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Cable Repairs: Vulcanized Splices

Cable Repairs: Vulcanized Splices

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Cable Repairs: Vulcanized Splices

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  1. Cable Repairs: Vulcanized Splices

  2. General procedure for vulcanized repair of mining cables type SHD-GC. • Introduction • Preparation • Insulation • Jacket • Vulcanization

  3. 1. Introduction

  4. Vulcanization: The ideal solution to repair a cable type SHD-GC is a repair that leaves the cable jacket and splice with the same properties and characteristics as previous to the repair. In this manner, the vulcanized cable repair is the best option, giving the splice better mechanical resistance, (traction and abrasion), resistance to water and humidity, resistance to extreme heat and cold outdoor temperature, resistance to oxidization caused by contact to oil and grease, and also resistance to flame.

  5. Vulcanization: • In order to do a vulcanized splice and cable repair, you • Need the following items: • Vulcanizer • Moulds for cables • Vulcanizing Kits (tapes, ThermoWeld, etc.)

  6. Vulcanizing, Repair and Cable Terminations Cables Vulcanizer • MCS supplies all necessary materials required to do a cable repair including: • Moulds and Vulcanizer • EPR and Insulating tapes • Reinforcing tapes • Semi-Conducting tapes • Jacket tapes, Hypalon or Neoprene • Miscellaneous accessories Complete Repair Kit

  7. Vulcanizing, Cable Repairs, and Cable Terminations Cable Vulcanizer MCS manufactures vulcanizers and cable moulds specifically for cable repairs. Vulcanizers are designed with dual heating platens, precision ground shaft supports and captive securing hardware. The control box includes temperature and timer controls for precise vulcanizer operation. Individual cable molds are machined from solid aluminum material and Teflon coated.

  8. Cable Vulcanizer Model 3000H

  9. 3. Vulcanizing, Cable Repairs, and Cable Terminations Cable Vulcanizer ModelMCS 4800HD (Hydraulic)

  10. Vulcanizing, Cable Repairs, and Cable Terminations Cable conductor connection systems: • MCS offers 3 conductor connection systems including: • Compression Connectors • Silver Solder • Thermoweld System with exothermic reaction

  11. Vulcanizing, Cable Repairs, and Cable Terminations Advantages of Vulcanized cable repair: • Cable repair is completely waterproof. • Flexible as the original cable up to -50°C. • Diameter of the splice is the same as the original cable. • Conductor connection is similar strength as original. • Cable jacket repair is strong and resistant. • System enables the repair of a wide variety and types of cable up to 35kV.

  12. 2. Preparation

  13. Damaged Cable

  14. Cut the cable and the 3 phase conductors and grounds.

  15. Cut conductors to required lengths, remove the copper shield.

  16. Remove semiconductive material

  17. Cut and remove insulation material leaving the conductors exposed.

  18. Conductor connection using ThermoWeld system.

  19. ThermoWeld Connection

  20. Conductor connection using silver solder.

  21. Connection of all 3 phases, grind and file connection.

  22. Pencil the ends of each of the 3 phases of the cable (on the insulation).

  23. 3. Insulation

  24. Once it has been sanded and cleaned

  25. Apply the semi-conductor tape over the connection and conductor.

  26. Apply the EPR insulator tape, to the same diameter of the original insulation.

  27. Over the EPR tape, cover once again with a layer of semi-conductor tape.

  28. Apply tinned copper braid tape.

  29. Repeat for each phase.

  30. Repair completed in all 3 phases.

  31. Connection of pilot conductor using silver solder.

  32. Connection of pilot cable using silver solder.

  33. Connection of ground cable using silver solder.

  34. Apply fiberglass tape and EPR insulation tape on the pilot cable.

  35. Add fiberglass tape to the pilot and ground cables. All the cable components have been completed.

  36. 4. Jacket

  37. Tighten and turn the cable to its original lay. It can be tied and held together by fiberglass tape.

  38. Apply separator tape.

  39. Pencil the ends of the jacket.

  40. Pencelling of the jacket.

  41. Apply reinforcing tape.

  42. Apply bonding cement at the ends of the splice.

  43. Apply cable jacket tape.

  44. Apply enough tape, so that the diameter is more then the mold.

  45. 5. Vulcanization

  46. Vulcanization: For the Vulcanization Process: 1. Heat the vulcanizer and mold to 150° C. 2. Apply mold release spray to both sides of the mold. 3. Open the vulcanizer, put a strip of jacket type in the bottom cavity of the mold. 4. Put the cable in the mold with a strip of jacket tape on top of it. 5. Close the mold and vulcanizer, apply pressure with the closing bolts. 6. Wait until the rubber is heated and begins to flow from the mold. 7. When the mold is completely closed, a small amount of rubber should continue to flow from the mold.

  47. Insert the mold with the cable into the vulcanizer.

  48. Set the timer for 60 minutes.

  49. The rubber from the jacket will continue to flow.

  50. Allow for the mold to cool to room temperature, then carefully remove the cable form the mold.