Publish Time: 2025-12-02 Origin: Site
When it comes to ensuring reliable power connections, MV cable terminations are incredibly compatible with cold shrink technologies, primarily due to their design, which allows them to match different cable sizes.
However, when installing an MV cable termination kit with cold-shrinkable components, it's important to be especially careful so as to avoid circuit problems. In this guide, we'll look into the right installation process using these cod-shrinkable tools.
Cold-shrinkable termination kits are electrical components used to insulate and finish the ends of MV cables. They work primarily with cables rated between 6kV and 36 kV, and they come with components such as:
A stress-control tube
Ant-tracking tube
Insulation tube
Sealing or mastic tapes
A cold-shrink tube
In terms of how it works, cold-shrink technology supplies tubes with a removable, pre-expanded core. The moment you pull the core out, its material shrinks to form a solid, consistent seal around the cable.
These components are preferred to heat shrink kits because you don't need gas torches to work with them. This means that you don't run the risk of overheating or a fire hazard. At the same time, cold shrink kits offer a more consistent shrink, lower risk of damage due to extreme temperatures, and a relatively easier installation process in closed spaces.
Now that we understand the link between MV cable termination kits and cold-shrinkable accessories, let's examine the materials you'll need for this installation process to go on without a hitch.
PPE: You can't have an installation process without protective gear. So, get insulated gloves and flame-retardant clothing to keep you safe.
Standard tools: For standard installation tools, get a crimping device, a tool for removing cores, a wire brush, a cable stripper, and cleaning wipes to prepare and assemble the termination.
Kit accessories: You need sealing mastics, stress-control materials, cold shrink tubes, and cable lugs that will come with the termination kit itself.
Optional but useful tools: While they're not exactly necessary, you will need a torque wrench to properly tighten lugs, as well as an insulation tester to perform checks after the process is done.
So, the stage is set. We have everything needed to install the MV cable termination kits, so let's begin with the process
Before you actually istall the MV cable termination kit, you will need to ensure a few critical checks. Here are a few pointers to consider:
First, check to see if the cable is a single-core or three-core cable. You also want to check the insulation material, since cold-shrink kits are usually built to fit specific constructions. The last thing you want is to use the wrong insulation material as it could cause issues with stress control.
You need to ensure a match between the kit and the cable's voltage rating and physical size. Fortunately, the manufacturer should provide a chart to help with this, so you can check it out.
Watch out for signs of dirt, moisture entry, mechanical damage, or even swelling at the end of the cable. If you notice any defect, it could severely compromise the termination nd lead to failure or partial discharge.
The entire installation process needs to be performed in a clean and dry environment that's free of any dust.
Refer to the manufacturer's data sheet to find the exact cutback length for the screen, outer sheath, and others. This accuracy is important to ensure a proper fit.
Cut the outer sheath carefully without damaging the metallic screen. This controlled action maintains the cable's electrical and mechanical integrity.
Get an appropriate solvent wipe to take out dust and grease from the exposed insulation. This leaves a clean surface that provides proper adhesion.
Cut the cable insulation to the proper length for conductor exposure. Remember to be as precise as possible here.
Once again, clean the conductor strands with a wire brush to remove any residual oxidation.
The conductor type and size need to match the lug size. A mismatch will lead to terrible compression and can even cause overheating.
With the right crimping tool and die, you'll be able to create a reliable, low-resistance connection.
Once the ccrimp is done, check it to ensure that all marks are present and there are no ccracks.
Here's the thing about MV levels - the point where the insulation ends will experience a lot of stress. Stress control mastics or tubes will spread this stress envenly, allowing you to prevent any breakdown.
All you have to do is slide the stress-control tube to form an accurate mastic later. Ensure uniform coverage as well, with the proper overlap on the insulation and screen cutback. Also, confirm that the tube is centered before you go ahead.
Put the pre-expanded tube over the termination area and make sure that alignment marks match the recommended positions.
Pull the internal core and watch the tube shrink uniformly as it unwindds. This will form an insulation barrier, but also remember to ensure that the tube stays centered and doesn't shift along the cable during shrinking.
Outdoor terminations need extra resistance to moisture, UV light, and other pollutants. To ensure this, you need anti-tracking tubes.
All you have to do is slide the tube into the proper position and take out the core to get a tight seal. You can also refer to the manufacturer's instructions to get proper coverage.
If you need extra sealing, then you can add sealing tape at the base - especially for installations done in harsh environments.
Once the installation is done, we recommend performing a few quality control steps just to be extra safe:
Make sure all your components are properly shrunk, aligned, and free from exposure.
You also want to make sure the lug is properly crimped and secured to the equipment terminal.
With an insulation tester, confirm ideal insulation resistance. Make sure valves fall within the acceptable range for the type of cable and for the voltage class as well.
Keep accurate records of things like termination type, cable size, and the results of all tests. For troubleshooting and maintenance, these documents will be needed.
Even in the most professional environments, it's important to avoid certain mistakes that can compromise the reliability of your termination. Here are a few to keep an eye on:
If the screen, insulation, or sheath aren't in the proper length, you won't be able to get a good fit for the termination components.
Make sure not to accidentally cut, nick, or score the insulation while removing the sheath. This could create weak points and even a partial discharge over time.
Issues like an inefficient crimping tie and poor compression can create high-resistance joints that will overheat as they work.
Primariy, MV cable termination kits are built to not need so much maintenance. However, it's still important to ensure periodic inspections so as to identify and address any signs of deterioration.
Always check for contamination or surface changes within the termination
Your outdoor terminations should also be checked for pollution, dust buildup, and other external elements
All components need to remain in firmly place without any mechanical strain
If any termination shows tracing or moisture access, we'd recommend replacing it entirely instead of repairing it.
You might need to ensure a more broader inspection once you notice different terminations on the same circuit showing similar signs of deterioration
Remember to only replace components based on the manufacturer's specifications
While it might seem easy, the process of installing MV cable termination kits is an intricate one that requires a lot of care. However, with the right tools, and by following the steps we've outlined, you should be able to enjoy a seamless process.
To learn more about MV cable termination kits, feel free to contact us at Haivol Electrical.
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