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High voltage cable splicing has different types and systems to repair or connect two ends of a cable. The splice type used depends on the application, cable construction, and environment. Here are the most common high-voltage cable splicing types.
Hydraulic splices use hydraulic machinery to apply pressure for a strong, permanent connection. Their compression installation provides excellent conductivity and helps reduce energy loss, hence applicable in power distribution.
Mechanical splices utilize metal fittings, screws, or clamps to connect conductors. It is easy to install with lower labor costs, although not as durable as other splices and often used in temporary repairs and low-to-mid voltage cables.
A resistance welding splice uses electrical resistance and pressure to fuse conductors at the joint. Its strong, heat, and current resistant make it ideal for extreme environments, and it is used in mining or chemical plants.
It involves using induction heating to melt a solder or weld core to bond conductors. Though less common, it provides a high-quality connection suited for environments where electrical resistance welding may fail. It is used primarily with specialty cables in high-performance applications.
Inline splices connect two cable sections by cutting one end of each cable and overlapping them in a straight line. This provides a low-resistance path where cable sections need to be joined, mainly used in long cable runs.
It combines elastomeric insulating materials and mechanical compression to splice cables. A rubber-like insulating layer protects and compresses the metal connection between conductors. The metal connection is fastened using bolts and applies pressure to ensure low-resistance electrical contact between conductors.
Durability is a key consideration when applying high voltage cable terminal connections since they are expected to last several years without failure while constantly exposed to power load, weather, and physical stress. Splices use materials that provide strength, flexibility, moisture and chemical resistance, and heat dissipation. The typical materials and features that enhance durability are described below:
Leak-proof Adhesive
Leak-proof adhesive along splice seams keeps moisture from infiltrating cable layers. Silicone, polyurethane, and other high-performance sealants fill gaps tightly and create a waterproof barrier.
Heat Shrink Insulation
Heat shrink materials are durable and form tight seals that protect splices from moisture and mechanical damage. Polyolefin and cross-linked polyethylene heat shrink are flexible but tough and provide excellent insulation.
Strength of Metal Materials
The mechanical part of the splice uses materials such as copper, aluminum, and steel alloys to connect the cables. These have good electrical conductivity, corrosion resistance, and high tensile strength to support the cable's weight and withstand pulling forces during installation and operation.
Flexibility and Rigidity
Flexible materials, such as copper and certain polymers, are critical for splices where cables bend or move. Rigid materials provide physical protection but must be carefully designed to avoid cracking from cable flexing. The right balance of flexibility and rigidity ensures splices tolerate mechanical stresses without premature failure.
Chemical Resistance
Splices often undergo exposure to corrosive chemicals, fuels, and solvents, especially in industrial and outdoor settings. Durables have properties that resist these materials, such as stainless steel, polyurethane, and cross-linked polyethylene, which protect against corrosion and degradation. Chemical-resistant materials prolong the lifespan of splices in harsh environments.
High-voltage cable splicing scenarios are specific applications or environments where it is commonly used to ensure the cables function properly and safely in their intended roles. Some of these scenarios are described below:
Splicing is used to connect lengths of underground cables in electrical grids to power homes and businesses. This maintains electrical continuity and capacity in power systems.
Mining, oil and gas, manufacturing, and chemical plants use high-voltage splicing in machinery to power heavy equipment and maintain production. Reliably links cables in high-demand industrial environments.
Splicing connects cables from solar farms, wind turbines, and other renewable energy installations to transmission grids. It is essential for transporting electricity from generation sites to consumers.
Subways, rail systems, electric vehicle charging stations, and other transportation infrastructure rely on high-voltage splicing to power trains, signals, and track systems. It keeps transportation networks operating smoothly by linking cables in transit systems.
The Office Tower and Campus to connect electrical supply cables for heating, ventilation, air conditioning, lighting, and other systems depend on high-voltage splicing. It distributes power effectively in large structures.
Telecom networks use splicing to power cell towers, fiber optic cable junction boxes, and other equipment. This maintains a reliable communication service by linking cables in telecommunications.
UPS, emergency generators, and other backup power systems use splicing to maintain seamless power delivery during outages. It ensures like emergency systems stay operational when primary power fails.
Choosing the right high voltage cable connectors for a specific application involves several considerations. Here are some of the factors to consider:
Splice Type
The kind of splice used to connect the cables will provide an option that meets the electrical load requirements of the environment. Those with hydraulic, mechanical, resistance welding, induction heating, inline, elastomer, and compression splices all have different electrical load capacities.
Environmental Factors
Client environments have to be considered when selecting high-voltage splices. For instance, marine, mining, chemical, or outdoor conditions require high protection and durability from a splice against moisture, chemicals, heat, and physical stress. In such situations, resistance-welding splices, heat-shrinkable insulations, and elastomer components are used.
Installation Requirements
Some splices have more stringent installation requirements, like specialized tools and skills, while others are simple. Mechanical splices are easier to install than resistance welding or induction heating splices, which require more specialized procedures. The project timeline and budget should be considered when dealing with installation complexity.
Cable Compatibility
The splice used must be compatible with the cable types in the job. This includes operating whether the splicing equipment and materials work with solid or stranded conductors and different cable insulations, such as cross-linked polyethylene and rubber.
Code and Standards Compliance
High-voltage splices are expected to comply with industry standards like IEEE, NEC, and local regulations. These codes have minimum performance requirements for high-voltage splicing to meet safety and reliability. Get the applicable standards ready to use as a reference when selecting the splices.
A1: High-voltage cable splicing electrically connects two high-voltage cable ends to create a continuous path for electricity. It joins longer cable lengths to accommodate installation needs, repair damaged cables, or split power among systems.
A2: High-voltage cable splicing has several uses, including repairing damage and connecting cable sections. It powers electrical infrastructure; without splicing, cables couldn't effectively transmit high-voltage power over long distances, making splicing essential for reliable power distribution and keeping up cable performance and safety.
A3: High voltage wire terminals work by carefully joining conductors of insulated cable together using techniques such as compression, welding, or heat. Proper protection and insulation prevent energy loss and safety risks like electrocution and fire.
A4: The common types of high-voltage cable splicing include hydraulic, mechanical, resistance welding, induction heating, inline, and compression splices.
