Cable Repairs: Vulcanized Splices

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Cable Repairs Vulcanized Splices
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General procedure for vulcanized repair of mining
cables type SHD-GC.

1. Introduction
2. Preparation
3. Insulation
4. Jacket
5. Vulcanization

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1. Introduction
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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.
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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.)

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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
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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.
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Cable Vulcanizer Model 3000H
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3. Vulcanizing, Cable Repairs, and Cable
Terminations
Cable Vulcanizer Model MCS 4800HD (Hydraulic)
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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

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Vulcanizing, Cable Repairs, and Cable Terminations
Advantages of Vulcanized cable repair

• Cable repair is completely waterproof.
• Flexible as the original cable up to -50C.
• 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.

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2. Preparation
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Damaged Cable
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Cut the cable and the 3 phase conductors and
grounds.
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Cut conductors to required lengths, remove the
copper shield.
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Remove semiconductive material
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Cut and remove insulation material leaving the
conductors exposed.
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Conductor connection using ThermoWeld system.
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ThermoWeld Connection
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Conductor connection using silver solder.
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Connection of all 3 phases, grind and file
connection.
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Pencil the ends of each of the 3 phases of the
cable (on the insulation).
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3. Insulation
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Once it has been sanded and cleaned
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Apply the semi-conductor tape over the connection
and conductor.
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Apply the EPR insulator tape, to the same
diameter of the original insulation.
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Over the EPR tape, cover once again with a layer
of semi-conductor tape.
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Apply tinned copper braid tape.
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Repeat for each phase.
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Repair completed in all 3 phases.
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Connection of pilot conductor using silver solder.
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Connection of pilot cable using silver solder.
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Connection of ground cable using silver solder.
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Apply fiberglass tape and EPR insulation tape on
the pilot cable.
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Add fiberglass tape to the pilot and ground
cables.
All the cable components have been completed.
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4. Jacket
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Tighten and turn the cable to its original lay.
It can be tied and held together by fiberglass
tape.
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Apply separator tape.
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Pencil the ends of the jacket.
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Pencelling of the jacket.
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Apply reinforcing tape.
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Apply bonding cement at the ends of the splice.
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Apply cable jacket tape.
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Apply enough tape, so that the diameter is more
then the mold.
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5. Vulcanization
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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.
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Insert the mold with the cable into the
vulcanizer.
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Set the timer for 60 minutes.
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The rubber from the jacket will continue to flow.
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Allow for the mold to cool to room temperature,
then carefully remove the cable form the mold.
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Let the vulcanized cable cool down.
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Sand and clean the finished jacket.
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Completed splice and jacket repair.
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Splice is of similar diameter to the original
cable.
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Completed cable repair splice.
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Advantages of Vulcanized Splice

• Completely impermeable to water and humidity.
• Vulcanized technique is for all types of jacket
  tape including, TPU, CPE, Hypalon.
• Vulcanized jacket has superior adhesion to the
  original cable jacket.
• The size and the diameter of the cable repair,
  allows for cable to be reeled.

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Thank You for your attention