The quick splice tools provide a complete metal-to-metal sealing system.

Pressure testable cable heads, connected to

each end of the tool, seal to the cable jacket with a patented sealing system that is robust and simple to use.

The tools covered in this manual are specifically designed to splice together lengths o single conductor tubing
encapsulated cable (TEC). Tough construction materials and tool design ensures that the splice tool can be deployed in
well conditions throughout the oil and gas industry, including high pressure, high temperature, corrosive and sour gas
environments.

This manual demonstrates the steps required to prepare the cable and to install and pressure test the splice tools.
 Compatible TEC Cable 4mm (0.16”) and 6.35mm (0.25”)

Conductor Single

Temperature 177°C
Stainless Steel 316L / SGS
Construction Material
Inconel 825 option
Outside Diameter 0.875” (22.23mm)

2.2.2 Quick Tee 1-1-1 Wire

Isolated Glass Feed-Through

53.97mm
(2.125”)

22.22mm
(0.875”)

361.95mm (14.25”)

Easy-Connect Cableheads

Pressure Test Ports

 3 Cable Preparation

This section details the procedure to prepare the cable lengths that are to be spliced, including stripping polypropylene
encapsulation, preparing the metal jacket (tubing), as well as preparing the wire conductor and connector pin. It is
important to follow the procedures correctly, wear appropriate PPE (safety glasses, gloves) and follow safe work
practices.

12-20 AWG Wire Stripper PN 101059

Hand Crimping Tool Frame MIL-C-22520/1-01 PN 100275
Hand Crimping Tool Turret Head PN 100276
Crimp-Quick Pin AWG 16-18 Gold PN 100645
Slim Taper File PN 100328
Turtle Collar OD 4mm, Length 6.35mm PN 101383
Emery Cloth Rolls, grit>320 PN 101078
Custom Vice Grip Locking Plier PN 101056
Closed Barrel Contact 4-indent Crimper AWG 12-24 PN 102210
3.1 Strip Encapsulation

Secure the encapsulated TEC in a bench vice.

DO NOT OVER-TIGHTEN

Mark the total length of encapsulation to be removed

(typically 10-12”); make intermediate marks to remove the
encapsulation in 2.5” sections.

Using a metal file, score the encapsulation all the way

around the cable.

DO NOT use excessive force while filing through the

encapsulation as it may potentially cut or scratch the TEC
metal tubing.

Repeat this for each marked section.

Secure locking-pliers on either side of the marked line.

Holding the main cable secure, twist the encapsulation

section to be removed back and forth until it breaks.

DO NOT over twist in one direction as this could damage

the TEC.

Work over the encapsulation to be removed and slide it off

over the TEC metal tubing.

Lubricate the TEC metal jacket with WD-40.

Repeat steps to remove each 2.5” section of encapsulation

until the total length has been removed.
3.2 Metal Jacket Preparation

Ensure that the 4mm TEC is straight and free from twists or
bends.

Using the tool as a guide, mark the position on the TEC that
the compression ferrules will be located (approx. 5”).

To secure the TEC for the next steps, attach locking pliers
near the mark, then secure them in a vice.

DO NOT engage locking pliers where the ferrules will be

located as it could prevent a proper seal from being
achieved.
Position of ferrules
INSPECT the metal jacket for visible damage, ensure that
there are no dents, cracks, punctures or cuts that could
prevent a good seal.

Metal-to-metal seals WILL NOT SEAL on defects.

Remove small defects by polishing the sealing areas with

Emery cloth, applying it circumferentially not lengthways.

Mark a point on the metal jacket 1.0” (2.5cm) from the end
of the cable.

Using a slim taper file, carefully score a groove all the way
around the metal tubing at the marked position.
1.0”
Ensure the groove is made evenly around the full
circumference of the TEC.

The groove depth should go most of the way through the

metal jacket but DO NOT cut all the way through (Note,
the tubing is <1mm thick).
 Using the locking pliers, gently bend the cable back and forth at the scored
groove until the metal jacket breaks.
Bend slightly
to snap Do not force the jacket to break, as this can permanently bend the cable.

If the cable does not snap easily, carefully deepen the groove and try again.

Still holding the main jacket steady with the pliers, gently wiggle the end section
with the other pliers to slide it off.
Gently wiggle
and slide
Pull the jacket straight off so as not to damage the wire insulation.
jacket off

INSPECT the wire insulation for damage.

Ensure that there are no cuts, breaks, cracks or splits – pay

particular attention to the insulation close to the score
where the jacket was cut.

Remove any rough edges or burrs around the score using

EMERY abrasive cloth, grit number 320 or higher.

NOT ACCEPTABLE:
The edge is burred and the score is not tapered.

GOOD:
No burred or rough edges and the score is properly tapered.

Using EMERY cloth, work circumferentially through 360°

around the tubing to remove any burrs and ensure it is
polished and free of imperfections.
DO NOT polish lengthways.

Check that cable head, ferrules and fittings slide easily over
the TEC.
3.3 Wire and Contact Pin Preparation

Cut the exposed conductor to 3/4" (19.05 mm) from the

edge of the metal jacket.
3/4 (0.75)”
This ensures that you are prepping “clean” conductor in
case any wire ends were damaged during the jacket
preparation.

Strip off 3/16 or 0.188” (4.76 mm) of insulator using the

wire stripper.
3/4”
Inspect wire for missing strands.

Note: On 18 AWG wire, use 14 AWG wire stripper so as not

to damage or strip any of the tinned copper strands.
9/16”) 3/16”

Slide the 0.25” turtle collar over the wire.

Carefully insert the wire into the contact pin, ensuring that
no wire strands remain outside of the pin.

Crimp position IMPORTANT: Use the inspection window in the contact

pin to verify that the wire is visible and fully inserted.

Inspection window
Install the tool turret head (PN 100276) into a hand crimping
tool frame (PN 100275).

Set turret head position to RED and tool selector position to

5.

Insert contact pin (with inserted wire) into the tool until it
seats at the back of the contact hole.

Firmly squeeze the handles of the crimp tool to create the

crimp.

IMPORTANT: Check that the wires are showing fully

through the inspection window.

To ensure the crimp is good, pull firmly on the wire to

make sure it does not detach.

Pull straight, DO NOT TWIST while pulling.

 4 Splice Tool Installation
This section details the procedure to install the Quick Splice and Quick Tee tools and cable heads onto the TEC cable
lengths to be spliced. It is important to follow the procedures correctly, wear appropriate PPE (safety glasses, gloves)
and follow safe work practices.

2 x ¾” wrenches
12mm wrench
Absorbent cloth or drip tray
Dielectric grease
O-ring lubricant such as Molykote 55
Anti-seize thread compound such as Nikal
Tape Measure
Marker

Secure the TEC cable in a vice using a non-marring jaw

accessory or soft rag to prevent damaging the cable.

DO NOT OVER-TIGHTEN

Slide the cable head onto the TEC cable.

Ensure that the front and back ferrules are properly

orientated.

Black O-ring / White Teflon Rings Ensure that the O-ring and Teflon rings are correctly
positioned and seated on the tool.

One white Teflon ring should be installed on each side of the

black O-ring.

Ensuring that the ferrules are correctly ordered and

oriented, loosely tighten the compression fittings onto the
tool.

Gently slide the TEC cable all the way into the tool, being
very careful not to pinch the pin and conductor.
 Mark TEC
Once the tool is pushed all the way on the cable, make a
mark on the TEC behind the cap.

Remove the tool from the TEC cable and align the end of the
Splice
cap at the point previously marked.
Shoulder
Ensure that the middle of the pin aligns with the shoulder of
Align end of cap
the splice body.
with mark

Using the syringe, fill the pin cavity with dielectric oil.

Place the tool back onto the TEC cable, ensuring the pin is
Orientation Marks properly engaged.

Hand-tighten the sealing cap and place orientation marks on

the cap, tool body and cable.

Using a 12mm and ¾” wrench, tighten the sealing cap one

rotation past hand tight so that the orientation lines are
back in alignment.

Follow this procedure to connect all cable lengths to the tool before sealing the cable heads onto the cable.
Quick Tee 1-1-1 Wire:

Apply Molykote 55 O-ring grease onto the O-rings.

Apply Nikal anti-seize compound onto the tool thread.

Carefully thread the cable head onto the tool body, ensuring
O-ring grease that it does not cross thread.

The cable head should thread by hand and seat against the
shoulder without much resistance.

With a marker, mark an orientation line that crosses both

sides of the join between the cable head and tool.

With two ¾” wrenches, apply approx. 30 ft-lbs of torque to

the wrenches to tighten the cable head up to the tool.

The lines should show the degree of separation shown here.

After tightening the cable head sealing hex cap hand tight,
mark an orientation line across the hex cap and the cable
head body.

Using a 12mm and ¾” wrench, tighten the cap one full turn
so that the orientation lines are back in alignment.
 5 Cable Head Pressure Test

This section demonstrates how to test the integrity of the cable head seal using hydraulic pressure, providing essential
steps to verify the metal-to-metal seal between the cable head, tool and TEC.

Recommended test pressure is 2000psi but the test can be performed up to 5000psi, depending on operator
requirements.

A portable pressure kit (PN: 101082) contains the following items required for this procedure:

PN: 102065 Pressure testing clamp and O-ring seal.

PN: 104399 Hydraulic hand pump 5kpsi
PN: 103226 Digital Gauge 5kpsi LCD
PN: 101552 Vacuum Pump and Brake Bleeder Kit
High Pressure Fittings Kit
Flat Head screwdriver
3 x wrenches, 1/4”, 7/8”, 13/16”
Dielectric oil

Carefully unscrew the pressure test M3 thread screw cover

from the cable head.

Using the syringe provided, fill the pressure test port with
dielectric oil.

New O-ring Spare O-rings

Ensure that a new O-ring (PN 102068: 005 Viton Duro 90) is
fitted onto the pressure test clamp.
 Place the cable head into the pressure testing clamp
ensuring that the O-ring fitting seats properly into the
pressure test port.

Hand-tighten the hex nut.

Do not apply too much force as the M3 threads are easily

damaged.

Attach the vacuum pump tube and cross-over assembly

(PN’s: 100432, 100433, 100434) to the pressure test clamp,
seal and secure with a hose clamp (PN: 104489).

Attach the tube from the cross-over assembly to the top of

the pump vessel cap, ensuring that is aligned with the
vessel’s internal tube that will draw the dielectric oil.

Tube from cross-over Attach the vessel containing dielectric oil (approx. 2/3 full).
Internal tube

Pump at approx. 22mmHg pressure, watching the bubbles

exiting through the tube.

When no more bubbles are seen, bleed off the pressure.

During the process, tap the cable head to ensure all air has
been liberated.

Repeat this process 2 or 3 times until there are no more

bubbles seen.

Disconnect the pump, then remove the tube and cross-over

from the pressure test clamp.
Using the syringe provided, fill the pressure test clamp cavity
with dielectric oil to ensure the cable head is filled before
proceeding with the pressure test.

Assemble the hydraulic hand pump with digital gauge and

hydraulic hose.

Thread the LM4 to ¼” NPTF adaptor (PN: 100446) into the

HIP valve.

Thread and tighten the hydraulic hose connector into the

HIP valve.

Using the ¼” HM4 gland, collar and coned tube assembly

(100432/100433/100434), connect the pressure test clamp to
the HIP valve.

Apply anti-seize lubricant to the coned/threaded tube

fittings, assemble and tighten to 25 ft-lbs
 Open the HIP valve (not shown).

Open and close the bleed valve (A) on the pump, allowing air
bubbles to escape.

Increase pressure to 2000psi. Open and close the valve

A again to allow bubbles to escape.

Repeat this until no more bubbles are observed.

B
With the bleed valve closed, pump to just below 2000psi
using the fine adjust valve (B) to adjust pressure.

Close HIP valve and leave for a minimum of 10 minutes to

monitor for any pressure drop. A 10% reduction is
acceptable.

Once the test is completed, carefully remove the test

equipment and high-pressure fittings connected to the
pressure test clamp.

Ensure that you remove the O-ring which will likely remain
seated in the cable head pressure port.

Replace the M3 thread screw cover back into the cable head
pressure test port.