30 June 2011

ISSUE 5
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UNCONTROLLED COPY IF PRINTED

Operational Procedure:
Underground Cable
Testing: High and Low
Voltage



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30 June 2011

OPERATIONAL PROCEDURE - Underground Cable Testing: High and Low Voltage
UNCLASSIFIED CEOP4005

30 June 2011 - Issue 5
Approved By: Group Manager Standards and Demand Management
Page 2 of 10
UNCLASSIFIED UNCONTROLLED COPY IF PRINTED



PREPARED BY: Underground Construction and Design Manager



AUTHORISED BY: Group Manager Standards and Demand Management



DOCUMENT NUMBER: CEOP4005 ISSUE 5































This plan is copyright. No part may be reproduced by any process without written permission,
except as permitted under the copyright act.

DISCLAIMER
1 Essential Energy may change the information in this document without notice. All changes
take effect on the date made by Essential Energy. A print version is always an uncontrolled
copy. Before using this document, please ensure that it is still current.
2 This document may contain confidential information. Restrictions on the use and disclosure
of confidential information by employees are set out in your contract of employment.
Restrictions on the use and disclosure of confidential information by contractors are set out in
your contract of engagement with Essential Energy. Sub-contractors are bound by the
confidentiality provisions set out in their contract with the contractor engaged by Essential
Energy.
2011 ESSENTI AL ENERGY


OPERATIONAL PROCEDURE - Underground Cable Testing: High and Low Voltage
UNCLASSIFIED CEOP4005

30 June 2011 - Issue 5
Approved By: Group Manager Standards and Demand Management
Page 3 of 10
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CONTENTS PAGE

1 INTRODUCTION ............................................................................................. 4
2 TOOLS AND EQUIPMENT ................................................................................. 4
3 TRAINING ..................................................................................................... 4
3.1 Training, Assessment and Authorisation ........................................................... 4
4 PRELIMINARY CHECKS ................................................................................... 4
4.1 Visual Check ................................................................................................. 4
4.2 Notification ................................................................................................... 4
4.3 Worksite Hazard Identification, Risk Assessment and Control (worksite HIRAC) ..... 4
5 METHOD ....................................................................................................... 5
5.1 High Voltage Cable Tests ................................................................................ 5
5.2 Insulated Resistance Test Level 1 .................................................................. 5
5.3 High Voltage Test Level 2 (Paper Lead Cables Only) ........................................ 6
5.4 Delayed Connection to Network ....................................................................... 6
5.5 Low Voltage Cable Test .................................................................................. 7
5.6 Continuity Test 1 ........................................................................................ 7
5.7 Serving Insulation Resistance Test 2 ............................................................. 8
5.8 Insulation Resistance Test 3 ......................................................................... 8
5.9 Method Streetlighting Cable Tests ................................................................. 8
5.9.1 Polarity Test ............................................................................................. 8
5.10 Failure to Comply .......................................................................................... 9
6 RECORDS ..................................................................................................... 9
7 KEY TERMS AND DEFINITIONS ........................................................................ 9
8 REFERENCES ................................................................................................ 10
9 REVISIONS .................................................................................................. 10


OPERATIONAL PROCEDURE - Underground Cable Testing: High and Low Voltage
UNCLASSIFIED CEOP4005

30 June 2011 - Issue 5
Approved By: Group Manager Standards and Demand Management
Page 4 of 10
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1 INTRODUCTION
This document proves the high and low voltage cable integrity after installation or jointing
work is completed and before connection or reconnection to the Essential Energys Network.
Such testing and commissioning will be undertaken by people, who are both qualified and
authorised, and the relevant test results will be duly entered into the relevant test report
form (refer to CEOF6022 and CEOF6023). This document is intended for use by Essential
Energys Accredited Service Providers and internal staff for testing of cables before being
energised.


2 TOOLS AND EQUIPMENT
Danger HV Test Signs 1000V DC Megger
Insulating Gloves 500V DC Megger
Insulated Ground Matting Low Voltage Tester
Suitable HV Test Equipment Foster Test Set (For paper cable only)


3 TRAINING
3.1 Training, Assessment and Authorisation
Where there is exposure to risk from electrical apparatus a person undertaking work will be
appropriately qualified, trained and assessed as competent and authorised to carry out the
work.


4 PRELIMINARY CHECKS
4.1 Visual Check
A visual check is carried out by the Authorised Person to ensure that the workmanship of
both the installation of the cable and cable jointing work meets Essential Energys
requirements before being connected to the Network.

4.2 Notification
The Quality Control Coordinator will be notified 3 working days prior to the commencement
of the cable tests. The Accredited Service Provider will be responsible for ensuring that the
completed work is tested and test reports are forwarded to the Quality Control Coordinator
promptly. The Quality Control Coordinator may be present to witness the testing
procedure.

4.3 Worksite Hazard Identification, Risk Assessment and Control
(worksite HIRAC)
Tests on underground cables are potentially hazardous to both personnel undertaking the
test and the general public in the vicinity. A Worksite HIRAC will be carried out, by the
Authorised Person, which will determine the precautions that need to be adopted. For
public areas warning signs may need to be displayed and barricades erected around the test
area (including all exposed cable terminations) prior to commencing any testing activity.

OPERATIONAL PROCEDURE - Underground Cable Testing: High and Low Voltage
UNCLASSIFIED CEOP4005

30 June 2011 - Issue 5
Approved By: Group Manager Standards and Demand Management
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For HV and LV cable Insulation Resistance tests, a Test Access Permit is not
mandatory if the Insulation Resistance test is performed at a 1000 volts DC or less
and the cable is discharged to earth for a time duration equal to the test time. If an
Access Permit for Testing is deemed necessary after a HIRAC evaluation it will be
completed and issued in accordance with CEOP2045 Access Permits. If currently on a
Work Access Permit, remove earths and cancel the Access Permit
If the cable has previously been commissioned and connected to Essential Energys
System call System Operations and inform them if you require a Test Access Permit to
test a high voltage cable, and at all times give full details of location, open points etc
Insulating gloves and ground matting to be utilised.


5 METHOD
5.1 High Voltage Cable Tests
Authorised Persons will complete the prescribed tests as specified. All cables must be fully
discharged for a time duration equal to the test time upon completion of each test by means
of discharge function on test equipment or an independent earth.

Test results will be recorded on the HV Underground Cable Test Report form, refer to
CEOF6022.

5.2 Insulated Resistance Test Level 1
Screen to Earth Test for XLPE insulated cables will record an insulation resistance as
per table below at 500V after one (1) minute. This test will be performed first so as to
assist in the reconnection process of the screen to earth connection
Phase to Screen/Earth, and Phase to Phase testing requires the Authorised Person to
measure insulation resistance at 1.kV after one (1) minute duration. Minimum IR as
per table below.

Insulation Resistance (IR) Values for HV Cables

Cable Rated
Voltage kV
Minimum IR
@ 1kV DC New
Cables
Ph-Ph, Ph-E
Minimum IR
@500V
Screen E
New Cables
Minimum IR
@ 1kV DC
Existing Cables
Ph-Ph, Ph-E
Minimum IR
@ 500V
Screen E
Existing Cables
11kV 400 megohms 100 megohm 100 megohms 1.0 megohm
22kV 400 megohms 100 megohm 100 megohms 1.0 megohm
33kV 800 megohms 100 megohm 200 megohms 1.0 megohm
66kV 800 megohms 100 megohm 200 megohms 1.0 megohm
132kV 800 megohms 100 megohm 200 megohms 1.0 megohm

Note: Insulation Resistance Tests will be applied for a period of 1 minute for cables less
than 100 m in length and 3 minutes for cables greater than 100 m in length.


OPERATIONAL PROCEDURE - Underground Cable Testing: High and Low Voltage
UNCLASSIFIED CEOP4005

30 June 2011 - Issue 5
Approved By: Group Manager Standards and Demand Management
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5.3 High Voltage Test Level 2 (Paper Lead Cables Only)
If the insulation resistance results for Paper Lead (PLY) cables are below the prescribed
minimum values, a high voltage DC test will be applied. See CEOF6022 HV Underground
cable Test Report for the prescribed minimum values. If prescribed minimum values are
required for higher voltage Paper Lead (PLY) cables, contact Quality Control Coordinator.
It is performed by applying a DC voltage between phases and between phases and
sheath. When making these tests, the voltage will be increased gradually to the full
specified value and be maintained for 15 minutes. After 15 minutes, the leakage
current should be steady or falling and less then 0.1mA with no transient spikes
occurring. Higher readings may be acceptable provided they are steady. For further
advice, contact Quality Control Coordinator
Commissioning new cables a cable not previously energised will be tested by
applying:

11kV cable 22kV cable
34kV DC between phases; and 68 kV DC between phases; and
25kV DC between phases and sheaths 50 kV DC between phases and sheath

The 3 phases can be bonded for the phase to sheath test and only 1 test made unless a
failure occurs. If a failure occurs, each phase will be tested individually to determine the
faulty phase.

Recommissioning Existing Cables where a cable that has been in service, is to be
tested prior to recommissioning, it will be tested at approximately 75% of the voltages
for a new cable, i.e.



The phases can be bonded for the phase to sheath test, and only one test made
unless a failure occurs.

5.4 Delayed Connection to Network
Insulation Integrity Test

If a cable is to be connected to the Network and the testing has occurred within 4 weeks
preceding this, a visual inspection of the cable location will be undertaken, for any obvious
signs that cable insulation integrity may have been compromised. After 4 weeks has
elapsed the standard test must be repeated before connection is carried out. This time
frame also applies to cables which have been removed from service for repair or have been
decommissioned.

If live line techniques are to be utilised for cable connection a documented cable test must
be carried out (CEOF6022 HV Underground Cable Test Report) to determine the insulation
integrity of the cable prior to carrying out live line technique.

11kV cable 22kV cable
26kV DC between phases; and 52kV DC between phases; and
15kV DC between phases and sheath 30kV DC between phases and sheath

OPERATIONAL PROCEDURE - Underground Cable Testing: High and Low Voltage
UNCLASSIFIED CEOP4005

30 June 2011 - Issue 5
Approved By: Group Manager Standards and Demand Management
Page 7 of 10
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If an Insulation Integrity test is to be undertaken the live line gang must inform System
Operations of the insulation integrity test before the live line work is carried out. Once the
integrity of the insulation is proven, inform System Operations of the result (if the cable
fails the test, commissioning of the cable will not proceed any further and Quality Control
Coordinator will be contacted for further advice).

Live Line work will be carried out as per switching sheet.

The Standard Tests, Phase to Phase and Phase to earth:
Measure insulation resistance at 1kV after one (1) minute.
Acceptable values for existing cables may be used as cable will now be connected to
switchgear etc.

A Phase to B Phase Greater than 100 megohms
B Phase to C Phase Greater than 100 megohms
C Phase to A Phase Greater than 100 megohms

A Phase to Screen and Earth Greater than 100 megohms
B Phase to Screen and Earth Greater than 100 megohms
C Phase to Screen and Earth Greater than 100 megohms.

All cables must be fully discharged for a time duration equal to the test time upon
completion of each test by means of discharge function on test equipment or an
independent earth.

The purpose of this test is to prove that the integrity of the insulation has not been
damaged since the original test date.

The energising/de-energising of an underground cable which is to be directly connected to
the overhead system and is isolated from the transformer must only be undertaken using a
temporary EDO (cut-out tool) fitted with a 25 amp K class fuse element.

5.5 Low Voltage Cable Test
Authorised Persons will complete the prescribed tests as specified. All cables must be fully
discharged for a time, duration equal to the test time upon completion of each test by
means of the discharge function on test equipment or an independent earth. Test results
will be recorded on CEOF6023 LV Underground Cable Test Report form.

5.6 Continuity Test 1
The continuity test (DC resistance measurement) will be carried out on each low voltage
circuit from the end of each branch or open point, to the origin of the circuit.

Step 1 At the circuit origin, to be tested, (normally at the Padmount transformer), connect
each of the phase conductors to the neutral of the cable circuit in turn, ensuring all
MEN points are disconnected.
Step 2 At the remote ends of the circuit, check for continuity between each phase and
neutral.
Results very close to a short circuit value should be obtained.
Step 3 At the circuit origin (normally at the Padmount transformer) connect the phase
conductors together, remaining separate from neutral conductor.
Alternatively, if cable is to be energised immediately after testing, neutral polarity
may be tested by lamping out conductors at each pit or pillar.

OPERATIONAL PROCEDURE - Underground Cable Testing: High and Low Voltage
UNCLASSIFIED CEOP4005

30 June 2011 - Issue 5
Approved By: Group Manager Standards and Demand Management
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Step 4 Proceed to each pit or pillar on the circuit and check neutral polarity with 500V
megger. If any reading other than an open circuit is recorded between the
connected phases and neutral, it will mean a phase has been connected to the
neutral which will be located, rectified and retested before connection to Essential
Energys Distribution System.

5.7 Serving Insulation Resistance Test 2
The integrity of the covering sheath will be proved by bonding the 4 cores and applying
500V DC for 1 minute between the bonded cores and earth. The minimum insulation
resistance will be 200 Megohms for new cables and 20 Megohms for cables older than 1
year.

If the cables fail this test, the point of failure will be located, rectified and retested before
connection to Essential Energys Distribution System.

5.8 Insulation Resistance Test 3
Ensuring all cores are separated from each other and using a 500V instrument measure the
insulation resistance between 2 cores in rotation, i.e.: N-R, R-W, N-W, R-B, N-B, B-W.

The minimum insulation resistance will be 200 Megohms for new cables and 20 Megohms
for cables older than 1 year.

If a cable fails to achieve the required minimum values, contact Quality Control Coordinator
or the Principals Superintendent for further advice.

Ensure all MEN points have been reconnected.

5.9 Method Streetlighting Cable Tests
5.9.1 Polarity Test
CHECK all connections in the service pit/pillar and ensure they are correct
ENSURE primary fuse is removed or circuit breaker is switched off, incoming neutral
isolated, earths disconnected, PE cell and tubes/globes removed
CONFIRM visually the colour coding of internal wiring at terminal block is correct.
Ensure terminal block is not earthed at light fitting
USING 500V megger measure insulation resistance between internal wiring and
standard (reading to exceed 1 megohm), test for short circuits and reconnect earth if
applicable
TEST and identify streetlight active and neutral. Connect service neutral to streetlight
neutral first, then service active to streetlight active
CHECK all connections in the street light column and ensure they are correct
INSERT PE cell, tube/globe, fuse or circuit breaker. Ensure streetlight operates
CONDUCT final test with streetlight on measuring between an independent earth and
neutral and earth or metal work for any voltage.


OPERATIONAL PROCEDURE - Underground Cable Testing: High and Low Voltage
UNCLASSIFIED CEOP4005

30 June 2011 - Issue 5
Approved By: Group Manager Standards and Demand Management
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5.10 Failure to Comply
If a cable or associated equipment fail a prescribed test, the Accredited Service Provider will
be responsible for the location of the fault, repair or replacement of faulty cable and/or
accessories, and any subsequent testing, as directed by Quality Control Coordinator.

Prior to the application of any fault location methods which have the potential to affect the
long-term insulation integrity of the installation, the Authorised Service Provider will submit
to Essential Energy a proposed fault location methodology. No fault location work will
proceed until Essential Energys Quality Control Coordinator has given approval.


6 RECORDS
The relevant test results will be duly entered on the relevant Test Report form, (See
CEOF6022 and CEOF6023.)

The Cable Test Report will be sighted by the person carrying out the commissioning who
completes the clearance certification by signing, therefore accepting the new asset.

The person carrying out the commissioning will quote the Cable Test Report No. to System
Operations when requesting energisation of new asset. This will be System Operations
record of compliance until paper copy is received.

The Quality Control Coordinator is also responsible for correct distribution of Cable Test
Report copies.

1 Quality Control Coordinator WHITE
2 Project File BLUE
3 System Operations YELLOW
4 Book copy PINK.


7 KEY TERMS AND DEFINITIONS
Accredited Service Provider: refers to companies/sole traders who have gained
accreditation through the Department of Fair Trading allowing them to perform contestable
works.
Authorised Person: means a person with technical knowledge or sufficient experience who
has demonstrated competency and has been approved by Essential Energy to carry out
specific duties with the supply or use of electricity.
Contestable Works: those works where the customer has a choice of Service Provider.
Continuity test: test to ensure correct cable core identity and continuity.
Essential Energys Network: Essential Energy Transmission and Distribution System
Assets.
Insulation Resistance: quantified measurement of insulation value.
Polarity test: test to ascertain correct identification and connection of active and neutral
conductors.
Principals Superintendent: Project Manager of the Accredited Service Provider.
Quality Control Coordinator: is the person nominated by Essential Energy with the
responsibility for auditing construction works to Essential Energys standards and quality.
System Operations: Essential Energy 24 hour Operational Control Centre.

OPERATIONAL PROCEDURE - Underground Cable Testing: High and Low Voltage
UNCLASSIFIED CEOP4005

30 June 2011 - Issue 5
Approved By: Group Manager Standards and Demand Management
Page 10 of 10
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8 REFERENCES
CEOF6022 HV Underground Cable Test Report
CEOF6023 LV Underground Cable Test Report
CEOP2018 Polarity and Neutral Identification Testing
CEOP2045 Access Permits
CEOP8029 Network Management Plan
CEOP8030 Electrical Safety Rules

Olex Cables Technical Informative PT-I 316 24th May 2001
Electricity Supply (Safety and Network Management) Regulation 2002


9 REVISIONS
Revision
Number
Section Details of Changes in this Revision
2 All Sections
Reduction in Meggering voltages to align with Manufacturers
recommendations.
3
All Sections Document changed to Plain English
Clause 8.1.3
Second paragraph was.If live line techniques are to
be utilised for cable connection it maybe prudent to undertake
an insulation integrity test regardless of the elapsed time
period.
Definitions
Accredited Service Provider was. refers to
companies/sole traders who have gained accreditation
through NSW Ministry of Energy and Utilities allowing them to
perform contestable works.
4
Clause 5.6
Step 1, Sentence 1 added, .. connect each of the phase
conductors to the neutral of the cable circuit in turn
Step 2 was
Each phase and neutral, and
Each phase
Clause 6
Second paragraph was . The Cable Test Report will
be signed by the Quality Control Coordinator..
Third paragraph, first sentence was.. The Quality
Coordinator
5 All Update to rebrand to Essential Energy