15 kV Feeder Refurbishment for a Distribution Utility in Southeast Asia

Client Background

A national distribution utility was replacing 15 kV feeder cable across three districts. The existing accessories were a mix of four brands accumulated over twenty years and the store held sixty three different part numbers for what were really eight cable configurations.

Project Challenge

Complete 820 terminations and 140 joints inside a 14 week outage programme with crews working night shifts in monsoon conditions, using an accessory family the utility could approve against IEC 60502-4 before the programme started.

Customer Pain Points

• Sixty three part numbers in store for eight real cable configurations
• Crews trained on four different installation methods
• Resin joints failing to cure in monsoon humidity and overnight temperatures
• No single supplier able to produce a complete IEC 60502-4 record inside the tender window

Our Solution

We mapped the utility's cable schedule onto eight C15 part numbers covering indoor terminations outdoor terminations and joints across two conductor bands. Outdoor kits carried four rain sheds per phase rather than the standard count because two of the three districts sit within salt spray range of the coast. The IEC 60502-4 and GB/T 12706.4 test record went to the design authority in week one of the tender.

Manufacturing Process

Kits were packed to an agreed bill of materials in Dalian. The stress control and non tracking layers were extruded and radiation cross linked in house. Molded rain sheds and breakout boots came from our own tooling. Every carton carried a production record traceable to the compound lot.

Supply Chain Coordination

Deliveries were phased in four shipments against the outage programme rather than one container. That kept the utility's district stores from overflowing and let us adjust the mix in shipment three after the first district reported higher joint consumption than forecast.

Quality Control

Per lot testing covered tensile strength ultimate elongation heat aging dielectric strength volume resistivity and tracking resistance. Twelve sample terminations were built and tested before the first shipment was released.

Final Result

The programme completed in 13 weeks. Store part numbers dropped from 63 to 8. Two joints were rebuilt during the programme both traced to semiconductive residue left on the insulation surface which was corrected with a WhatsApp video refresher for that crew.

Customer Benefit

The utility now holds eight part numbers instead of sixty three, its crews are trained on one installation method, and the accessory family is on the approved list for the next three districts.