IEEE STD 404-2012

IEEE Standard for Extruded and
Laminated Dielectric Shielded Cable

Joints Rated 2.5 kV to 500 kV
IEEE Power & Energy Society
Sponsored by the
Insulated Conductors Committee
IEEE
3 Park Avenue IEEE Std 404-2012
New York, NY 10016-5997 (Revision of
USA IEEE Std 404-2006)
18 June 2012
Authorized licensed use limited to: Universidad de Tarapaca. Downloaded on March 27,2017 at 13:11:29 UTC from IEEE Xplore. Restrictions apply.
IEEE Std 404-2012
(Revision of
IEEE Std 404-2006)

Sponsor
Insulated Conductors Committee

of the
IEEE Power & Energy Society
Approved 29 March 2012
IEEE-SA Standards Board
Abstract: Electrical ratings and test requirements of cable joints used with extruded and
laminated dielectric shielded cable rated in preferred voltage steps from 2.5 kV to 500 kV are
established in this standard. In addition, test requirements for joint metallic-shield and jacketing
components are defined. A variety of common joint constructions are also defined. This standard
has been designed to provide uniform testing procedures that can be used by manufacturers and
users to evaluate the ability of underground power cable joints, and associated metallic-shields
and jacketing components, to perform reliably in service.
Keywords: basic insulation level (BIL), cable joints, dielectric integrity tests, extruded dielectric
cable, IEEE 404, laminated dielectric cable, sheath/shield sectionalizers, transition joints,
withstand voltage
The Institute of Electrical and Electronics Engineers, Inc.

3 Park Avenue, New York, NY 10016-5997, USA
Copyright 2012 by The Institute of Electrical and Electronics Engineers, Inc.

All rights reserved. Published 18 June 2012. Printed in the United States of America.
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PDF: ISBN 978-0-7381-7267-5 STD97242

Print: ISBN 978-0-7381-7373-3 STDPD97242
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v
Participants
At the time this IEEE standard was completed, the Revision of IEEE Cable Joint Standard 404 Working
Group had the following membership:
Glenn J. Luzzi, Chair

Saleman Alibhay, Vice Chair
Edward Bradley Mike Jackson Thomas J. Parker

Jim Braun Edward M. Jankowich Todd Richardson
Thomas C. Champion, III Margaret Jasek Tim Robeson
Philip Cox Farris Jibril Michael Smalley
David E. Crotty Ivan Jovanovic Gregory Stano
Frank DiGuglielmo Sherif Kamel Stan Szyszko
Mike Dyer Carlos Katz William Taylor
Chad Eckhardt Dan Kennedy Milan Uzelac
Jon Erickson Albert Kong Tim Wall
Robert Gear, Jr. John M. Makal Carl Wentzel
Richard L. Harp Shoji Mashio Jade Wong
Harry Hayes, III Tim McLaughlin Vitaliy Yaroslavskiy
Jeffrey Helzer Aaron Norris Harry Yaworski
David Hughes Neal Parker
The following members of the individual balloting committee voted on this standard. Balloters may have
voted for approval, disapproval, or abstention.
Roy Alexander Werner Hoelzl Bartien Sayogo

Saleman Alibhay David Hughes Dennis Schlender
Martin Baur Edward M. Jankowich Gil Shultz
Michael Bayer A. S. Jones Michael Smalley
Vern Buchholz John Kay Jerry Smith
William Byrd Dan Kennedy Gregory Stano
Thomas C. Champion, III Gael Kennedy Gary Stoedter
Robert Christman Joesph L. Koepfinger William Taylor
David E. Crotty Robert Konnik Peter Tirinzoni
Gary Donner Jim Kulchisky Nijam Uddin
Donald Dunn Chung-Yiu Lam John Vergis
Gary Engmann Michael Lauxman Martin Von Herrmann
Michael Faulkenberry Glenn J. Luzzi Carl Wall
James Fitzgerald Jeff Madden Mark Walton
Robert Gear, Jr. Arturo Maldonado Yingli Wen
Steven Graham Gary Michel Carl Wentzel
Randall Groves Jerry Murphy Kenneth White
Frank DiGuglielmo Michael S. Newman Jian Yu
Richard L. Harp Joe Nims Dawn Zhao
Jeffrey Hartenberger Lorraine Padden Tiebin Zhao
Timothy Hayden Serge Pelissou J. Zimnoch
Jeffrey Helzer Johannes Rickmann
Lauri Hiivala Michael Roberts
vi
When the IEEE-SA Standards Board approved this standard on 29 March 2012, it had the following
membership:
Richard H. Hulett, Chair

John Kulick, Vice Chair
Robert M. Grow, Past President
Judith Gorman, Secretary
Satish Aggarwal Alexander Gelman Oleg Logvinov

Masayuki Ariyoshi Paul Houz Ted Olsen
Peter Balma Jim Hughes Gary Robinson
William Bartley Young Kyun Kim Jon Walter Rosdahl
Ted Burse Joseph L. Koepfinger* Mike Seavey
Clint Chaplin John Kulick Yatin Trivedi
Wael Diab David J. Law Phil Winston
Jean-Philippe Faure Thomas Lee Yu Yuan
Hung Ling
*Member Emeritus
Also included are the following nonvoting IEEE-SA Standards Board liaisons:
Richard DeBlasio, DOE Representative

Michael Janezic, NIST Representative
Julie Alessi
IEEE Standards Program Manager, Document Development
Malia Zaman
IEEE Standards Program Manager, Technical Program Development
vii
Introduction
This introduction is not part of IEEE Std 404-2012, IEEE Standard for Extruded and Laminated Dielectric Shielded
Cable Joints Rated 2.5 kV to 500 kV.
This standard provides manufacturers and users with a consistent set of qualification test requirements for
all cable joints. It also provides production test requirements for many cable joints used on extruded
dielectric cables. Material properties and sampling rates are included for joint designs not easily production
tested in their final form.
This revision of the standard provides closer harmonization to international standards for those cable joints
used on extruded dielectric cables rated 69 kV and above.
It provides more applicable testing protocols to verify appropriate joint operation in the field for extruded
dielectric cable joints in a joint-series. A joint-series is a family of joints designed and manufactured to
cover a wide range of cable including various conductor sizes and materials as well as various extruded
insulation thicknesses and materials.
It changes the format of the design test sequence tables to provide a more clear and concise format to
eliminate interpretation errors.
viii
Contents
1. Overview .................................................................................................................................................... 1
1.1 Scope ................................................................................................................................................... 1
2. Normative references.................................................................................................................................. 1
3. Definitions .................................................................................................................................................. 3
3.1 Cable joint categories .......................................................................................................................... 3
3.2 Joint constructions ............................................................................................................................... 3
3.3 Other terms .......................................................................................................................................... 4
4. Service conditions ...................................................................................................................................... 4
5. Ratings........................................................................................................................................................ 5
5.1 Voltage ................................................................................................................................................ 5
5.2 Current and temperature ...................................................................................................................... 5
6. General requirements.................................................................................................................................. 7
6.1 Identification........................................................................................................................................ 7
6.2 Shielding.............................................................................................................................................. 8
6.2.1 Semiconducting shield...................................................................................................................... 8
6.3 Jacket seal............................................................................................................................................ 8
6.4 Sheath/shield sectionalizers ................................................................................................................. 8
7. Design testing ............................................................................................................................................. 8

7.1 Design tests and testing sequence for all joint types............................................................................ 9
7.2 Design test conditions.......................................................................................................................... 9
7.3 Dielectric integrity tests..................................................................................................................... 11
7.4 Voltage tests ...................................................................................................................................... 15
7.5 Short-time current test ....................................................................................................................... 17
7.6 Cyclic aging test for extruded dielectric and transition joints............................................................ 17
7.7 High-voltage time test........................................................................................................................ 20
7.8 Sectionalizer tests .............................................................................................................................. 20
7.9 Shielding test ..................................................................................................................................... 21
7.10 Joint metallic-shield and jacketing components .............................................................................. 22
7.11 Connector thermal and mechanical tests.......................................................................................... 25
8. Routine production testing........................................................................................................................ 25

8.1 Premolded and single-component cold-shrink joints......................................................................... 26
8.2 Heat-shrink and multi-component cold-shrink joints ........................................................................ 26
8.3 Elastomeric taped joint components .................................................................................................. 27
Annex A (informative) Typical values of heat-shrinkable and multi-component cold-shrink joint

component tests and sampling rates ............................................................................................................. 30
Annex B (informative) Typical values of elastomeric taped joint component tests and sampling rates ..... 31
Annex C (informative) DC test voltage reference ....................................................................................... 32
Annex D (informative) Bibliography .......................................................................................................... 34
ix
x
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Concerning IEEE Documents. They can also be obtained on request from IEEE or viewed at
http://standards.ieee.org/IPR/disclaimers.html.
1. Overview
1.1 Scope
This standard establishes electrical ratings and test requirements of cable joints used with extruded and
laminated dielectric shielded cables rated in preferred voltage steps from 2.5 kV to 500 kV. In addition, it
defines test requirements for joint jacket seal devices and joint metallic-shield devices.
This standard also defines a variety of common joint constructions.
Joints that connect more than two cables or connect cables with two different conductor sizes are not
covered by this standard. However, manufacturers and users are encouraged to use appropriate parts of this
standard to evaluate these joints.
2. Normative references
The following referenced documents are indispensable for the application of this document (i.e., they must
be understood and used, so each referenced document is cited in text and its relationship to this document is
1
IEEE Std 404-2012
IEEE Standard for Extruded and Laminated Dielectric Shielded Cable Joints Rated 2.5 kV to 500 kV
explained). For dated references, only the edition cited applies. For undated references, the latest edition of
the referenced document (including any amendments or corrigenda) applies.
AEIC CS1, Specification for Impregnated Paper-Insulated Metallic-Sheathed Cable, Solid Type. 1
AEIC CS2, Specification for Impregnated Paper and Laminated Paper Polypropylene Insulated Cable, High
Pressure Pipe Type.
AEIC CS3, Specification for Impregnated-Paper-Insulated Metallic Sheathed Cable, Low Pressure Gas-
Filled Type.
AEIC CS4, Specification for Impregnated-Paper-Insulated Low and Medium Pressure Self-Contained
Liquid Filled Cable.
AEIC CS8, Specification for Extruded Dielectric Shielded Power Cables Rated 5 Through 46 kV.
AEIC CS9, Specification for Extruded Insulation Power Cables and Their Accessories Rated Above 46 kV
Through 345 kV ac.
ANSI C119.4, Electric ConnectorsConnectors to Use Between Aluminum-to-Aluminum or Aluminum-

to-Copper Conductors. 2
ASTM D149-97a, Standard Test Method for Dielectric Breakdown Voltage and Dielectric Strength of
Solid Electrical Insulating Materials at Commercial Power Frequencies. 3
ASTM D412-98, Standard Test Methods for Vulcanized Rubber and Thermoplastic Elastomers.
ASTM D991-89, Standard Test Method for Rubber Property-Volume Resistivity of Electrically Conductive
and Antistatic Products.
ASTM D4325-08, Standard Test Methods for Nonmetallic Semi-Conducting and Electrically Insulating
Rubber Tapes.
ASTM D4496-04, Standard Test Method for DC Resistance or Conductance of Moderately Conductive
Materials.
ICEA P-32-382, Short-Circuit Characteristics of Insulated Cable. 4
ICEA P-45-482, Short-Circuit Performance of Metallic-shields and Sheaths on Insulated Cable.
IEEE Std 4, IEEE Standard Techniques for High-Voltage Testing. 5, 6
IEEE Std 82, IEEE Standard Test Procedure for Impulse Voltage Tests on Insulated Conductors.
1
AEIC publications are available from the Association of Edison Illuminating Companies, 600 N. 18th Street, P.O. Box 2641,
Birmingham, AL 35291-0992, USA (http://www.aeic.org/). AEIC publications are also available from Global Engineering
Documents, 15 Inverness Way East, Englewood, CO 80112-5704, USA (http://global.ihs.com/).
2
ANSI publications are available from the Sales Department, American National Standards Institute, 25 West 43rd Street, 4th Floor,
New York, NY 10036, USA (http://www.ansi.org/).
3
ASTM publications are available from the American Society for Testing and Materials, 100 Barr Harbor Drive, West Conshohocken,
PA 19428-2959, USA (http://www.astm.org/).
4
ICEA publications are available from ICEA,, P.O. Box 1568, Carrollton, GA 30112, USA (http://www.icea.net/).
5
IEEE publications are available from The Institute of Electrical and Electronics Engineers, 445 Hoes Lane, Piscataway, NJ 08854,
USA (http://standards.ieee.org/).
6
The IEEE standards or products referred to in this clause are trademarks of The Institute of Electrical and Electronics Engineers, Inc.
2
IEEE Std 404-2012
IEEE Std 575-1988, IEEE Guide for the Application of Sheath-Bonding Methods for Single-Conductor
Cables and the Calculation of Induced Voltages and Currents in Cable Sheaths. 7
IEEE Std 592, IEEE Standard for Exposed Semiconducting Shields on High-Voltage Cable Joints and
Separable Insulated Connectors.
IEEE Std C37.09, IEEE Standard Test Procedure for AC High-Voltage Circuit Breakers Rated on a
Symmetrical Current Basis.
3. Definitions
For the purposes of this document, the following terms and definitions apply. The IEEE Standards
Dictionary Online should be consulted for terms not defined in this clause. 8
3.1 Cable joint categories
Cable joints are generally described by one of the categories that follow. These descriptive categories are
provided only for convenience. They are not intended to cover all possible joint constructions. Some joint
constructions may incorporate characteristics of two or more of the design categories listed.
extruded: A joint in which both cables are insulated with extruded dielectric materials rated 2.5 kV to 500
kV.
laminated: A joint in which both cables have a dielectric that consists of fluid-impregnated paper or
paper/synthetic laminated tape, or varnished cloth.
transition: A joint that connects an extruded dielectric cable to a laminated dielectric cable.
3.2 Joint constructions
field vulcanized: A joint constructed in the field using externally applied heat and pressure to cross-link
the joint polymeric materials.
filled: A joint consisting of an outer shell that is filled with an insulating material to occupy the space
around the individual insulated conductor(s).
heat-shrink: A joint provided to the end user as one or more expanded polymeric components that undergo
thermally activated recovery when heated to an appropriate temperature. Production electrical testing
cannot be performed on this type of joint because the stress control, insulation, and shield layers are not
integrated during the molding or extrusion process.
multi-component cold-shrink: A joint provided to the end user as two or more expanded components that
are applied over a prepared cable and reduced in diameter without the use of heat by removal of the
supporting cores. Production electrical testing cannot be performed on this type of joint because the stress
control, insulation, and shield layers are not integrated during the molding or extrusion process. See also:
single-component cold-shrink.
7
IEEE Std 575-1988 has been withdrawn; however, copies can be obtained from Global Engineering, 15 Inverness Way East,
Englewood, CO 80112-5704, USA, tel. (303) 792-2181 (http://global.ihs.com/).
8
IEEE Standards Dictionary Online subscription is available at
http://www.ieee.org/portal/innovate/products/standard/standards_dictionary.html.
3
IEEE Std 404-2012
premolded: A joint that is factory molded in the shape that it will take when installed. Installation is
performed by sliding the joint over a prepared cable. The use of heat is not a part of the installation
procedure. Production electrical testing can be performed on this type of joint because the stress control,
insulation, and shield layers are integrated during the molding process.
single-component cold-shrink: A joint provided to the end user as an expanded single component device
that is applied over a prepared cable and reduced in diameter without the use of heat by removal of a
supporting core. Production electrical testing can be performed on this type of joint because the stress
control, insulation, and shielding layers are integrated during the molding or extrusion process. See also:
multi-component cold-shrink.
taped: A joint constructed in the field with the use of one or more tapes that are applied over the cable
layers. Heat may or may not be applied as part of the installation procedure. Production electrical testing
cannot be performed on this type of joint.
3.3 Other terms
family of joints: A group of two or more joints designed for use on extruded and/or laminated dielectric
cables rated 2.5 kV to 46 kV. All joints within the family shall have the same insulation and conductive
materials, conductive shield thickness, and maximum electrical stresses within the insulation and along the
joint/cable interfaces.
fingerprinting: Tests made to establish and subsequently confirm the properties of materials or
components used in cable accessories. The samples used for the initial tests shall be from the same batch as
those used in the accessory design tests. For the purposes of this standard, this only applies to field-
fabricated joint constructions such as heat shrinkable, multi-component cold-shrink joints, field vulcanized,
and taped joints.
sectionalizer: A sectionalizer is used to minimize induced current in the cable sheath/shield by electrically
interrupting the semiconducting shield and conducting metallic sheath or shield of the two cable lengths
that are joined together. Sectionalizers are described in IEEE Std 575-1988.
splice body: The component in a power cable joint kit that provides the dielectric insulation and may or
may not contain the stress control and shielding as integral components.
4. Service conditions
Todays cable joint designs are considered suitable for use under the following service conditions.
However, it should be understood that this list was compiled based more on user and manufacturer
experience than on specific requirements of this standard. It is not meant, in any way, to imply that any or
all of these conditions are fully verified in this standard. For specific questions regarding these or other
service conditions, the manufacturer should be consulted.
a) Alternating currents
b) In-air, including exposure to direct sunlight
c) Buried in earth
d) Intermittently or continuously submerged in water at a depth not exceeding 7 m (23 ft)
e) Environmental temperatures within the range of 30 C to +50 C for joints used on fluid-filled
and laminated dielectric cables. All other cable joints are suitable for use at temperatures within
the range of -40 C to +65 C.
4
IEEE Std 404-2012
f) In underground chambers, tunnels, conduits, manholes, and vaults

g) Approximately horizontal installation of laminated dielectric joints rated 69 kV to 500 kV
5. Ratings
5.1 Voltage
The voltage ratings and test levels of cable joints shall be in accordance with Table 1 through Table 4.
5.2 Current and temperature
The current and temperature ratings of the cable joint shall be equal to or greater than those of the cable for
which it is designed as verified in 7.5, 7.6, 7.11, and the basic insulation level (BIL) test conducted at
emergency operating temperature in 7.4.3. For transition joints, the maximum temperature rating is based
on the cable with the lower temperature rating.
Table 1 Voltage ratings and design test levels for extruded dielectric cable joints
rated 2.5 kV to 46 kV
Voltage AC voltage design tests Minimum

Voltage Column D partial
rating Basic
rating Column A 1-min AC discharge
phase-to- insulation Column B Column C
phase-to- cyclic withstand voltage
ground, level (BIL) 5-min at 5 h at 3.5
phase, U aging voltage (kV level,
U0 (kV (kV crest) 4.5 U0 U0
(kV rms) a voltage rms) 1.5 U0
rms) b (kV rms) (kV rms)
(kV rms) (kV rms)
2.5 1.4 60 4 6 5 9 2
5 2.9 75 9 13 10 18 4
8 4.6 95 14 21 16 23 7
15 8.7 110 26 39 31 35 13
25 14.4 150 43 65 50 52 22
35 20.2 200 61 91 71 69 30
c c c
46 26.6 250 67 100 80 80 40
a
To obtain test values for voltage classes that are not listed, use linear interpolation between the next higher and lower listed values
and round off to the nearest whole kilovolt.
b
For grounded systems.
c
Theses values are interpolated between 35 kV and 69 kV class and not as multipliers of U0.
5
IEEE Std 404-2012
Table 2 Voltage ratings and design test levels for extruded dielectric cable joints
rated 69 kV to 500 kV
AC voltage tests
Minimum
Voltage Voltage
Basic partial
rating rating Column A Column B
insulation discharge
phase-to- phase-to- 15 min 6 h HV
level (BIL) voltage
phase, U ground, U0 withstand time test
(kV crest) level, 1.5 U0
(kV rms) a (kV rms)
b
test at 3 U0 at 2.5 U0 (kV rms)
(kV rms) (kV rms)
69 39.8 350 120 100 60

115 66.4 550 200 166 100
138 79.7 650 240 200 120
161 93.0 750 280 232 140
230 132.8 1050 400 332 200
345 199.2 1300 600 500 300
500 288.7 1550 870 725 435
a
To obtain test values for voltage classes that are not listed, use linear interpolation between the
next higher and lower listed values and round off to the nearest whole kilovolt.
b
Table 3 Voltage ratings and design test levels for transition cable joints
AC HV time test
Voltage Basic
Voltage
rating insulation 1-min ac
rating phase- Time Voltage
phase-to- level (BIL) withstand
to-phase, U (h) (kV rms)
ground, U0 (kV crest) voltage
(kV rms) a
(kV rms) b (kV rms)
2.5 1.4 60 8 6 8
5.0 2.9 75 16 6 16
8.7 5.0 95 20 6 20
15 8.7 110 35 6 35
25 14.4 150 58 6 58
35 20.2 200 80 6 80
46 26.6 250 100 6 100
69 39.8 350 100 24 100
115 66.4 450 170 24 170
120 69.3 550 170 24 170
138 79.7 650 200 24 200
161 93.0 750 230 24 230
230 132.8 1050 330 24 330
345 199.2 1300 500 24 500
500 288.7 1550 720 24 720
a
To obtain test values for voltage classes that are not listed, use linear interpolation between
the next higher and lower listed values and round off to the nearest whole kilovolt.
b
6
IEEE Std 404-2012
Table 4 Voltage ratings and test levels for laminated cable joints
Voltage Basic AC withstand test

Voltage
rating insulation
rating phase-
phase-to- level (BIL) Time Voltage
to-phase, U
ground, U0 (kV crest) (h) (kV rms)
(kV rms) a
(kV rms) b
2.5 1.4 60 6 8
5.0 2.9 75 6 16
8.7 5.0 95 6 20
15 8.7 110 6 35
25 14.4 150 6 58
35 20.2 200 6 80
46 26.6 250 6 100
69 39.8 350 24 100
115 66.4 550 24 170
120 69.3 550 24 170
138 79.7 650 24 200
161 93.0 750 24 230
230 132.8 1050 24 330
345 199.2 1300 24 500
500 288.7 1550 24 720
a
To obtain test values for voltage classes that are not listed, use
linear interpolation between the next higher and lower listed
values and round off to the nearest whole kilovolt.
b
6. General requirements
6.1 Identification
Cable joints should be permanently and legibly identified with the following information:
a) Company name or logo

b) Part identification
c) Date of manufacture (month and year)
Joints that cannot accommodate this information should be supplied with a label that contains this
information. The manufacturer should also provide a method of securely attaching the label to the outside
of the joint after it is assembled in the field unless otherwise specified by the user. In all cases, the
identification should be legible for the life of the joint.
In addition, the following information shall be contained on either the joint, joint components, or the
packaging material:
d) Use before date and storage conditions, if applicable

e) Maximum phase-to-phase or phase-to-ground voltage rating
f) Cable insulation diameter range
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IEEE Std 404-2012
If the joint consists of a kit that contains a variety of materials manufactured at different times, then the
date of manufacture should be the date that the kit is packaged.
6.2 Shielding
Cable joints should have a shielding system that is capable of maintaining the outer surface of the joint
effectively at ground potential as well as initiating fault current.
6.2.1 Semiconducting shield
Joints with exposed semiconductive shields rated 15 to 35 kV, which operate with minimal or no metallic-
shielding directly contacting the semiconductive shield, shall comply with 7.9.
6.2.2 Metallic-shield
Metallic-shielding component systems supplied with joints or as an integral part of a joint design shall
comply with 7.10. Subclause 7.10 shall also be used to qualify stand-alone metallic-shielding components
which are not supplied with a complete joint.
6.3 Jacket seal
Environmental-seal component systems supplied with joints or as an integral part of a joint design shall
comply with 7.10. Subclause 7.10 shall also be used to qualify stand-alone environmental seal components
which are not supplied with a complete joint.
6.4 Sheath/shield sectionalizers
The sheath/shield sectionalizer shall meet the requirements of 7.8 to verify it is capable of withstanding ac
and lightning voltages.
Sectionalizers need to be impervious to moisture entry to be functional. The requirements of 7.10.2 are
used to verify the moisture integrity of a sectionalizer design.
7. Design testing
Design tests are performed to qualify a particular product design, materials, and production process for the
general purpose or application covered in this standard. Design tests shall be performed on prototype and
preproduction units to shake out problems, but shall be performed on final production units for the purpose
of certifying that the process, as well as the materials and design, comply with the requirements of this
standard. Once a product design is qualified to the design test requirements, quality is maintained, at a
minimum, through the application of the production tests.
To claim conformance to this standard, a cable joint manufacturer shall:
8
IEEE Std 404-2012
a) Qualify the particular joint design, including the specific joint insulating and conductive materials,
and manufacturers installation details, according to the design tests of Clause 7
b) Meet the general requirements of Clause 6
c) Satisfactorily complete the testing sequences of the applicable flowcharts:
1) Flowchart 1 for extruded dielectric cable joints, 2.5 kV to 46 kV
2) Flowchart 2 for extruded dielectric cable joints, 69 kV to 500 kV
3) Flowchart 3 for all transition cable joints
4) Flowchart 4 for all laminated dielectric cable joints
d) For all cable joints designed for use on extruded dielectric cables rated 2.5 kV to 46 kV:
1) Satisfactorily complete the design tests on aluminum conductor cable in order to claim the
design is suitable for use on aluminum or copper conductor cable. A cable joint design,
qualified on copper conductor cable, can be rated for application only on copper conductor
cables.
2) Satisfactorily complete the design tests on cable insulated with the material of Table 5 to
claim conformance on the particular cable insulation material referenced.
e) For cable joints 69 kV to 500 kV the user should consult the manufacturer for applicability of the
design test report data regarding the cable conductor material and insulation materials as it pertains
to the specific application;
f) Perform the production tests according to the requirements of Clause 8 for that particular joint
design.
Table 5 Range of conforming cable insulation materials

Cable insulation material Joint design conformance for these
used for design testing cable insulation materials
XLPE XLPE, EPR
EPR EPR
7.1 Design tests and testing sequence for all joint types
Figure 1, Figure 2, Figure 3, and Figure 4 list the design tests and sequences required by this standard. Each
sequence group in each of the flowcharts represents one test sequence. These design tests shall be
performed on extruded, transition, and laminated dielectric cable joints, respectively. All design tests shall
be performed on production units (or production materials if the joints are fabricated in the field) to
demonstrate compliance of the design with this standard. The results of these tests shall be recorded in the
form of a report certifying that a joint design meets the requirements of this standard, including the cable
conductor and insulation materials used for qualification testing. The report shall be available from the
manufacturer upon request.
7.2 Design test conditions
The following design test conditions shall apply unless otherwise specified:
a) Cable joints shall be properly assembled with actual production components according to the
manufacturers instructions. All parts that are normally grounded shall be connected to the ground
of the test circuit.
b) Ambient air temperature shall be between 10 C and 40 C.
9
IEEE Std 404-2012
c) All ac voltages shall have a frequency of 47 Hz to 63 Hz, and a sine wave shape of acceptable
commercial standards as defined in IEEE Std 4.
d) Voltages shall be measured in accordance with IEEE Std 4.
e) The cable used in these tests should conform to the applicable AEIC specification. Insulation
thickness should be in accordance with the latest revision of AEIC specifications or ANSI/ICEA
standards for the 100% insulation level. If testing is performed on non-conforming cable, it is
incumbent on the manufacturer to verify that the tests are at least as severe on the joint as would be
the case on the appropriate cable. The cable construction and corresponding cable specification
shall be referenced in the joint test report. The cable conductor type and the cable insulation
materials shall be as described in Clause 7.
f) The cable conductor size, cable insulation material, as well as the specific splice body size in a
family of joints used in these design tests can significantly affect the outcome of certain tests. The
following requirements shall be followed:
1) Sequence 1 of Figure 1 or Figure 2, shall be performed as follows:
i) For joints rated 2.5 kV to 46 kV, Figure 1, Sequence 1, sample number 1 through
number 6, testing shall be performed on the smallest available conductor cable as well as
the largest available conductor cable for which the joint is designed. To qualify a family
of joints the smallest splice body in the family shall be tested on the smallest available
conductor size cable for which it is designed and the largest splice body in the family
shall be tested on the largest available conductor size cable for which it is designed.
ii) For joints rated 69 kV to 500 kV, Figure 2, Sequence 1, sample number 1 through
number 4, testing shall be performed on the largest nominal conductor size cable for
which the joint is designed.
2) The short-time current test of 7.5 shall be performed on the largest available size cable
conductor for which the joint is designed. When qualifying a family of joints, use the splice
body size that accommodates a cable size rated as close as possible to 40 kA, 0.17 s.
3) For extruded dielectric cable joints rated 15 kV to 35 kV, the semiconducting shield must
meet the resistance and fault current initiation tests of 7.9 and can be performed on any
conductor size. When qualifying a family of joints the test shall be performed on the
particular splice body in the family which has the highest resistance from the cable entrance to
the midpoint of the joint body, usually the housing for the smallest cable size in the family.
Any conductor size in that housing may be used.
4) Connector thermal and mechanical tests of 7.11 shall be performed on appropriate connectors,
cable conductor materials and sizes.
g) If a cable failure occurs during a design test, the failed cable may be reterminated provided that the
minimum specified distance between the joint and the termination is met. The test shall be resumed
by repeating the step during which the cable failed. If the minimum length cannot be met, the joint
on the failed cable or a new joint shall be assembled on a new cable, and the entire design test
sequence shall be repeated.
h) If a joint failure occurs during a design test, all qualification tests in that sequence in Figure 1,
Figure 2, Figure 3, or Figure 4 shall be repeated for the number of samples specified for that
sequence. Any joint samples that passed the original tests may be used to repeat that column of
testing if desired.
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IEEE Std 404-2012
7.3 Dielectric integrity tests
7.3.1 Partial discharge voltage level test
This procedure is part of the design test sequence for all joints intended for use on extruded dielectric
cables. It is also used as a routine production test for premolded and single-component cold-shrink joints.
The purpose of this test is to verify that the partial discharge voltage level of the test specimen is not less
than the value given in Table 1 or Table 2 for design testing or Table 10 or Table 11 for production testing
when tested in accordance with IEC 60270.
The test voltage shall be raised to 20% above the partial discharge voltage level specified in Table 1 or
Table 2 for design tests or Table 10 or Table 11 for production testing. If partial discharge exceeds 5 pC,
the test voltage shall be lowered to the partial discharge voltage level specified in the tables and shall be
maintained at this level for at least 3 s, but not more than 1 min. If partial discharge readings still exceed 5
pC, the joint design does not meet the requirements of this standard.
7.3.2 Ionization test
This test is applicable only for transition joints. The purpose of this test is to verify that the ionization factor
of transition joints remains within the limits specified in Table 6. The ionization factor is the difference, at
50 Hz or 60 Hz, between the dissipation factor measured at an average stress in the cable of 4000 V/mm
and the dissipation factor measured at an average stress of 800 V/mm. The measurement voltage is based
on the insulation thickness of the laminated cable.
Table 6 Maximum allowable ionization factor values for transition joints

Joints connecting paper-insulated Joints connecting self-contained and
lead-covered (PILC) cable high-pressure pipe-type cables
Maximum Maximum
Rated voltage Rated voltage
ionization factor ionization factor
(kV) (kV)
(%) (%)
1020 0.60 161 0.10
2135 0.40 > 161 0.05
3669 0.20
The measurement shall be made at ambient temperature. For pressurized cables, the gas or liquid pressure
shall be within the operating limits specified by the appropriate AEIC cable specification.
For transition joints on self-contained or pipe-type cables, the ionization factor is defined as the difference,
at 50 Hz or 60 Hz, between the dissipation factor measured at 1.2 U0 and the dissipation factor measured at
0.125 U0. U0, the phase-to-ground voltage, should be that of the cable with the lower rating.
If the measured value is outside the limits specified in Table 6, the joint design does not meet the
requirements of this standard.
This test is not required for joints that employ nonlinear, high dielectric constant or impedance layer
materials. However, the manufacturer shall demonstrate that the nonlinear material is stable and will
perform effectively over the life of the joint.
11
IEEE Std 404-2012
a
Sample number 1, number 2, and number 3 to be used for cyclic aging in-air, according to 7.6.1. Joint-metallic-shield and jacketing
components shall be assembled on these in-air samples if applicable.
b
Sample number 4, number 5, and number 6 to be used for cyclic aging in water, according to 7.6.1.
c
Joint-metallic-shield and jacketing component testing shall be performed in the sequence shown if tested in conjunction with design
tests of a completed joint. If testing either or both of these components independent of a joint design test, it is not necessary to perform
the previous dielectric integrity or voltage tests in this sequence.
d
Sequence 1 performed on the smallest and largest available conductor sizes.
e
Sequence 2 performed on the largest available conductor size.
f
Sequence 3, shielding test, per IEEE Std 592, latest revision.
Figure 1 Flowchart 1
12
IEEE Std 404-2012
a
Sample number 1 and number 2 to be used for cyclic aging in-air, according to 7.6.2. Joint-metallic-shield and jacketing components
shall be assembled on these in-air samples if applicable.
b
Sample number 3 and number 4 to be used for cyclic aging in water, according to 7.6.2. These two samples in water are not required
if the joint design incorporates a solid metal housing that is welded or soldered to a solid cable sheath or pipe.
c
Joint-metallic-shield and jacketing component testing shall be performed in the sequence shown if tested in conjunction with design
d
Sequence 1 and sequence 2 performed on the largest available conductor size.
13
IEEE Std 404-2012
a
Sample number 1 and number 2 to be used for cyclic aging in-air, according to 7.6.1 or 7.6.2. Joint-metallic-shield and jacketing
components shall be assembled on these in-air samples if applicable.
b
Sample number 3 and number 4 to be used for cyclic aging in water, according to 7.6.1 or 7.6.2. For 69 kV to 500 kV, the two
samples in water are not required if the joint design incorporates a solid metal housing that is welded or soldered to a solid cable
sheath or pipe.
c
Joint metallic-shield and jacket component testing shall be performed in the sequence shown if tested in conjunction with design
d
Sequence 2, shielding test, per IEEE Std 592, latest revision.
14
IEEE Std 404-2012
a
Three samples, number 1, number 2, and number 3, are required for 2.5 kV to 35 kV joints, and one sample is required for 46 kV to
500 kV joints.
7.4 Voltage tests
The purpose of these tests is to verify that the insulation of the test specimen will withstand the design test
voltages shown in Table 1, Table 2, Table 3, or Table 4. Some of the tests are also used as routine
production tests for premolded and single-component cold-shrink joints shown in Table 10 and Table 11.
The test voltage shall be applied to the parts of the cable joint that are energized in service.
For transition cable joints, all electrical test values are based on the cable with the lower test requirements.
For pressurized cables, the gas or liquid pressure shall be within the operating limits specified by the
appropriate AEIC specification.
7.4.1 AC voltage
This test is applicable as a design test for all joint types. It is also one of the routine production test options
for premolded and single-component cold-shrink joints.
For design testing, the voltage shall be raised at a rate of 5 kV/s 3 kV/s, to the value specified in one of
the following:
Table 1, column D, for extruded dielectric cable joints 2.5 kV to 46 kV

Table 2, column A, for extruded dielectric cable joints 69 kV to 500 kV
Table 3, ac withstand test for transition cable joints
Table 4, ac withstand test for laminated dielectric cable joints
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IEEE Std 404-2012
For routine production testing of premolded and single-component cold-shrink joints, the voltage shall be
raised at a rate of 5 kV/s 3 kV/s, to the value specified in one of the following:
Table 10, ac withstand test for extruded dielectric cable joints 2.5 kV to 46 kV, for 1 min
Table 11, ac withstand test for extruded dielectric cable joints 69 kV to 500 kV, for 15 min
The cable joint shall withstand the specified test voltage for the time specified in the tables.
7.4.2 DC voltage
See Annex C.
7.4.3 Basic Insulation Level (BIL)
This test is applicable as a design test for all joint types. It is also one of the routine production test options
for premolded and single-component cold-shrink joints.
The test voltage wave shape shall be as specified in IEEE Std 4 for full lightning-impulse voltages.
For design testing, the procedure (including sample conditioning) shall be as specified in IEEE Std 82. The
cable joint shall withstand ten positive and ten negative impulses with a magnitude equal to the BIL value
specified in Table 1, Table 2, Table 3, or Table 4.
Design tests at emergency operating temperature shall correspond to the impulse temperature requirements
outlined in the applicable specifications (see Table 7). The cable manufacturer should be consulted in the
case of special-use cables.
Table 7 Reference cable specification for temperature requirements

Cable type Standard
1.0 kV to 69 kV paper-insulated metallic-sheathed AEIC CS1
69 kV to 765 kV high-pressure pipe-type AEIC CS2
8 kV to 46 kV low-pressure gas-filled AEIC CS3
69 kV to 500 kV self-contained AEIC CS4
5 kV to 46 kV extruded dielectrics AEIC CS8
Above 46 kV to 345 kV extruded dielectrics AEIC CS9
600 V to 28 kV varnished cloth NEMA WC4*
*historical document
For extruded dielectric cable joints, the test shall be performed first with the conductor at ambient
temperature, then again with the conductor at the maximum emergency operating temperature of the cable,
+0/-10 C.
For transition joints, the test shall be performed first with the conductor temperature of both cables at
ambient temperature, then again with the cables at elevated temperature, +0/-10C. The elevated
temperature is based on the maximum emergency operating conductor temperature of the cable with the
lower temperature rating.
For laminated dielectric cable joints, the test shall be performed only at the maximum emergency operating
conductor temperature of the cable, +0/-10 C.
Elevated conductor temperatures are primarily obtained by circulating ac current in the conductor of the
cable. There shall be no current in the metallic-shields of the cable or joint. The reference location for all
conductor temperature requirements is midway between the end of the joint and the base of the termination.
16
IEEE Std 404-2012
In all cases, the test temperature shall be reported in the test report. Elevated conductor temperatures
produced by means other than by circulating current in the conductor of the cable is permissible only by
mutual agreement between the supplier and the end user. When such alternate methods are used, it is
necessary to verify that the conductor temperature is at the maximum emergency operating temperature of
the cable, +0/-10 C.
When the impulse voltage withstand test is used as a production test, the cable joint shall withstand one
impulse at each polarity with a magnitude equal to the BIL value specified in Table 10 or Table 11.
7.5 Short-time current test
The purpose of this test is to verify that the extruded dielectric cable joint is capable of withstanding short-
time, short-circuit currents. The magnitude shall be equal to the short-circuit rating (in rms symmetrical
amperes) of the conductor size defined in 7.2 for a duration of 0.17 s. The 50 Hz or 60 Hz current
magnitude shall be sufficient to raise the cable conductor temperature from ambient to its rated short-circuit
temperature. The current magnitude used for this test should not exceed 40 kA and shall be determined by
using ICEA P-32-382 and utilizing the formulas given to correct the curves to the appropriate ambient
temperature condition.
The current magnitude shall be measured in accordance with IEEE Std C37.09.
Following the short-time current test, the cable joint shall be tested in accordance with the ac voltage test of
7.4.1 to further verify its integrity.
7.6 Cyclic aging test for extruded dielectric and transition joints
The purpose of this test is to verify that cyclic loading will not adversely affect the ability of the cable joint
to operate in-air or submerged in water. If a joint design or construction requires specific jacketing or
environmental sealing components for proper operation, and the manufacturer only provides the joint with
this device as a complete kit, then 7.6.1 or 7.6.2 shall be performed with this cover or seal installed.
If desired, joint metallic-shield components and/or jacketing components may be qualified simultaneously
with a cable joint qualification. In this case, either or both of these components shall be assembled only on
the in-air samples as described in 7.10.
7.6.1 Extruded cable joints rated 2.5 kV to 46 kV
If joint metallic-shield and/or jacketing components are to be qualified simultaneously with a specific joint
design, the appropriate components shall be assembled on the in-air joints. The joint samples in water shall
be cycled without jacketing components to verify that these devices do not influence potentially marginal
joint electrical interfaces unless their design or construction specifically requires an integral jacketing kit or
environmental seal for proper operation and the manufacturer only provides the joint with this device as a
complete kit.
The test may be conducted on each joint individually or with two or more joints connected in series for
either of the two groups of tests performed.
The required number of tests, as well as the specific cable sizes required for each test, are described in 7.2.
Each test group shall be performed on a minimum of three cable joints in-air and a minimum of three cable
joints in tap water. The cable insulation material and cable conductor material used for each test group shall
be according to Clause 7. The same six joints in each group shall be used for all tests in Sequence 1 of
17
IEEE Std 404-2012
Figure 1. The cable joints in water shall be submerged at a minimum depth of 0.3 m (1 ft), measured from
the top surface of the joints. The water shall neither be heated nor cooled during this test, but shall be left to
follow the load cycling unconstrained.
A minimum length of 2 m (6.5 ft) of cable is required between joint ends and the base of each termination.
The six joints in each test group shall be subjected to 30 cycles. Each cycle is defined as a 24 h time span
with a current-on period and a current-off period. During the current-on period, sufficient ac current shall
be passed through the conductor to achieve a cable conductor temperature within +0/-10 C of the cable
rated emergency operating temperature for a period of at least 6 h. The 6 h period does not include the time
it takes to achieve the emergency operating temperature. There shall be no current in the cable metallic-
shield. The cable emergency operating temperature shall be determined by reference to the applicable
specification (see Table 7). The cable manufacturer should be consulted in the case of special-use cables.
The samples shall be subjected to the continuous ac voltage shown in Table 1, Column A, for the 30 cycles.
The reference location for all conductor temperature requirements is midway between the water surface and
the base of the end terminations for joints tested in water, or midway between the joint end and the base of
the end terminations for joints tested in-air. The temperature at this location shall not be influenced by the
joint, water, or end terminations.
The following information shall be recorded in the test report:
a) The maximum temperature of the outside of each joint body in water

b) The maximum temperature of the outside of each joint body in air
c) The temperature of the outside surface of the cables in air
d) The cable rated emergency operating temperature used to qualify the joint
During the current-off period, the reference cable conductor temperature shall drop to within 5 C of the
ambient air temperature. If this condition cannot be met, the test shall be interrupted at the end of the 5th
cycle, 10th cycle, 15th cycle, 20th cycle, and 25th cycle. During these interruptions, the voltage, current,
and any supplemental heat source shall remain off for a minimum period of 24 h to allow the joints to cool
as close to room temperature as possible. The load cycle (current and voltage) and supplemental heat
source (if used) shall be resumed at the end of the interruption period. This procedure may be followed
even if the temperature condition during the current-off period can be met.
The test samples shall complete 30 cycles. The 24 h interruption periods are not considered part of a cycle.
If, for any reason, the voltage or conductor temperature falls below the specified level for more than 5 min
during any given load cycle, then that load cycle shall be repeated. Cycles may be contiguous, or there may
be periods with no voltage and no current between cycles to accommodate schedule variations or
equipment failures.
7.6.2 Extruded cable joints rated 69 kV to 500 kV and transition joints rated 2.5 kV to 500
kV
If joint metallic and jacketing components are to be qualified simultaneously with a specific joint design,
the appropriate components shall be assembled on the in-air joints. The joint samples in water are cycled
without jacketing components to verify that these devices do not influence potentially marginal joint
electrical interfaces unless their design or construction specifically requires an integral jacketing kit or
complete kit.
18
IEEE Std 404-2012
The test may be conducted on each joint individually or with two or more joints connected in series. The
conductors of multi-conductor joints should be connected in series.
The cable joints shall be assembled on cables with conductor sizes as described in 7.2. Sheath/shield
sectionalizers shall be incorporated if they are part of the joint design. They shall remain shorted until the
tests in 7.8 are performed.
Testing shall be performed on four cable joints. The same four joints are to be used for all tests in Sequence
1 of Figure 2 or Figure 3. Multi-conductor joints in a common housing are considered one joint. Two joints
are suspended in-air, and two are submerged in tap water to a depth of 1 m (3.3 ft). The two samples in
water are not required if the joint design incorporates a solid metal housing that is welded or soldered to a
solid cable sheath or pipe.
Conduit may be used for the in-water portion of this test and may be made of any appropriate material. The
conduit (or enclosure) should be longitudinally centered on the joints and shall extend a minimum of 300
mm (12 in) beyond each joint end. A vertical tube having a minimum inside diameter of 50 mm (2 in)
should be attached to the conduit. It should be of sufficient length to provide the specimen with a head of
tap water measuring a minimum of 1 m from the top surface of the joint. The water shall neither be heated
nor cooled during this test, but shall be left to follow the load cycling unconstrained.
A minimum length of 2 m (6.5 ft) of cable is required between the conduit or water tank and the base of
each end termination for joints tested in water or between the joint ends and the base of each termination
for joints tested in-air.
The four joints shall be subjected to 30 cycles. Each cycle is defined as a 24 h time span with a current-on
period and a current-off period. During the current-on period, sufficient ac current shall be passed through
the conductor to achieve a cable conductor temperature within +0/-10 C of its rated emergency operating
temperature for a period of at least 6 h. The 6 h period does not include the time it takes to achieve the
emergency operating temperature. For transition joints, the emergency operating temperature of the cable
with the lower rating should be used. The cable emergency operating temperature shall be determined by
reference to the applicable specification (see Table 7). The cable manufacturer should be consulted in the
case of special-use cables.
Two times the rated phase-to-ground ac voltage shall be applied continuously for the 30 cycles. For
transition joints, two times the rated phase-to-ground ac voltage of the cable with the lower rating should be
used. There shall be no current in the cable metallic-shield.
The reference location for all conductor temperature requirements is midway between the end of the
conduit or water tank and the base of the end terminations for joints tested in water or midway between the
joint ends and the base of the end terminations for joints tested in-air. For transition joints, this
measurement is made on the cable with the lower temperature rating. The temperature at this location shall
not be influenced by the joint, water-filled conduit or tank, or end terminations.
The following information shall be recorded in the test report:
a) The maximum temperature of the outside of each joint body in water

b) The maximum temperature of the outside of each joint body in-air
c) The temperature of the outside surface of the cables in-air
d) The cable rated emergency operating temperature used to qualify the joint
During the current-off period, the reference cable conductor temperature shall drop to within 5 C of the
ambient air temperature. If this condition cannot be met, the test shall be interrupted at the end of the 5th
cycle, 10th cycle, 15th cycle, 20th cycle, and 25th cycle. During these interruptions, the voltage and current
shall remain off for a period of at least 24 h to allow the joints to cool as close to room temperature as
19
IEEE Std 404-2012
possible. The load cycle (current and voltage) shall be resumed at the end of the interruption period. This
procedure may be followed even if the temperature requirement during the current-off period can be met.
The test samples shall complete 30 cycles. The 24 h interruption periods are not considered part of a cycle.
If, for any reason, the voltage or conductor temperature falls below the specified level for more than 5 min
during any given load cycle, then that load cycle shall be repeated. Cycles may be contiguous or there may
be periods with no voltage and no current between cycles to accommodate schedule variations or
equipment failures.
For transition joints, the ionization factor shall be measured as specified in 7.3.2 at the beginning of the test
period and at the end of the load cycle test (the completion of 30 cycles). The ionization factor shall be in
accordance with Table 6.
For transition joints, the internal pressure of the pressurized and laminated dielectric cable shall be
maintained at normal operating pressure throughout this test, except for solid-type laminated dielectric
cables, which shall have a maximum pressure during the test of 103 kPa (14.9 psi) gauge.
7.7 High-voltage time test
The purpose of this test is to verify the electrical integrity of extruded dielectric and transition joints. Figure
1, Figure 2, and Figure 3 specify the design test sequence. Test voltage is applied as follows:
For extruded dielectric cable joints rated 2.5 kV to 46 kV:
Test voltage specified in Table 1, Column C, for 5 h followed by:

Test voltage specified in Table 1, Column B, for 5 min.
For extruded dielectric cable joints rated 69 kV to 500 kV:
Test voltage specified in Table 2, Column B, for 6 h.

For transition joints rated 2.5 kV to 500 kV:
Test voltage and time as specified in the ac High Voltage (ac HV) time test column of Table 3.
All joints subjected to this test shall be completely submerged in ambient temperature tap water. The
submersion depth is a minimum of 0.3 m (1 ft) for 2.5 kV to 46 kV extruded dielectric cable joints and a
minimum of 1 m (3.3 ft) for 69 kV to 500 kV extruded dielectric cable joints and all transition joints. These
submersion depths correspond to the submersion depths required during the load cycle tests for each joint
construction. They are measured from the top surface of the joint.
The joint shall be submerged for at least 1 h before the test voltage is applied. Samples previously tested in
a water-filled conduit may be left in the conduit. Samples previously tested in-air shall be submerged in tap
water using any convenient method.
7.8 Sectionalizer tests
Cable joints with sectionalizers, samples 1, 2, and 3 of Figure 1 or samples 1 and 2 of Figure 2 or Figure 3,
shall be tested in accordance with the following procedures. All joints subjected to this test shall be
completely submerged in ambient temperature tap water. The minimum submersion depth shall be 0.3 m (1
ft) for extruded cable joints rated 2.5 kV to 46 kV and 1 m (3.3 ft) for all other joints. This depth
20
IEEE Std 404-2012
corresponds to the submersion depth required during the load cycle test, 7.6.1 and 7.6.2, for each joint
construction and is measured from the top surface of the joint.
7.8.1 AC voltage
A voltage of 20 kV ac shall be applied across each sectionalizer for a minimum of 1 min.
WARNING
Serious injury may result if the water is not grounded during this test.
The sectionalizer shall then be shorted, and 20 kV ac shall be applied between the sectionalizer and the
grounded water for a minimum of 1 min. The sectionalizer shall withstand both tests without arcing across
or to ground.
7.8.2 Basic Insulation Level (BIL)
The impulse test voltage shall be a 1.2 s 50 s wave that meets the requirements of IEEE Std 4.
The joints containing sectionalizers shall remain submerged in the water.
WARNING
Serious injury may result if the water is not grounded during this test.
The sectionalizer shall remain shorted following the ac test of 7.8.1, and ten 30 kV-crest, positive impulses
followed by ten 30 kV-crest, negative impulses shall be applied between the sectionalizer leads (cable
shields) and the grounded water.
The joints containing sectionalizers shall then be removed from the water and the short across the
sectionalizer removed. Ten 60 kV-crest, positive impulses followed by ten 60 kV-crest, negative impulses
shall be applied across the sectionalizer.
The sectionalizers are considered satisfactory if all impulse voltage surges are withstood without any
physical damage to the joint, cable, or sectionalizer.
7.9 Shielding test
Many cable joints are supplied with exposed semiconductive insulation shields and minimal or no metallic-
shielding in direct contact with the semiconducting shield. The purpose of this test is to verify that these
cable joint designs will maintain their outer semiconducting shield effectively at ground potential under
normal operating conditions and initiate fault current arcing if the cable joint insulation system should fail.
Extruded dielectric cable joints rated 15 kV to 35 kV shall meet the shield resistance and fault-current
initiation requirements of IEEE Std 592 to verify the adequacy of the shielding system. This test is a
requirement only if the joint kit is supplied to the end customer in any of the following configurations:
a) with no metallic-shielding
b) with metallic-shielding having a cross-sectional area less than that of #4 AWG copper (the
conductor size which would fuse at 10kA, 0.17 s)
21
IEEE Std 404-2012
c) with metallic-shielding having a cross-sectional area greater than that of #4 AWG copper (the
conductor size which would fuse at 10 kA, 0.17 s) but not in direct contact with the exposed
semiconductive shield
7.10 Joint metallic-shield and jacketing components
Virtually all modern cable designs are provided with jacketing components over the cable metallic-
shielding. Therefore, when cables are joined, it is necessary to replace or restore these cable components
with appropriate devices that will provide the same current carrying capability and environmental
protection as the non-spliced portions of the cable. In many cases, the components needed to restore the
cable metallic-shield and jacket are provided with the joint kit.
Sections 7.10.1 and 7.10.2 provide qualification requirements for both the metallic-shield components and
jacketing components of a joint. These tests may be performed simultaneously with the joint design test
sequence or as independent component tests on separate samples. When testing these components
independently on separate samples, the samples shall be assembled as they would be installed in service. In
this case, it is only necessary to perform the appropriate tests of clause 7.10.1 or 7.10.2 without the
continuous voltage requirement of 7.6 or any of the dielectric integrity or voltage tests in the design
sequence.
The joint metallic-shielding and/or jacketing components shall be installed on three complete extruded
dielectric joint assemblies rated 2.5 kV to 46 kV, two complete extruded dielectric joint assemblies rated 69
kV to 500 kV, or two complete transition joint assemblies rated 2.5 kV to 500 kV. It is not possible to
perform a dielectric test to verify the integrity of the environmental sealing of the jacketing components in
certain situations without altering the design of the device. An example is when either bare metallic-shield
materials emerge from the jacketing devices or when the cable jackets are semiconductive. Therefore, the
integrity of the sealing capability of the jacketing device shall be determined using moisture sensitive tape.
Prior to installing the jacketing component(s), apply a moisture sensitive tape within 25 mm (1 in) of the
inner moisture barrier of the jacketing component on each side of the joint. A sufficient length of this tape
shall be used to go completely around the circumference of the cable.
The metallic-shielding and jacketing components are only installed on the cable joints that will be
cyclically aged for 30 days in-air according to the requirements of 7.6.1 or 7.6.2. The joint samples in water
are cycled without jacketing components as these devices may influence potentially marginal joint
electrical interfaces. If the joint design or construction specifically requires an integral jacketing kit or
complete kit then the joint samples in water shall be cycled with these components installed.
7.10.1 Joint metallic-shield components
When qualifying metallic-shield component designs independent of any joint design, complete the 30
cycles of the cyclic aging test on in-air samples, according to either:
a) 7.6.1 for components used on joints rated 2.5 kV to 46 kV, noted as sample numbers 7, 8, and 9 in
Figure 1; or
b) 7.6.2 for components used on joints rated 69 kV to 500 kV, noted as sample numbers 5 and 6 in
Figure 2; or
c) 7.6.2 for components used on transition joints rated 2.5 kV to 500 kV, noted as sample numbers 5
and 6 in Figure 3.
Following the cyclic aging, verify that the metallic-shield components are capable of withstanding two
short-time, short-circuit current tests as described below.
22
IEEE Std 404-2012
When qualifying a metallic-shield component design along with a specific joint design, complete sequence
1 from Figure 1, Figure 2, or Figure 3 on in-air samples, according to either:
a) 7.6.1 for joint ratings of 2.5 kV to 46 kV, noted as sample numbers 1, 2, and 3 in Figure 1; or
b) 7.6.2 for joint ratings of 69 kV to 500 kV, noted as sample numbers 1 and 2 in Figure 2; or
c) 7.6.2 for joint ratings of 2.5 kV to 500 kV, noted as sample numbers 1 and 2 in Figure 3.
In this case, the joint samples together with the metallic-shield components shall undergo all dielectric
integrity tests, voltage tests, cyclic aging tests, as well as final dielectric tests and voltage tests. Following
this sequence, verify that the metallic-shield components are capable of withstanding two short-time, short-
circuit current tests as described below.
The two short-time, short-circuit 50 Hz or 60 Hz current tests shall have a magnitude (in rms symmetrical
amperes) and duration (in seconds) as determined by Eq. (1). The current magnitude shall be sufficient to
raise the cable shield temperature from ambient to its rated short-circuit temperature, either 350 C if all
cable materials in direct contact with the metallic-shield are thermosetting (e.g., XLPE or EPR), or 200 C
if any cable materials in direct contact with the metallic-shield are thermoplastic or laminated dielectric
material. For example, as stated in ICEA P-45-482, a cable having a cross-linked semiconducting shield
under the metallic-shield and a cross-linked jacket over the metallic-shield would have a maximum
allowable shield temperature of 350 C. Or, if the cable sheath is lead, the short-circuit temperature should
be limited to 200 C regardless of the other cable materials. The 350 C or 200 C short-circuit
temperatures are calculated values only and need not be measured during the test. Unless otherwise
required by customer or manufacturer specifications, the current magnitude used for this test should not
exceed 40 kA.
The current source shall be connected between the cable conductor and the cable shield at one end of the
cable. The conductor and shield shall be connected together at the other end of the sample. The test may be
performed on several joints simultaneously if connected in series. If the shielding components exit the
jacketing components on each end of the joint, a jumper of appropriate cross section shall be used to join
them across each joint. The current magnitude shall be measured in accordance with IEEE Std C37.09.
In accordance with ICEA P-45-482, the required short-circuit test current magnitude for the shield is
calculated by the following equation:
2
I T +
t = K log10 2 (1)
A T1 +
where
I is the short-circuit current in amperes

A is the cable metallic-shield cross-sectional area in circular mils (calculated from Table 9)
t is the duration of short circuit in seconds (shall be 1 s)
T1 is the starting ambient temperature in degrees Celsius
T2 is equal to 350 C if all cable materials in direct contact with the metallic-shield are thermosetting
(e.g., XLPE or EPR) or 200 C if any cable materials in direct contact with the metallic-shield are
thermoplastic or laminated.
, K are determined from Table 8
23
IEEE Std 404-2012
Table 8 Values for or K

Cable shielding material Value of Value of K
Aluminum a 228 0.0125
Bronze b 564 0.0297
Copper c 234 0.0297
Lead d 236 0.0010
Steel e 180 0.0036
Zinc f 219 0.0080
Cupro-nickel alloy g 1800 0.0140
a
3/4 hard, 1350 aluminum
b
Commercial bronze, 90% copper, 10% zinc
c
Annealed, 100% conductivity copper
d
Pure lead, 99.99%
e
Mild or low carbon steel
f
Commercial rolled zinc, 0.08% lead
g
80% copper, 20% nickel
Table 9 Calculation of cross-sectional area [the symbol A in Eq. (1)]

Formula for calculating A
Type of shield or sheath
(See Note 2)
Wires applied either helically, as a braid or serving; or
longitudinally with corrugations nds2 (a)
Helically applied tape or flat wires, not overlapped 1.27 nwb (b)
4 b dm (c)
Helically applied flat tape, overlapped (See Note 3) 100
2 (100 L )
Corrugated tape, longitudinally applied 1.27 [ (dis + 50) + B] b (d)

Tubular sheath 4bdm (e)
NOTE 1
A is the effective cross-sectional area, shield, or sheath
B is the tape overlap (in mils) (usually 375)
b is the thickness of tape or flat wires (in mils)
dis is the diameter over semiconducting insulation shield (in mils)
dm is the mean diameter of shield or sheath (in mils)
ds is the diameter of wires (in mils)
w is the width of tape or flat wires (in mils)
n is the number of serving or braid wires or tapes
L is the overlap of tape (in percentage)
NOTE 2The effective area of composite shields is the sum of the effective areas of the components. For
example, the effective area of a composite shield consisting of a helically applied, not overlapped tape and a
wire serving would be the sum of the areas calculated from Eq. (b) of Table 9 and Eq. (a) of Table 9.
NOTE 3The effective area of thin, helically applied overlapped tapes depends, also, on the degree of
electrical contact resistance of the overlaps. Eq. (c) of Table 9 may be used to calculate the cross-sectional
area of the shield of new cable. An increase in contact resistance may occur after cable installation or during
service involving exposure to moisture and heat. Under these conditions the contact resistance may approach
infinity, where Eq. (b) of Table 9 could apply.
If practical, the test duration should be 0.17 s (10 cycles at 60 Hz). If the calculated fault current cannot be
achieved due to equipment limitations, then an alternate current and time combination shall be used as long
as the alternate time and current have the same I2t as the originally calculated values and the alternate time
(t) is not longer than 1 s. The test samples may be allowed to cool to ambient after the first short-time
current test.
24
IEEE Std 404-2012
All shield components shall withstand two short-time current tests without signs of arcing of the metallic
components, and without catching on fire. All metallic-shield components shall remain intact. Slight
melting of polymeric components is allowed as long as no material leaves the assembly.
7.10.2 Joint jacket seal integrity
If the joint jacket seal is being qualified independent of any joint or metallic-shield component, the
following test is performed following the cyclic aging for 30 days in air. If the joint jacket seal is being
qualified in conjunction with the metallic-shield component test of 7.10.1, the following procedure is
performed after the two short-time current tests of that clause.
The joint jacket component assemblies shall be completely submerged in ambient temperature tap water for
a minimum of 24 h. The minimum depth of water shall be 0.3 m (1 ft) for extruded cable joints rated 2.5
kV to 46 kV and 1 m (3 ft) for all other joints. This depth corresponds to the submersion depth required
during the load cycle test of 7.6.1 and 7.6.2 for each joint construction and is measured from the top surface
of the joint. The assemblies shall then be subjected to an additional ten thermal cycles using a current equal
to the cyclic aging current requirements of 7.6.1 or 7.6.2. It is not necessary to apply the continuous, ac
phase-to-ground voltage of 7.6.1 or 7.6.2. Afterward, the assemblies shall be removed from the water and
the external surfaces fully dried. Within 2 h of removal from the water, the environmental seals shall be
removed and the moisture sensitive tape examined. The jacketing /environmental seal component design is
acceptable if there is no evidence of water migration beyond the water block area as determined by the
color of the moisture sensitive tape.
7.11 Connector thermal and mechanical tests
Connectors used in cable joints to join two aluminum conductors, two copper conductors, or an aluminum
conductor to a copper conductor, shall meet all Class A current cycle requirements given in ANSI C119.4.
In addition, connectors used to join two aluminum conductors or an aluminum conductor to a copper
conductor for use in any cable joint excluding pipe-type, laminated dielectric cable joints, shall meet all
Class 2 partial tension requirements given in ANSI C119.4. The tensile strength requirements for
connectors used in pipe-type laminated dielectric cable joints should be established between the supplier
and the end user.
NOTEThere is a wide variety of compression tools and dies for any particular connector design as well as a variety
of connector designs (such as overall length and diameter) for any particular conductor size. There is also variation in
crimping techniques such as the number of crimps, rotation of successive crimps, etc. It should be understood that these
tests may only have been performed on a representative compression tool, die, and crimp technique.
8. Routine production testing

Production tests shall be performed on 100% of all premolded joints produced and 100% of all single-
component cold-shrink joints produced according to 8.1.
The production electrical tests of 8.1 cannot be performed on field-fabricated joints, such as heat-
shrinkable, hand-taped, or certain multi-component cold-shrinkable joints. To assure the reliability of these
field-fabricated joints, the manufacturer shall perform a series of physical and electrical tests on the
materials that make up the joint according to 8.2 for heat-shrink or multi-component cold-shrink joint
components and 8.3 for taped joint components.
25
IEEE Std 404-2012
8.1 Premolded and single-component cold-shrink joints
The following production tests shall be performed by the manufacturer on 100% of all premolded and
single-component cold-shrink joints produced:
a) Partial discharge voltage level (see 7.3.1, Table 10, and Table 11)
b) AC withstand or BIL (see 7.4.1 or 7.4.3, Table 10, and Table 11)
8.2 Heat-shrink and multi-component cold-shrink joints
The following fingerprint tests shall be performed by the manufacturer according to the sampling rate
shown in Table A.2. These tests shall be performed on stress control, conductive, insulating, and protective
tubes whether extruded or molded. The tests are performed after these components have completed all
manufacturing processes, such as molding, extruding, cross-linking, and expansion (i.e., in the as-supplied
forms). The required tests are summarized in Table A.1 along with typical values.
8.2.1 Visual examination
Expanded tubes shall be free from splits, pinholes, inclusions, or other visible defects. Tubing edges shall
be straight and smooth.
8.2.2 Dimensions
The wall thickness of expanded tubes shall be measured at four equally-spaced positions around the
sample. The length of the expanded tubes shall also be measured.
The same tubes shall then be fully recovered and cooled (if applicable). The above measurements shall then
be repeated. Calculate the ratio of minimum thickness to maximum thickness expanded and the ratio of
minimum thickness to maximum thickness recovered. Calculate the change in length after recovery.
See Table A.1 for typical values of expanded wall thickness ratio, recovered wall thickness ratio, and
length change.
8.2.3 Tensile strength and ultimate elongation
Specimens shall be prepared from fully-recovered tubing or molded components. Specimen thickness shall
be between 2 mm and 4 mm (0.079 in and 0.157 in). From each of the samples in the lot, five specimens of
each material shall be prepared in accordance with ASTM D412-98. Tubing specimens shall be cut along
the length of the tubing.
The test shall be performed at a cross-head speed of 500 mm/min 50 mm/min (20 in/min 2 in/min).
The tensile strength shall be determined using the maximum applied load and the initial specimen cross-
sectional area.
Ultimate elongation is the increase in length at the point of break over the initial length expressed as a
percentage.
See Table A.1 for typical values of tensile strength and elongation.
26
IEEE Std 404-2012
8.2.4 Volume resistivity of conductive tubes
From each of the samples in the lot, five specimens shall be prepared from tubing or molded components
and tested in accordance with ASTM D991-89.
See Table A.1 for typical values.
8.2.5 Dielectric strength of insulating tubes
The dielectric strength of tubing or molded components shall be determined at room temperature in
accordance with ASTM D149-97a.
From each sample of the lot, five specimens of tubing or molded components shall be recovered onto a
cylindrical mandrel of diameter equal to the fully recovered specimen inside diameter plus 10%. The
specimen thicknesses for each test shall be reported.
See Table A.1 for typical values of dielectric strength.
8.2.6 Sampling rate
Unless otherwise required by customer or manufacturer specifications, the component sampling

requirements after each manufacturing step, including molding, extrusion, cross-linking, and expansion,
shall be according to the sampling rate shown in Table A.2.
8.3 Elastomeric taped joint components
The following fingerprint tests for taped joint components shall be performed by the manufacturer
according to the sampling rate shown in Table B.2. These tests shall be performed on non-metallic and
electrically insulating rubber tapes according to 8.3.1, 8.3.2, 8.3.3, and 8.3.5 and on semiconducting rubber
tapes according to 8.3.1, 8.3.2, 8.3.3, and 8.3.4. The required tests for each type of tape, along with the
corresponding ASTM tape classification, are summarized in Table B.1 along with typical values.
All tests are performed on the sample rolls after removing and discarding at least 610 mm (24 in) of the
outer layer.
All sample rolls shall be subjected to 23 C 2 C and 50% 2% relative humidity for a minimum of 16 h
before specimens are removed.
All samples are then removed from the rolls at a slow, uniform rate without jerking. The individual samples
shall be left for a minimum period of 1 h at 23 C 2 C and 50% 2% relative humidity. All tests shall
then be conducted at these same standard conditions.
8.3.1 Fusion
Remove three specimens, 280 mm in length, from each roll of the sample lot. Using the winding fixture and
procedure described in ASTM D4325-08, wind the specimens using 300% elongation. After wrapping,
condition the specimens at 23 C 2 C and 50% 2% relative humidity for a minimum of
24 h. Following the conditioning, the maximum flag for any specimen shall meet the requirements of Table
B.1.
27
IEEE Std 404-2012
8.3.2 Dimensions
8.3.2.1 Length
Unwind the tape and separator from each roll of the sample lot. After the conditioning in 8.3, place each
tape/separator sample on a hard, smooth surface and measure its length. The length shall meet the
requirements of Table B.1.
8.3.2.2 Width
Unwind the tape and separator from each roll of the sample lot. After the conditioning in 8.3, place each
tape/separator sample on a hard, smooth surface and measure its width. The width shall meet the
requirements of Table B.1.
8.3.2.3 Thickness
Unwind the tape and separator from each roll of the sample lot. Measure the tape/separator sample
thickness at five locations uniformly distributed over the length of the test specimen using the procedure
described in ASTM D4325-08. The average of the five measurements shall meet the requirements of Table
B.1.
8.3.3 Tensile strength and ultimate elongation
For each roll in the sample lot, cut five specimens, 610 mm in length, from a single ply of tape (rubber and
separator) that is free from visible defects using the ASTM standard die, as shown in Figure 1 (die A) of
ASTM D412-98, except that the ends of the specimens cut from 19 mm tape need not be full width. Place
bench marks on the specimens as directed in ASTM D412-98. Measure the thickness in accordance with
ASTM D4325-08, removing the separator where it is not an integral part of the tape. The average breaking
strength and average percent elongation shall meet the requirements of Table B.1. When specimens break
at the jaws, discard the results and retest.
8.3.4 Volume resistivity
This test is applicable only to semiconducting tapes. For each roll in the sample lot, test five specimens.
Condition the tapes at 90 C 2 C for 168 h. Remove the specimens from the oven, assemble in
electrodes, and test within 2 min. Use strip electrodes for tape as shown in Figure 2 of ASTM D4496-04.
Apply direct voltage of 5 V 0.5 V for the time specified in ASTM D4496-04. The average volume
resistivity shall meet the requirements of Table B.1.
8.3.5 Dielectric strength
This test is applicable only to insulating tapes. Make five breakdown tests on each roll of the sample lot.
Use Type-3 electrodes as described in Table 1 of ASTM D149-97a. To prevent flashover of the sample,
insulating fluid may be used, or the tape width can be increased by attaching additional tape strips to each
edge of the test sample. Measure and calculate the dielectric strength in kilovolts per millimeter (kV/mm)
in accordance with ASTM D149-97a using the short-time test by increasing the voltage at a uniform rate of
500 V/s. The average dielectric strength in kV/mm shall meet the requirements of Table B.1. The specimen
thicknesses for each test shall be reported.
28
IEEE Std 404-2012
8.3.6 Sampling
Unless otherwise required by customer or manufacturer specifications, the tape sampling requirements shall
be according to the sampling rate shown in Table B.2.
Table 10 Routine production test levels for extruded dielectric cable joints
Minimum partial
Voltage rating Voltage rating Basic insulation discharge
1-min ac
phase-to-phase, U phase-to-ground, level (BIL) voltage level,
withstand
(kV rms) a U0 (kV rms) b (kV crest) 1.5 U0
voltage (kV rms)
(kV rms)
2.5 1.4 60 9 2
5 2.9 75 18 4
8 4.6 95 23 7
15 8.7 110 35 13
25 14.4 150 52 22
35 20.2 200 69 30
46 26.6 250 80 40
a
To obtain test values for voltage classes that are not listed, use linear interpolation between the next higher and lower listed
b
Table 11 Routine production test levels for extruded dielectric cable joints
Minimum
Voltage Voltage
Basic partial
rating rating 15-min ac
Insulation discharge
phase-to- phase-to- withstand
Level (BIL) voltage
phase, U ground, U0 test at 3 U0
(kV crest) level, 1.5 U0
(kV rms) a (kV rms) b (kV rms)
(kV rms)
69 39.8 350 120 60
115 66.4 550 200 100
138 79.7 650 240 120
161 93.0 750 280 140
230 132.8 1050 400 200
345 199.2 1300 600 300
500 288.7 1550 870 435
a
To obtain test values for voltage classes that are not listed, use linear interpolation
between the next higher and lower listed values and round off to the nearest whole
kilovolt.
b
29
IEEE Std 404-2012
Annex A
(informative)
Typical values of heat-shrinkable and multi-component cold-shrink joint

component tests and sampling rates
Table A.1Heat-shrink and multi-component cold-shrink joint component

tests and requirements
Shrinkable tubing or Stress
Reference Conductive Insulating Protective
molded component control
Visual examination 8.2.1 No splits, pinholes, inclusions, or other defects
Dimensions
Expanded (min/max wall thickness ratio) 8.2.2 60 % 60 % 60 % 60 %
Recovered (min/max wall thickness ratio) 8.2.2 80 % 80 % 80 % 80 %
Length change after recovery 8.2.2 15 % 15 % 15 % 15 %
Tensile strength (MPa) 8.2.3 10 10 10 10
Elongation at break 8.2.3 200 % 200 % 200 % 200 %
Volume resistivity ( cm) 8.2.4 50k
Dielectric strength (kV/mm) 8.2.5 N/A N/A 10
Table A.2Heat-shrink and multi-component cold-shrink joint component sampling rates

Length of lot size Sampling size
(m) (pieces)
1 to 500 2
501 to 2000 4
2001 to 5000 7
5001 to 10 000 10
> 10 000 15
30
IEEE Std 404-2012
Annex B
(informative)
Typical values of elastomeric taped joint component tests and sampling

rates
Table B.1Taped joint component tests and requirements

Up to Up to Up to
Voltage class of tape Reference Semiconductive
35 kV 138 kV 325 kV
ASTM tape classification II III V IV
Fusion (max flag) 8.3.1 2 mm 2 mm 2 mm 2 mm
Dimensions (acceptable variations
from nominal)
Length 8.3.2.1 nominal nominal nominal nominal
Width 8.3.2.2 0.76 mm 0.76 mm 0.76 mm 0.76 mm
Thickness (avg) 8.3.2.3 0.076 mm 0.076 mm 0.076 mm 0.076 mm
Tensile strength (MPa, min) 8.3.3 1.7 1.7 2.4 0.69
Elongation at break (min %) 8.3.3 500 700 700 300
Volume resistivity ( cm, min) 8.3.4 103
Dielectric strength for 0.76 mm
thickness (kV/mm, min) 8.3.5 20 24 28 N/A
Table B.2Taped joint component sampling rates

Number of rolls in Number of sample
shipment rolls
50 to 200 2
201 to 500 3
501 to 1000 4
1001 to 5000 50
31
IEEE Std 404-2012
Annex C
(informative)
DC test voltage reference

For reference only, the following dc test voltages have been used in the past for design qualification testing
of cable joints. Many standards-making bodies have eliminated the use of dc testing since industry data has
determined that ac testing is more appropriate for extruded dielectric cables.
Table C.1Voltage ratings and reference dc test levels for extruded dielectric cable joints
Voltage rating DC withstand

phase-to-phase, voltage
U (kV rms) a 15-min (kV)
2.5 30
5 35
8 45
15 75
25 105
35 140
46 172
a
To obtain test values for voltage classes
that are not listed, use linear interpolation
between the next higher and lower listed
values and round off to the nearest whole
kilovolt.
Table C.2Voltage ratings and reference dc test levels for extruded dielectric cable joints
Voltage rating DC withstand

phase-to-phase, voltage
U (kV rms) a 15-min (kV)
69 240
115 300
138 315
161 375
230 525
345 650
500 775
a
To obtain test values for voltage classes
that are not listed, use linear interpolation
between the next higher and lower listed
values and round off to the nearest whole
kilovolt.
32
IEEE Std 404-2012
Table C.3Voltage ratings and reference dc test levels for transition

and laminated cable joints
Voltage rating phase-to- DC withstand voltage

phase, U (kV rms) a 15-min (kV)b
2.5 30
5.0 38
8.7 48
15 55
25 75
35 100
46 125
69 175
115 225
120 275
138 325
161 375
230 525
345 650
500 775
a
To obtain test values for voltage classes that are not listed, use
linear interpolation between the next higher and lower listed
b
Voltages represent 0.5 times the BIL values shown in Table 3.
33
IEEE Std 404-2012
Annex D
(informative)
Bibliography
Bibliographical references are resources that provide additional or helpful material but do not need to be
understood or used to implement this standard. Reference to these resources is made for informational use
only.
[B1] ANSI/ICEA S-94-649, Standard for Concentric Neutral Cables Rated 5 Through 46 kV. 1
[B2] ANSI/ICEA S-97-682, Standard for Utility Shielded Power Cables Rated 5 Through 46 kV.
[B3] ANSI/ICEA S-108-720, Standard for Extruded Insulation Power Cables Rated Above 46 kV
Through 345 kV.
[B4] ASTM D4388-02, Standard Specification for Nonmetallic Semi-Conducting and Electrically
Insulating Rubber Tapes. 2
[B5] CEI/IEC 60502-4, Power Cables with Extruded Insulation and Their Accessories for Rated Voltages
from 1 kV up to 30 kV. 3
[B6] CEI/IEC 60840, Power Cables with Extruded Insulation and Their Accessories for Rated Voltages
above 30 kV up to 150 kV.
1
ICEA publications are available from ICEA, P.O. Box 1568, Carrollton, GA 30112, USA (http://www.icea.net/).
2
ASTM publications are available from the American Society for Testing and Materials, 100 Barr Harbor Drive, West Conshohocken,
PA 19428-2959, USA (http://www.astm.org/).
3
CEI/IEC publications are available from the Sales Department of the International Electrotechnical Commission, Case Postale 131,
3, rue de Varemb, CH-1211, Genve 20, Switzerland/Suisse (http://www.iec.ch/). IEC publications are also available in the United
States from the Sales Department, American National Standards Institute, 11 West 42nd Street, 13th Floor, New York, NY 10036,
USA.
34

IEEE STD 404-2012

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IEEE Standard for Extruded and

Laminated Dielectric Shielded Cable

IEEE Power & Energy Society

IEEE Standard for Extruded and

Insulated Conductors Committee

Approved 29 March 2012

IEEE-SA Standards Board

The Institute of Electrical and Electronics Engineers, Inc.

Copyright 2012 by The Institute of Electrical and Electronics Engineers, Inc.

PDF: ISBN 978-0-7381-7267-5 STD97242

Comments on standards should be submitted to the following address:

Secretary, IEEE-SA Standards Board

Laws and regulations

Updating of IEEE documents

Glenn J. Luzzi, Chair

Edward Bradley Mike Jackson Thomas J. Parker

Roy Alexander Werner Hoelzl Bartien Sayogo

Richard H. Hulett, Chair

Satish Aggarwal Alexander Gelman Oleg Logvinov

Richard DeBlasio, DOE Representative

4. Service conditions ...................................................................................................................................... 4

7. Design testing ............................................................................................................................................. 8

8. Routine production testing........................................................................................................................ 25

Annex A (informative) Typical values of heat-shrinkable and multi-component cold-shrink joint

Annex C (informative) DC test voltage reference ....................................................................................... 32

Annex D (informative) Bibliography .......................................................................................................... 34

This standard also defines a variety of common joint constructions.

ANSI C119.4, Electric ConnectorsConnectors to Use Between Aluminum-to-Aluminum or Aluminum-

ICEA P-32-382, Short-Circuit Characteristics of Insulated Cable. 4

ICEA P-45-482, Short-Circuit Performance of Metallic-shields and Sheaths on Insulated Cable.

IEEE Std 4, IEEE Standard Techniques for High-Voltage Testing. 5, 6

3.1 Cable joint categories

3.2 Joint constructions

3.3 Other terms

f) In underground chambers, tunnels, conduits, manholes, and vaults

5.2 Current and temperature

Voltage AC voltage design tests Minimum

69 39.8 350 120 100 60

Voltage Basic AC withstand test

a) Company name or logo

d) Use before date and storage conditions, if applicable

6.2.1 Semiconducting shield

6.3 Jacket seal

6.4 Sheath/shield sectionalizers

To claim conformance to this standard, a cable joint manufacturer shall:

Table 5 Range of conforming cable insulation materials

7.2 Design test conditions

7.3 Dielectric integrity tests

7.3.1 Partial discharge voltage level test

7.3.2 Ionization test

Table 6 Maximum allowable ionization factor values for transition joints

7.4 Voltage tests

Table 1, column D, for extruded dielectric cable joints 2.5 kV to 46 kV

7.4.3 Basic Insulation Level (BIL)

Table 7 Reference cable specification for temperature requirements

7.5 Short-time current test

7.6.1 Extruded cable joints rated 2.5 kV to 46 kV

The following information shall be recorded in the test report:

a) The maximum temperature of the outside of each joint body in water

The following information shall be recorded in the test report:

a) The maximum temperature of the outside of each joint body in water

7.7 High-voltage time test

For extruded dielectric cable joints rated 2.5 kV to 46 kV: