete. Should it be necessary to leave an incomplete
cable termination overnight, the exposed cable insulation shall be protected by
a carefully applied covering of tape of the final type to be applied to the
termination and, in damp locations, this tape shall be covered by a waterproof
rubber or plastic tape. Suitable protection (depending on moisture and dirt
conditions and the voltage of the termination being made up) shall also be
applied to exposed insulation when terminating is interrupted for break time or
for necessary tests.

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TRANSMISSION ENGINEERING STANDARD TES-P-104.04, Rev. 01

The permanent storage of cable termination for manufacturer’s specified period

shall be strictly as per manufacturer recommendations.

3.3 Locating Cable Terminations

Cable terminations are frequently attached directly to the equipment terminals,

buses or other conductors. This application determines to an appreciable
extent, the location of the termination. However, there may be some choice
with regards to the direction from which the cable approaches the termination.
The cable shall be so arranged as to permit locating the last cable support close
to the termination. This will avoid putting undue strains on the equipment
terminals or the terminal lugs on the cable. Usually, such terminal supports
shall be located 600-900mm from the equipment terminals. Terminal supports
shall be so located that no sharp edges are made on the cable and no bend
occurs in the taped portion of the cable termination.

3.4 Grounding of Cable Terminations

Metal parts of terminating devices, concentric neutral copper, tinsel braid or

other metallic shielding on stress cones in cable terminations shall be
effectively grounded to the system ground. These various components usually
are bonded together within the cable termination so that a single grounding
connection serves to ground the complete termination. However, precautions
must be taken to make sure that all parts of a termination requiring grounding
are properly connected together.

An exception can be there, when the open end of a single point grounded
section of circuit is terminated. Special provisions will be required to isolate
the cable shield or concentric neutral from the ground potential of metal parts
of the terminating rack or device.

3.5 Partial Discharge Measurement

Partial discharge measurements shall be carried out for extra high voltage cable
230 kV & 380 kV at site after completion of termination of the cable to detect
the weak points. The tests shall be carried out preferably during the HV test or
immediately thereafter.

3.6 Elbow Terminations

3.6.1 When specified by the Design Engineer, elbow type separable

connector terminations may be used to terminate 15kV and 34.5kV
rated cables to compartment type pad mounted transformer or pad
mounted switching cubicles.

3.6.2 All elbow terminations shall be rated 200 amperes for load break
service and 600 amperes for no-load break services.

3.6.3 The elbow terminations shall be provided with a capacitive test point.

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TRANSMISSION ENGINEERING STANDARD TES-P-104.04, Rev. 01

3.6.4 The application of elbow terminations shall be performed in strict

accordance with the manufacturer's installation procedures.

3.6.5 All elbows shall comply with IEEE Standard No. 386.

4.0 STRESS RELIEF CONE (FOR JOINTS/SPLICES & TERMINATIONS)

4.1 Definition

The term "Stress Relief Cone" as used in this section is an essential part of
joints/splices & terminations, refers to a rubber or elastomer body which is
pushed over the insulation of the cable. The electric field/equipotential lines
are evenly spread out by the shape of the stress cone. The electric field
concentrations are prevented in this way. For insulated power cables,
however, it is necessary to remove a section of the outer jacket and shielding
etc and slip the body of stress cone that is stretched over the cable end.

4.2 General Requirements

The joints & splices/terminations must manage the electric field, otherwise the
electric field will concentrate at the end as shown in figure-1. The figure-1
shows the equipotential lines, the nearer these lines are to each other, the
greater the electric field, which can cause an electric breakdown in this region.

Fig-1

4.3 Locating Stress Cone

In order to control the equipotential lines (electric field), “Stress Cone” is

pushed over the insulation of the cable as shown in figure-2. The stress relief
cone shall evenly spread out the equipotential lines to guarantee a low electric
field and to prevent the field concentrations.

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TRANSMISSION ENGINEERING STANDARD TES-P-104.04, Rev. 01

Fig-2

The bore diameter of the Stress Cone shall be narrower than the diameter over
cable insulation. The interface between cable and stress cone shall be brought
under mechanical pressure so that no cavities or air pockets can be formed
between cable and cone to prevent the electric breakdown.

The construction can further be surrounded by a porcelain or silicone insulator

for outdoor use or by contraptions to enter the cable into a power transformer
under oil or switch gear under gas pressure.

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TRANSMISSION ENGINEERING STANDARD TES-P-104.04, Rev. 01

5.0 BIBLIOGRAPHY

1. F.H. Kreuger, Industrial High Voltage, Delft University Press, 1991, ISBN 90-
6275-561-5. Parts 1, 2 and 3 in one Volume.

2. IBID, Industrial High Voltage, Delft University Press, 1992, ISBN 90-6275-
562-3. Parts 4, 5 and 6 in one Volume.

3. E. Kuffel, W.S. Zaengl, High Voltage Engineering, Pergamon Press, Oxford;

later edition 2004, Butterworth-Heinemann, ISBN 0-7506-3634-3.

4. Underground Systems Reference Book, Edison Electric Institute, New York,

1957, no ISBN

5. R. M. Black The History of Electric Wires and Cables, Peter Pergrinus,

London 1983 ISBN 0 86341 001 4

6. IEEE-48 (Test Procedures and Requirements for Alternating-Current Cable

Terminations 2.5kV through 765kV)

7. IEEE-404 (Extruded and Laminated Dielectric Shielded Cable Joints rated

2500V to 500 000V)

8. IEEE 1300 (IEEE Guide for Cable Connections for Gas-Insulated Substations)

9. 12-TMSS-10 (Splice & Termination Kits for Power Cables)

10. TES-P-104.08 Rev.# 1 (Bonding & Grounding of Insulated Metallic Sheath of

Power Cable System 69kV to 380kV)

11. 12-SDMS-01 Rev.# 1 (Cable Joints, Terminations and Accessories up to

36kV)

12. EPRI Underground Transmission Systems Reference Book, 2006 Edition, 1014840

TESP10404R01/YM Date of Approval: June 19, 2012 PAGE NO. 12 OF 12