…your final connection. mine cable services corporation. cable repairs: vulcanized splices

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Mine Cable Services Corporation.

Cable Repairs: Vulcanized Splices



General procedure for vulcanized repair of mining cables type SHD-GC.

1. Introduction

2. Preparation

3. Insulation

4. Jacket

5. Vulcanization



1. Introduction



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.



Vulcanization:

In order to do a vulcanized splice and cable repair, you

Need the following items:

1. Vulcanizer

2. Moulds for cables

3. Vulcanizing Kits (tapes, ThermoWeld, etc.)



Vulcanizing, Repair and Cable Terminations

Cables Vulcanizer

Complete Repair Kit

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



Vulcanizing, Cable Repairs, and Cable Terminations

Cable Vulcanizer

Individual cable molds are machined from solid aluminum material and Teflon coated.

The control box includes temperature and timer controls for precise vulcanizer operation.

Vulcanizers are designed with dual heating platens, precision ground shaft supports and captive securing hardware.

MCS manufactures vulcanizers and cable moulds specifically for cable repairs.



Cable Vulcanizer Model 3000H



3. Vulcanizing, Cable Repairs, and Cable Terminations

Cable Vulcanizer Model MCS 4800HD (Hydraulic)




Cable conductor connection systems:

MCS offers 3 conductor connection systems including:

Compression Connectors

Silver Solder

Thermoweld System with exothermic reaction




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.



2. Preparation



Damaged Cable



Cut the cable and the 3 phase conductors and grounds.



Cut conductors to required lengths, remove the copper shield.



Remove semiconductive material



Cut and remove insulation material leaving the conductors exposed.



Conductor connection using ThermoWeld system.



ThermoWeld Connection



Conductor connection using silver solder.



Connection of all 3 phases, grind and file connection.



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



3. Insulation



Once it has been sanded and cleaned



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



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



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



Apply tinned copper braid tape.



Repeat for each phase.



Repair completed in all 3 phases.



Connection of pilot conductor using silver solder.



Connection of pilot cable using silver solder.



Connection of ground cable using silver solder.



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



All the cable components have been completed.

Add fiberglass tape to the pilot and ground cables.



4. Jacket



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



Apply separator tape.



Pencil the ends of the jacket.



Pencelling of the jacket.



Apply reinforcing tape.



Apply bonding cement at the ends of the splice.



Apply cable jacket tape.



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



5. Vulcanization



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.



Insert the mold with the cable into the vulcanizer.



Set the timer for 60 minutes.



The rubber from the jacket will continue to flow.



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



Let the vulcanized cable cool down.



Sand and clean the finished jacket.



Completed splice and jacket repair.



Splice is of similar diameter to the original cable.



Completed cable repair splice.



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.



Thank You for your attention

…your final connection. mine cable services corporation. cable repairs: vulcanized splices

Documents

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