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IEEE Guide for Preparation Techniques of Extruded Dielectric, Shielded Cables Rated 2.5 kV through 46 kV and the Installation of Mating Accessories

IEEE Power and Energy Society

Sponsored by the Insulated Conductors Committee

IEEE 3 Park Avenue New York, NY 10016-5997 USA

IEEE Std 1816™-2013

9 April 2013

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IEEE Std 1816™-2013

IEEE Guide for Preparation Techniques of Extruded Dielectric, Shielded Cables Rated 2.5 kV through 46 kV and the Installation of Mating Accessories Sponsor

Insulated Conductors Committee of the

IEEE Power and Energy Society Approved 6 March 2013

IEEE-SA Standards Board

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Abstract: Accepted best industry practices for the preparation of extruded dielectric shielded medium voltage cables rated 2.5 kV through 46 kV for the installation of mating accessories are defined in this guide. The information is intended to supplement cable accessory manufacturer installation instructions. The guide aims to provide a single source covering the proper methods to prepare cables for termination and jointing to maximize long-term, reliable operation of electrical power cable systems. Keywords: accessory installation, cable, cable preparation, IEEE 1816™, separable connectors, system reliability

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Participants At the time this IEEE guide was completed, the B19W Working Group had the following membership: David E. Crotty, Chair Michael Smalley, Vice Chair Saleman Alibhay Glen Bertini Edward Bradley Tom Campbell Thomas Champion Michael Dyer Jon Erickson Michael Faulkenberry

Mark Furtick John Hans Richie Harp Jeff Helzer David Hughes Margaret Jasek Farris Jibril Glenn Luzzi John Makal

Tim McLaughlin Aaron Norris Armando Rios Ewell Robeson Stan Szyszko Bill Taylor Carl Wentzel Harry Yaworski

The following members of the individual balloting committee voted on this guide. Balloters may have voted for approval, disapproval, or abstention. Thomas Barnes Earle Bascom III Michael Bayer Kenneth Bow Kent Brown William Byrd Thomas Champion Robert Christman Jacques Cote David Crotty Frank Di Guglielmo Gary Donner Randall Dotson Gary Engmann Michael Faulkenberry David Gilmer Steven Graham Randall Groves Ajit Gwal Richard Harp Jeffrey Hartenberger

Timothy Hayden Lee Herron Lauri Hiivala Werner Hoelzl David Horvath Edward Jankowich A. Jones John Kay Gael Kennedy Joseph L. Koepfinger Robert Konnik Jim Kulchisky Chung-Yiu Lam Benjamin Lanz Greg Luri Glenn Luzzi John Mcalhaney, Jr. William McBride Jerry Murphy Arthur Neubauer Michael S. Newman

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Joe Nims Lorraine Padden Serge Pelissou Howard Penrose Christopher Petrola Robert Resuali Michael Roberts Bartien Sayogo Gil Shultz Michael Smalley James Smith Jerry Smith Nagu Srinivas Gregory Stano Gary Stoedter Peter Tirinzoni John Vergis Martin Von Herrmann Carl Wall Kenneth White Dawn Zhao

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When the IEEE-SA Standards Board approved this guide on 6 March 2013, it had the following membership:

John Kulick, Chair David J. Law, Vice Chair Richard H. Hulett, Past Chair Konstantinos Karachalios, Secretary Masayuki Ariyoshi Peter Balma Farooq Bari Ted Burse Wael William Diab Stephen Dukes Jean-Philippe Faure Alexander Gelman

Mark Halpin Gary Hoffman Paul Houzé Jim Hughes Michael Janezic Joseph L. Koepfinger* Oleg Logvinov

Ron Petersen Gary Robinson Jon Walter Rosdahl Adrian Stephens Peter Sutherland Yatin Trivedi Phil Winston Yu Yuan

*Member Emeritus

Also included are the following nonvoting IEEE-SA Standards Board liaisons: Richard DeBlasio, DOE Representative Michael Janezic, NIST Representative

Malia Zaman IEEE Standards Program Manager, Technical Program Development

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Catherine Berger IEEE Standards Program Manager, Document Development

Introduction This introduction is not part of IEEE Std 1816-2013, IEEE Guide for Preparation Techniques of Extruded Dielectric, Shielded Cables Rated 2.5 kV through 46 kV and the Installation of Mating Accessories.

This guide is the first IEEE guide issued that addresses solid dielectric cable preparation and installation of cable accessories. This application guide is the product of close collaboration between representatives of both end users and manufacturers of cable accessories. Members of the B19 discussion and B19 working groups of the Insulated Conductors Committee provided valuable input and support.

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This guide is intended to be used in concert with IEEE Std 48™, IEEE Std 386™, IEEE Std 404™, IEEE Std 592™, and IEEE Std 1215™, which define the construction specifications, qualification tests, ratings, and service conditions for terminations, separable connectors, and joints.

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Contents 1. Overview .................................................................................................................................................... 1 1.1 Scope ........................................................................................................................................... 1 1.2 Purpose ........................................................................................................................................... 1 2. Normative references.................................................................................................................................. 2 3. Definitions .................................................................................................................................................. 2 4. Cable construction ...................................................................................................................................... 3 4.1 General ........................................................................................................................................... 3 4.2 Conductor ........................................................................................................................................... 3 4.3 Conductor shield .................................................................................................................................. 4 4.4 Insulation ........................................................................................................................................... 4 4.5 Insulation shield ................................................................................................................................... 4 4.6 Electrical stress control ........................................................................................................................ 4 4.7 Metallic shield ..................................................................................................................................... 7 4.8 Metallic shield water block .................................................................................................................. 7 4.9 Outer jacket ......................................................................................................................................... 7

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5. Cable preparation........................................................................................................................................ 7 5.1 Cable accessory selection and tool requirements ................................................................................. 7 5.2 Cable training and termination ............................................................................................................ 8 5.3 Final cable cut ...................................................................................................................................... 8 5.4 Jacket removal ..................................................................................................................................... 8 5.5 Exposing metallic shield ...................................................................................................................... 9 5.6 Non-metallic insulation shield removal ............................................................................................... 9 5.7 Insulation ..........................................................................................................................................10 5.8 Conductor shield removal ...................................................................................................................11 5.9 Insulation chamfering .........................................................................................................................11 5.10 Cleaning the insulation .....................................................................................................................11 5.11 Strands and miscellaneous ................................................................................................................11 6. Conductor connector installation ...............................................................................................................12 6.1 Connector types ..................................................................................................................................12 6.2 Conductor preparation ........................................................................................................................12 6.3 Preparing for Installation ....................................................................................................................13 6.4 Connector markings ............................................................................................................................13 6.5 Crimping the connector ......................................................................................................................14 6.6 Bolted connectors ...............................................................................................................................16 6.7 Excess inhibitor ..................................................................................................................................16 6.8 Flash ..........................................................................................................................................16 7. Cable accessory installation.......................................................................................................................17 8. Metallic shield connection .........................................................................................................................18 9. Cable seal and jacket restoration ...............................................................................................................19 9.1 Cable end seal .....................................................................................................................................19 9.2 Joint jacket restoration ........................................................................................................................19 10. Cable shield ground connection ..............................................................................................................19 ix

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Annex A (informative) Bibliography ............................................................................................................20 Annex B (informative) Compression tools ....................................................................................................21 B.1 Scissor-type tools ...............................................................................................................................21 B.2 Tool using two opposing dies ............................................................................................................21 B.3 Tools using four-head indents ............................................................................................................21 B.4 Tools using single indents ..................................................................................................................21 B.5 Tool adjustment and calibration .........................................................................................................21 Annex C (informative) Recommended minimum cable bending radii ..........................................................22

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Annex D (informative) Suggested cleaning procedure for corroded conductors ..........................................23

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IEEE Guide for Preparation Techniques of Extruded Dielectric, Shielded Cables Rated 2.5 kV through 46 kV and the Installation of Mating Accessories

This IEEE document is made available for use subject to important notices and legal disclaimers. These notices and disclaimers appear in all publications containing this document and may be found under the heading “Important Notice” or “Important Notices and Disclaimers Concerning IEEE Documents.” They can also be obtained on request from IEEE or viewed at http://standards.ieee.org/IPR/disclaimers.html.

1. Overview 1.1 Scope This document defines accepted best industry practices for the preparation of extruded dielectric shielded medium voltage cables rated 2.5 kV through 46 kV and the installation of mating accessories.

1.2 Purpose The purpose of this guide is to provide general information on cable preparation for the installation of cable accessories. It is intended to be basic and to supplement the manufacturer’s specific recommendations and established utility practices.

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IMPORTANT NOTICE: IEEE Standards documents are not intended to ensure safety, health, or environmental protection, or ensure against interference with or from other devices or networks. Implementers of IEEE Standards documents are responsible for determining and complying with all appropriate safety, security, environmental, health, and interference protection practices and all applicable laws and regulations.

IEEE Std 1816-2013 IEEE Guide for Preparation Techniques of Extruded Dielectric, Shielded Cables Rated 2.5 kV through 46 kV and the Installation of Mating Accessories

2. Normative references The following referenced documents are indispensable for the application of this document (i.e., they must be understood and used, so each referenced document is cited in text and its relationship to this document is explained). For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments or corrigenda) applies. IEEE Std 48™-2009, IEEE Standard for Test Procedures and Requirements for AC Cable Terminations 2.5kV through 765 kV.1, 2 IEEE Std 386™-2006, IEEE Standard for Separable Insulated Connector Systems for Power Distribution Systems Above 600 V. --`,```,,,```,``,,,,,`,`,,````-`-`,,`,,`,`,,`---

IEEE Std 404™-2012, IEEE Standard for Extruded and Laminated Dielectric Shielded Cable Joints Rated 2,500 V to 500,000 V. IEEE Std 592™-2007, IEEE Standard for Exposed Semiconducting Shields on High-Voltage Cable Joints and Separable Insulated Connectors. IEEE Std 1215™-2001, IEEE Guide for the Application of Separable Insulated Connectors.

3. Definitions For the purposes of this document, the following terms and definitions apply. The IEEE Standards Dictionary Online should be consulted for terms not defined in this clause. 3 bi-metallic connector: A connector made from two different materials (usually copper and aluminum joined together). The aluminum portion of the connector is used to join the connector to the aluminum or copper conductor. cable adapter: A component of a Dead-Break or Loadbreak Connector kit that is used to adapt the diameter of various cable sizes to one standardized inside diameter of the Dead-Break or Loadbreak connector. conductor strand sealant: A material that may be applied to a stranded conductor to impede longitudinal water flow down the conductor. drain wire tab: A molded tab on a premolded rubber product that is intended to accept a small wire (e.g., a #14 AWG copper wire) to prevent the buildup of static charge due to capacitive coupling. drain wire: A small wire (usually #14 AWG copper) that is used to connect a cable accessory to ground to prevent the buildup of static charge due to capacitive coupling. This wire is not intended to carry fault current. dual-rated connector: A connector that is designed and tested to be used on both copper and aluminum conductors. longitudinal cut: A cut made parallel to the conductor. 1 IEEE publications are available from the Institute of Electrical and Electronics Engineers, 445 Hoes lane, Piscataway, NJ 08854, USA (http://standards.ieee.org/). 2 The IEEE standards or products referred to in this clause are trademarks of the Institute of Electrical and Electronics Engineers, Inc. 3 IEEE Standards Dictionary Online subscription is available at: http://www.ieee.org/portal/innovate/products/standard/standards_dictionary.html.

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IEEE Std 1816-2013 IEEE Guide for Preparation Techniques of Extruded Dielectric, Shielded Cables Rated 2.5 kV through 46 kV and the Installation of Mating Accessories

metallic shield water block: A material that is applied between the cable non-metallic insulation shield and jacket that impedes water migration longitudinally along the cable. The material may be a tape, powder, or other similar material. oxide inhibitor: A material that is used to coat a metallic conductor (usually aluminum) to prevent the buildup of surface oxides on the conductor. Some oxide inhibitors include abrasive particles to help break up oxides on oxidized conductors. ring cut: A cut made around the circumference of a cable’s non-metallic insulation shield for the purpose of stripping the insulation shield from the cable core. Ring cuts are also made on cable jackets to expose the metallic shield. (Also referred to as a radial cut.) shield adapter: A product used to adapt a metallic shield for connection to the system ground.

4. Cable construction

4.1 General General cable construction is illustrated in Figure 1.

Strand-Filled Conductor Conductor Shield

Insulation OD

Insulation

Insulation Shield

Insulation Shield OD

Metallic Shield

Jacket

Jacket OD

Figure 1 —Cable construction

4.2 Conductor The conductor is typically aluminum or copper. Current flows through the conductor at line voltage. Strands typically are: (1) all round; (2) compressed, where the outer layer of strands are slightly squeezed down to reduce the diameter about 3%; (3) compact, where all strands are deformed to reduce the outer diameter (OD) by about 8–10%; or (4) solid, where there is a single strand. Solid conductors are limited to

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IEEE Std 1816-2013 IEEE Guide for Preparation Techniques of Extruded Dielectric, Shielded Cables Rated 2.5 kV through 46 kV and the Installation of Mating Accessories

relatively small sizes due to the reduced flexibility. By reducing the strands’ OD, the overall OD of the cable is also reduced. This is both a cost benefit and in some cases a physical size benefit. Some stranded conductors contain a conductor sealant or longitudinal water block, which may be a viscous compound, yarn, powder, or some other material. The purpose is to prevent water from migrating through the strands should the cable ends be left uncapped or if the cable experiences a failure. Water in the strands can lead to numerous potential problems.

The conductor or strand shield is applied over the conductor to form a smooth, concentric shape. It equalizes electrical stress over the surface of the conductor and maintains all air within and around the strands at line potential. It also prevents insulation material from flowing into the strands during the manufacturing process. Typically, the strand shield is manufactured from material similar to the insulation. The strand shield is usually semi-conductive or in some cases is made of a high dielectric constant material.

4.4 Insulation The insulation is usually ethylene propylene rubber (EPR) or tree retardant cross-linked polyethylene (TRXLPE). Other insulations have been used in the past such as high molecular weight polyethylene (HWPE), cross-linked polyethylene (XLPE), and natural rubber. The insulation insulates the medium voltage conductor from ground. The insulation’s thickness is determined by the stress it is to withstand.

4.5 Insulation shield The insulation shield, sometimes called “semi-con” because it is usually semi-conductive, contains the electrical field within the insulation and is part of the cable’s dead-front configuration. The insulation shield and the conductor shield work together to control stress within the insulation.

4.6 Electrical stress control There are two types of electrical stress. Radial stress (see Figure 2) projects from the energized conductor and semi-conductive conductor shield toward the grounded shield. The lines of electric flux are closer together at the conductor shield, causing maximum stress at this point. The lines are wider apart at the insulation shield, which corresponds to minimal stress. The average electrical stress would fall somewhere between the two electrodes.

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4.3 Conductor shield

IEEE Std 1816-2013 IEEE Guide for Preparation Techniques of Extruded Dielectric, Shielded Cables Rated 2.5 kV through 46 kV and the Installation of Mating Accessories

Figure 2 —Radial stress The second type of electrical stress is referred to as longitudinal or axial stress. This type of stress is normally not present in a cable. However, it is present (along with radial stress) at a cable termination or at a joint. Longitudinal stress can be identified in areas where the equipotential lines are not parallel with the cable conductor. When the insulation shield is removed, the dielectric field changes and the stresses are no longer confined within the cable’s insulation. A high concentration of stress occurs at the end of the insulation shield. Without adding additional insulation or a means to control the stress, the air near the insulation shield cutback will be exposed to a high electrical stress that will likely initiate corona. The corona will slowly erode the cable insulation causing a failure. (See Figure 3.)

Figure 3 —Stress plot for an unterminated shielded cable

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IEEE Std 1816-2013 IEEE Guide for Preparation Techniques of Extruded Dielectric, Shielded Cables Rated 2.5 kV through 46 kV and the Installation of Mating Accessories

At the insulation shield termination, the equipotential lines are closer together indicating that this is an area of high electrical stress in the cable insulation and in the air.

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As shown in the additional stress plots below (Figure 4), there are several ways to control the electrical stress at the insulation shield termination. Figure 5 shows the use of geometric stress control (adding extra insulation) to control the voltage stress. Figure 6 shows the use of a capacitively graded stress control tube (Hi K) to control the voltage stress.

Figure 4 —Stress plot showing geometric stress control

Figure 5 —Stress plot showing capacitively graded stress control

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IEEE Std 1816-2013 IEEE Guide for Preparation Techniques of Extruded Dielectric, Shielded Cables Rated 2.5 kV through 46 kV and the Installation of Mating Accessories

Notice in Figure 5 and Figure 6 that the equipotential lines have greater spacing at the insulation shield cutback compared to Figure 4 showing no stress control. Even with proper stress control, the area at the insulation shield cutback remains a critical area demanding quality workmanship.

4.7 Metallic shield The metallic shield is usually copper but it may also be aluminum or lead. It is supplied in a variety of shapes and configurations including concentric neutral wires, copper tape, longitudinally corrugated copper tape, drain wires, flat strap, lead sheath, or a combination of thereof. The metallic shield performs the following functions when properly grounded: a) b) c) d) e)

Provides a path to the source for any fault currents resulting from a cable or accessory failure Returns load current in single-phase applications Returns 3-phase imbalance/harmonic currents Drains charge off of the nonmetallic insulation shield Provides for worker safety

4.8 Metallic shield water block There may be a water block surrounding the metallic shield to prevent damage to the shield by the intrusion of water. This water block may be an extruded polymer, water swellable powder or tape, or a combination of the two. This material must be removed to allow proper connection to the system ground and/or neutral.

4.9 Outer jacket Lastly there may be an outer jacket that provides protection to the metallic shield during cable pulling and after installation. When properly sealed, the jacket minimizes the possibility of metallic shield corrosion.

5. Cable preparation

5.1 Cable accessory selection and tool requirements Confirm that the cable accessory kit is correctly sized for the cable, is appropriate for the intended application, contains all necessary components in good condition, and that any shelf life requirements are not exceeded. Measure the diameter over the cable insulation and/or insulation shield to verify that the kit is suitable for the cable. Similarly, if unsure of the conductor size and stranding, measure it to be sure that the connector is appropriate. Use all personal protective equipment (PPE) in accordance with utility practices. Have all necessary tools and equipment on hand. Follow appropriate work practices to de-energize and ground the cable. Lastly, read the instructions completely before starting work.

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5.2 Cable training and termination

Where an enclosure is to be installed over a vault, including a loop of extra cable in the vault may be considered, provided the cable’s bending radius is not exceeded. This extra cable can be used for contingent shortening due to craft errors or to facilitate enclosure reconfigurations. Do not bury extra cable under the enclosure as its presence will be forgotten, it may become a safety concern, and could confound future diagnostic and fault-finding efforts. Confirm that the cable is in good condition and that the end was sealed to prevent water from entering either the conductor stranding or the metallic shield. Clean the outer surface of the cable to remove dirt, grime, cable pulling lubricant, and any lubricant residue remaining from the manufacturing process. The jacket should be cleaned a significant distance to allow for the temporary storage of components during assembly. Use only water or approved cleaners and a rag to clean outside cable surfaces. WARNING Many solvent manufacturers require or recommend the use of protective gloves, eye protection, and respirators when handling or working with cable cleaning solvents. Refer to the product’s Material Safety Data Sheet for complete information. Train and position cable for proper operation while conforming to minimum bending radius requirements, typically 8 to 12 times the outside diameter of the cable. (See Annex C.) For joints, straighten the cable approach so that cables and connectors are in line and not under undue mechanical stress. For separable connectors, use the natural bend in the cable to assist in operating if possible; refer to other guides such as IEEE P971™ [B7]4 and the manufacturer’s installation instructions. NOTE—Care should be taken to maintain a clean working environment and protect the cable and

accessories from harsh environmental conditions.5

5.3 Final cable cut The cable end should be cut square so the conductor strands are all of uniform length. A hack saw, reciprocating saw, or band saw is commonly used to create a square cut.

5.4 Jacket removal Remove outer jacket to the dimensions defined in manufacturer’s instructions. Care should be exercised to not nick or cut metallic shield. Damage to the metallic shield reduces the current carrying capacity of the shield. The wires can break, possibly compromising the integrity of the ground circuit.

4 5

The numbers in brackets correspond to those of the bibliography in Annex A. Notes in text, tables, and figures are given for information only and do not contain requirements needed to implement the standard.

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For concentric neutral cable on some accessories, leaving extra cable is required so that the concentric neutral wires will be long enough for required ground connections.

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There are numerous tools available to aid in the removal of the outer jacket. These include one to ring cut the jacket and another to score the jacket longitudinally. An alternative method is to pull one of the neutral wires to score and split the jacket. If this method is used, care must be exercised to not damage the wire. In some cable constructions the neutral wires are embedded into the jacket. The only accepted means to expose embedded neutrals is to pull them through the jacket material.

Inspect metallic shield for damage. Concentric neutral wires, drain wires, and sometimes flat strap neutral wires are typically bent back during installation and later will be jumpered across a joint or attached to system ground for a separable connector or terminator. A special shield adapter may be used to terminate copper tape, longitudinally corrugated tape, flat strap, or lead-sheathed shields. The adapter manufacturer’s installation instructions should be followed to determine cut back dimensions. In all cases, the neutral shields should be terminated as close to the cable accessory as possible, preferably within two inches. Do not exceed the manufacturer’s recommended distance for the neutral termination location. WARNING Removing neutrals and exposing extensive lengths of insulation shield may cause leakage current that can degrade the insulation shield and lead to cable failures. In the event of a fault, if the neutrals are removed, the fault current may not be taken to ground due to the limited current carrying capacity of the non-metallic insulation shield.

5.6 Non-metallic insulation shield removal The insulation shield (semi-con) needs to be terminated to the manufacturer’s dimensions in a clean, square cut. Care needs to be taken to prevent damage to the insulation. If the insulation is damaged during scoring or the ring cut, the cable must be re-terminated. The end of the insulation shield is a high stress area. CAUTION Nicks in the insulation at the ring cut point will lead to partial discharge and eventual dielectric breakdown of the insulation. Nicks at this location cannot be repaired. Insulation shield material is typically an extruded semi-conductive material, which can be removed with hand tools or scoring tools. Some insulation shields may be bonded to the insulation. On older cables, the insulation shield may have become bonded due to thermal cycling. This situation will require bonded shield removal tools and techniques. They may include a heat source, an insulation shield shaving tool, broken glass, draw knives, aluminum oxide cloth, etc. When sanding is utilized, it should be done with both hands using a back and forth motion similar to the way a shoe is shined and sanded equally around the circumference of the cable leaving no flat spots. Only 120 grit or finer aluminum-oxide abrasive should be used. Do not use any other abrasives. The backside of the sandpaper can be used to polish or finish the surface.

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5.5 Exposing metallic shield

IEEE Std 1816-2013 IEEE Guide for Preparation Techniques of Extruded Dielectric, Shielded Cables Rated 2.5 kV through 46 kV and the Installation of Mating Accessories

CAUTION Failure to sand insulation around the entire circumference of the insulation may result in a flat spot on the insulation. Removing too much insulation around the circumference may result in an insulation thickness lower than the kit tolerances or the cable minimum insulation thickness requirement. Either condition may result in tracking along the insulation interface leading to a failure. Scoring tools or insulation shield removal tools should be adjusted for the specific cable being prepared to avoid damaging the underlying insulation. A good method is to utilize a scrap piece of the cable being prepared to adjust the settings. CAUTION Failure to comply with the following step may result in electrical tracking along the insulation interface resulting in a dielectric failure.

The use of a knife and a constant force spring or other means will assist in terminating the fabric tape to the dimensions specified by the manufacturer. The end of the fabric tape should be restrained with semiconductive tape per manufacturer’s instructions to prevent unraveling.

5.7 Insulation The insulation surface should be examined for cable imperfections such as indents made by concentric neutral wires, bits of semi-con material, or pressure marks left during removal of the insulation shield. Great care should be taken to not nick, gouge, or score the insulation. Dielectric grease only temporarily covers up installation defects. Grease migrates away from the interfaces over a multi-year period and is no substitute for good craftsmanship. Concentric neutral indents in the insulation and pressure marks from the removal of the insulation shield do not need to be removed. These will go away during load cycling. Scores in the insulation that are located at the insulation shield ring cut are not repairable. Cables with score marks at this location must be re-terminated. If there is not enough cable length to complete the termination or joint, the following backup options should be considered in no particular order: ⎯

Remove the damaged portion of the cable and install a repair-length termination or repair-length joint following directions provided with these kits.

⎯

Cut off the damaged cable end and splice in a short length of cable.

⎯

Minor nicks and cuts may be repaired by sanding out the damaged area. An equal amount of sanding must be completed around that entire circumference of the cable insulation to keep the insulation cylindrical. Efforts should be made to remove the minimum amount of insulation. The finished diameter over the cable insulation must remain above the minimum diameter shown in the manufacturer’s installation instructions.

The following methods are not recommended to clean the cable insulation:

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The last type of shield is the fabric tape. These are sometimes applied over semi-conductive paint or a graphite layer. Care needs to be exercised so that the paint or graphite is terminated in line with the fabric and completely removed beyond that point.

IEEE Std 1816-2013 IEEE Guide for Preparation Techniques of Extruded Dielectric, Shielded Cables Rated 2.5 kV through 46 kV and the Installation of Mating Accessories

⎯

Use of scrubbing or scouring pads as they often contain conductive particles.

⎯

Application of flames will trap contaminants in the insulation surface.

5.8 Conductor shield removal The conductor or strand shield should be removed per the manufacturer’s instructions with a clean, square cut. Care should be exercised to prevent damaging the conductor strands. CAUTION Nicking or cutting the conductor may cause it to break after thermal cycling or operating. Broken strands will reduce the ampacity, which could cause failure due to overheating. For solid conductors, a nick could lead to mechanical breakage and failure. If the conductor is damaged, the damaged portion should be cut off and the cable end prepared again. Damaged strands cannot be repaired.

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5.9 Insulation chamfering If directed by the manufacturer’s instructions, the end of the insulation may be beveled or chamfered, no more than 3 mm (1/8”), to assist in installing the cable accessory. The insulation should not be penciled. A “penciled” insulation has a long 25 mm to 38 mm (1” to 1-1/2”) taper. Penciling is reserved for hand-taped joints and terminations.

5.10 Cleaning the insulation WARNING Many solvent manufacturers require or recommend the use of protective gloves, eye protection, and respirators when handling or working with cable cleaning solvents. Refer to the product’s Material Safety Data Sheet for complete information. The insulation surface shall be cleaned with an approved solvent to remove any dirt or semi-conductive material. Contact the cable manufacturer for a list of approved cable cleaning solvents. The cleaner should be applied to a clean rag (not sprayed directly on the cable), then the surface wiped toward the insulation shield. Wiping in the opposite direction can spread semi-con material onto the interface just cleaned. After cleaning the surface, it should be wiped with a second, clean, dry, lint-free rag to remove any residue of the cleaner. Any foreign material may adversely affect the dielectric strength of the interface and possibly lead to a tracking failure.

5.11 Strands and miscellaneous Confirm that there is a clean, square final cut on the conductor end. Care should be exercised to prevent distorting or splaying the strands. Prior to installation of the connectors or other cable accessories, remember to position shield adapters, cover-ups, and other portions of the final assembly onto the cable.

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6. Conductor connector installation

6.1 Connector types The majority of connectors are of the compression variety. The compression barrel is either aluminum or copper and may be tin plated. Aluminum barrels are intended for use on aluminum conductors, or if dualrated, on either aluminum or copper conductors. Aluminum barrels are typically preloaded with an oxide inhibitor. The inhibitor helps break down any oxide film on the conductor strands and minimizes oxidation on clean conductors. Copper connectors can only be used on copper conductors. If a copper barrel is installed on an aluminum conductor, it will most likely result in a poor connection. Due to the different coefficients of expansion, an aluminum conductor will expand faster than the copper barrel. This will result in the aluminum conductor cold-flowing over an extended time period. As the parts cool down, the aluminum will shrink back faster than the copper. After numerous thermal cycles, the connection will become loose and result in overheating. Over-heated connections degrade the dielectric strength of the insulation and lead to failure. Bi-metal or copper-top connectors were developed to help reduce thermal issues in 200 amp elbows. A bimetal connector typically has an aluminum compression barrel that is joined to a copper top through an inertial weld process. Other connector types include mechanical, bolted, soldered, welded, or thermally welded. No matter what the design, make sure that the connector is properly sized and rated for the intended application.

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6.2 Conductor preparation CAUTION Failure to comply with the following steps will result in a poor electrical connection with high resistance. Overheating may lead to failure of the connection. 6.2.1 Wire brushing Wire brush the conductor and immediately insert the conductor into the connector barrel. Aluminum connectors should include an oxide inhibitor approved for the application. Wire brushing improves the current-carrying capability of the connection by removing the non-conductive aluminum oxide film. If the cable has been in service for a considerable length of time and shows signs of corrosion or water in the strands, the decision to use the cable should be made by the system owner. See Annex D. 6.2.2 Oxide inhibitor WARNING Some manufacturers recommend or require the use of protective gloves and eye protection when handling oxide inhibiting compounds. Some manufacturers also recommend the use of a respirator in certain applications. Refer to the Material Safety Data Sheet for complete information.

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If the connector is pre-filled with oxide inhibitor, do not remove it from the barrel of the connector before installation. The inhibitor minimizes oxidation and moisture penetration. It also may contain grit that breaks down the oxide film on the conductor. SPECIAL APPLICATION

6.2.3 Insertion of the conductor Verify that the conductor(s) is completely inserted into the barrel. 6.2.4 Alignment If applicable, align the connector so that it is properly oriented with mating components or other equipment.

6.3 Preparing for Installation Refer to the manufacturer’s instructions if a check dimension is provided. Determine what tooling (die or die-less) is required for proper installation. Refer to the die information on the barrel or supplied in the manufacturer’s instructions. Select a tool that will accommodate the recommended die.

6.4 Connector markings Check that the connector meets the dimensional requirements of the accessory kit. The connector should be permanently marked with the manufacturer’s name or trademark, the catalog number, and the conductor’s size and stranding, e.g., “1/0 Str., 2/0 Compt”. A knurl mark or similar mark will delineate the location of the first indent. Crimp die index and industry standard dies, such as EEI or CSA, should be included. If there is insufficient room on the connector, the information can be provided on a separate crimp chart. The location of the markings is up to the manufacturer. This information should also appear on the smallest packaging in which the connector is supplied. CAUTION If the tool/die combination recommended by the connector manufacturer is unavailable, contact the manufacturer for a suitable alternate tool/die combination.

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For cables that will be injected, some portion of the oxide inhibitor can be removed just prior to installation if the inner barrel of the connector and the strands are both wire brushed with inhibitor.

IEEE Std 1816-2013 IEEE Guide for Preparation Techniques of Extruded Dielectric, Shielded Cables Rated 2.5 kV through 46 kV and the Installation of Mating Accessories

6.5 Crimping the connector CAUTION Improperly adjusted or damaged tools can result in poor crimps that could lead to overheating, and eventual failure of the accessory. Install the crimps per the manufacturer’s directions using the recommended tool and die combination (refer to Annex B for a general description of compression tools). When present, a line, a knurl mark, or a dimple on the barrel will indicate where the first indent should be. The crimp should not be on the indicator line, but just slightly beyond it. Refer to Figure 6 through Figure 8 for examples.

Figure 6 —Compression lug crimp location

Figure 7 —Pin terminal lug crimp location

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Figure 8 —Compression splice crimp location

⎯

For a splice, the first indent is near the center with subsequent indents working outward to the ends.

⎯

For a termination or separable connector, the first indent will be furthest from the end of the insulation and each subsequent indent progressing towards the cable insulation.

CAUTION If indents are applied in any manner other than stated above, a poor connection, bird-caging of the strands, and/or overheating could occur.

CAUTION On a bi-metal connector, crimping on or above the knurl line may damage the copper-aluminum weld causing the connector to overheat. It may also cause severing of the copper-top from the aluminum barrel. Apply the recommended number of compressions. If not specified, apply the greatest number possible without overlapping or exceeding manufacturer’s check dimension. Overlapping crimps on aluminum connectors is not normally done unless specifically required by the manufacturer’s instructions as it can cause excessive connector growth. The conductor and the compression barrel will grow in length during crimping. Aluminum barrels will grow more when installed on copper conductor. If a manufacturer’s specific check dimension is provided, monitor the growth of the crimped barrel so that it does not exceed the maximum allowed. The splice connector used in a joint typically has a center stop. This is used primarily as a check that both conductors are inserted to the same depth and the splice is centered in the joint. Do not crimp over the center stop.

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Fully close the tool; do not stop before completing the compression cycle. Rotate successive indents 180º or 90º to prevent the barrel from becoming banana-shaped.

IEEE Std 1816-2013 IEEE Guide for Preparation Techniques of Extruded Dielectric, Shielded Cables Rated 2.5 kV through 46 kV and the Installation of Mating Accessories

6.6 Bolted connectors Alternatives to compression connectors are bolted connectors. The connector sleeve has multiple threaded holes that contain a variety of bolts or set screws. After the conductors are prepared and inserted into the sleeve, the bolts or set screws are tightened to ensure a proper connection. If set screws are used, correct torque must be applied. This value will be detailed in the assembly instructions packaged with the connector. Shear bolts are designed to be threaded into the connector and then fracture when a specific torque value is reached. This eliminates the need for a torque wrench. When the head shears off, correct torque has been applied and the bolt cannot be removed or reused. In this fashion they are similar to a compression connector.

6.7 Excess inhibitor After crimping, remove excess inhibitor, which may be squeezed out during compression. Some inhibitors may degrade insulating materials and affect the dielectric strength of the product being installed. WARNING Some manufacturers recommend or require the use of protective gloves and eye protection when handling oxide inhibiting compounds. Some manufacturers also recommend the use of a respirator in certain applications. Refer to the Material Safety Data Sheet for complete information.

6.8 Flash After the crimping process, flash may be found protruding from the barrel. Properly adjusted tools and correct dies should not create excessive flash. In unique situations, certain tool/die/barrel/conductor combinations may result in excessive flash. Remove all sharp-edged flash. Excessive, sharp flash may damage the cable entrance interface of the mating cable accessory. A cut or scored interface could degrade the dielectric strength and result in a creep failure along the insulation. It does not need to be removed entirely, just eliminate sharp edges. (See Figure 9 and Figure 10.) --`,```,,,```,``,,,,,`,`,,````-`-`,,`,,`,`,,`---

Flash

Figure 9 —Connector with flash after crimping

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Figure 10 —Connector after flash removal

CAUTION When filing a connector to remove flash, any exposed insulation shall be protected from conductive debris. Any debris from flashing removal must be removed from the assembly.

7. Cable accessory installation The cable insulation and accessory should be clean and free from contamination. If directed by the manufacturer’s instruction, apply a tape marker to determine where the cable accessory should be positioned. WARNING Some manufacturers recommend or require the use of protective gloves and eye protection when applying the recommended lubricant. Refer to the Material Safety Data Sheet for complete information. Follow manufacturer’s instructions for applying lubricant. If directed to lubricate the insulation surface, use clean hands or a clean disposable glove to apply a thin, uniform film with supplied lubricant or approved equivalent. Other lubricants may be harmful to the cable accessory and/or the insulation. Lubricate the bore of the cable accessory in a similar manner if directed. Some permanent joints and live-front terminations may be supplied with silicone oil, which tends to be more slippery than the silicone grease provided with separable connectors and makes installation easier. CAUTION Silicone oil should never be used on a separable connector as it will migrate away after thermal cycling and lead to elbow sticking issues. Slide the housing onto the cable using a slight back and forth rotating motion until it is fully seated. Verify that the housing is properly orientated. This is particularly important with separable connectors. Remove the tape marker only if directed by the manufacturer’s instructions. Wipe off excessive lubricant that may have been forced out during the installation process.

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8. Metallic shield connection

Figure 11 —Typical shield adapter

Figure 12 —Braid installed and secured

All cable accessory shields (grounding tabs on pre-molded accessories), cable shields, and cable shield adapters must be tied to a common ground point. For pre-molded accessories, this is typically accomplished with a piece of #14 AWG or larger copper wire. For joints or separable connectors with exposed shields, proper grounding will maintain the dead front system. When installing a joint, the metallic shields are normally continued over the joint. The metallic shields should be adjacent to the joint exterior to provide a short path to ground in the event of a joint failure. SPECIAL APPLICATION In some special cases involving joints and terminations, the metallic shields may not be continued if required to form cross-bonding or shield break. Please refer to manufacturer’s or circuit owner’s specific requirements.

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Following the manufacturer’s instructions, the metallic shields of the cable may need to be connected to a system ground either directly or with the assistance of a shield adapter. Figure 11 and Figure 12 show a typical shielded adapter kit and how it is secured to the cable’s metallic shield.

IEEE Std 1816-2013 IEEE Guide for Preparation Techniques of Extruded Dielectric, Shielded Cables Rated 2.5 kV through 46 kV and the Installation of Mating Accessories

9. Cable seal and jacket restoration

9.1 Cable end seal Seal the end of a cable’s jacket using either the device previously stored on the cable or a separate method such as mastic and tape, or an integral part of the accessory. Refer to the directions packaged with the seal kit. CAUTION Only use mastic material provided with the sealing kit or mastics that are approved and compatible with cable accessories and cable. Other materials may degrade the cable and/or the accessory. Sealing the cable end will prevent moisture entering under the jacket and possibly corroding the cable’s metallic shield.

9.2 Joint jacket restoration Use heat-shrink tubes, cold-shrink tubes, gel wraps, or tape and mastic to restore the cable’s outer protective jacket. This will prevent moisture and chemicals from corroding the cable’s metallic shields. For cables with lubricated or “slick” jackets, the jackets must be cleaned and abraded for sealant or mastic to function. CAUTION Clean and remove debris from outer jacket if a joint or other product will be temporarily parked in this area prior to installation.

10. Cable shield ground connection

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The neutral wires or copper lead from the cable metallic shield needs to be connected properly to the system ground.

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Annex A (informative) Bibliography [B1] ANSI C119.4-2004, American National Standard for Electric Connectors for Use Between Aluminum-to-Aluminum and Aluminum-to-Copper Conductors.6 [B2] Dang, C. and Fournier, D., “Dielectric Performance of Interfaces in Premolded Cable Joints,” IEEE Transactions on Power Delivery, Vol. 12, No. 1, pp. 29–32, January 1997. [B3] Dang, C. and Fournier, D., “A Study of the Interfacial Breakdown in Cable Joints,” IEEE Conference on Electrical Insulation and Dielectric Phenomena, Arlington, TX, pp. 518–523, October 1994. [B4] Fournier, D., “Effect of the Surface Roughness on Interfacial Breakdown Between Two Dielectric Surfaces,” IEEE International Symposium on Electrical Insulation, Montreal, Quebec, Canada, pp. 699– 702, June, 1996. [B6] IEEE Std 575™-1988, IEEE Guide for the Application of Sheath-Bonding Methods for SingleConductor Cables and the Calculations of Induced Voltages and Currents in Cable Sheaths.8, 9 [B7] IEEE P971™/D2, Draft Guide for the Installation and Removal of Power Cables Installed in Duct Systems. [B8] IEEE Std 1493™-2006, IEEE Guide for the Evaluation of Solvents Used for Cleaning Electrical Cables and Accessories. [B9] NEMA CC4-1986 (R1992), 8.3kV and 8.3/14.4kV Probe for Separable Insulated Loadbreak Connectors.10 [B10] OSHA 1910.269-1994, Electric Power Generation, Transmission, and Distribution.11

6 ANSI publications are available from the Sales Department, American National Standards Institute, 25 West 43rd Street, 4th Floor, New York, NY 10036, USA (http://www.ansi.org/). 7 ICEA publications are available from Global Engineering Documents, 15 Inverness Way East, Englewood, CO 80112, USA (http://global.ihs.com/) 8 IEEE publications are available from the Institute of Electrical and Electronics Engineers, 445 Hoes Lane, Piscataway, NJ 08854, USA (http://standards.ieee.org/) 9 The IEEE standards or products referred to in this clause are trademarks of the Institute of Electrical and Electronics Engineers, Inc. 10 NEMA publications are available from Global Engineering Documents, 15 Inverness Way East, Englewood, CO 80112, USA (http://global.ihs.com/) 11 OSHA publications are available from the U.S. Department of Labor, Occupational Safety & Health Administration, 200 Constitution Avenue, NW, Washington, DC 20210 (http://www.OSHA.gov)

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[B5] ICEA T-31-610-2007, Longitudinal water penetration resistance tests on blocked conductors. 7

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Annex B (informative) Compression tools

B.1 Scissor-type tools Either manually or ratchet powered, these tools develop a minimum amount of force, so are limited to approximately #4/0 AWG aluminum and smaller conductors. They use either replaceable dies, fixed dies, or are die-less.

B.2 Tool using two opposing dies These are typically hydraulic-driven tools that develop output forces from 6 to 60 tons or more. They can be powered by hand, electric or gas-driven pump, or battery. The replaceable dies are sized to specific barrel/conductor combinations. The dies can be either circumferential or hexagonal.

B.3 Tools using four-head indents Similar to the two opposing die tools, they are hydraulic-driven tools powered by hand, pumps, or batteries. Instead of replaceable dies, they have four fixed nibs that apply four indents to the connector.

B.4 Tools using single indents Normally hydraulic, but can be hand-powered, these tools have an indent nib and a nest and provide one indent. They are available in a broad range of output forces.

B.5 Tool adjustment and calibration Compression tools should be periodically checked to verify that they are in proper working order. They should be adjusted and calibrated to provide proper compression. --`,```,,,```,``,,,,,`,`,,````-`-`,,`,,`,`,,`---

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IEEE Std 1816-2013 IEEE Guide for Preparation Techniques of Extruded Dielectric, Shielded Cables Rated 2.5 kV through 46 kV and the Installation of Mating Accessories

Annex C (informative)

Table C.1—Power cables without metallic shielding/armor or wire shielded power cables without metallic shielding/armor Outside diameter of cable Thickness of insulation

≤ 1.000"

≤ 0.156" 0.157" To 0.315" > 0.316"

4 5 —

1.001" to 2.000"

> 2.000"

Bending radius multiplier 5 6 7

6 7 8

Table C.2—Power cables with metallic shielding and/or armored cables Cable construction

Bending radius multiplier

Flat Or Round Steel Wire Armor Smooth Aluminum Sheath: Outside Diameter Of Cable ≤ 0.75" Outside Diameter Of Cable 0.76" To 1.5" Outside Diameter Of Cable > 1.5" Interlocked Or Corrugated Sheath Armor: With Non-Shielded Cable With Single Conductor Shielded Cable With More Than One (1) Shielded Cable Flat Or Corrugated Non-Armored With One (1) Tape Shielded Single Conductor With More Than One (1) Tape Shielded Single Conductor Multi-Conductor With Overall Tape Shield Longitudinally Applied Corrugated Shield & PVC Jacket Flat Strap Shielded Without Armor Wire Shielded Without Armor Concentric Neutral Shielded Without Armor

12 10 Or 12 (See Note 1) 12 15 7 12 (See Note 2) 12 (See Note 2) 12 15 8 See Table C.1 8

NOTE 1— If smooth aluminum sheath contains non-shielded cables the multiplier is ten (10); however, if the cables are shielded, the multiplier is twelve (12). NOTE 2—The multiplier is either: twelve (12) times the outside diameter of a single conductor cable contained within the overall covering, or seven (7) times the outside diameter of the overall covering, whichever is greater.

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--`,```,,,```,``,,,,,`,`,,````-`-`,,`,,`,`,,`---

Recommended minimum cable bending radii

IEEE Std 1816-2013 IEEE Guide for Preparation Techniques of Extruded Dielectric, Shielded Cables Rated 2.5 kV through 46 kV and the Installation of Mating Accessories

Annex D (informative) Suggested cleaning procedure for corroded conductors If the cable has been in service for a considerable length of time and shows signs of excessive corrosion the cable strands should be fanned so that the circumference of the strands can be brushed. Apply a small amount of approved oxide inhibitor (with grit) to the wire brush and brush the strands. The oxide inhibitor will coat the native aluminum after the oxide film or patina has been mechanically removed, slowing the reformation of oxidation. The strands shall be returned to their original lay after wire brushing. A temporary cinch (see Figure D.1) can be applied as shown to facilitate the insertion of the re-bundled strands into the compression connector. Once the strands are slightly inserted into the compression connector the cinch shall be removed.

--`,```,,,```,``,,,,,`,`,,````-`-`,,`,,`,`,,`---

Figure D.1—Temporary cinch to hold strands

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Licensee=CB&I Houston, TX Riverway/Rogerdale/5926330013, User=Rodriguez, Wilson Not for Resale, 10/01/2014 14:18:53 MDT