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Full Scale Wet Age Testing of XLPE Insulated Power Cables in Salt Water
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Full Scale Wet Age Testing of XLPE Insulated Power Cables in Salt Water
INSULATION THICKNESS
A thicker wall thickness has an increased material volume
applied. With this increased volume comes an increased
number of flaws or contaminants per metre length of cable,
and hence a reduced breakdown stress could be expected
with increased wall thickness. Orton & Hartlein indicate, for
a particular, unspecified, insulation material, that doubling
the insulation wall thickness from 5.5mm to 11mm leads to
around a 10% reduction in breakdown stress. If the same
relationship holds true for the selected insulation system,
then based on the large margin seen in the 20kV wet age
tests, this would indicate that such a design would still pass
full scale breakdown acceptance criteria.
WATER SALINITY Figure 1. Full scale ageing drum with cable loaded
Hampton et al in 2003 stated that ‘Few explicit studies have
been conducted to examine the effects of salinity. However
the main body of evidence shows that the NaCl in sea water
will act as an accelerant for water treeing’. It is understood
that this comment is based on laboratory scale testing.
Johansson et al in 2011 presented results for XLPE and
WTR-XLPE wet ageing tests carried out under hydrostatic
pressure (30 bars, equivalent to 300m water depth) and in
artificial seawater at 500Hz compared to both standard
50Hz and standard 500Hz tests (i,e. ‘standard’ is without
pressure and in tap water). The results presented are AC
breakdown strengths for the XLPE cable of around
42kV/mm for the standard 50Hz and standard 500Hz tests,
and around 56kV/mm for the ‘subsea’ 500Hz test. The
researchers concluded that ‘the selected simulated subsea
conditions do not provide harsher situation than Figure 2. Wet age test laboratory
represented by the standard Cenelec atmospheric test
year and 2 years, however the 66kV average values are electrical stress at breakdown, i.e. (Eo+Ei)/2, for the
some 15% higher. datasets. This shows good correlation, within 5%, between
the two datasets.
At first sight this is a surprising result, particularly as the
66kV samples were aged at a much higher electrical stress
(Ei=16.2kV/mm for 66kV samples, Ei=8.7kV/mm for 20kV MOISTURE CONTENT MODELLING &
samples). The fact that this hasn’t had a significant impact DEFINITION OF CONDITIONING PERIOD
on breakdown stress is in line with the finding of Meurer &
Sturmer, where it was found that there was no significant There is a critical relative humidity threshold required to
influence of ageing at 12kV/mm compared to 9kV/mm. On initiate water tree growth, and the aim is to have reached
the one hand, these test results do question the range of this threshold within the conditioning period, see, for
validity of the inverse power law often quoted for instance, Karlstrand et al.
accelerated ageing and as given in Equation (3) above, but Comsol finite element analysis, using Fick’s diffusion laws,
on the other hand, provide some support for the CIGRE TB was undertaken to model the rate of moisture ingress into
722 protocol of ageing at ≥ 9kV/mm where Edesign is up to cables with differing insulation thicknesses, and including
5.5kV/mm. the impact of salinity. The model was successfully validated
One candidate explanation for the higher breakdown levels against published data from Hellesø et al.
of the 66kV samples could be that the thicker insulation From this analysis, it was found that the duration of
was not fully saturated; however moisture content conditioning to provide equivalent saturation level at the
measurements, as discussed in the below section, showed conductor screen to a 5.5mm insulation thickness sample
that full saturation had been reached within the conditioning after 500hours could be expressed as:
period.
Conditioning Time (hours) = 100 + 46t [4]
Another, more satisfactory, explanation is that breakdown
voltage is not only a function of the conductor screen Where t is the insulation thickness in mm.
electrical stress (Ei), but also of the insulation screen stress This relationship between the conditioning time and
(Eo); the thinner insulation of the 20kV samples have a thickness was subsequently included in CIGRE TB 722.
significantly higher ratio of Eo/Ei (0.59 for the 20kV
samples, 0.43 for the 66kV samples). For a 10.5mm insulation thickness, the calculated required
duration is 583hours. For the 6 month, 1 year and 2 tests
Figure 6 shows the test results in terms of Eo rather than Ei described above, a safety factor was added as contingency
at breakdown. Now the lines are reversed, with the 20kV to give 650hours; this decision pre-dated the publication of
data-points above the 66kV data-points by a similar margin. the CIGRE recommendation, and provided additional
margin.
550
Moisutre Content (ppm)
REFERENCES
450
[1] BICC Cables, ‘Electric Cables Handbook’, 3rd Edition,
350 1997
[2] CENELEC HD605 S2, ‘Distribution Cables with
250 Extruded Insulation for rated Voltages from 3.6/6kV up
to and including 20.8/36(42)kV’
150
[3] CENELEC HD620 S2, ‘Distribution cables with
50
extruded insulation for rated voltages from 3,6/6 (7,2)
0 5000 10000 15000 20000 kV up to and including 20,8/36 (42) kV’
Time (Hours) [4] CIGRE TB 490 (2012), ‘Recommendations for Testing
of long AC Submarine Cables with Extruded Insulation
for System Voltage above 30 (36) to 500 (550) kV
Fig 8. Moisture Content Comparison between dry, pre- [5] CIGRE TB 722 (2018), ‘Recommendations for
conditioned for 650 hours, and the 6, 12, and 24 Additional Testing For Submarine Cables from 6kV
month energised samples for the 66kV cable (Um=7.2kV) Up To 60kV (Um=72.5kV)’
[6] Cree S, Cariona P & Person T, ‘Potential Use of New
MICROSCOPIC ANALYSIS Water Tree Retardant Insulation in Offshore Wind
Farm Array Cables’, Jicable 2015
Some limited analysis was performed to determine the
[7] Hampton RN, Rydin C & Smedberg A, ‘Subsea XLPE
extent of electrical degradation within the insulation.
Cables’, JiCable 2003
Sections of approximate 500 µm thickness were taken from
dry unaged cable, and the location of electrical breakdown [8] Hellesø SM, Hvidsten S, Balog SG and Furuheim KM,
on the 6, 12, and 24-month time points. These sections "Calculation of Water Ingress in a HV Subsea XLPE
were stained with methylene blue to aid visualisation of any Cable with A Layered Water Barrier Sheath System,"
electrical degradation. Journal of Applied Polymer Science, vol. 121, pp.
2127-2133, 2011.
No bow-tie trees were present in the unaged sample,
[9] IEC 60502-2 (2014) ‘Power cables with extruded
whereas all the 66kV wet aged samples examined had
insulation and their accessories for rated voltages from
evidence of bow-tie trees. From the samples analysed, the
6kV (Um=7.2kV) up to 30 kV (Um= 36kV)’
bow-tie trees were mostly below 100 µm in size, and the
number and size of trees at the 12 and 24 month time [10] IEC 60840 (2011) ‘Power cables with extruded
points did not appear to have grown significantly from the insulation and their accessories for rated voltages
6 month sample. This is consistent with results from above 30 kV (Um= 36 kV) up to 150 kV (Um= 170kV)
extended (500Hz) testing on HV cable reported by – Test methods and requirements’
Karlstrand et al. [11] Johansson K, Davidsson A, Jakobsson M, Nilsson U,
Bostrom J-O, Faremo H, Lillevik O, ‘Influence of
CONCLUSIONS Subsea Conditions on the Long term performance of
AC XLPE Cables’, Jicable 2011
The main conclusions of this work are: [12] Karlstrand J, Furuheim KM, Wolneberg HM, Hvidsten
Residual breakdown strength of the full size 66kV samples S & Faremo H, ‘Wet Designs for HV Submarine Power
tested is well above the pass criteria specified in the Cables’, Jicable 2015
relevant standards and recommendations for both 500Hz [13] Meurer D & Sturmer M, ‘The CENELEC long term test
3000hrs and 50Hz 1 year and 2 year testing. for XLPE MV cables – everything new and different?’,
Jicable 2003
Full scale testing in saline water resulted in higher residual
breakdown strength (at the conductor screen), when [14] Orton H & Hartlein R, ‘Long Life XLPE Insulated Power
compared against the scaled test samples in tap water, Cables’, 2006, sponsored by Dow & Borealis
however good correlation of the results was achieved in
terms of the average of the residual breakdown strength at GLOSSARY
the conductor screen and at the insulation screen. The test
results suggest that the influence of salinity on breakdown HV High Voltage (above 36kV)
strength is not that significant, at least for the insulation MV Medium Voltage (up to 36kV)
system tested. WTR-XLPE Water Tree Retardant XLPE
XLPE Cross Linked Polyethylene
Moisture analysis showed good correlation with modelling
and indicated that the full scale test samples were fully
saturated within the conditioning period.
Microscopic analysis showed that electrical ageing has
taken place, with the presence of bow-tie trees in the
dielectric insulation seen after ageing at 6 months, however
analysis after 12 and 24 months showed the growth of bow-
tie trees for this material has slowed down or stopped.