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The reasons for corrosion cracking of secondary cable joints used in outdoor terminal boxes of a 220 kV substation in humid environment were investigated by scanning electron microscopy (SEM), X-ray diffractometer (XRD), infrared spectroscopy (IR) and ion dissolution test. According to the results of ion dissolution test, polyvinyl chlorid (PVC) insulated and sheathed cable material would precipitate chloride (Cl) ions under humid environment and at a certain temperature, which leads to accelerated corrosion cracking of the exposed copper core wires of secondary cable. In addition, the newly supplied PVC and cross-linked polyethylene (XLPE) materials without Cl precipitation under the same experimental conditions, indicating that PVC materials would precipitate Cl after reaching a service time threshold. Therefore, it is recommended that XLPE used for the insulation materials and accessories of secondary cable in outdoor terminal box of substation, as well as humidity in the terminal box should be controlled.

The corrosion analysis and prevention of secondary cable joints used in outdoor terminal boxes of substation in humid environment