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ISBN 978-0-626--30436-2
SANS
S 6284
4-5:20
007
Ed
dition 2

SO
OUTH AFRIC
A CAN N
NATIO
ONAL
L STAN
NDAR
RD

Tes
st meth
hods for
f cro oss-lin
nked polyeth
p hylene
e
(XL
LPE) in
nsulate
ed electric cables
c s

geing tests
Parrt 5: Ag

Publishhed by SABS Standards Division

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G  Private Bag
g X191 Pretorria 0001
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7 12 428 7911
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SANS 6284-5:2007
Edition 2

Table of changes
Change No. Date Scope

Foreword
This South African standard was approved by National Committee SABS/TC 066, Electric cables, in
accordance with procedures of the SABS Standards Division, in compliance with annex 3 of the
WTO/TBT agreement.

This document was published in August 2007.

This document supersedes SABS 1284-5:2001 (edition 1.1).

SANS 6284 consists of the following parts, under the general title Test methods for cross-linked
polyethylene (XLPE) insulated electric cables:

Part 1: Tests on XLPE insulation.

Part 2: Tests on extruded semi-conducting screens.

Part 3: Tests on finished cable.

Part 4: Tests after installation.

Part 5: Ageing tests.

Annex A forms an integral part of this part of SANS 6284.

Introduction
Where possible, this part of SANS 6284 was technically aligned with the test methods contained in
the IEC 60502 series, Power cables with extruded insulation and their accessories for rated
voltages from 1 kV (Um = 1,2 kV) up to 30 kV (Um = 36 kV).

Reaffirmed and reprinted in June 2014.

This document will be reviewed every five years
and be reaffirmed, amended, revised or withdrawn.

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Contents
Page

Foreword

Introduction

1 Scope .................................................................................................................................... 3

2 Test at 50 Hz ......................................................................................................................... 3

3 Test at 500 Hz ....................................................................................................................... 7

Annex A (normative) Water tree examination .......................................................................... 10

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Test methods for cross-linked polyethylene (XLPE) insulated

electric cables

Part 5:
Ageing tests

1 Scope
This part of SANS 6284 specifies methods for carrying out ageing tests on samples of triple-
extruded core of an XLPE cable to demonstrate the long-term reliability of the materials used and
their resistance to the growth of water trees.

2 Test at 50 Hz
2.1 Principle
Cable specimens are aged in a tank of water while being supplied with power for a period of 2
years. The cable specimens are thereafter subjected to specified voltages in order to determine the
break down voltage, and this breakdown voltage is compared with the manufacturer’s claimed
break down voltage.

2.2 Apparatus

2.2.1 Water tank

A water tank large enough to accommodate the specified number of samples of triple extruded
core, either as individual samples or as a complete length from which the samples may be taken, as
required. Some means of maintaining the water at the specified temperature for the duration of the
preconditioning period shall be provided.

2.2.2 Power supply

A single-phase or three-phase transformer that has a continuous rating sufficient to supply the load
current drawn by the cable samples at the specified test voltage. If a three-phase transformer is
used, the high-voltage winding shall be star connected and the neutral point of the winding shall be
earthed.

Since the load provided by the cable samples is capacitive, some form of inductive compensation is
desirable in order to limit the kVA rating of the transformer and the kWh consumed for the duration
of the test period.

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A variable voltage transformer or transformers shall be provided to adjust the test voltage to the
specified value.

2.3 Test specimens

2.3.1 Core

12 samples of triple-extruded core, each of length 10 m, and of the specified conductor size and
voltage rating. If intermediate samples are to be taken throughout the two-year test, these shall be
in addition to the 12 samples specified above.

2.3.2 Terminations

Two test terminations shall be required for each sample. These shall be suitable for continuous
operation at 3 Uo (see SANS 1339). It is permissible to test all the samples in one continuous length
and for intermediate samples, if required, to be cut from this length as the test proceeds. However,
the cable shall be reterminated at the cut end after the removal of each sample.

2.4 Test procedure

2.4.1 Installation

2.4.1.1 Individual samples

Install the samples as shown in figure 1.

Each 10 m sample is wound into a coil having 2 or 3 turns, depending on the diameter of the core
and the size of the tank, and the ends are brought out well above the water level, so that the bottom
end of the termination is at least 50 mm above the top of the tank. Each coil and termination shall
be adequately secured so that no movement can occur during the test.

Mount a clear plastic conservator, of at least 1 L capacity, on each end of each sample, as shown in
figure 1.

Figure 1 — Arrangement of individual samples in water tank

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2.4.1.2 Continuous length

The complete coil is best mounted horizontally as shown in figure 2.

Arrange the coil on a circular former, which will allow samples to be taken at intervals throughout
the test, if required. If the diameter of the former is made 1 060 mm, three complete turns will
comprise 10 m, the length of one sample.

The ends of the coil are brought out well above the water level, so that the bottom end of each
termination is at least 50 mm above the top of the tank. The coil and terminations shall be
adequately secured so that no movement can occur during the test.

Mount a clear plastic conservator, of at least 1 L capacity, on each end of the coil, as shown in
figure 2.

Figure 2 — Arrangement of complete coil in water tank

2.4.2 Conditioning

2.4.2.1 Water level

Fill the tank with tap water to a level at least 100 mm above the coil or coils, check the water level
regularly, and top up to replace any evaporation during the conditioning period or the subsequent
ageing test.

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2.4.2.2 Conservators

Fit clear plastic conservators, having a capacity of at least 1 L, to the ends of each sample, and fill
with tap water. Each conservator shall be topped up as necessary throughout the conditioning
period and subsequently throughout the ageing test. Any topping up required during the ageing test,
shall be carried out with the supply voltage disconnected to avoid accidental contact.

2.4.2.3 Heating

Heat the water in the tank to a steady temperature of 50 °C ± 5 °C and maintain at that temperature
for a period of 1 000 h.

2.4.3 Ageing

Allow the water in the tank to cool to room temperature. With the tank (if it is metallic) earthed, apply
the specified high voltage to the conductor at one end of each sample by way of the water-filled
conservator. If the tank is non-metallic, a metal plate shall be provided in the bottom of the tank to
act as an earth electrode.

Maintain the voltage at the specified value for a period of two years. The supply may be
disconnected for short periods, each not exceeding 24 h, to enable any necessary maintenance or
repairs to be carried out, but the test period shall be extended to allow for any such lost time.

Samples, not exceeding 3 in total, can be taken from the tank (see 2.2.1) at agreed intervals
throughout the two-year test period, provided that due allowance has been made for the required
additional length of core at the start of the test.

2.4.4 Voltage test

2.4.4.1 Sample preparation

Disconnect the core or cores, which has/have been subjected to the above ageing procedure, from
the high-voltage test supply, and remove it/them from the tank. If aged as a continuous length in
accordance with 2.4.1.2, cut the core into 12 equal lengths of 10 m each.

Prepare the ends of each 10 m sample for the high-voltage test using deionized water terminations
or other approved means. It will be necessary to wrap the exposed semiconducting core screen of
the sample in a metallic foil or braid in order to make an adequate earth connection.

2.4.4.2 Voltage application

Apply a voltage of 3 Uo for a period of 5 min, then raise the voltage to 4 Uo for a further 5 min,
increasing the voltage in 1 Uo, 5 min steps to breakdown.

Record the voltage that the sample withstood for 5 min prior to the voltage at which it broke down.

Repeat the test on the remaining 11 samples and record the voltage withstand values.

2.5 Evaluation
Compare the results obtained in 2.4.4 with the voltage withstand values specified for the cable.

Do a water tree examination if additional samples for water tree examination have been included
(see annex A).

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3 Test at 500 Hz
3.1 Principle
Cable specimens are aged in a tank of water while being supplied with power at 500 Hz for a period
of 3 000 h. The cable specimens are thereafter subjected to specified voltages in order to determine
the break down voltage, and this breakdown voltage is compared with the manufacturer’s claimed
break down voltage.

3.2 Apparatus

3.2.1 Water tank

A water tank large enough to accommodate the specified number of samples of triple-extruded
core, either as individual samples or as a complete length from which the samples may be taken, as
required. Some means of maintaining the water at the specified temperature for the duration of the
preconditioning period shall be provided.

3.2.2 Power supply

The required 500 Hz ± 5 % waveform may be obtained either from a motor/generator set or from a
solid-state converter/inverter. A step-up transformer, designed for operation at 500 Hz ± 5 %,
together with some means of varying the output voltage to that specified, shall also be required.

Since the load current at 500 Hz ± 5 % will be ten times that at 50 Hz, some form of reactive
compensation is recommended to minimize both the rating of the 500 Hz ± 5 % supply and the
energy costs for the period of the test.

3.3 Test specimens

3.3.1 Core

12 samples of triple-extruded core, each of length 10 m, and of the specified conductor size and
voltage rating. If intermediate samples are to be taken throughout the 3 000 h test, these shall be in
addition to the 12 samples specified above.

3.3.2 Terminations

Two test terminations shall be required for each sample. These shall be suitable for continuous
operation at 3 Uo. It is permissible to test all of the samples in one continuous length and for
intermediate samples, if required, to be cut from this length as the test proceeds. However, the
cable shall be reterminated at the cut end after the removal of each sample.

NOTE Some types of termination that employ materials with stress dependent resistivity for stress relief at the
end of the semiconducting core screen, may not be suitable for operation at 500 Hz ± 5 %. The manufacturers
should be consulted as to their suitability before use in this application.

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3.4 Test procedure

3.4.1 Installation

3.4.1.1 Individual samples

Install the samples as shown in figure 1.

Each 10 m sample is wound into a coil having 2 or 3 turns, depending on the diameter of the core
and the size of the tank, and the ends are brought out well above the water level, so that the bottom
end of the termination is at least 50 mm above the top of the tank. Each coil and termination shall
be adequately secured so that no movement can occur during the test.

Mount a clear plastic conservator, of at least 1 L capacity, on each end of each sample, as shown in
figure 1.

3.4.1.2 Continuous length

The complete coil is best mounted horizontally as shown in figure 2.

Arrange the coil on a circular former, which will allow samples to be taken at intervals throughout
the test, if required. If the diameter of the former is made 1 060 mm, three complete turns will
comprise 10 m, the length of one sample.

The ends of the coil are brought out well above the water level, so that the bottom end of each
termination is at least 50 mm above the top of the tank. The coil and terminations shall be
adequately secured so that no movement can occur during the test.

Mount a clear plastic conservator, of at least 1 L capacity, on each end of the coil, as shown in
figure 2.

3.4.2 Conditioning

3.4.2.1 Water level

Fill the tank with tap water to a level at least 100 mm above the coil or coils, check the water level
regularly, and top up to replace any evaporation during the conditioning period or the subsequent
ageing test.

3.4.2.2 Conservators

Fit clear plastic conservators, having a capacity of at least 1 L, to the ends of each sample, and fill
with tap water. Each conservator shall be topped up as necessary throughout the conditioning
period and subsequently throughout the ageing test. Any topping up required during the ageing test,
shall be carried out with the supply voltage disconnected to avoid accidental contact.

3.4.2.3 Heating

Heat the water in the tank to a steady temperature of 50 °C ± 5 °C and maintain at that temperature
for a period of 1 000 h.

3.4.3 Ageing

Allow the water in the tank to cool to room temperature. With the tank (if it is metallic) earthed, apply
the specified high voltage to the conductor at one end of each sample by way of the water-filled
conservator. If the tank is non-metallic, a metal plate shall be provided in the bottom of the tank to

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act as an earth electrode.

Maintain the voltage at the specified value for a period of 3 000 h. The supply may be disconnected
for short periods, each not exceeding 24 h, to enable any necessary maintenance or repairs to be
carried out, but the test period shall be extended to allow for any such lost time.

Samples, not exceeding 3 in total, can be taken from the tank at agreed intervals throughout the
3 000 h test period, provided that due allowance has been made for the required additional length of
core at the start of the test (see 3.3.1).

3.4.4 Voltage test

3.4.4.1 Sample preparation

Disconnect the core or cores, which has/have been subjected to the above ageing procedure, from
the high-voltage test supply and remove it/them from the tank. If aged as a continuous length in
accordance with 3.4.1.2, cut the core into 12 equal lengths of 10 m each.

Prepare the ends of each 10 m sample for the high-voltage test using deionized water terminations
or other approved means. It will be necessary to wrap the exposed semiconducting core screen of
the sample in a metallic foil or braid in order to make an adequate earth connection.

3.4.4.2 Voltage application

Apply a voltage of 3 Uo for a period of 5 min, then raise the voltage to 4 Uo for a further 5 min,
increasing the voltage in 1 Uo, 5 min steps to breakdown.

Record the voltage that the sample withstood for 5 min prior to the voltage at which it broke down.

Repeat the test on the remaining 11 samples and record the voltage withstand values.

3.5 Evaluation
Compare the results obtained in 3.4.4.2 with the voltage withstand values specified for the cable.

3.6 Water tree examination

Do a water tree examination if additional samples for water tree examination have been included
(see annex A).

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Annex A
(normative)

Water tree examination

A.1 Additional samples

If additional samples have been included (see 2.3.1 and 3.3.1), these shall be removed from the
tank after 6 months, 12 months and 18 months for the 50 Hz, two-year test, or after 750 h, 1 500 h
and 2 250 h for the 500 Hz ± 5 %, 3 000 h test. Each sample shall be tested to breakdown in
accordance with 2.4.4.2 or 3.4.4.2 and the 5 min voltage withstand values recorded.

A.2 Sample machining

Cut a specimen from near the centre of the sample about 100 mm long. If a microtome is available,
carefully remove the conductor and prepare 20 disc samples, each approximately 0,5 mm thick.

Alternatively, mount the specimen, complete with conductor, in the chuck of a lathe, with the end of
the specimen flush with the face of the chuck. Machine a centring hole in the end of the conductor.
Loosen the specimen and retighten the chuck with about 50 mm of the specimen protruding from
the chuck. Support the exposed end of the specimen from the tailstock of the lathe, and check that
it runs true.

Grind a cutting tool to the shape indicated below in figure A.1, and hone the cutting edge to razor
sharpness.

Figure A.1 — Cutting tool

Position the tool as shown in figure A.2, making a cut at right angles to the axis of the specimen,
until the conductor is exposed, leaving about 10 mm of the extruded insulation and screens to
support the conductor.

Figure A.2 — Positions of specimen and cutting tool in lathe

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Set the back gearing of the lathe to give an auto-feed of 0,5 mm per revolution. Cut at about
15 r/min, converting a 10 mm length of the specimen into a 20 turn continuous helix.

A.3 Staining

To avoid touching the surface of the disc samples or the helical specimen, thread them on to a short
length of copper wire. Using the copper wire as a handle, carefully wash the surfaces to be stained
in ethanol and leave for a few minutes to dry.

Prepare a solution of methylene blue in a 250 mL glass beaker from 6 g ± 0,1 g of microscopy-
quality methylene blue and 0,5 g ± 0,1 g of Na2CO3 in 200 mL of distilled water. Heat the solution to
70 °C ± 2 °C for a period of 4 h, stirring continuously. Cover the beaker with polyethylene film to
minimize evaporation.

Before using the solution for the first time, place it in a heating cabinet and maintain it at
70 °C ± 2 °C for a period of not less than 10 h.

Taking care not to touch the surface of the disc samples or helical specimens, immerse them in the
methylene blue solution at 70 °C ± 2 °C for a period of about 4 h, stirring occasionally. Remove
them from the solution and wash them under a tap for a few seconds and shake well. Wash them in
ethanol and wipe them with a tissue moistened with ethanol and leave to dry.

Any vented or bow-tie trees should now be clearly visible to the naked eye or with a 3X magnifying
glass.

A.4 Examination

Cut the helical specimen into discs for detailed examination under a microscope.

A.5 Recording of results

Examine carefully each of the 20 discs and record the total number of vented trees and bow-tie
trees observed, by size, as indicated in table A.1.

Table A.1 — Water tree record

1 2 3 4
Sample reference number
Total number of trees observed
Size range Vented trees
Bow-tie trees
Inner screen Outer screen
less than 100 µm
100 µm – 250 µm
250 µm – 500 µm
500 µm – 1 mm
more than 1 mm

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