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Type Test Procedure

For
66 kV 1c X 500sqmm XLPE Cable and Accessories
at TAIHAN Cable - Works, Korea

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130906

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Contents:
1. Scope
2. Cable and accessories subject to type test
2.1 Cable
2.2 Joints
2.3 Terminations
3. Applicable Standard
4. Type Test Procedure
4.1 Electrical type test on complete cable systems
4.2 Description and Procedure of tests for joints
4.3 Test on cable components
5. Type Test Scheme
6. Type Test Schedule

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Type Test Procedure


For
66 kV 1c X 500sqmm XLPE Cable and Accessories
1. Scope.
This document covers the type test procedure for 66 kV, single-core 1 c X
500sqmm copper conductor, XLPE insulated, copper wire screened, lead
sheathed cable and accessories.
2. Cable and accessories subject to type test.
2.1 Cable:
66 kV, single-core 1 c X 500sqmm copper conductor XLPE
Insulated, copper screen, lead alloy sheathed and HDPE outer
covered power cable. (Document N0. 05-4/00/SIE/36/3001)
Cable ratings:
- Service voltage
: 66kV
- Highest system voltage : 72.5kV
- Power frequency
: 50Hz
- Symmetrical fault level : 31.5kA/1sec
- Basic insulation level
: 325kV
- Power frequency short duration withstand
140kV/1min.

voltage:

2.2 Joint:
Elastimold Straight through Joint for 1C x 500 Sq mm Cable
69TCJ-Q (Document N0. 05-4/00/SIE/18/4021)
2.3 Terminations:
66kV Cable accessories, GIS/Transformer sealing Ends, Size
4 & 5s Terminations from Pfisterer (Document No. 054/00/SIE/36/0035)
66KV Outdoor Sealing End from G & W Electric (Document
No. 05-4-00-SIE-18-4025)

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3. Applicable Standards:

Standard No.

Title

Contract Specification

TENDER NO. GTC/5/2004


QATAR POWER TRANSMISSION SYSTEM
EXPANSION - PHASEVI VOLUME3B
- SECTION 3.3.8.5 66kV XLPE INSULATED
CABLE & ACCESSORIES

IEC 60840(2004)

Power cables with extruded insulation and


their accessories for rated voltages
above 30kV(Um=36kV)
up to l5OkV(Um=l7OkV)
Test methods and requirements

IEC 60228(2004)

Conductors of insulated cables

IEC 60230 (1966)

Impulse tests on cables and their


accessories
Common test methods for insulating and
sheathing materials of electric cables and
optical cables - Part 1-1: Methods for general
application - Measurement of thickness and
overall dimensions - Tests for determining
the mechanical properties

IEC 60811-1-1 (2001)

IEC 60811-2-1 (2001)

Common test methods for insulating and


sheathing materials of electric and optical
cables - Part 2-1: Methods specific to
elastomeric compounds - Ozone resistance,
hot set and mineral oil immersion tests

IEC 60885 (1987)

Electrical test methods for electric cables.

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4. Type Test Procedure.

4.1 Electrical type test on complete cable systems

Test Standards

Schedule
Description of Test
TYPE TEST
1.1 Measurement of insulation
thickness
1.2 Bending test

Tender
specification

Reference
standard

Requirements

IEC 60840

tMin.Ave. 12.6mm

Section 3.3.8.5
Clause 1.4.2.2 b.
-

IEC 60840
Clause 12.3.3
-

Dia. of cylinder 25x(d+D)


+5% 3times
-

Section 3.3.8.5
Clause 1.4.2.2 b.
Section 3.3.8.5
Clause 1.4.2.2 c.

IEC 60840
Clause 12.3.4
IEC 60840
Clause 12.3.5

1.6 Heating cycle voltage test

Section 3.3.8.5
Clause 1.4.2.2 d.

IEC 60840
Clause 12.3.6

1.7 Partial discharge test at


ambient temperature
1.8 Partial discharge test at
high temperature

Section 3.3.8.5
Clause 1.4.2.2 d.
Section 3.3.8.5
Clause 1.4.2.2 d.

IEC 60840
Clause 12.3.4
IEC 60840
Clause 12.3.4

1.9 Lightning impulse voltage


test

Section 3.3.8.5
Clause 1.4.2.2 e.

IEC 60840
Clause 12.3.7

1.10 High voltage test

Section 3.3.8.5
Clause 1.4.2.2 e.

IEC 60840
Clause 12.3.7

Max. 5pC at AC 57kV,


ambient temp'
Max. 0.0008 at AC 38kV,
95~100oC conductor temp'
No breakdown at AC 76kV
during 20cycles at 95~100oC
conductor temp' and ambient
temp' alternately
Max. 5pC at AC 57kV,
ambient temp'
Max. 5pC at AC 57kV,
95~100oC conductor temp'
No breakdown at 325kVp/
10times, 95~100oC conductor
temp'
No breakdown at AC 95kV for
15min. at ambient temp' or
during cooling period

1.11 Examination

1.12 Test of Outer protection for


buried joint

Section 3.3.8.5
Clause 1.4.2.4

1.3 Assembly of system line


1.4 Partial discharge test at
ambient temperature
1.5 Tan measurement

IEC 60840
Clause 12.3.8
IEC 60840
Annex H
DC Test Volt.:
20kV / 1 min.

No signs of deterioration
No Breakdown

4.2 Description and Procedure of tests for joints


We propose to carry out the tests as per IEC 60840 annex H, H.3 and H.4 to a
Joint which has passed the heating cycle voltage test as described (1.6 of 4.1) of
Type Test Procedure or on a separate joint which has undergone at least three
thermal cycles as per 1. and 2. (below) without voltage. This in line with clause
H.2 of annex H (IEC 60840)

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The selection of any one of the above procedure depends on availability of test
bay in the lab at the time of carrying out the tests.
1. In case of use a separate joint the first step will be the three thermal cycles
without voltage:
Operation of heating Cycle:
Total number of cycles:

Heating 8 hours (95 to 100 C at least 2 hours)


3 times

2. Water immersion and heat cycling.


Operation of heating Cycle:

Heating 5 hours (105 to 110 C at least 2


hours)
20 times

Total number of cycles:


3. DC. Voltage Test.
Test Voltage:

Between metallic sheath and the earth: DC 20 kV

Test Duration:

1 minute

4.3 Test on cable components


Test Standards

Schedule

Tender
specification

Description of Test
CABLE SAMPLE TESTS

Reference
standard

a)Examination
of conductor
IEC60228
2.1 Check of cable construction

Section 3.3.8.5
Clause 1.4.2.3 f.

2.2 Measurement of thickness


of insulation
2.3 Measurement of insulation
concentricity

Section 3.3.8.5
Clause 1.4.2.3 g.
Section 3.3.8.5
Clause 1.4.2.3 h.

2.4 Measurement of insulation


purity

Section 3.3.8.5
Clause 1.4.2.3 i.

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b)Measurement
of metallic
sheath
IEC60811-1-1
c)Measurement
of outer
covering
IEC60811-1-1
IEC 60840
Clause 12.4.1
-

Requirements

Outside Diameter of
conductor: Approx. 26.5 mm
Ratio of diameters of two
different wires: Max. 2
Thickness of metallic sheath:
Min. 1.8mm
Thickness of outer covering
Min. ave. 3.7mm
Min. 3.05mm
Min. 10.8mm
Max. 0.08
[(tmax-tmin)/tavg 0.08]
Void: Max. 0.05mm
Contaminant: Max. 0.15mm
Translucent: Max. 0.6mm

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2.5 Measurement of moisture


content in extruded insulation
and screens

Section 3.3.8.5
Clause 1.4.2.3 j.

Insulation: Max.150ppm
Screen: Max.500ppm

2.6 Hot set test for XLPE


insulations

Section 3.3.8.5
Clause 1.4.2.3 k.

IEC 60840
Clause 12.4.10

Max. elongation under load:


175%
Max. permanent elongation
under cooling: 15%

2.7 Shrinkage test for XLPE


insulation

Section 3.3.8.5
Clause 1.4.2.3 l.

IEC 60840
Clause 12.4.13

Max. 4%
Conductor screen: Max. 1000
ohm.m

2.8 Measurement of resistivity


of semi-conducting screens

Section 3.3.8.5
Clause 1.4.2.3 m.

IEC 60840
Clause 12.3.9

2.9 Measurement of screen


protrusions

Section 3.3.8.5
Clause 1.4.2.3 n.

2.10 Tests for determining the


mechanical properties of the
insulation before and after
ageing

2.11 Tests for determining the


mechanical properties of the
non-metallic sheaths before
and after ageing

Section 3.3.8.5
Clause 1.4.2.3 o.

Section 3.3.8.5
Clause 1.4.2.3 p.

2.12 Ageing tests on pieces of


complete cable to check
compatibility of materials

Section 3.3.8.5
Clause 1.4.2.3 q.

2.13 Impact test on metallic


sheath

Section 3.3.8.5
Clause 1.4.2.3 r.

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IEC 60840
Clause 12.4.2

IEC 60840
Clause 12.4.3

IEC 60840
Clause 12.4.4

Insulation screen: Max. 500


ohm.m
Max. 0.125mm
[Before aging]
- Tensile strength: Min.
12.5N/mm2
- Elongation at break: Min.
200%
[After aging at 1353oC for
7days]
-Variation of tensile strength:
Max. 25%
- Variation of elongation at
break: Max. 25%
[Before aging]
- Tensile strength: Min.
12.5N/ mm2
- Elongation at break: Min.
300%
[After aging at 1102oC for
10days]
- Elongation at break: Min.
300%
[After aging at 1002oC for
7days] for insulation
- Variation of tensile strength:
Max. 25%
- Variation of elongation at
break: Max. 25% for
oversheath
- Variation of elongation at
break: Min. 300%
No cracks in the cable sheath
or evidence of damage to the
cable core

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2.14 Pressure test at high


temperature on sheaths
2.15 Measurement of density of
HDPE insulation
2.16 Measurement of carbon
black content of black PE
sheaths
2.17 Shrinkage test for PE
oversheaths
2.18 Water penetration test

Section 3.3.8.5
Clause 1.4.2.3 s.
Section 3.3.8.5
Clause 1.4.2.3 t.

IEC 60840
Clause 12.4.6

Section 3.3.8.5
Clause 1.4.2.3 u.

IEC 60840
Clause 12.4.12

Section 3.3.8.5
Clause 1.4.2.3 v.
Section 3.3.8.5
Clause 1.4.2.3 w.

IEC 60840
Clause 12.4.14
IEC 60840
Clause 12.4.18

Max. 50%

IEC 60840
2.5 0.5%
Max. 3%
No emersion of water

5. Type Test Scheme:

OUTDOOR SEALING END


Drawing GTC 05-4/00/SIE/18/4025

TEST JOINT BOX


Type 5s

Type 4

Drawing GTC 05-4/00/SIE/36/0035

Drawing GTC 05-4/00/SIE/36/0035

66KV, 500 SQMM CABLE


Drawing GTC 05-4/00/SIE/36/3005

Drawing GTC 05-4/00/SIE/18/4021


Straight Through Joint

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