Jointing of Cables: Unit Iv

JOINTING OF CABLES
UNIT IV
Need
• The emphasis should be laid on quality and selection of
proper cable accessories, proper jointing techniques and skill
and workmanship of the working personnel.
• The quality of joint should be such that it does not add any
resistance to the circuit.
• The materials and techniques employed should give

adequate mechanical and electrical protection to the joints
under all service conditions.
• The joint should further be resistant to corrosion and other

chemical effects.
Types of Joints
• Straight through joint
• This joint is used to connect two cables lengths together.
• Teel branch joint

• This is normally used for jointing a service cable to the main
distribution cable in city distribution network
• Termination or sealing end

• This is generally used to connect a cable to switchgear
terminal in switchboards and distribution pillars, transformers
boxes, motor terminal boxes and to overhead lines.
Types of Cable Jointing Accessories
• The basic types of cable jointing accessories available in
the country, at present, are:
• Joint sleeves with insulating and bitumen based filling

compound
• It is suitable for jointing cables of voltages up to and including 33 kV.
• Cast resin based cable accessories

• It is suitable for jointing cables of voltages up to and including) 11 kV.
• Heat shrinkable tubes
• Taped joints and slip-on (pre-moulded) joints.

Sleeve Type Joint
• This joint comprises:
• Dressing of cable ends and conductor joints
• Replacing factory made insulation by manual wrapping of

tapes or application of pre-formed insulating sleeves
• Plumbing metallic sleeve or wiping gland to the lead sheath of

the cable to prevent moisture from entering the joint
• Filling the metallic sleeve with molten bitumen compound or

insulating compound, and
• Fixing a cast iron or any other protective shell around the joint
filling the same once again with molten bitumen compound.
Cast Resin Joint
• This joint comprises:
• Dressing of cable ends and conductor joints:
• Wiping dry - The core insulation should be wiped dry and
all parts, which are to be embedded in the casting resin
should be roughened and cleared with
relevant/degreasing agents;
• Fixing two halves of mould around the cable joints or
ends and sticking them together and sealing to form a
leak proof cast mould;
• Pouring pre-mixed cast resin and hardner into the mould;
• Allowing sufficient time for setting casting resin;
• Removing plastics mould. In case of buried joint, the
plastics mould may be left intact.
General Installation Guidelines
• Joint Position
• During the preliminary stages of laying the cable, consideration should be given to
proper location of the joint position so that when the cable is actually laid the
joints are made in the most suitable places.
• There should be sufficient overlap of cables to allow for the removal of cable ends
which may have been damaged.
• This point is extremely important as otherwise it may result in a short piece of the
cable having to be included.
• The joint should not be near pipe end or at the bend.
• Joint Pits
• Whenever practicable, joint pit should be of
sufficient dimensions so as to allow jointers to
work with as much freedom of movement and
comfort as possible.
• For this purpose, the depth of the pit should

be at least 0·3 m below the cables to be
jointed. The sides of the pit should be draped
with small tarpaulin sheets to prevent loose
earth from falling on the joint during the
course of making.
• Joint Pits
• If the ground has been made up by tipping, or if running sand
is met with, the pit should be well shored up with timber so as
to prevent collapse, The floor of the joint pit should be well
consolidated.
• The two lengths of cable meeting at a joint are laid with an
overlap of at least half the length of joint box when pulling in.
This enables the jointer to adjust the position of his joint
slightly to allow for any obstructions that may be
encountered.
• When two or more cables are laid together, the Joints are
arranged to be staggered so as to reduce the excess width of
trench and also to Isolate the joints from each other and
reduce the possibility of one joint failure affecting the other
joints.
• Sump Holes
• When joining cable In water-logged ground or under monsoon
conditions, a sump hole should be excavated at one end of the joint
hole in such a position so that the accumulating water can be
pumped or baled out without causing interference to the jointing
operation.
• Tents
• As far as possible a tent should be used where jointing work is being
carried out in the open.
• In case of paper insulated cable, the cable seals should be examined

to ascertain that they are intact and also that the cable ends arc not
damaged, If the seals are found broken or the lead "heath
punctured, the cable ends should not be jointed until after due
examination and testing by the engineer-in-charge of the work.
• Aluminium Conductor Connections
• There are number of method of jointing aluminium
conductors. Four standard methods which are move
commonly used are
• Fluxeless friction solder method
• Soft soldering method using organic fluxes
• Welding method
• Crimped or compressed connection

• Fluxless Friction Solder Method
• In this method each strand of the conductor is carefully
cleared and scraped with scraper tongs to remove oxide film.
• Then all the strands are tinned by rubbing a special friction

solder stick over the heated strands. This is known as
metallizing.
• Aluminium conductor thus prepared may be soldered on to

copper cable lugs, ferrule, terminal studs using 60 percent
solder: No flux is used in any of the operation.
• This method is not recommended for jointing conductors in

XLPE cables.
• Soldering Method Using Organic Flux
• The individual strands should be separated and cleaned
thoroughly by a scraper and the impregnation compound and
oil if any, should be removed.
• If necessary the strands can be stepped. The conductors

should then be preheated by basting with solder, the
temperature of which should be maintained at 316°C or as
recommended by manufacturers.
• The excess solder should then be wiped off quickly and

aluminium solder flux should be applied to the conductor by a
stiff brush on all sides of conductor.
• The conductor should then be basted several times with
solder. If necessary the flux should be applied again and the
conductor basted with solder till a bright shining appearance
is obtained.
• The copper ferrule, which is generally of a weak-back type,
should be tinned and fitted on to the conductor and closed
firmly but not completely.
• The ferrule should then be basted with solder and the gap
should be filled in with the solder.
• The ferrule should then be closed firmly and basted with
solder, till the solder solidifies.
• The excess solder should be wiped off and the joint allowed to
cool.
• During jointing operation copious fumes are given off when
the flux is heated. These fumes contain small quantities of
fluorine and it is, therefore, advisable to avoid inhaling them
as far as possible.
• It is also recommended that proper ventilation be maintained

at the place of jointing.
• Organic fluxes tend to char and are rendered ineffective when

exposed to temperature in excess of 300°C. Emphasis should,
therefore, be laid on the need to control pot temperature.
• Welding Method
• Welding method gives the best possible results.
• Welded conductor joints have lesser resistance and equal or better
mechanical strength than the conductor itself.
• Welding, therefore, should be given preference for all larger cross
sections.
• For smaller cross section welding may not always be feasible or
economical.
• In this method the end of the stranded conductor are first welded
to the cable lug, terminal stud or to each other, in open or closed
mould using aluminium welding rods or strands taken from
conductor.
• After cooling welded connections are filed smoothened and
cleaned.
• Crimped or Compressed Connections
• In this method conductor and lug ferrules are pressed

together firmly by means of tools and dies to form a joint.
• The methods normally used are indent compression,

hexagonal compression or circular compression.
• Tools and accessories should meet the requirement of

relevant Indian Standards where available.

Jointing of Cables: Unit Iv

Uploaded by

Copyright:

Available Formats

Jointing of Cables: Unit Iv

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Jointing of Cables: Unit Iv

Uploaded by

Copyright:

Available Formats

JOINTING OF CABLES

• The materials and techniques employed should give

• The joint should further be resistant to corrosion and other

• Teel branch joint

• Termination or sealing end

• Joint sleeves with insulating and bitumen based filling

• Cast resin based cable accessories

• Heat shrinkable tubes

• Taped joints and slip-on (pre-moulded) joints.

• Replacing factory made insulation by manual wrapping of

• Plumbing metallic sleeve or wiping gland to the lead sheath of

• Filling the metallic sleeve with molten bitumen compound or

• For this purpose, the depth of the pit should

• In case of paper insulated cable, the cable seals should be examined

• Fluxeless friction solder method

• Soft soldering method using organic fluxes

• Crimped or compressed connection

• Then all the strands are tinned by rubbing a special friction

• Aluminium conductor thus prepared may be soldered on to

• This method is not recommended for jointing conductors in

• If necessary the strands can be stepped. The conductors

• The excess solder should then be wiped off quickly and

• It is also recommended that proper ventilation be maintained

• Organic fluxes tend to char and are rendered ineffective when

• In this method conductor and lug ferrules are pressed

• The methods normally used are indent compression,

• Tools and accessories should meet the requirement of

You might also like