Cable Testing:

On-site Test

Dr. Asawin Rajakrom

11 July 2019
1
 Presentation Outline
Defects in cable and cable accessories

Detection of defects

Cable testing concept

Tests with different voltages

Standards for on-site cable testing

Defects in Cable & Accessories
1. Protrusions on the semi
conductive layers
2. Stripping void between the
insulation and semi
conductive layers,
conductor and insulation
shield
3. Voids
4. Moisture
5. Impurities (Metal, Amber)
6. Water tree from conductor
shield
7. Water tree form insulation
shield
8. Electrical tree caused by
partial discharge
9. Bow-tie tree
Defects in Cable & Accessories
Defects in Cable & Accessories
 Water Tree
➢ Water trees are formed only in the presence of a liquid.
➢ The applied voltage must be greater than zero.
➢ The site at which propagation begins can be inclusions,
micro-voids, irregularities, or ionic contaminants which
have seeped from the extruded shields into the
insulation.
➢ As partial discharges are not necessary for the inception
and propagation of water trees.
➢ Propagation time through the insulation wall is long
(years).
Water Tree
 Water Tree

Four distinct phases of the treeing

process:
1. Moisture permeation
2. Initiation of water trees
3. Propagation of water trees
4. Conversion to electrical trees
leading to failure
Water Tree in Polymeric Insulation

Bow- tie- tree growing from an included particle

inside the insulation of a 30 kV- PE- cable
Water Tree in Polymeric Insulation

Puncture
Punctureout
outofofa avented-
vented-tree
tree
 Water Tree and Electrical Tree

electrical field conditions for

water development of
disturbance field "water trees"
time

"bow-tie trees"
outer semiconducting layer

insulation

inner semiconducting layer

"vented trees"
conductor
Electrical Tree

Electrical trees are formed only

under the influence of partial
discharges in the insulation wall
or at the shielding layers.
These discharges may occur at
voids, inclusions or asperities.
The applied voltage must be
above the corona inception level
for electrical trees to form.
Water Tree and Electrical Tree

Stress enhancement areas, sites of possible electrical trees (ET),

created by a water tree (WT).
Water Tree and Electrical Tree

Vented water tree (WT) and electrical tree (ET) growing into each
other from opposite screens
 Water Tree and Electrical Tree

Electrical trees (ET) are linking two contaminants and another ET is

emanating from the conductor screen.
 Water Tree and Electrical Tree
Comparison of Water Treeing - Electrical Treeing
Water Treeing (WT)
Already seen at small field strength
(e.g. < 1kV/mm)
Extremely slow tree growth (e.g. over
6-10 years)
No partial discharge recognizable
No visible channels
Not visible without special coloring
procedure
Electrical Treeing (ET)
At high local field stress
Very fast tree growth in PE or XLPE
insulation
Accompanied by partial discharge
Long channel structures (visible trees)
Clear indication of an electrical
breakdown
 How to Avoid Water Trees

• Insulation material should be clean.

• Shield material should be clean.
• The insulation should be extruded tightly over
the conductor shield.
• Shield/insulation interfaces should be smooth
and clean.
• The curing process should minimize formation
of microvoids.
• There should be no water in the strands.
 XLPE Process to Avoid Water
Trees

• Dry cured
• Triple extrusion
• Super clean XLPE compound
• Super smooth semi conductive
compound
• Contamination free raw material
handling system
• Computerized process control
• Inline dimension control
 Space Charge

DC hipot output negatively charge up void. These trapped space charges

remain after test. When AC is reapplied, there’s a high difference of potential
across very little insulation. Leads to electrical trees – cable fails.
 Partial Discharge in Cables
• A localized electrical breakdown in the electrical insulation
system under voltage stress that only partially bridged the
insulation between conductors.

• A consequence of local breakdown either as a result of

– An electric field enhancement within or on the surface of the
insulation, or
– A region of low breakdown field

• Occurred at:
– Voids or cavities within the insulation or at interfaces
– Interfacial cavities in cable and accessory interfaces
– High-resistance insulation shield or broken neutral
– Electrical trees initiated from protrusions, voids, or water trees
 Partial Discharge in Cables

Several kinds of cable defect

1. interface gap formation
2. cavities
3. cavities eventually with conductive sharp points
Partial Discharge in Cables
 Partial Discharge in Cables

Acoustic Heat

PD
Chemical
EMW reaction

Light
 Partial Discharge in Cables
Voids may be formed in insulation Heat and other forms of
systems due to manufacturing or energy released by PD cause
installation defects, ageing, water tree erosion of the internal surface
growth. Continued stress and of void.
overvoltages can initiates PD in voids.

Continued erosion forms

Cable channels that develop into
so-called electrical trees in
Failure insulation.

Continued PD produced further

erosion until the electrical tree
bridges the insulation
 Partial Discharge in Cables

Electric Stress Distribution With No Void Electric Stress Distribution With a Void
( 12.7 kV rms on the cable conductor ) ( 12.7 kV rms on the cable conductor )
PD in Insulation Cavity
Partial Discharge in Cables
PD Patterns
Partial Discharge in Cables
PD Patterns
 PD Tests
What PD parameters are measured?

• PD inception voltage (PDIV) • PD density

• PD extinction voltage (PDEV) • Phase angle of PD pulse

• PD location • Phase resolved PD plot

• PD magnitude • PD magnitude vs. voltage plot

• PD repetition rate
 Voltage Sources

Resonance Test System (AC)

Oscillating Wave Test Very Low Frequency

System (DAC) (VLF)
 PD Tests
PD test methods:

• Offline test:
– An elevated AC voltage of about 1.5-2.0 U0 is applied to generate PD and then
a proprietary digital signal analysis platform is used to detect transient signals
that are generated at the discharge site and travel through the cable to the
detection equipment
– Test voltage source can be selected from VLF, resonance or damped AC voltage
tester

• Online test:
– Cable circuit is under normal operating voltage and loading condition
– Sensors – HFCT or CCV – are used to detect transient signals and digital signal
analysis platform is used to capture and record signals

• Tests shall be done in comparative manner, i.e. PD growth

 PD Offline Test

Typical test setup for offline PD testing

 PD Offline Test

Generation of Test Voltage (DAC)

HV Solid - Inductor L
Test Object: power cable
State Switch Test Object: Power Cable
HV Source

S Cc

For short cable

an additional CC
is required.

HV Divider
Embedded PC HV Divider
PD Coupling Capacitor
Process
200 MHzControl Unit
AD Converter PD Coupling Capacitor
adaptive PD detector
Data Storage PD detector
PD Analysis
Dielectric losses
estimation

Source: SebaKMT
Dissipation Factor (Tan d)
 Dissipation Factor (Tan d)

voltage

current

0 10
time/sec

true power U² / R 1
Dissipation Factor tan d = = =
reactive power U². w C w C. R
Dissipation Factor (Tan d)

Simplified Model of a Water Tree

wt

R2 C2

C1 R1
Dissipation Factor (Tan d)

Test sutup for Tan d

 Dissipation Factor (Tan d)
How to test Tan d
➢ Non-destructive and integral procedure, and is hence useful for assessing the
entire tested cable route eg. gross defects
➢ 6 to 10 measurements are performed at 0.5U0, 1.0 U0, 1.5U0 and 2U0
➢ Tan delta mean value (MTD) of measurements in the individual voltage steps
➢ Delivers information on water trees, i.e. damages caused by water in the
insulation of plastic-insulated cables. (These water trees can become electrical
trees where partial discharges and breakdowns may occur).
➢ Gives information on the thermal or chemical ageing behaviour of the cable
route.
➢ Tan delta standard deviation (STD) of measurements in the individual
voltage steps
➢ Indicates of partial discharges (PD)
➢ Detect moist joints
➢ Mean value difference (DTD) in the various voltage steps
➢ Detect water trees
➢ Detect partial discharges
➢ Detect vaporisation effects (e.g. at terminations)
Cable Testing Concept
Field Distribution in Cables: AC vs DC

• AC Conditions:
– tan δ = ↓↓
– Ic >> Ir
– Capacitive field control

• DC conditions (without
consideration of space
charges):
– C becomes irrelevant
– Resistive field control
– Defects usually have lower
resistance and lower field
Insulation of MV, HV and EHV Cables
• Examples for Typical Cable Geometry
– MV Cable: 24 kV, insulation thickness 5.5 mm, mean
operational field strength at voltage peak 3.1 kV/mm
– HV Cable: 138 kV, insulation thickness 17.8 mm, mean
operational field strength at voltage peak 6.3 kV/mm
– EHV Cable: 400 kV, insulation thickness 26 mm, mean
operational field strength at voltage peak 12.6 kV/mm
Insulation of MV, HV and EHV Cables
Technical Consequences

➢ Field strength increases with cable voltage

➢ Recommended limit for test field strength: 27-30 kV/mm

➢ Allowed ratio between test voltages and operational voltages for MV 4

times and for HV 2 times higher than for EHV XLPE cables

➢ Test methods using higher overvoltages can be applied for MV cables

➢ Using these methods for HV and EHV cables test voltages would have
to be reduced, in turn reducing sensitivity of test
Continuous Alternating Voltage Test
IEC 60060-3 (2006) High-voltage test techniques
Part 3: Definitions and requirements for on-site testing
 AC Resonance Testing
Series Resonant Circuit
AC Resonance Testing
ACTC = conventional test Transformers with
Compensating reactors

ACRL = Resonant circuits based on tuneable HV reactors

(inductance)

ACRF = Resonant circuit based on HV reactors with fixed

inductance tuned into resonance by variable Frequency

Circuits for AC test voltage generation

1– test object
2 – voltage divider/coupling capacitor
3 – test transformer
4 – compensating reactor
5 – regulating transformer
6 – switchgear,
7 – control and measuring unit
8 – tuneable reactor
9 – exciter transformer
10 – fixed reactor
 AC Resonance Testing

Source: HIGHVOLT
 AC Resonance Testing

Source: HIGHVOLT
 AC Resonance Testing

1 – Power inverter (400 kVA)

2 – Power inverter (200 kVA)
3 – Fiber optic links
4 – Three identical exciter transformers
5 – Resonant reactors ((110 kV / 194 A)
6 – Voltage divider
7 – Test objects (Cables under test)
Source: HIGHVOLT
 AC Resonance Testing

Source: HIGHVOLT
 Damped AC System
IEC 60060-3 (2006) High-voltage test techniques
Part 3: Definitions and requirements for on-site testing
 Damped AC System
Features
➢ Combination of Resonant and Pulse Technologies
➢ DAC based field test equipment capable of High Test Capacitance @
HV (highest test capacitance 13μF @ 350kV Peak)
➢ DAC wave shape to allow PD testing within power frequency range
(20-300Hz)
➢ DAC wave shape simultaneously displays PDIV and PDEV
➢ DAC wave shape visualizes & estimates Dielectric Losses (tan ∂)
➢ DAC represents very low “risk” of cable due to short HV pulse
exposure
Summary
➢ Cost effective method to PD test larger, longer & higher voltage cables
Damped AC System
Working Principle
 Damped AC System
Block Diagram DAC Technology
Damped AC System
Damped AC System
Damped AC System
PDIV
can be detected simultaneously

PDEV

Dielectric Losses = tan∂ can be calculated

from attenuation of wave shape
Damped AC System
Damped AC System
 VLF System
IEC 60060-3 (2006) High-voltage test techniques
Part 3: Definitions and requirements for on-site testing
 VLF System
Features
➢ Makes use of the VLF technology to reduce “reactive” power
➢ Most effective technology for small test capacitance @ fairly modest
test voltages
➢ Only suitable wave shape to perform tan∂ measurements
➢ “Electrical Stress” dV/dt approx.500 x less compared to 50Hz
➢ Higher test capacitances are achieved by reducing the test frequency
from 0.1Hz to as low as 0.01Hz,
➢ Caution: Results not directly comparable between different
frequencies. Stress Level dV/dt very different & # of cycles different
Summary
➢ The only wave shape for VLF tan ∂ measurement,
➢ Cost effective for smaller & lower voltage type cables
 VLF System
Working Principle
 VLF System
The Growth Rate of Electrical trees
depends on the Frequency

All test voltage values in RMS

 VLF System
Dissipation Factor tan ∂ of New and Serviced
aged XLPE Cables
VLF System
VLF System
Comparison of Different Tests
 Comparison of Different Tests
Norms AC Resonance DAC VLF DC
IEC 60060-3 (2006) √ √ √ √
IEC 60502-2(2014) √ √ √
IEC 60840 (2011) √
IEC 62067 (2011) √
IEC 60229 (2007) √
IEEE 400 - 2012 √ √ √ √
IEEE400.1 - 2007 √
IEEE 400.2 - 2013 √
IEEE 400.4 - 2015 √
PD/TD possibility √ √ √
Portability √ √
Power consumption √ √ √
 IEC Standards
❑ IEC 60060-3 (2006)
➢ High-voltage test techniques
➢ Part 3: Definitions and requirements for on-site testing
❑ IEC 60502-2(2014)
➢ Power cables with extruded insulation and their accessories for rated voltages
from 1kV (Um =1.2kV) up to 30kV (Um =36kV)
➢ Part 2: Cables for rated voltages from 6kV (Um =7.2kV) up to 30kV (Um
=36kV)
❑ IEC 60840 (2011)
➢ Power cables with extruded insulation and their accessories for rated voltages
above 30 kV (Um = 36 kV) up to 150 kV (Um = 170 kV)
➢ Test methods and requirements
❑ IEC 62067 (2011)
➢ Power cables with extruded insulation and their accessories for rated voltage
above 150 kV up to 500 kV
➢ Test methods and requirements
❑ IEC 60229 (2007)
➢ Electric cables – Tests on extruded oversheaths with a special protective
function
 IEC 60060-3 (2006)
❑ Due to a variety of external factors not present in factory and
laboratory tests such as external electric and magnetic fields,
weather conditions, etc.

❑ Apply for electrical equipment with a highest voltage Um greater

than 1 kV

❑ On-site high-voltage tests are required:

➢ As withstand tests as part of a commissioning procedure on
equipment to demonstrate that transport from manufacturer to site,
and the erection on-site complies with manufacturer’s specification;
➢ As withstand tests after on-site repair, to demonstrate that the
equipment has been successfully repaired, and is in a suitable
condition to return to service;
➢ For diagnostic purposes, e.g. PD measurement, to demonstrate if the
insulation is still free from dangerous defects, and as an indication of
life expectation
 IEC 60060-3 (2006)
❑ Provide information about:
➢ General
➢ Definitions
➢ Test voltage
➢ Measurement of the test voltage
➢ Tests and checks on measuring systems
➢ Test procedure

❑ Types of voltage to be performed on site:

➢ Direct voltage;
➢ Alternating voltage;
➢ Lightning impulse voltage of aperiodic or oscillating shape;
➢ Switching impulse voltage of aperiodic or oscillating shape.
➢ Very low frequency voltage;
➢ Damped alternating voltage.
IEC 60502-2(2014)
IEC 60502-2(2014)
IEC 60840 (2011)
IEC 60840 (2011)
IEC 62067 (2011)
IEC 62067 (2011)
IEC 60229 (2007)
 IEEE Standards
❑ IEEE 400 - 2012 (Omnibus)
➢ IEEE Guide for Field Testing and Evaluation of the Insulation of Shielded
Power Cable Systems Rated 5 kV and Above.

❑ IEEE400.1 - 2007
➢ IEEE Guide for Field Testing of Laminated Dielectric, Shielded Power Cable
Systems Rated 5 kV and Above with High Direct Current Voltage.

❑ IEEE 400.2 - 2013

➢ IEEE Guide for Field Testing of Shielded Power Cable Systems Using Very Low
Frequency (VLF) (Less Than 1 Hz).

❑ IEEE 400.3 - 2006

➢ IEEE Guide for PARTIAL Discharge Testing of Shielded Power Cable Systems
in a Field Environment.

❑ IEEE 400.4 - 2015

➢ IEEE Guide for Field Testing of Shielded Power Cable Systems Rated 5 kV and
Above with Damped Alternating Current (DAC) Voltage.
 IEEE 400 - 2012
❑ Suggested steps for field testing and evaluation of shielded power cable
systems

a) Identify testing objectives.

b) Identify cable systems to be tested.

c) Review specifications and operating conditions of cable and cable system

components to be tested.

d) Select and apply suitable field tests.

e) Record information or documentation for analysis.

f) Perform recommended corrective actions on cable system.

 IEEE 400 - 2012
❑ Tests: For the purpose of this guide, several test categories are
considered:
❑ From the application point of view, there are three categories of tests:
➢ Installation test:
➢ A field test conducted after cable installation but before the application of joints or
terminations.
➢ Intended to detect shipping, storage, or cable installation damage with the
advantage of testing cable sections only.
➢ Care should be taken to have a proper interface for tests at cable ends to avoid
excessive leakage or a possible flashover. Temporary terminations are generally
required.
➢ Acceptance test:
➢ A field test made after cable system installation, including terminations and joints,
but before the cable system is placed into normal service.
➢ To demonstrate that the transportation, handling and installation have not
damaged the cable system components;
➢ To identify poor workmanship as well as to demonstrate that the equipment has
been successfully repaired after an on-site repair of new components and
significant defects in the insulation have been eliminated.
➢ Maintenance test:
➢ A field test made during the operating life of a cable system.
➢ To assess the present condition of in-service cable systems
➢ Test data serve as reference for future evaluation and be used for trending to
enhance diagnostics.
➢ Test data on other cables similar in design and service conditions can be used to
establish decision criteria
 IEEE 400 - 2012
❑ From the technical point of view, there are five broad sets of tests:

➢ Diagnostic test: A field test made during the operating life of a cable
system to assess the condition of the cable system and, in some cases, locate
degraded regions that can result in a failure.

➢ Non-monitored or simple withstand test: A diagnostic test in which a

voltage of a predetermined magnitude is applied for a predetermined time
duration. If the test object survives the test it is deemed to have passed the
test.

➢ Monitored withstand test: A diagnostic test in which a voltage of a

predetermined magnitude is applied for a certain time period. During the test,
other properties of the test object are monitored to help determine its
condition and also evaluate if test duration needs to be extended or may be
reduced.

➢ Offline testing: The cable system under test is disconnected from the
service power source and energized from a separate field test power supply.

➢ Online testing: The cable system under test is energized by its normal
service power source, usually at 50 Hz or 60 Hz. This type of test enables
temporary or permanent monitoring.
 IEEE 400 - 2012
❑ Field testing methods:

a) Voltage withstand

b) Dielectric response
❖ Dissipation factor (tan delta)
❖ Leakage current
❖ Recovery voltage
❖ Polarization/Depolarization current
❖ Dielectric spectroscopy

c) Partial discharge
❖ Electrical measurement
❖ Acoustic measurement

d) Time-domain reflectometry

e) Thermal infrared imaging

 IEEE 400.1 - 2007
IEEE Guide for Field Testing of Laminated Dielectric, Shielded Power Cable
Systems Rated 5 kV and Above with High Direct Current Voltage

❑ Point standard for testing laminated insulated cables with HVDC

❑ Includes testing procedures

❑ Provides guidelines for test voltages

❑ Methods of evaluation

➢ Current-time relationship

➢ Resistance values

❑ Not recommend for service aged solid dielectric cables

 IEEE 400.2 - 2013
IEEE Guide for Field Testing of Shielded Power Cable Systems Using Very
Low Frequency (VLF) (Less Than 1 Hz) Point standard for testing laminated
insulated cables with HVDC

❑ Point standard for VLF withstand tests

❑ Presents rational for VLF versus DC

❑ Test parameters for tan delta

❑ Test values in appendix

 IEEE 400.3 - 2006
IEEE Guide for Partial Discharge Testing of Shielded Power Cable Systems in
a Field Environment Point standard for testing laminated insulated cables with HVDC

❑ Background information on partial discharge detection and location

❑ Interpretive guidance provided

❑ Technology has improved sensitivity of measurements

❑ Very good and very bad cables identified

❑ Remaining life cannot be predicted with great accuracy

 IEEE 400.4 - 2015
IEEE Guide for Field Testing of Shielded Power Cable Systems Rated 5 kV
and Above with Damped Alternating Current (DAC) Voltage

❑ Provides for use of damped alternating current voltages for field testing

❑ Guidelines for evaluation of test results

❑ DAC applications advanced diagnostic testing

❑ Most common use partial discharge and dissipation factor

MEA Standards for Cable Tests (115 kV)
MEA Standards for Cable Tests (24 kV)
MEA Standards for Cable Tests (24 kV)
MEA Standards for Cable Tests (24 kV)
MEA Standards for Cable Tests (24 kV)
 “Thank you”

asawinraja@gmail.com