DC HIGH-POT TESTING OF MEDIUM

VOLTAGE 5kV-35kV POWER CABLES

DC HIGH-POT TESTING OF MEDIUM VOLTAGE 5kV-
35kV POWER CABLES
PROCEDURES OF MEDIUM VOLTAGE CABLE TESTING
Only qualified employees are allowed to perform high voltage test or work.

Contractor shall appoint qualified employees as their ‘competent persons’. Such persons
shall be capable of working safely and shall be knowledgeable on the precautionary
techniques, personnel protective equipment, shielding and insulating materials and tools.

High voltage cables shall be DC high-potential tested in accordance with SAES-P-104

Para. 13.

This DC hi-pot testing applies to cable voltage rated 5kV and above. Refer to  SAES-P-104
Para. 13.3, Table 3).

Prior to DC hi-pot testing, perform cable continuity and phasing check for each cable.

Check the insulation resistance of the cable using 5000 volts DC megger   tester. The
insulation resistance of each core should be checked to ground  and between cores.

All permanent and consumable materials shall be prepared prior to testing.

Manpower, equipment, tools, and other logistics shall be prepared and ready for
installation.

Prepare the workplace such as barricading the area and housekeeping.

Electrically hazardous task plan / permit shall be completed and signed before any work
proceeds.

CABLE TESTING 5kV – 35kV Power Cable

1. Switch the MAIN BREAKER ON of the test equipment. The AC ON lamp will light.
2. Close external interlock switch, if used.
3. Push the HV ON push button. The HV ON lamp will light. The VOLTAGE
CONTROL must be at 0 (RESET) for the HV ON push button to operate. CAUTION: The
unit is now capable of producing high voltage at the OUTPUT.
4. Advance the VOLTAGE CONTROL slowly until the desired test voltage is read on
the OUTPUT VOLTAGE kilo-volt meter.
5. Maintain the test voltage for 15 minutes. The OUTPUT CURRENT meter indicates
the leakage current of the specimen under test. Select appropriate current range. See
manufacturer’s instruction manual for notes on interpretation of current
readings.  NOTE: Refer to SATR-P-3210 and SATR-P-3214 for more detailed  procedure
& Test Results Acceptance Criteria.                                   
6. After maintaining test voltage for 15 minutes, turn the VOLTAGE CONTROL, slowly,
in the counterclockwise direction to 0 (RESET).
7. Press the HV OFF push button, or open the external interlock switch.
8. Allow sufficient time for the specimen charge to bleed off, which is indicated when
the kilo-volt meter reading returns to zero.
9. Switch MAIN BREAKER off.  WARNING: The specimen under test may
retain a lethal electrical charge even when the test set is turned off. The
specimen must be discharged with a properly grounded grounding stick.
Keep the HV                          terminal of the specimen and the test set’s output
cable grounded at all times except when actually performing tests. Do not
approach the HV module until ground bonds have been applied.
10. Results shall be filed and recorded on applicable test form per approved SATIP.
 HV SHIELDED CABLE TESTING
1. Check the voltage rating of the cable and select the test voltage which one wants to
supply for examination, refer to Table 3 of SAES- P-104 for DC High Potential Field Test
Voltage. See below table.
2. Start the high potential test equipment.
3. The test voltage shown on Table 3 of SAES-P-104 shall be reached in equal voltage
and time increments. Each increase shall be made
4. Divide the test voltage rating by 5 (means 5 steps), apply the voltage slowly in a
minimum of five increments until the maximum test voltage is reached.
5. After each voltage increase, the leakage current shall be allowed to If the time
intervals chosen are on insufficient duration to stabilize the current, the cable shall be
discharged and the test    repeated with new time intervals of greater, but still equal
duration.
6. Record the stabilized leakage current, in micro ampere, at the end of each time
intervals.
7. Allow the voltage to remain constant at the full test voltage and record the leakage
current at 15, 30, and 45 seconds and at one minute intervals thereafter for 15 minutes for
shielded cable.                                                                                        Compute the    cable
resistance using Ohm’s Law; R=V/I, where R=Resistance of Cable, V=Voltage injected,
and I=Leakage current recorded.
NOTE: Plot the test voltage vs. leakage current on graph paper as the test The step voltage
slope should be reasonable linear for  the graphic plots.

SAFETY PRECAUTION
o Secure the approved work permit from the concerned Representative before
starting any work.
o Fire Watcher with Fire Extinguisher shall be assigned at work area whenever
there is hot work.
o All electrical tools shall be checked and color-coded.
o Hazardous area and its precautionary measure requirements shall be properly
discussed to the working crew following all safety requirements.
o Continuous monitoring and checking shall be conducted by concerned
supervisor/foreman to detect and correct unsafe practices while performing the work
activities.
o Provide warning sign and sufficient barricade on working areas to avoid
unauthorized entry. Only assigned personnel shall be allowed in the area.
o Safety harness with double lanyards shall be used when working at elevated
temporary platforms (1.8 meters and above).
o Safety Supervisor shall monitor the work activities to help and protect all
assigned workers against exposure to safety hazards. He shall ensure that Personal
Protective Equipments (PPE’s) are being supplied and used and shall comply with
Contractor and client applicable general instruction and standards.
o Toolbox meeting shall be conducted by Electrical Supervisor daily so that work
activities will be properly coordinated to all concerned and all safety measures will be
carried out on the entire work duration.
o Housekeeping shall be maintained and working area shall be kept clean and
tidy in accordance with Site Housekeeping Procedure.
o Job Hazard and Risk Assessment of this procedure shall be disseminated and
explained to workers for safety awareness.

TOOLS AND EQUIPMENT

Tools and equipment needed should be in good condition and must be checked by
Supervisor / Safety Engineer prior to use in the construction area.  These includes but not
limited to:

o Boom Truck
o Electrical Hand Tools
o High Voltage Module
o Control Unit
o Ground Leads
o High Voltage Output Cable
o Interconnection Cable
o Kilovoltmeter
o Term Shield Conn.
All tools utilized in a classified area should be intrinsically safe and suitable for hazardous
areas.

Industry Codes and Standards

NFPA70                              National Electrical Code