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1, JANUARY 2002
Abstract—Older solid dielectric cables are now approaching the contact between metallic shield and the semiconducting shield.
end of their life and failing. Consequently there has been a sus- However, studies on corrosion related problems have mainly fo-
tained effort for the development of techniques to assess the re- cused on the ability of the shields to carry the fault currents [4], [5]
maining life of in-service cables for the purpose of establishing re-
placement criteria. Because of the generally accepted belief that the while the failure modes associated with corrosion or damage to
failure mode is due to the aging of the insulation, these techniques the metallic shield have not been thoroughly investigated. Failure
have mainly focused on measuring changes in the electrical prop- analysis of samples that had failed in service has shown that corro-
erties of the insulation. However, it has been determined that there sion of the metallic shields is adirect consequence of the loss of the
are other failure modes associated with loss of the protective func- protective function of the jacket. Under certain conditions, corro-
tion of the jacketing material leading to corrosion and breaks in
the metallic shields and poor contact between semicon and metallic sion/breaks in the metallic shieldor poor contact between metallic
shield, causing arcing damage and eventual failure of the cable. shield and semiconducting shield will lead to arcing damage at
This failure mode is more prevalent in cables operated in a harsh the metallic shield/semiconducting shield interface which pro-
chemical environment. gresses into the insulation until failure occurs.
This paper presents the results of a research program aimed at The main conclusion from these investigations was that the
developing a test protocol that is based on evaluating the condition
of all the cable components and not just the insulation. The tests failure mode(s) of an aging cable system dictate the methods of
were designed to evaluate the condition of jacket, extent of corro- assessment.
sion of the metallic shield, and degree of degradation of the cable
insulation. The results are discussed in terms of correlations be- II. INTEGRATED APPROACH TO CABLE CONDITION
tween the field measurement parameters and the condition of the ASSESSMENT
cable, and prioritization criteria for cable replacement.
Index Terms—Condition assessment of solid dielectric cables, This approach relies on evaluating all the cable components:
failure modes of solid dielectric cable, neutral corrosion. jacket, metallic shields, and dielectric insulation. The need for
this approach was driven by the increasing number of failures
that were found to be associated with corrosion or damage to the
I. INTRODUCTION
metallic shields, anomalies in the temperature dependence of the
Fig. 3. (a) Photographs of a cable with an artificial break in the copper tape
and (b) corona, at the metal edges using an image intensifier.
TABLE I the condition of the cable components and the overall condition
VOLUME RESISTIVITY OF THE INSULATION SHIELD OF THE CABLE of the cable system. To determine the effectiveness of the
SHOWN IN FIG. 1
test protocol, the measured properties of the cables in service
were compared to those of a “reference cable” that had same
construction and service history as the in-service cables. The
condition of the reference cable was established by electrical
tests in the laboratory followed by microscopic examination.
These tests included electrical breakdown, full evaluation of the
condition of jacket and copper tape, and water tree examination.
tained for each section. The cables were then subjected to the
LIPATEST, followed by ac breakdown in accordance with AEIC
CS5-94. The active part of the cables was kept wet for the du-
ration of the tests.
The extent of corrosion of the copper tape was examined by
removing the jacket of random sections of the cable with varying
degrees of coloration to the jacket. A similar examination was
carried out on the sections of cable in the immediate vicinity of
the ac breakdown failure site. A microscopic examination and
water tree analysis was also carried out on the failure site for
each sample that was subjected to the ac breakdown tests.
Chemical analysis on the jacket consisted of Shore hardness,
thermograviometric analysis (TGA) to determine the cause of
hardening of the jacket, and Energy Dispersive X-ray Analysis Fig. 4. AC breakdown versus resistance of the copper tape.
(EDXR) for elemental analysis.
Fig. 4 is a plot of the resistance of the copper tape versus ac
V. RESULTS OF LABORATORY TESTS breakdown voltage. It is interesting to note that there is a direct
TDR response for all the cable samples tested in the labora- correlation between ac breakdown and extent of corrosion.
tory was characterized by multiple strong reflection peaks from Fig. 5(a) and (b) shows the size distribution of the maximum
localized corrosion sites near the launch end of the cable and bowtie and streamer water trees in each wafer for the cables sec-
heavily attenuated reflection peaks from similar sites near the tions that were subjected to microscopic and water tree exam-
opposite end of the cable. The attenuation of the reflection pulse ination. The longest bowtie tree was 3.62 mm (about 80% of
is caused by reflections at discontinuities and dispersion. the insulation thickness). The longest streamer tree was greater
The ac breakdown data was analyzed by Weibull statistics. than 3.9 mm. This water tree was found in a cable sample which
The Weibull parameters were found to be had a breakdown voltage of 31.5 kV. Fig. 5(c) shows the break-
down path through the water tree. It is interesting to note that the
breakdown voltage for this sample was higher than that of cable
kV kV kV with a severely corroded copper tape where the water trees were
much shorter.
where and are upper and lower 90% confidence limits on There were no streamers at the insulation shield interface.
and is the shape parameter. Although no attempt was made to determine the exact count for
For comparison, the for unaged 15 kV XLPE cable is water trees of various sizes, for comparison it was qualitatively
greater than 200 kV. The Weibull parameters for 15 kV steam noted that the extent of water treeing in the “reference” cable
cured double pass extruded cables aged in service for 17 years was less than what is normally found in other similar cables with
are [4] an equivalent service record.
The volume resistivity of the insulation semiconducting
kV kV kV shield of the reference cable was measured on sections of
the cable with varying degrees of the corrosion of the copper
The main findings from the laboratory tests were as follows. tape. There was no apparent correlation between the extent of
corrosion and the conductivity of the insulation semiconducting
• Discoloration and loss of pigment of the jacket was ob-
shield.
served in several locations along the full length of the
cable. The jacket was hard and brittle where there was
discoloration. The cause of the hardening and brittleness VI. RESULTS OF FIELD TESTS
of the jacket was found to be due to loss of plasticizer.
This was confirmed by Hardness measurements and ther- The main findings from the field tests were as follows.
mograviometric analysis on the jacket of unaged samples • Loss of integrity of the jacket of the cables as judged from
and on samples with different levels of discoloration. the low insulation resistance values obtained.
• The copper tape was severely corroded in numerous loca- • The insulation resistance of the jacket for most of the ca-
tions along the full length of the cable. bles tested was low ( 1 M ). For comparison, the insula-
• There was a direct correlation between level of corrosion tion resistance of the jackets of new cables is greater than
and condition of the jacket of the cable. The corrosion was 200 M .
most severe in the places where there was discoloration of • Significant degradation of the copper tape, as revealed by
the jacket and loss of plasticizer as shown in Fig. 1. The TDR and resistance measurements. The resistance of the
cable had suffered significant moisture related degrada- copper tape for most of the cables was significantly higher
tion as evidenced by the presence of large water trees that than that of new cables.
spanned about 80% of the insulation thickness and the rel- • Corrosion activity in the majority of the cables as revealed
atively low ac breakdown values. by the presence of a dc voltage between the copper tape
22 IEEE TRANSACTIONS ON POWER DELIVERY, VOL. 17, NO. 1, JANUARY 2002
Fig. 5. (a), (b) Size distribution of water trees and (c) failure path through a
water tree.
Group the condition of the metallic shield is essential for any ranking
2: Resistance of copper tape is less than 10 /100 M; scheme for cable replacement.
TDR attenuation greater than 0.1 dB/M. The two main parameters that can be effectively used as indi-
Group cators of the condition of the metallic shield are the resistance
3: Resistance of copper tape is less than 10 /100 M; of the copper tape and TDR attenuation. Together, these param-
TDR attenuation less than 0.1 dB/M. eters can be effectively used to infer the nature and degree of
Fig. 7(b) is a graph of “calculated” cable length versus resis- damage to the copper tape. Specifically, the following types of
tance of copper tape for the three different groups of cables. It damage can be identified.
can be seen that for Group 1 and Group 2 there is no direct corre- Type 1: Tears/breaks, and localized corrosion.
lation between the cable length and the resistance of the copper Type 2: Multiplicity of tears/breaks, and localized corrosion
tape. For Group 3 cables, on the other hand, there is a definite sites.
correlation between the resistance of the copper tape and cable Type 3: Uniform corrosion of long sections of cable.
length. Very high values of copper tape resistance would indicate
Type 1 damage. However, resistance measurements would not
“detect” partial breaks, skips in the tape, partially corroded sec-
VII. DISCUSSION
tions, or any damage where the different sections of the copper
The predictive capability of any procedure for evaluating the tape remain electrically connected, unless they exist in large
condition of underground distribution cables depends on an ac- numbers. For Type 1 damage, the resistance of the copper tape is
curate choice of measurement parameters that can be used as in- not a function of the length of the cable. High resistance values
dicators for cable degradation. A successful choice for the mea- of the copper tape would also indicate Type 3 damage. A def-
surement parameters is determined by the failure mode of the inite correlation between the resistance of the copper tape and
cable. Therefore, it is necessary to evaluate the cable system and cable length will indicate uniform corrosion over the full cable
not just the insulation in the development of a cable assessment length.
program. The tests for this study were designed to evaluate the TDR measurements are sensitive to any discontinuities
condition of the jacket, corrosion activity, extent of corrosion of in the cable. Isolated discontinuities in an otherwise healthy
the copper tape, and degree of degradation of the cable insula- copper tape (Type 1 damage) produce well-resolved reflection
tion. peaks in a TDR reflectogram. A multiplicity of closely spaced
The function of the jacket is mainly protective. Compro- breaks/discontinuities (Type 2 damage) will result in a series
mising the jacket in any way will result in moisture ingress of overlapping nonresolved peaks. Uniform corrosion of long
leading to electrochemical potentials, corrosion of the metallic sections of copper tape (Type 3 damage) will result in severe
shield, and scale buildup. Even newly installed cables exhibited attenuation of the TDR pulse.
low jacket resistivity and a dc voltage could be measured
between the copper tape and ground. This indicates that even
VIII. CONCLUSION
new jackets are permeable to electrolytes in the ground water
causing corrosion activity at the copper tape. The main conclusions from this work are as follows.
The finding that there is correlation between the extent of • Cable failures are not always due to insulation aging.
corrosion and residual dielectric strength suggests that the re- Metallic shield damage or poor contact between metallic
sistance of the copper tape is a good indicator in establishing a shield and semiconducting shield will lead to arcing and
prioritization criterion for the replacement of these cables. Trace eventual failure.
element analysis in the XLPE of some of the cables subjected • An integrated approach that evaluates the condition of all
to the ac breakdown tests show high concentrations of copper. the cable components is essential for condition assessment
This may be due to the diffusion of copper ions into the insula- of underground cables.
tion as a result of the corrosion of the copper tape. The presence • The test protocol is dictated by the failure mode. Work is
of copper ions in the insulation would contribute to water tree in progress on the design of various tests to detect damage
growth and the reduction of the dielectric strength. In addition, caused by the different failure mechanisms. Two parame-
the insulation of the cable in the regions of corroded copper tape ters that can be effectively used as indicators of metallic
would be subjected to high electrical stresses. This would lead shield condition are TDR attenuation and the resistance of
to accelerated aging of the insulation in these locations, and pre- the metallic shield. Together, they can be used to infer the
mature failure of the cable. nature and extent of degradation of the metallic shield.
A scheme for ranking the condition of cables in service must
take into account the failure modes of the cables in a particular
REFERENCES
installation. As mentioned earlier, broken/corroded shields can
lead to cable failure “from outside in.” The worst situation is [1] J. D. Mintz, “Failure analysis of polymer insulated power cables,” IEEE
Trans. Power App. Syst., vol. PAS-103, Dec. 1984.
realized if there are multiple breaks in the copper tape causing [2] J. C. Chan, E. T. Cometa, M. D. Hartley, and L. J. Hivala, “Field failure
certain sections to float. This will cause electric stress enhance- analysis of medium voltage XLPE-insulated cables,” in Conf. Record
ment at the edges of the copper tape, arcing, and eventual failure 1990 IEEE Int. Symp. Electrical Insulation, June 1990.
[3] V. I. Kogan and T. L. Jones, “An explanation for the decline in URD
from outside in. This failure mode is more prevalent in cables cable failures and associated nonhomogenous Poisson process,”, 93WM
that undergo wetting and drying. Therefore, an assessment of 111-5 PWRD.
24 IEEE TRANSACTIONS ON POWER DELIVERY, VOL. 17, NO. 1, JANUARY 2002
[4] J. Densley and J. M. Braun, “Effect of damaged insulation shield on Guy L. Halldorson received the Dipl. Electrical
the life of polymeric underground distribution cables,”, CEA Rep. Technology degree from the British Columbia
117D797, Apr. 1998. Institute of Technology in 1973.
[5] B. Burniak, “Neutral corrosion problem overstated,” Transmission Dis- He worked with the Telecontrol Department of
trib. World, Aug. 1996. B.C. Hydro until 1981 when he joined the Electrical
[6] D. K. Baver, “Overground method pinpoints concentric neutral corro- Technologies Department of Powertech Labs.
sion,” Transmission Distrib., July 1989. His work has focused on the measurement of the
dielectric properties of insulating materials used in
the manufacture of cables, accessories, and large
machines, high voltage testing, and laboratory and
in-service testing of high voltage equipment. He
was involved in the development of IEEE 1043—Recommended Practice
for Voltage Endurance Testing of Form Wound Bars and Coils and IEEE
P1310—Trial Use Recommended Practice for Thermal Cycle Testing of Form
Khaled Abdolall received the B.Sc. degree in Wound Stator Bars and Coils for Large Generators.
honors coop physics from the University of Waterloo
in 1972, and the M.Sc. and Ph.D. degrees from the
University of British Columbia in 1974 and 1978,
respectively. Dennis Green graduated from Salford University in
He spent two years as a research Fellow at UBC 1959.
and MPB Technologies developing field tracking He has extensive industrial experience in high
methods for measuring the Fermi surfaces of voltage cable installations gained in the steel industry
metals, and techniques for depositing selective solar with the Lancashire Steel Corporation and British
absorbers. Since 1980, he has been working with Steel Corporation. He was a Graduate Member of the
Powertech Labs (formerly B.C. Hydro Research and IEE in the UK until 1978, when he joined Syncrude
Development). His work has concentrated on studying the aging phenomena of Canada. Since then, he has been working in the
solid dielectric cables, development of test techniques for condition assessment Utilities Operations of Power Distribution at the Oil
of in-service cables, and microwave thermal imaging. His contributions to Sands Plant at Fort McMurray, Alberta supporting a
engineering technology and practice include extensive work on development growing oil output, with a present rate of 82 million
of methods for monitoring porcelain and polymer clad high voltage equipment barrels of premium grade oil being shipped in to the North American pipelines.
by microwave imaging, development of aging tests for high voltage cables, and Reliability of the electrical supply in the harsh environment of Northern Alberta
failure mechanisms and condition assessment of underground cables. being one of the focal points of responsibility.