REPAIR OF NON-METALLIC SHEATH

1.0 Purpose
To describe the method for repairing the non-metallic outer sheath, damaged or cut.

2.0 Scope
This procedure covers the repairing of non-metallic sheath of LV, MV, and HV cables as and when
damages of the cable sheath(s) are noticed while pulling cables or during conducting DC sheath
electrical test on site for HV cables, where repair should be implemented by a professional
technician.

3.0 Applicable Standards

ANSI C 119.1 / ANSI C 119.4
Saudi Electricity Co. Specification 12-SDMS-01
WUC 2.4 (Western Under-ground Committee)
IEEE 404

4.0 Equipment and Tools

1.
2.
3.
4.
5.

Burner
Knife
Scotch 23 Self vulcanizing tapes / PVC Nitto tape
Glass paper # 80
Raychem heat shrinkable sleeves, OR equivalent (type to be chosen as per cable diameter)

5.0 Procedure
1. Cut and remove the portion of the damaged sheath and remove all damaged/carbonized
portions graphite sediments from around the damaged location (keep sheath if only cut).
2. Using a glass paper No. 80, clean the defective area to be free of dirt and other sedimentary
particles in a length of 300 mm each side of the damaged /defective area.

3. Wrap 4 layers of Scotch 23 Self-Vulcanizing Tape with an overlap of 50% on a length of

100 mm each side of the damaged/defective area.
Note: All the tapes are wrapped with 50% overlapping.

4. Wrap 2 layers of PVC Tape over the length of the Scotch 23 Self-Adhesive Tape extending
50 mm on each side of Scotch 23 Tape.

5. Wrap up the completed repair portion with Raychem sleeve (Zipper Type if suitable)
heat shrinkable sleeve.
6. At both ends of the Raychem sleeve, wrap two layers of Scotch 23 Tape and then
2 layers of PVC Nitto Tape.

Cleaning the Cable:

Use an approved solvent, like alcohol, to clean the cable.
Some newer solvents do not evaporate quickly and need to be removed with a clean, lint-free cloth.

General Shrinking Instructions for Raychem Sleeve:

Apply outer 3- to 4-inch tip of the flame to heat-shrinkable material with a rapid brushing
motion.
Keep flame moving to avoid scorching.
Unless otherwise instructed, start shrinking tube at centre, working flame around all sides of the
tube to apply uniform heat.

Raychem Sleeve Installation Instructions:

Determine the length of the repair area:
Note: If space allows, the full length of the sleeve may be used. If a smaller length is necessary,
follow the directions for cutting the sleeve to the required length (Fig. 4).
For jacketed cables, remove 6 (150mm) of cable jacketing material on each side of the damage
area to expose the lead sheath or armour or bedding below.

Fig. 4

Mark cut length of the wraparound sleeve:

Lay the sleeve on a flat surface.
Measure the required length of the sleeve using a straight edge (preferably a square) and mark
along the line to be cut. Cut-line must be as nearly square to the rails as practical.
2

Fig. 5
Cut the HVS-LR sleeve to required length:
Cut the sleeve using tin snips or a sharp knife (Cut edges must be smooth, not jagged), Fig. 6.
Note: If a knife is used, support the sleeve on a flat surface and use a straight edge guide.

Fig. 6
Trim flap; cut channel to length:
For neater installation, trim the overlap flap as shown in Fig. 7.

Fig. 7

Cut or break the channel 1/2" (10mm) longer than the sleeve.
Remove sharp corners and burrs from the channel, (If longer than one channel, lay end to end
before measuring.).
Clean cable:
Using an approved solvent, clean, abrade, and degrease the damaged area and the cable on either
side of the damage as shown. Remove any sharp points from the area to be covered with the sleeve,
Fig. 8.
3

Note: Raychem recommends conducting all sheath repairs when the applicable circuit is not
energized.

Fig. 8

Centre sleeve; mark cable:

Centre sleeve over damaged area.
Mark the cable as shown in Fig. 9.

Fig. 9

Apply oil sealing mastic:

Remove backing from one side of the strip of oil sealing mastic.
Roll the mastic and remaining backing strip into a convenient size.
Removing the remaining backing strip and stretching the mastic to at least half its original width,
tightly wrap two half-lapped layers of yellow oil sealing mastic over the damage area and overlap
by 1" (25mm) onto the lead sheath or armour or bedding at each end, Fig. 10.

Fig. 10

Position sleeve between cable marks:

Centre sleeve between cable marks and butt the rails together taking care to not pinch the flap
where the two ends connect (Fig. 11).

Fig. 11

Slide channel over rails:

Butt the rails together and slide the channel over the rails.
Centre sleeve between marks.
Note: Channel must extend beyond the sleeve edge as shown, Fig. 12.

Fig. 12

Shrink the wraparound sleeve:

Preheat evenly along both sides of the rail/channel area until this area begins to shrink, Fig. 13.
Begin shrinking at the centre of the sleeve and work toward each end. Apply heat until the sleeve is
fully shrunk and the heat sensitive paint is completely converted.
Continue heating the rail/channel area for another 5 seconds per foot.
A white line should be visible in the channel gaps indicating sufficient heating.
Note: Heat-sensitive paint will turn black as sleeve shrinks in place, Fig. 14.

Fig. 13

Lead

Fig. 14

Repair is complete.
Note: Allow to cool before moving or placing in service.

Recommended Raychem Sleeve Sheath Repair Selection Table:

Kit

Diameter Range

Sleeve Length

HVS-LR-75/15-600

0.65-2.65" (17-67mm)

24" (610mm)

HVS-LR-75/15-1200

0.65-2.65" (17-67mm)

48" (1219mm)

HVS-LR-160/42-600

1.80-5.70" (46-145mm)

24" (610mm)

HVS-LR-160/42-1200

1.80-5.70" (46-145mm)

48" (1219mm)

HVS-LR-200/50-600

2.15-7.10" (55-180mm)

24" (610mm)

HVS-LR-200/50-1200

2.15-7.10" (55-180mm)

48" (1219mm)

Test After Repair:

1- LV Cables : No sheath test required, only Insulation Resistance to be checked, if required.
2- MV Cables: No sheath test required, only Insulation Resistance to be checked, if required.
3- HV Cables : DC Sheath test to be conducted according to IEC 60229, since outer sheath is
covered with graphite powder.