QC & Testing of Power Cables

Power Cables Handbook
POWER CABLES HANDBOOK
1
QUALITY CONTROL & CABLE TESTING

Introduction
Cabling is an expensive business and must be treated carefully. The expenditure of substitution once the
routes are all concealed is bigger. The fault is not always visible like crushing, bending or kinking. Make
sure that your cabling installer have made provision to protect installed cabling from other worker’s actions.
This is substantially less costly than changing cabling in the future. If cable routes are guarded with no way
of opening them between termination and installation, it is ideal to terminate the cables for the time being,
so they can be tested before the routes are protected.
In addition, Medium, High and Extra High voltage cables production requires the highest possible precision
measurements at the manufacturing stages, so the same is required for Quality Control in experience and
precise equipment to achieve the highest quality products.
Why is Cable Testing Needed?
Cable testing is made to drop down testing times. This is done to check the:
• Cable conformity
• Cabling quality
• Cable functionality
Many times, a fault in a cable can be seen well before it becomes an actual problem. A visual inspection
of all the cables in your facility is a great way to find trouble before it causes you a downtime. We look for
corrosion on the copper, cracks in the insulation, moisture on the cables and many other indicators of
damage to the cables.
Cable faults cost money and create disruption, so there is an enormous demand for cable test techniques
to ensure cables and joints are in good condition, and to allow cable faults to be located rapidly.
Cable testing to both predict and then deal with faults is a vital concern for all those involved with the
distribution of electricity. A wide range of test techniques and test equipment are available to allow this
concern to be effectively addressed, but cable testing can, nevertheless, be a challenging task.
For this reason, a resource that’s as important as the test equipment itself is access to expertise that will
help with selecting the best equipment for the job, and using it in such a way that it delivers the best
results.
What is done during Cable Testing?

• Given below are the tests and inspections that must be done before energizing low voltage cable
rated 600V or below.
• Compare cable data with drawings and specifications. Pay attention to the number of sets, the
cable size, routing, and insulation ratings. Note these items on the test sheet.
• Check uncovered parts of cable for material damage. Look at the condition of the cable jacket and
insulation of exposed sections. Verify that the connection points match what is shown on the
project single-line diagram.
• Check bolted electrical connections for high resistance with the use of a calibrated torque-wrench,
low-resistance ohmmeter or thermographic survey.
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• When using a calibrated torque wrench, reference ANSI/NETA Table 100.12 US Standard
Fasteners, Bolt Torque Values for Electrical Connections.
• The values of similar bolted connections must be compared and check which value shift by more
than fifty percent of the smallest value in the case where a low resistance ohmmeter is utilized.
• Look at the condition of the exposed cable jacket and insulation when performing a visual
inspection on low voltage wire and cable.
• Inspect compression-applied connections by verifying that the connector is properly rated for the
installed cable size and has the proper indentations.
• Perform an insulation-resistance test on each conductor with respect to ground and adjacent
conductors. Test period must be for 1 minute using a voltage according to manufacturer’s
published data.
• If no literature from the manufacturer is available, apply 500 volts dc for 300-volt rated cable and
1000 volts dc for 600-volt rated cable. Insulation-resistance values must be according to the
manufacturer’s published data. If no data from the manufacturer exists, the values should be no
less than 100 megohms. Perform continuity tests to ensure correct cable connection and phasing.
• Verify uniform resistance of parallel conductors using a low-resistance ohmmeter. Measure the
resistance of each cable individually and investigate deviations in resistance between parallel
conductors.
Given below are various kinds of tests that are conducted on cables:
The following tests are type test of electrical power cable.
1. Persulphate test (for copper)

2. Annealing test (for copper)
3. Tensile test (for Aluminium)
4. Wrapping test (for Aluminium)
5. Conductor resistance test (for all)
6. Test for thickness of insulation (for all)
7. Measurement of overall diameter (where specified) (for all)
Physical tests for Insulation and Sheath
1. Tensile strength and elongation at break

2. Ageing in air oven
3. Ageing in air bomb
4. Ageing in oxygen bomb
5. Hot set
6. Oil resistance
7. Tear resistance
8. Insulation resistance
9. High voltage (water immersion) test
10. Flammability test (only for SE-3, SE-4)
11. Water abortion test (for insulation)
3
Acceptance test: The following shall constitute acceptance test:
1. Annealing test (for copper)

2. Tensile test (for Aluminium)
3. Wrapping test (for Aluminium)
4. Conductor resistance test
5. Test for thickness of insulation and sheath and overall diameter
6. Tensile strength and Elongation at break of insulation and heath
7. Hot set test for insulation and sheath
8. High voltage test
9. Insulation resistance test
Routine test: The following shall constitute the routine test.

Conductor resistance test
High voltage test
Insulation resistance test
How is Cable Testing Performed?

Given below are the tests done while cable testing is done:
Continuity Test
• The continuity test (also called low resistance measurement) is measuring the low resistance of
cables, from 1 mΩ to 250 Ω.
• The continuity test can be made in 2 or 4 wires according to the resistance to be measured: 2
wires for resistances > 1 Ω, and 4 wires for resistances < 1 Ω.
• The continuity test in 2 wires mode consists in injecting a programmable current and measuring
voltage and current at the terminals of the resistance to be tested. Ohm’s law will give the exact
value.
• In four wires mode or Kelvin method continuity test divide the switching matrix into 2 internal buses
• directing the test current
• Conveying the voltage of the terminals of the element under measurement.
Insulation Test:
• The insulation test also known as high resistance test is always made DC. The insulation test is
combined with a short-circuit test and high voltage test in DC.
• The insulation test combines several functions.
• The insulation test can perform:
o Determining insulation resistances from fifty kilo ohm to two thousand mega ohm at high
voltage i.e. from 20V to 2000V.
o Measurement of dielectric strength and detection of short circuits.
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• The insulation test proceeds as follows:

o An initial test at low voltage (continuity measurement) to detect any short circuit.
o If a short circuit is found, the insulation test stops (the message SHORT CIRCUIT appears
in the error list).
If there is no short circuit, the high voltage is applied. During the programmable rise time, if breakdown
occurs, the voltage is displayed and the test stops (the breakdown voltage is given in the error list).
If no breakdown occurs and if the voltage does not reach the required value (±10%), the message
U<Uprog appears in the error list.
Next, the voltage is applied for the duration of the programmed application time. If breakdown occurs
during this period, the moment when the fault appears is displayed in the error list and the test stops.
Lastly, if all goes well, at the end of the application time, the insulation test is made, and the insulation
resistance measured. The tester will add a measurement time as a function of the range requested. The
measurement time varies from 20ms to 240ms according to range.
To end the sequence, the tester reduces the high voltage and then discharges the unit tested to an earth
resistance (total time 20ms).
This procedure is identical at the end of every measurement of insulation.
The dielectric strength test detects any sudden variation in the increase of the test current outside the
programmed limit.
Insulation Resistance (IR)

IR Value Measurement (Conductors to conductor (Cross Insulation))
• The first conductor for which cross insulation is being measured shall be connected to Line terminal
of the megger. The remaining conductors looped together (with the help of crocodile clips) i. e.
Conductor 2 and onwards, are connected to Earth terminal of megger. Conductors at the other end
are left free.
• Now rotate the handle of megger or press push button of megger. The reading of meter will show
the cross Insulation between conductor 1 and rest of the conductors. Insulation reading shall be
recorded.
• Now connect next conductor to Line terminal of the megger & connect the remaining conductors to
earth terminal of the megger and take measurements.
IR Value Measurement (Conductor to Earth Insulation)
• Connect conductor under test to the Line terminal of the megger.

• Connect earth terminal of the megger to the earth.
• Rotate the handle of megger or press push button of megger. The reading of meter will show the
insulation resistance of the conductors. Insulation reading shall be recorded after applying the test
voltage for about a minute till a steady reading is obtained.
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Phasing Test:
The correct phasing of all LV circuits shall be checked at all positions where the LV cables are terminated
into fuse bases and where any LV cable is run from point to point.
This test shall be performed with an instrument designed for the purpose. Mains frequency voltage of 240
Volts is not acceptable for this test.
The neutral conductor shall be connected to the earth stake for this test.
Earth Resistance Test:
In any overhead or underground network, the earth resistance at any point along the length of a LV feeder
is to have a maximum resistance of 10 ohms prior to connection to the existing network.
In any overhead or underground network, the overall resistance to earth Shall be less than 1 ohm prior to
connection to the existing network.
High Voltage Test:
The high voltage test (also called dielectric strength test or hipot test) can be made in AC or DC. If the
high voltage test is made in DC, it is then combined with insulation; if the high voltage test is made in AC,
it is then, this is then, more stressful for the sample and made according to the sketch below.
Measurement of high voltage test under alternating current is performed using an alternating voltage
(50Hz) adjustable to an effective 50V to 1,500V. As is the case with direct current, the high voltage test
detects any sudden rise of current up to a programmed threshold.
The short circuit test is maintained by default. The rise time is more than 500 ms and the application time
at least one period.
Warning: The high voltage test under alternating current is penalized by the capacitive value of the tested
equipment. It must be remembered that the generator power is limited to 5 mA.
Benefits of Cable Testing

• Product warranties are limited
• Testing is less expensive than repair
• Periodic testing will futureproof the infrastructure
6
QUALITY CONTROL OF POWER CABLES

PROVEN QUALITY ELEMENTS FOR PRODUCTION SAFETY:
• The technical specifications for cables: perfect design as per customer request, and consistent with
local and international specifications or build on the development to be done.
• Quality control of materials: measuring quality of materials leads to perfect production processes.
• Quality assurance: measurement of progress during various operating stages.
• Adjust the quality of the final product: measure cable components dimensions and inspected
electrically and check the integrity of the packaging.
• Quality control of measuring devices: make sure its accuracy and calibration are periodically.
• Pursue product quality after sale: measuring customer satisfaction.
Quality
Plan
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QUALITY PLAN
Physical
Properties
Chemical
Properties
Electrical
Properties
MOM (Machine Operating Manual)
PES (Process Engineering Specification)
Work Instructions
Non-Electrical Tests
Electrical Tests
Packing, Lagging,
Transportation
QUALITY CHECK
SAMPLE SAMPLING PLAN

PREPARATION (SAP)
TEST METHOD
ACCEPTANCE
SPECIFICATION
CRITERIA
(TMS)
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INSPECTION OF
RAW-MATERIALS
RAW MATERIALS SUPPLIERS EVALUATION
Check 10% samples of the total lot.

Grade A Material whose quality is excellent
and consistent in relation to the
required specifications.
Check 25% samples of the total

Grade B lot.
Materials whose quality is good
in relation to the required
Suppliers specifications
Check 50% samples of the total lot.

Grade C Materials meet the critical
requirements in the specifications
but may not meet all requirements or
is inconsistence.
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RAW-MATERIAL INSPECTION FLOW-CHART
RM Arrived Stores
Under Inspection
Sample Collection
as per W.I
Test & Measure Samples

as per TMS
Fix NCR Tag Not OK Fix Inspected OK Tag

Test Result
(Kept in NCR Area) OK (Kept in Ready to Use Area)
Issue to Production
Return to
Supplier
RAW-MATERIALS CHECK PROCEDURES
Physical Check
Metallic Raw Materials
Copper, Aluminum,
Diameter Measure
Steel Wire, Steel Tape, Elongation Measure
Copper Tape, Tinned * Physical Check W.I
Copper Tensile Strength
* Sample Prepare W.I
Resistivity Measure * TMS
* Measuring Device
Physical Check * Sample Test W.I
Non-Metallic Raw- * Acceptance/Rejection
Elongation Test Criteria
Materials
PVC, XLPE, PE, LSHF, Tensile Test
Filler, Yarns, Tapes
Dimension Measure
Density Measure
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IN-PROCESS QUALITY CHECK
R.M USED IN PRODUCTION

STAGES
SAMPLING PLAN
TESTING/CHECK SAMPLES
AS PER QUALITY PLAN
ISSUE NCR NOT OK TO BE USED IN NEST

Test Result STAGE
NOTIFICATION OK
SCRAP
NOT Immediate Action OK
C/A – P/A
Remanufacture OK Or MRG
OK
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SAMPLING PLAN
• Copper / AL Wires: Sample from each

coil in drawing
• CU / AL Conductors: Sample per shift
fro same size
Metal • Sample length: 2 – 2.2 m
Non
Metal
• Non-Metallic: For same size, two
samples per shift
PRODUCTION • Sample Length: 20 cm
STAGES
IN-PROCESS CHECK OF DR / STR
Physical Check
Diameter Measure
Copper, Aluminum,
Elongation Measure
Tinned Copper
• Physical Check W.I
Tensile Strength
• Sample Prepare W.I
Resistivity Measure • TMS
• Calibrated Measuring
Physical Check Device
• Sample Test W.I
Lay Length • Acceptance/Rejection
Stranded Conductors Dimension Check Criteria
Mass Measure
DCR Measure
IN-PROCESS CHECK OF STAGES
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FINISHED GOOD QUALITY PLAN
Thickness Measure & Eccentricity
Diameter Measure
Extruded
Insulation & Thermal Stability Check
Sheath
Mass Measure • Physical Check W.I
• Sample Prepare W.I
• Test Method Specification
Physical Check
(TMS)
• Calibrated Measuring
Devices
Diameter Measure • Sample Test W.I
• Acceptance/Rejection
Lay Length Criteria
Screening,
Assembly, Tape Thickness, Width
Armoring
Wires Lay Length
Physical Check
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PRODUCT AT FINAL STAGE

FG
TESTING OF ALL PRODUCTS

ELEC/NON-ELEC
CA / PA
AS PER STANDARDS
OK
Issue NCR Not Transfer to Packing
OK Test Result
Notification
Transport to Customer
QC Decision MRG
Follow Customer
For RW / Repair Satisfaction
Hi - Pot “ HV ” Test
PD Test
DCR Measurement
DC Sheath Test (MV/HV)
Physical Check
Electric Test on 100% of Products
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Measure Diam. of Each

Layer
Measure Thickness of
Each Layer
TEST Measure Mass of Each
Layer
Fire Resistant Check for LSHF
Cables
CLASSIFICATIONS OF CABLES TESTING
1- Routine Tests
Tests made by the manufacturer on each manufactured length of cable to check that each
length meetsthe specified requirements.
2- Sample Tests
Tests made by the manufacturer on samples of completed cable or components taken from a
completedcable, at a specified frequency, so as to verify that the finished product meets the
specified requirements.
3- Type Tests
Tests made before supplying, on a general commercial basis, a type of cable covered by this
standard, in order to demonstrate satisfactory performance characteristics to meet the
intended application.
NOTE These tests are of such a nature that, after they have been made, they need not be
repeated, unless changes are made in the cable materials or design or manufacturing process
which might change theperformance characteristics.
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INTERNATIONAL STANDARDS FOR TESTING
Routine Tests:
▪ Electrical resistance of conductors

▪ Voltage test
Electrical resistance of conductors

▪ The complete cable length, or a sample from it, shall be placed in the
test room, which shall bemaintained at a reasonably constant
temperature, for at least 12 h before the test.
▪ In case of doubt whether the conductor temperature is the same as the
room temperature, theresistance shall be measured after the cable has
been kept in the test room for 24 h.
▪ Alternatively, the resistance can be measured on a sample of conductor conditioned
for at least 1 h in atemperature controlled liquid bath.
DC Resistance Results (DCR)
According to conductor type, the measured values of DCR should not exceed that specified in IEC
60228.
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High Voltage Test

Test procedure for single-core cables
For single-core screened cables, the test voltage shall be applied for 5 min between the
conductor and the metallic screen.
Single-core unscreened cables shall be immersed in water at room temperature for 1 h
and the testvoltage then applied for 5 min between the conductor and the water.
Inprocess Spark Test

Spark test is an inline voltage test used either during cable manufacturing or during a
rewinding process.Spark testing is primarily for low voltage insulations of non-conducting
jacket or sheaths.
The test unit generates an electrical cloud around the cable which in high frequency AC units
appears as a blue corona around the cable.
Any pin holes or faults in the insulation will cause a grounding of the electrical field and this
flow of currentis used to register an insulation fault.
Spark testers are fitted with counters indicating the number of faults.
Different spark test voltages are applied according to the cross-sectional area of the conductor
and insulation material, with the appropriate voltage specified in the relevant cable standard.
Spark Test Voltage Setting
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Coils immersed in water -

Spark Tester
Voltage Test applied between
Conductor and Water
Test procedure for multicore cables
▪ For multicore cables with individually screened cores, the test voltage shall be applied for 5 min
between each conductor and the metallic layer.
▪ For multicore cables without individually screened cores, the test voltage shall be applied for
5 min in succession between each insulated conductor and all the other conductors and
collective metalliclayers, if any.
▪ The conductors may be suitably connected for successive applications of the test voltage to
limit the totaltesting time, provided that the sequence of connections ensures that the voltage
is applied for at least 5 min without interruption between each conductor and each other
conductor, and between each conductorand the metallic layers, if any.
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Test voltage
▪ The power frequency test voltage shall be 2,5 U0 + 2 kV. Values of single-phase test
voltages for the standard rated voltages are given in Table
Routine test voltages
▪ When a direct voltage is used, the applied voltage shall be 2,4 times the power frequency
test voltage.
▪ In all cases, the test voltage shall be increased gradually to the specified value.
Requirement
No breakdown of the insulation shall occur.
Sample Tests
1. Conductor examination
2. Measurement of thickness of insulation and of non-metallic sheaths (including extruded
separation sheaths, but excluding inner extruded coverings)
3. Measurement of thickness of lead sheath
4. Measurement of armor wires and tapes
5. Measurement of external diameter
6. Hot set test for EPR, XLPE insulations and elastomeric sheaths
Number of samples for sample tests
19
Measurement of Thicknesses
Digital Image Projector

Caliper
Micrometer
HOT SET Test (IEC 60811-507:2012)

SAMPLE PREPARATION
Low Voltage
Cut the insulation from the core sample, long enough to give several dumb‐bells.
The test specimen should be prepared from the inner part of the insulation wall after
removing ridges and irregular conductor marks in order to be smooth and parallel on both
sides and 0.80 ‐ 2.00 mmin thickness.
Medium & High Voltage

Same procedure as LV cables, except test specimen should be cut by slice cutting
machine, from thenearest part to the conductor screen.
In case of the radial thickness of insulation is about 3 mm. or less, cut carefully a 55 mm long
piece of corewith both ends neat and smooth.
Cut very thin slices in the beginning till a flat surface is obtained.
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Hot set test, cont.
▪ Hot set testing is performed on the

insulation or sheathingmaterial, so the
first step is to prepare the cable
sample by removing the conductors
and any braiding, armoring or tapes.
▪ Depending on the cross-sectional
size and shape of the overall cable,
the samples are either cut as a
tubular sliceor cut into smooth dumb-
bell shaped pieces.
▪ For small slices:
Area = π (D ‐ d) d
D = Outer diameter in mm
d = Smallest R/T in mm
▪ The central 20 mm (or 10 mm for smaller samples) is marked by two lines.
▪ Calculate the load in grams using the formula:

Load = smallest thickness x average width x 20.4 grams
▪ Samples are hung inside oven capable of maintaining the required temperature at 200 °C .
▪ Open the oven door momentarily and suspend the loaded test piece in the oven on wire shelf.
Shut the oven and start the time (clock).
▪ On the completion of 15 minutes, measure the elongation without opening the glass door.
▪ If the door has to be opened for the measurement, then the elongation should be
measured asquickly as possible, using the calibrated elongation card.
▪ After the hot‐set measurements, cut the weight off from below the lower gauge
mark, shut theOven and let the temperature be stable at 197 – 200 deg.C.
▪ Wait for 5 minutes and then take the test piece out, remove the load clamp and let it cool
down to roomtemperature (about 10 minutes).
▪ Measure the distance between the gauge marks and calculate the permanent set.
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CALCULATION ‐ PERMANENT SET
Curing the Sample for In-Process‐Testing ( For Un‐cured materials / Self‐curing materials)
For Low Voltage:
Boil two sample strips in water for one hour.
Take out one strip, cool it in running tap water and cut two dumb‐bells for testing.
HOT SET Test Requirements
Type Test
Type tests, electrical
• Insulation resistance measurement at ambient temperature
• Insulation resistance measurement at maximum conductor temperature
• Voltage test for 4 h
• Impulse test for cables of rated voltage 1,8/3 (3,6) kV
Type tests, non-electrical

• Measurement of thickness of insulation
• Measurement of thickness of non-metallic sheaths (including extruded
• separation sheaths, but excluding inner coverings)
• Tests for determining the mechanical properties of insulation before and after ageing
• Tests for determining the mechanical properties of non-metallic sheaths
• before and after ageing
• Additional ageing test on pieces of completed cables
• Loss of mass test on PVC sheaths of type ST2
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• Pressure test at high temperature on insulations and non-metallic sheaths

• Test on PVC insulation and sheaths and halogen free sheaths at low temperatures
• Test for resistance of PVC insulation and sheaths to cracking (heat shock test)
• Ozone resistance test for EPR and HEPR insulations
• Water absorption test on insulation
• Fire tests
• Measurement of carbon black content of black PE oversheath
• Shrinkage test for XLPE insulation
• Special bending test
• Determination of hardness of HEPR insulation
• Determination of the elastic modulus of HEPR insulation
• Shrinkage test for PE oversheath
• Additional mechanical tests on halogen free oversheath
• Water absorption test for halogen free oversheath
Insulation resistance measurement at ambient temperature

Procedure
▪ This test shall be made on the sample length before any other electrical test.
▪ All outer coverings shall be removed and the cores shall be immersed in water at ambient
temperature for at
least 1 h before the test.
▪ The d.c. test voltage shall be between 80 V and 500 V and shall be applied for sufficient
time to reach areasonably steady measurement, but in any case for not less than 1 min
and not more than 5 min.
▪ The measurement shall be made between each conductor and the water.
▪ If requested, measurement may be confirmed at a temperature of (20 ± 1) °C.
Insulation resistance measurement at maximum conductor temperature

Procedure
• The cores of the cable sample shall be immersed in water at a temperature within ±2 °C
of the maximumconductor temperature in normal operation for at least 1 h before the test.
• The d.c. test voltage shall be 80 V to 500 V and shall be applied for sufficient time to
reach a reasonablysteady measurement, but in any case, for not less than 1 min and not
more than 5 min.
• The measurement shall be made between each conductor and the water.
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Calculations for Both Measurements
The volume resistivity shall be calculated from the measured insulation resistance by the following
formula:
where
ρ is the volume resistivity, in ohms · centimeters; R is the measured insulation resistance, in
ohms;l is the length of the cable, in centimeters;
D is the outer diameter of the insulation, in millimetres;
d is the inner diameter of the insulation, in millimetres.
The "insulation resistance constant “Ki" expressed in megohms. Kilometers may also be
calculated,using the formula:
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Requirements
The values calculated from the measurements shall be not less than those specified in below Table.
FIRE TEST (IEC 60331 – IEC 60332)
25
Smoke Density,
IEC 60754 – IEC 61034
IEC 60502-2:
Routine tests:
Routine tests are normally carried out on each manufactured length of cable.
1. Electrical resistance of conductors
2. Partial Discharge test
3. Voltage test
4. DC sheath test, if required
DCR MEASURE HV TEST PD TEST
26
TEST VOLTAGES FOR MV CABLES
Partial Discharge Test for MV Cables
27
Voltage Test for MV Cables
Test procedure for single-core cables
For single-core screened cables, the test voltage of 3.5 Uo shall be applied for 5 min
between theconductor and the metallic screen.
Test procedure for multicore cables
For multicore cables with individually screened cores, the test voltage of 3.5 Uo shall be
applied for 5 min between each conductor and the metallic layer.
For multicore cables without individually screened cores, the test voltage of 3.5
Uo shall be appliedfor 5 min in succession between each insulated conductor and all the
other conductors and collective metallic layers, if any.
The conductors may be suitably connected for successive applications of the test voltage tolimit the
total testing time.
EQUIPMENT (Same as that used for PD Test)
Voltage Regulator is connected to the mains through a main power circuit breaker.
It supplies a variable voltage to the Exciter Transformer to adjust its output voltage to the proper value
required for the test.
Exciter Transformer supplies the necessary power to the resonant circuit (HV variable inductance
reactorand the test object.
For the series resonance, the exciter transformer is connected in series with the reactor (i.e. Type Test
Cage set‐ up).
For parallel resonance without excitation transformer, the reactor has an excitation transformer winding
which is in the same magnetic circuit as the reactor winding (i.e. Routine Test Cage set‐up).
HV Variable Reactor is the heart of the resonant circuit.
This device is designed to provide the complete reactive compensation to the highly capacitive load
(e.g. cable) when the system is turned to resonance.
The Capacitive Load represents the combined effects of the test object, voltage divider, filter capacitors
(if used) and stray capacitance due to the test set up.
A capacitive load is required for proper operation of the system in the series resonant mode.
Operating Desk: Where all functions related to HV testing are performed
28
DC Electric Test on Outer Sheath
Procedure
29
Sample tests
1. Conductor examination
2. Measurement of thickness of insulation and of non-metallic sheaths (including extruded
separation sheaths, but excluding inner extruded coverings)
3. Measurement of thickness of lead sheath
4. Measurement of armor wires and tapes
5. Measurement of external diameter
6. Voltage test for 4 hours
7. Hot set test for EPR, XLPE insulations and elastomeric sheaths
HV Test at 4Uo for 4 hrs.
This test is applicable only to cables of rated voltage above 3,6/6 (7,2) kV
Sampling
The sample shall be a piece of completed cable at least 5 m in length between the test terminations.
Procedure
A power frequency voltage shall be applied for 4 h at ambient temperature between each conductor and
the metal layer(s).
Test voltages
The test voltage shall be 4 U0. Values of the test voltage for the standard rated voltages are given
below.
HOT SET Test (IEC 60811-507:2012)

Same as applied for LV cables. Insulation sample should be sliced from the nearest dissected
section to the inner Semicon (conductor screen).
30
Type tests:
Type tests, electrical
Cables having conductor screen and insulation screens

• Bending test
• Partial Discharge test
• Tan d measurement for cables of rated voltage 6/10 (12) KV, and
above
• Heating cycle test
• Impulse test followed by a voltage test
• Resistivity of semi-conductive screens
Cables of rated voltages 3.6/6 (7.2) KV having unscreened insulation
• Insulation resistance measurement at ambient temperature
• Insulation resistance measurement at maximum conductor
temperature
• Impulse test
Type tests, non-electrical

• Measurement of thickness of insulation
• Measurement of thickness of non-metallic sheaths (including extruded
• separation sheaths, but excluding inner coverings)
• Measurement of thickness of lead sheath
• Tests for determining the mechanical properties of insulation before and after ageing
• Tests for determining the mechanical properties of non-metallic sheaths before and after aging
• Additional ageing test on pieces of completed cables
• Loss of mass test on PVC sheaths of type ST2
• Pressure test at high temperature on insulations and non-metallic sheaths
• Test on PVC insulation and sheaths and halogen free sheaths at low temperatures
• Test for resistance of PVC insulation and sheaths to cracking (heat shock test)
• Ozone resistance test for EPR and HEPR insulations
• Hot set test for EPR, HEPR and XLPE insulations and elastomeric sheaths
• Oil immersion test for elastomeric sheaths
• Water absorption test on insulation
• Flame spread test on single cables
• Measurement of carbon black content of black PE oversheath
• Shrinkage test for XLPE insulation
• Thermal stability test for PVC insulation
• Determination of hardness of HEPR insulation
• Determination of the elastic modulus of HEPR insulation
• Shrinkage test for PE oversheath
• Strippability test for insulation screen
• Water absorption test
31
Routine Tests on Cables

Routine tests are normally carried out on each manufactured length of cable.
• Partial Discharge test
• Voltage test
• DC sheath test, if required (same as MV cables).
Partial Discharge Test
▪ The partial discharge test shall be carried out in accordance with IEC 60885-3 for cables and the
sensitivityas defined in IEC 60885-3 s hall be 10 pC or better.
▪ The test voltage shall be raised gradually to, and held at, 1,75 U0 for 10 s and then slowly reduced to 1,5
U0.
▪ There shall be no detectable discharge exceeding the declared sensitivity from the test object at 1,5 U0.
Voltage Test
The voltage test shall be made at ambient temperature using an alternating test voltage at power
frequency.
The test voltage shall be raised gradually to 2,5 U0 and then be held for 30 min between the conductor
and metal screen/sheath.
No breakdown shall occur.
TEST VOLTAGES FOR HV CABLES
32
EQUIPMENT:
1- Reactor:
Which provides the complete reactive compensation to the highly capacitive load (e.g. cable).
2- Exciter:
▪ Which gives necessary excitation to the resonant circuit.
▪ For the series resonance, the exciter transformer is connected in series with the reactor.
▪ For parallel resonance without excitation transformer, the reactor has an excitation transformer
winding which is in the same magnetic circuit as the reactor winding (i.e. Routine Test Cage set‐up).
3- Regulator:
▪ Which adjusts the output of the exciter transformer.
▪ It is also where the test system receives its line voltage.
4- Voltage Divider:
where it measures the output voltage of the reactor.
5- Operating Terminal:
Where all functions related to HV testing are performed
Diagram of Cable Routine Test
33
REQUIREMENT:
Routine Test:
AC Voltage test:
▪ The voltage test shall be made at ambient temperature.
▪ The test voltage shall be raised gradually to the specified value which shall then be held for 30
minutesbetween the conductor and metallic screen.
▪ The test voltage shall be at 2.5 Uo.
▪ No breakdown of the insulation shall occur.
Type Test:
Heat Cycling:
During the test period, a voltage of 2 Uo shall be applied to the sample.
Tan Δ Measurement:
A voltage Uo shall be applied to the cable during tan Δ measurement.
AC Voltage Test:
▪ After the impulse test, the cable sample shall be subjected at ambient temperature to a power frequency
voltage at 2.5 Uo for 15 minutes.
▪ No breakdown of the insulation shall occur.
34
Sample Tests on HV Cables

The following tests shall be carried out on samples which, for the tests in items b) and g), may bedrum
lengths of cable, taken to represent batches:
a) Conductor examination;
b) Measurement of electrical resistance of conductor and of metallic screen;
c) Measurement of thickness of insulation and over-sheath;
d) Measurement of thickness of metallic sheath;
e) Measurement of diameters, if required;
f) Hot set test for XLPE, EPR and HEPR insulations;
g) Measurement of capacitance;
h) Measurement of density of HDPE insulation;
i) Lightning impulse voltage test for a cable with calculated nominal electrical stress at conductor
screen > 8,0 kV/mm (to be calculated as per formulas in next slide).
j) Water penetration test, if applicable;
k) Tests on components of cables with a longitudinally applied metal foil.
Electric Stress Calculation for item (i)
Frequency of tests
The sample tests in items a) to h) and k) shall be carried out on one length from each batch of the same
type and cross-section of cable but shall be limited to not more than 10 % of the number of lengths in any
contract, rounded to the nearest whole number.
The frequency of the tests in items i) and j) shall be in accordance with agreed quality control
procedures. In the absence of such an agreement, one test shall be made for contracts with a
cable length greater than20 km.
35
Electrical resistance of conductor and of metallic screen
▪ The cable length, or a sample thereof, shall be placed in the test room, which shall be maintained at a
reasonably constant temperature for at least 12 h before the test.
▪ If there is a doubt that the conductor or metal screen temperature is not the same as the room
temperature, the resistance shall be measured after the cable has been in the test room for 24 h.
▪ Alternatively, the resistance may be measured on a sample of conductor or metal screen, conditioned
forat least 1 h in a temperature-controlled liquid bath.
▪ The d.c. resistance of the conductor or metal screen shall be corrected
▪ The d.c. resistance of the conductor or metal screen shall be corrected to a temperature of 20°C and a1
km length in accordance with the formulae and factors given in IEC 60228.
▪ For screens other than copper or aluminium, temperature coefficients and correction formulae shall be
taken respectively from Table in slide # 67.
Requirement:
The corrected d.c. resistance of the conductor at 20°C shall not exceed either the appropriate
maximum
value specified in IEC 60228 or the declared value.
The corrected d.c. resistance of the metal screen at 20°C shall not exceed the declared value.
Electrical Resistivities & TemperatureCoefficients of Metals Used
DC Resistance per unit length of theconductor at max. operating temperature θ:
Where:
R’ = Resistance at θ°C
Ro = Resistance at 20°C
 = Temp. Coefficient
36
Measurement of Thickness of Insulation & Oversheath:
Lead or Lead Alloy Sheath

The thickness of the lead sheath shall be measured by one of the following methods, at the discretion of
the manufacturer.
Plain Aluminum Sheath
The minimum thickness of the sheath shall not fall below 90 % of the nominal thickness by more
than 0,1mm for plain aluminium sheath:
37
Measurement of Capacitance
The capacitance shall be measured between conductor and metal screen/sheath at ambient
temperature,
where the ambient temperature shall be recorded with the test data.
The measured value of the capacitance shall be corrected to a 1 km length and shall not exceed the
declared nominal value by more than 8 %.
Lightning Impulse Voltage Test
▪ Impulse testing systems are designed to generate impulse voltages that simulate lightning
strikes andswitching surges.
▪ This test is only required for cables with a nominal electric conductor stress > 8,0 kV/mm.
▪ The test shall be performed on a complete cable at least 10 m in length excluding test accessories, at
aconductor temperature 5°C to 10°C above maximum conductor temperature in normal operation.
▪ The assembly is heated by conductor current only, until the cable conductor reaches the required
temperature.
▪ The assembly shall withstand without failure or flashover 10 positive and 10 negative voltage values
as specified for each KV rating.
▪ Pictures below show Impulse test 2.4 MV, HV-EHV Resonant test system 700 KV.
38
Measurement of Density of HDPE Insulation

Procedure
The density of HDPE shall be measured using the sampling and test procedure given in Clause 8 of IEC
60811-1-3.
Suspension Method (general method)

Testing materials & equipment
1) Ethanol (ethyl-alcohol) of analytical grade or another suitable liquid for densities below 1 gm/cc.
2) Zinc chloride solution for densities equal to or greater than 1 gm/cc.
3) Distilled or deionized water.
4) Mixing cylinder.
5) 5) Thermostat.
6) 6) Hydrometer calibrated at (23,0 +/- 1°C).
7) Thermometer graduated in tenths of a degree Celsius
Procedure
• A sample from the insulation or the sheath to be tested, shall be taken perpendicularly to the
conductor axis and cut into small pieces of 1 mm to 2 mm edge length.
• The density shall be determined by putting the sample suspended in a liquid which does not react
with thematerial to be tested.
• Three pieces of the sample shall be placed in the liquid at a temperature of 23,0 °C.
The following liquids are suitable:
. for a density expected to be lower than 1 gm/cc, a mixture of ethanol and water;
. for a density of 1 gm/cc and higher, a mixture of zinc chloride and water.
39
Requirements
The results of the test shall comply with the requirements of HDPE given below.
Water Penetration Test
▪ A 6 m length of cable shall be cut from the length which

has been subjected to the bending test and placed
horizontally.
▪ A ring approximately 50 mm wide shall be removed
fromthe Centre of the length.
▪ This ring shall comprise all the layers external to the
insulation screen.
▪ Where the conductor is also claimed to contain a
longitudinal water barrier, the ring shall comprise all
layers external to the conductor.
Procedure
▪ The tube shall be filled within 5 min with tap water at a temperature of (20 ± 10) °C so that the height
of the water in the tube is 1 m above the cable centre (see Figure).
▪ The sample shall be allowed to stand for 24 h.
▪ The sample shall be subjected to sample shall then be subjected to 10 heatingcycles.
▪ The conductor shall be heated by a suitable method until it has reached a steady temperature5 °C
to 10 °C above the maximum conductor temperature in normal operation; not reach the boiling
point of water.
▪ The heating shall be applied for at least 8 h. The conductor temperature shall be maintained within
the stated temperature limits for at least 2 h of each heating period.
▪ The water head shall be maintained at 1 m.
Requirements
During the period of testing, no water shall emerge from the ends of the test piece.
40
IEC 60840: HV Cables up to 150 KV
IEC 62067:
Routine tests on cables and on the main insulation of prefabricated accessories:
1- Partial discharge test
2- Voltage test
3- Electrical test on over-sheath of the cable
TEST VOLTAGES FOR EHV CABLES
41
Sample Tests on EHV Cables
The following tests shall be carried out on samples which, for the tests in items b) and g), may be
drum lengths of cable, taken to represent batches:
a) Conductor examination;
b) Measurement of electrical resistance of conductor and of metallic screen;
c) Measurement of thickness of insulation and over-sheath;
d) Measurement of thickness of metallic sheath;
e) Measurement of diameters, if required;
f) Hot set test for XLPE, EPR and HEPR insulations;
g) Measurement of capacitance;
h) Measurement of density of HDPE insulation;
i) Lightning impulse voltage test for a cable with calculated nominal electrical stress at conductor
screen > 8,0 kV/mm (to be calculated as per formulas in next slide).
j) Water penetration test, if applicable;
k) Tests on components of cables with a longitudinally applied metal foil.
Frequency of Tests
The sample tests in items a) to h) and k) in previous slide shall be carried out on one length from each
batch of the same type and cross-section of cable, but shall be limited to not more than 10 % of the
numberof lengths in any contract, rounded to the nearest whole number.
The frequency of the tests in items i) and j) in previous slide shall be in accordance with agreed quality
control procedures.
In the absence of such an agreement, one test shall be made for contracts with a cable length between
4km and 20 km and two tests for contracts with longer cable lengths.
Electrical resistance of conductor and of metallic screen
▪ The cable length, or a sample thereof, shall be placed in the test room, which shall be maintained at a
reasonably constant temperature for at least 12 h before the test.
▪ If there is a doubt that the conductor or metal screen temperature is not the same as the room
temperature, the resistance shall be measured after the cable has been in the test room for 24 h.
▪ Alternatively, the resistance may be measured on a sample of conductor or metal screen, conditioned for
at least 1 h in a temperature-controlled liquid bath.
▪ The d.c. resistance of the conductor or metal screen shall be corrected
42
▪ The d.c. resistance of the conductor or metal screen shall be corrected to a temperature of 20°C and
a one km length in accordance with the formulae and factors given in IEC 60228.
▪ For screens other than copper or aluminium, temperature coefficients and correction formulae shall be
taken respectively from Table in page # 37.
Requirement:
The corrected d.c. resistance of the conductor at 20°C shall not exceed either the appropriate maximum
value specified in IEC 60228 or the declared value.
The corrected d.c. resistance of the metal screen at 20°C shall not exceed the declared value.
Type Test on HV / EHV Cables

Range of Type Approval
a) The voltage group is not higher that of the tested cable system.
b) the conductor cross-section is not larger than that of the tested cable;
c) the cable and the accessories have the same or a similar constructions as that of the tested cable
system(s);
d) the calculated nominal electrical stress and the impulse voltage stress calculated using nominal
dimensions at the cable conductor screen do not exceed the respective calculated stresses of
the tested cable system(s)by more than 10 %;
e) the calculated nominal electrical stress at the cable insulation screen and the impulse
voltage stress calculated using nominal dimensions do not exceed the respective
calculated stresses of the tested cablesystem(s);
f) the calculated nominal electrical stresses and the impulse voltage stresses calculated using
nominal dimensions within the main insulation parts of the accessory and at the cable and
accessory interfaces do notexceed the respective calculated stresses of the tested cable
system(s).
Sequence of Electrical Type Test, HV Cables

▪ Bending test on the cable followed by installation of accessories and a partial discharge test at
ambient temperature;
▪ Tan Δ measurement;
o Note: This test may be carried out on a different sample with special test terminals from that
used forthe remainder of the sequence of tests. .
• Heating cycle voltage test
43
▪ Partial discharge tests

o at ambient temperature, and
o at high temperature.
• The tests shall be carried out after the final cycle of item c) above or, alternatively, after the lightning
impulse voltage test in item e) below;
• Lightning impulse voltage test followed by a power frequency voltage test;
• Partial discharge tests, if not previously carried out in item d) above;
• Additional tests for accessories,
• Examination of the cable system with cable and accessories on completion of the above tests;
• The resistivity of the cable semi-conducting screens (see 12.4.9) shall be measured on a separate
sample.
Sequence of Electrical Type Test, EHV Cables
a) Bending test on the cable followed by installation of accessories and a

partial discharge test atambient temperature;
b) tan Δ measurement;
c) Heating cycle voltage test
d) Partial discharge tests
• at ambient temperature, and
• at high temperature.
The tests shall be carried out after the final cycle of item c) above or, alternatively,
after the lightningimpulse voltage test in item f) below;
e) Switching impulse voltage test (required for Um > 300 kV,
f) Lightning impulse voltage test followed by a power frequency voltage test;
g) Partial discharge tests, if not previously carried out in item d) above;
h) Tests of outer protection for joints;
Note: These tests may be applied to a joint which has passed test in item c),
i) Examination of the cable system with cable and accessories on completion of the above tests
j) The resistivity of the cable semi-conducting screens shall be measured on a separate sample.
Heat cycling voltage test
EQUIPMENT:
44
Procedure
▪ The cable shall have a U-bend diameter as per the following calculations.
❖ Bending Diameter Calculations:
▪ Turn the current adjust potentiometer until desired temperature or current is reached.
▪ The heating shall be applied for at least 8 hours and shall be followed by at least 16 hours of natural
cooling.
▪ The conductor temperature shall be maintained within the stated temperature limits at least for the
last twohours of each current loading period.
▪ The cycle of heating and cooling shall be carried out 20 times.
▪ Apply HV @ 2 Uo to the sample during the whole of the test period
45
▪ After the final cycle, the sample at ambient temperature shall be subjected to Partial discharge test.
▪ Refer to Inspection Test procedures of Partial Discharge Test as described before.
Requirement
No breakdown of the insulation shall occur
Lightning Impulse Test
It is a dielectric test conducted on an electrical cable to demonstrate that the insulation will
withstandimpulses that strike it externally due to lightning during its service period.
High voltage surges resembling lightning that are simulated in laboratories are commonly
known as highvoltage impulses.
Equipment
▪ Impulse voltage generator: which generate impulse voltages simulating lightning strokes and switching
surges.
▪ Impulse generator charging rectifier and SCR control unit: which provides the rectified voltage input to
the impulse generator.
▪ Impulse voltage divider: which measures the output impulse voltage.
▪ Sphere‐gap: for calibration of output impulse voltage.
▪ Peak measurement device (DIAS 730): which provides a digital impulse analysis to the output impulse
voltage. It generates and records impulse shapes and parameters.
▪ Controlling module: Where impulse generation is being controlled.
46
Procedure
1- Insert the cable sample to the yoke of the Heat cycling transformer.
2- For H.V. cables, prepare cable end termination as per Work Instruction, and make an
electrical connectionas per diagram in previous slide.
3- Calibrate the impulse generator with positive polarity.
Note: Calibration can be done immediately before or during the period when the temperature of
the cable is maintained at a constant value.
4- For calibration of output impulse voltage, Increase the sphere gap setting so that
no flash over occursacross the gap during testing.
5- Enter the required test voltage at the “setting” control box (voltage as per page # 42).
6- Heat the sample cable and with the cable conductor temperature maintained at 85-100 °C,
apply a series of10 positive impulses to the sample.
7- Print the results recorded in the setting control box when 10 positive impulses are completed.
8- The impulse will automatically switch off when 10 positive impulse is completed.
9- Follow the same procedures above except that in the “setting” box, change polarity to “Negative”.
Note:
It is very important to exercise caution when applying impulse voltage to the cable.
It is highly recommended to test the cable with less voltage and increase until the required test
voltage is reached.
One Cycle Positive One Cycle Negative
47
Non-electrical type tests on cable components and on complete cable, HV Cables

a)check of cable construction;
b)tests for determining the mechanical properties of insulation before and after ageing
c)tests for determining the mechanical properties of over sheaths before and after ageing
d)ageing tests on pieces of complete cable to check compatibility of materials
e)loss of mass test on PVC over sheaths for type ST2
f)pressure test at high temperature for over sheaths (ST1, ST2, ST7, and ST12)
g)tests for PVC and LSHF over sheaths (ST1, ST2, ST12) at low temperature
h)heat shock test for PVC over sheaths (ST1 and ST2)
i) ozone resistance test for EPR and HEPR insulations
j) hot set test for EPR, HEPR and XLPE insulations
k) measurement of density for HDPE insulation
l) measurement of carbon black content for black PE over sheaths (ST3 and ST7)
m) test under fire conditions (ST1, ST2 and ST12)
n) water penetration test
o) tests for components of cables with a longitudinally applied metal tape or foil, bonded to the
oversheath
p) shrinkage test for PE, HDPE and XLPE insulations
q) shrinkage test for PE and LSHF over sheaths (ST3, ST7 and ST12).
Non-electrical type tests on cable components and on complete cable, EHV Cables
a) check of cable construction;

b) tests for determining the mechanical properties of insulation before and after ageing;
c) tests for determining the mechanical properties of overs heaths before and after ageing;
d) ageing tests on pieces of complete cable to check compatibility of materials;
e) loss of mass test on PVC over sheaths of type ST2;
f) pressure test at high temperature on over sheaths;
g) tests on PVC over sheaths (ST1 and ST2) at low temperature;
h) heat shock test for PVC overs heaths (ST 1 and ST2);
i) ozone resistance test for EPR insulations;
j) hot set test for EPR and XLPE insulations;
k) measurement of density of HOPE insulation;
I) measurement of carbon black content of black PE over sheaths (ST 3 and ST7),
m) test under fire conditions;
n) water penetration test;
o) tests on components of cables with a longitudinally applied metal tape or foil, bonded to the
oversheath.
48
EXAPLE. TYPE TEST for HV CABLE
CABLE CONSTRUCTION (1x2000 mm2- 132KV)
*As per internal standard or customer requirements.
Test Conditions
1- Ambient temperature
All tests are carried out at an ambient temperature of (20±15) C°.
2- Frequency and waveform of test voltage
The frequency of the alternating test voltage was in the range of 49 Hz to 61 Hz and the
Waveform was substantially sinusoidal.
3- Waveform of the impulse test voltage
The impulse wave was having a virtual front time between 1 µs and 5 µs and nominal time
attain half peak value between 40 µs and 60 µs.
4- All test conditions are in accordance with IEC 60060-1.
49
132 kV CABLE TYPE TEST SCHEDULE - 1X2000 MM2 106 days

Electrical Type Tests 46 days
Check on insulation thickness of cable ( IEC 60840 - 10.6.2 ) 1 day
Bending test on the cable ( IEC 60840 - 12.3.3 ) 1 day
Partial discharge test (Of Cable) at ambient temperature (IEC 60840 - 12.3.4) 1 day
Installation of Accessories 15 days
Partial discharge test at ambient temperature (IEC 60840 - 12.3.4) 1 day
Tan δ measurement (IEC 60840 clause 12.3.5), Cables 1 day
Heating cycle voltage test (IEC 60840 - 12.3.6) 21 days
Partial discharge test at ambient temperature (IEC 60840 - 12.3.4) 1 day
Partial discharge test at high temperature (IEC 60840 - 12.3.4) 1 day
Lightning impulse voltage test followed by a power frequency voltage test (IEC 60840 - 12.3.7) 1 day
AC withstand test (IEC 60840 - 12.3.7) 1 day
Examination ( IEC 60840 clause 12.3.8 ), Cables 1 day
Non-Electrical Type Tests 42 day

Check of cable construction ( IEC 60840 - 12.4.1 ) 1 day
Shrinkage test for XLPE Insulation ( IEC 60840 - 12.4.13 ) 1 day
Resistivity of semi-conducting screen ( IEC 60840 - 12.3.9 ) 2 days
Tests for determining the mechanical properties of insulation before & after ageing ( IEC 60840 - 12.4.2 ) 10 days
Tests for determining mechanical properties of over sheaths before & after ageing ( IEC 60840 -12.4.3 )
12 days
Ageing tests on pieces of complete cable to check compatibility of materials ( IEC 60840 - 12.4.4 ) 10 days
Pressure test at high temperature on over sheaths ( IEC 60840 - 12.4.6 ) 1 day
Hot set test for XLPE insulation ( IEC 60840 - 12.4.10 ) 1 day
Measurement of density of HDPE outersheath ( IEC 60840 - 12.4.11 ) 1 day
Measurement of carbon black content of black PE oversheaths ( IEC 60840 - 12.4.12 ) 2 days
Shrinkage test for PE oversheaths ( IEC 60840 - 12.4.14 ) 1 day
Water Penetration Test 10 days

Water penetration test with 10 heat cycles ( IEC 60840 - 12.4.18 ) 10 days
Tests of Outer Protection for Buried Joint ( IEC 60840 - Annex H ) 8 day
Water immersion & heat cycling(7 cycles) 4 days
DC Voltage tests 1 day
Check Insulation Thickness of cable
Impulse voltage tests 1 day
Prior to the electrical type test the insulation thickness of the cable is measured and the average
thickness isofchecked.
Examination test assembly 2 days
50
NOTES:
• If the average thickness of the insulation does not exceed the nominal value by more than 5% the
test voltages shall be as specified in table 4 (IEC 60840) for the rated voltage of the cable
• If the average thickness of the insulation exceeds the nominal value by more than 5% but by not
more 15% the test voltages shall be adjusted to give an electrical stress at the conductor screen
equal to the applying when the average thickness of the insulation is equal to the nominal value
and the test voltage are the normal value specified for the rated voltage of the cable
• The cable length used for the tests shall not have an average thickness exceeding the nominal
value by more than 15%.
Bending Test on the cable

The cable sample is bent around a test cylinder at ambient temperature for at least on complete turn and
unwounded without axial rotation of the sample, then be rotated through 180 and the process repeated.
This cycle of operations is carried out three times in total
NOTES:
The diameter of the test cylinder should not be greater than:
- For cables with plain AL sheaths;
- 36(d+D) +5% For single core;
- 25(d+D) +5% For three core;
- For cables with lead, lead alloy corrugated metallic
Sheath or with longitudinally applied metal foils:
- 20(d+D) +5% For three core;
- For other cable:
- 15(d+D) +5% For three core ;
Where
d is the nominal diameter of the conductor in mm.
D is the nominal diameter of the cable in mm.
The diameter of the test cylinder:

Dc = 25(d + D) + 5%
d = conductor diam. mm
D = overall cable diam. mm Dcyl mm
Dcyl = 25 * (58 + 120 )*1.05
= 4673 mm
51
BENDING
Cycle no 1
A B
Directio
Direction of
n of
pulling
pulling
C D
Directio
Direction of
n of
pulling
pulling
52
Installation of the accessories

* The Accessories
1- OUTDOOR TERMINATION TYPE TE 1.72-01SP (BRUGG)
2- SF6 JOINT (PFISTERER)
3- INSULATED JOINT (BRUGG)
4- WATER TERMINATION
* Note that
- The electrical stress at the insulation screen of the cable for which the accessory is to be applied shall
not exceed that in the cable used in the accessories type test.
- Accessories shall be dry and clean
- Neither the cable nor the accessories shall be subjected to any form of conditioning not specified in
the manufacture instruction which might be modify the electrical, thermal or mechanical performance
of the test assemblies
- The minimum length of free cable between the joint and the bottom of each termination has to be 5 m.
DIAGRAM-SAMPLE WITH ACCESSORIES AFTER INSTALLATION
Outdoor
Water termination termination
Cable 1 x 2000 mm2

132 KV
GIS System Insulated

SF6 joint Bonded cable joint
5M
5 M 5M
53
SAMPLE WITH ACCESSORIES AFTER INSTALLATION
1
4
1- OUTDOOR TERMINATION YPE TE 1.72-01SP
54
2- SF6 JOINT (PFISTERER
3- INSULATED JOINT MP 1.72-31
55
4- WATER TERMINATION
Partial Discharge Test after installation

The sensitivity should be 5 pc or better
The test voltage shall be raised gradually to and held at 1.75 Uo for 10 sec. and then slowly reduced to
1.5 Uo.
There shall be no detectable discharge exceeding the declared sensitivity from the test object at 1.5 Uo.
56
Tan Delta Measurement

• The sample shall be heated by a suitable method and the temperature of the conductor determined
by thermocouples on the sheath of the sample and on the conductor of another sample of the
same cable heated by the same means (dummy sample)
• The sample shall be heated by conductor current until the cable conductor reaches a steady
temperature 50 C to 100 C above the maximum conductor temperature in normal operation
• The tan delta shall then be measured at a power frequency voltage of Uo at the temperature
specified above
• The measured value shall not exceed 10x10-4
H.V Transformer
Heating Current
Outdoor
Water termination termination
Cable 1x1600 mm2

66 KV
GIS System Insulated

SF6 joint Bonded cable joint
Heater transformer
5M
5 M 5M
Dummy cable
Heater transformer
Heating Cycle Test

• The sample shall be heated by conductor current until the cable conductor reaches a steady
temperature 50 C to 100 C above the maximum conductor temperature in normal operation.
• The heating shall be applied for at least 8 h and the conductor temperature shall be maintained
within the steady temperature limits for at least 2 h of each heating period.
• This shall be followed by at least 16 h of natural cooling to a conductor temperature within 10 c of
the test ambient temperature.
• The conductor current during the last 2 h of each heating period shall be recorded.
• The cycle of heating and cooling shall be carried out 20 times.
• During the whole of the test period a voltage of 2 U0 shall be applied
57
H.V TRANSFORMER
OUTDOOR
TERMINATION
WATER
TERMINATION
HEATING
TRANSFORMERS
HEATING
TRANSFORMER
INSULATED JOINT
SF6 JOINT
THERMOCOUPLE
CONECTOR
DUMMY
GRAPH OF ONE HEATING CYCLE (TYPICAL FOR 20 CYCLES )
Lightning Impulse Voltage Test followed by a power frequency AC voltage test for Cable &
Accessories
• The test shall be performed on the assembly with the cable conductor temperature 5 °C to 10 °C
above the maximum conductor temperature in normal operation.
• The impulse voltage shall be applied according to the procedure given in IEC 60230.
• The assembly shall withstand without failure or flashover 10 positive and 10 negative voltage.
• After the impulse voltage test, the assembly shall be subjected to a power frequency voltage test at
2,5 U0 for 15 min.
• No breakdown of the insulation or flashover shall occur.
58
• Waveform of lightning impulse test voltages In accordance with IEC 60230, the front time of the
standard lightning impulse voltage shall be between 1 μs and 5 μs.
The time to reach half value shall be 50 μs ± 10 μs as specified in IEC60060-1.
Positive wave-form of lightning impulse test voltages
Negative wave-form of lightning impulse test voltages
59
P.D measurement at ambient & high temperature after Lightning impulse voltage test
• The sensitivity should be 5 PC or better.

• The test voltage shall be raised gradually to and held at 1.75 Uo for 10 sec and then slowly
reduced to 1.5 Uo.
• There shall be no detectable discharge exceeding the declared sensitivity from the test object at
1.5 Uo.
• The test shall be repeated on the assembly with the cable conductor temperature 5 °C to 10 °C
above the maximum conductor temperature in normal operation.
60
Joint with Cable after Burying With Load
61
Water Penetration test with 10 heating cycles
62
Fire Performance Standard

At present, in cable industry, Fire Retardant, Low Smoke Halogen Free (LSZH), Low
Smoke Fume (LSF) and Fire Resistant cables are all described as Fire survival Cables.
◎ Flame Retardant
Fire retardant cables are designed for use in fire situations where the spread of flames
along a cable route needs to be retarded. Due to relative low cost, fire retardant cables are
widely used as fire survival cables. No matter the cables are installed in single wire or in
bundles, during a fire, the flame spread will be retarded and the fire will be confined to a small
area, thus reducing the fire hazard due to fire propagation.
◎ Low Smoke & Halogen Free & Fire Retardant (LSZH)

LSZH cables are not only characterized by the fire retardant performance but also by the
halogen free properties, thus offering low corrosivity and toxicity. During a fire, the LSZH
cables will emit less smoke and acid gases which may damage the human being and
expensive equipment. Compared with normal PVC cables, LSZH cables outperform by their
fire retardancy, low corrosivity and low smoke emission properties, however, normal PVC
cables have better mechanical and electrical properties.
◎ Low Smoke Fume (LSF)

The low halogen content and low corrosivity of low smoke fume cables lies somewhat in
between that of fire retardant cables and LSZH cables. LSF cables also contain halogen but
the content is much less than that of PVC cables. LSF cables are designed to reduce the spread
of fire, toxic gases and smoke during fire. The LSF cables are usually manufactured from flame
retardant PVC blended with HCL additive and smoke absorbent. These materials help improve
the fire performance
of the LSF cables.
◎ Fire Resistant (FR)

Fire resistant cables are designed to maintain circuit integrity of those vital emergency
services during the fire. The individual conductors are wrapped with a layer of fire resisting
mica/glass tape which prevents phase to phase and phase to earth contact even after the
insulation has been burnt away. The fire resistant cables exhibit same performance even under
fire with water spray or mechanical shock situation.
◎ Fire Performance Class

The main concerns for the cables in their fire survival properties are their flame spread,
smoke characterization and gas toxicity. In American fire standard, the concern lies more on
the first two and it differs from the European standard which concerns all these aspects. In
USA, it is believed that the fire hazard is mainly due to CO toxic gas emitted and the heat
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release during the conversion of CO to CO2 during the fire. Therefore, to control the heat
release is the most important concern for reducing the fire hazard. However, in European
countries, halogen content, the corrosivity of the gases, the smoke density and the toxicity of
the gas are equally important factors affecting the safety and survival of human during a fire.
IEC Standard for Flame Retardancy

The European Electrical Committee categorizes the fire performance of the cables
into three classes, namely IEC 60332-1, IEC 60332-2, IEC 60332-3, IEC 60332-1 and IEC
60332-2 are used to assess the flame propagation characteristics of a single wire. IEC
60332-3 is used to assess the flame propagation characteristics of bundled cables.
Comparatively speaking, IEC 60332-3 for bundled cables is more demanding than IEC 60332-
1 for single wires.
◎ IEC 60332-1/BS 4066-1 (Flame Test on Single Vertical Insulated

Wires/Cables)
This test details a method of test for the assessment of the flame propagation
characteristics of a single wire or cable. In this test, a 60cm cable sample is fixed vertically
inside a metallic box and a 175mm long flame is applied at 45℃ from a gas burner placed at
450mm from the top at the upper portion. The specimen is deemed to have passed this test,
if after burning has ceased, the charred or affected position does not reach within 50mm of the
lower edge of the top clamp which is equivalent to 425mm above the point of flame application.
The test method is not suitable for the testing of some small wires due to the melting of the
conductors during the time of application of the flame.
◎ IEC 60332-3/BS 4066-3 (Flame Test On Bunched Wires/Cables)
IEC60332-3C describes a method of type approval testing to define the ability of

bunched cables to resist fire propagation. In this test, a cable specimen, consisting of number
of 3.5m length of cables are fixed to a vertical ladder tray where they are applied with a
flame from a gas burner for a specified times under controlled air flow. Four categories (A, B,
C & D) are defined and distinguished by test duration and the volume of non-metallic material
of the sample under test. The cable specimen is deemed to have met the requirements of the
standard if, after burning has ceased, the extent of charred or affected portion does not reach
a height exceeding 2.5m above the bottom edge of the burner.
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UL Standard for Fire Retardancy

If a cable can pass a specified UL fire standard, an UL performance verification mark can be
applied onto the cable jacket illustrating both the UL class and the number. There are five primary
fire testing standards as follows:
◎ CMP (Plenum Flame Test/ Steiner Tunnel Test)

Plenum rated cables meet the NFPA -262 standard (formerly
known as UL910) which provides the most stringent requirement of
all the tests. Cable samples on a horizontal tray in a tunnel type of
chamber are burned at 87.9KW (300,000 BTU/Hr) for 20 minutes. To
qualify for a plenum rating the cable specimen musthave the flame
spread of less than 5 feet or 1.5 meters with a smoke density during
the test of (a) 0.5 peak and 0.15 maximum average. The CMP cables
are usually installed in air ventilation ducts and air returns widely used
in Canada and USA. The fire retardant properties of CMP cables are
much better than that of normal LSZH cables complying with IEC
60332-1 and IEC 60332-3.
◎ CMR (Riser Flame Test)

Riser rated cables meets UL1666. Cable samples on a vertical
shaft are burned at 154.5KW (527,500 BTU/Hr) for 30 minutes. To
qualify for a riser rating, cable specimen must have the flame spread
of less than 12 feet beyond the ignition point. This test does not look
at the smoke density or toxicity. Riser rated cables are suitable for
vertical shafts not defined as an environmental air plenum.
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◎ CM (Vertical Tray Flame Test)
General purpose cables meet UL 1581. Cable samples on a 8

feet vertical tray are burned at 20KW (70,000 BTU/Hr) for 20
minutes. The cable specimen is deemed to pass the test if the
flame spread will not extend to the upper portion and extinguish
by itself. UL 1581 is similar to IEC 60332-3C except for that the
number of testing samples is different. This test does not look at
the smoke density or toxicity. The CMG cables are usually used in
runs penetrating single floor. These cables cannot be installed in
vertical pathways.
◎CMG (Vertical Tray Flame Test)
These general purpose cable also meet UL1581. CM and

CMG are similar and both are recognized in Canada and USA.
This test does not look at the smoke density or toxicity. The CMX
cables are usually used in runs penetrating single floor. The
cables cannot be installed in vertical pathways.
◎CMX (Vertical Wire Flame Test)

The restricted cables meet UL1581 Limited-use. The test
consists of 25 feet long ventilated tunnel. The cable
specimen is placed on a ladder inside the tunnel and the
flame of 30,000 BTU/Hr is applied to the cable 15 seconds
on and 15 seconds off five times for a total exposure to the
flame of 1 minute and 15 seconds. To qualify for this test,
after the test flame is removed the cable specimen can
flame for not more than 60 seconds and the charred portion
will not exceed by 25%. UL 1581 VW-1 is similar to IEC
60332-1 except for the difference in the time for flame
applied. This test does not look at the smoke density or
toxicity. The CMG cables are suitable for use in dwellings
and for use in raceway. These cables cannot be installed
in bundles and must be protected in metal conduit. This
type of cable is chosen as the minimum requirement for
commercial installations.
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Standard for Fire Resistance

Fire resistant cables are designed for maintaining circuit integrity during a fire. The IEC and the BS
adopted two different standards, namely the IEC 60331 and BS 6387.Comparatively speaking, the
fire performance requirement for BS 6387 is more demanding.
◎IEC60331 Fire Resistance Test

A cable sample is placed over a gas burner and connected to an electrical supply at its rated
voltage. Fire is applied for a period of 3 hours. The temperature on the cable is between 750℃and
800℃. After 3 hours, the fire and the power is switched off. 12 hours later, the cable sample is
reenergized and must maintain its circuit integrity.
◎BS6387 Fire Resistance Test

BS6387 specifies the performance requirements for cables required to maintain circuit integrity under
fire conditions.
It details the following methods to categorize the cables according to cable withstand capacities.
Resistance to fire alone - the cables is tested by gas burner flame while passing a current at its
rate voltage. Four survival categories are defined Cat A (3 hours at 650℃), Cat B (3 hours at 750℃),
Cat C (3 hours at 950℃), and Cat S (20 minutes at 950℃ ).
Resistance to fire with water spray - a new sample of cable is exposed to flame at 650℃ for 15
minutes while passing a current at its rated voltage and then the spray is turned on to give exposure
to both fire and water for a further 15 minutes. A single survival category W is defined if the cables
surpassed the testing requirement.
Resistance to fire with mechanical shock - the final requirement is mechanical shock damage. A
fresh sample is mounted on a backing panel in an S bend and is exposed to flames while the
backing panel is stuck with a steel bar with the same diameter as the cables under test every 30
seconds for 15 minutes. The cables will be tested under the following
Temperatures: X (650℃ /15min), Y (750℃ /15min) and Z (950℃ /15min).
The highest standard for BS 6387 is CWZ.
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Standard for Halogen

Horizontal Burning Test & Smoke
Water Spray Emission,
Burning Test Corrosivity
Mechanical-Shock Burning &
Standard for Halogen & Smoke Emission, Corrosivity & Toxicity
◎IEC 60754-1/BS6425-1 (Emission of Halogen)

This specifies a test for determination of the amount of halogen
acid gas other than the hydrofluoric acid evolved during combustion
of compound based on halogenated polymers and compounds
containing halogenated additives taken from cable
constructions. Halogen includes Florine, Chlorine, Bromine, Iodine
and Astatine. All these elements are toxic by their nature. In this
test, when the burner is heated to 800℃, 1g sample is placed inside
and the HCL is absorbed into water inside the chamber fed with air
flow. The water is then tested with its acidity. If the hydrochloric
acid yield is less than 5 mg/g, the cable specimen is categorized
as LSZH. If the hydrochloric acid yield lies between 5mg/g to
15mg/g, the cable specimen is categorized as LSF. IEC60754-1
cannot be used for measuring the exact HCL yield if the yield is less
than 5mg/g. This test cannot determine if the cable is 100% halogen
free or not. To determine if the cable specimen is 100% halogen free
or not, IEC60754-2 has to be employed.
◎IEC 60754-2 (Corrosivity)
This test specifies a method for the determination of degree

of acidity of gases evolved during combustion of the cable
specimen by measuring its pH and conductivity. The specimen is
deemed to pass this test if the pH value is not less than 4.3 when
related to 1 liter of water and conductivity is less than 10us/min.
When the HCL yield lies between 2mg/g and 5mg/g, a cable
specimen can pass IEC 60754-1 but its pH value will likely be
less than 4.3 and therefore cannot pass the IEC 60754-2 test.
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◎IEC 61034-1/ASTM E662 (Emission of Smoke)
This specifies a test for determination of smoke density. The

3 meter cube test measures the generation of smoke from electric
cables during fire. A light beam emitted from a window is projected
across the enclosure to a photo cell connected to a recorder at
the opposite window. The recorder is adjusted to register from
0% for complete obscuration to 100% luminous transmissions. A
1 meter cable sample is placed in the centre of the enclosure
and is applied with a fire. The minimum light transmission is
recorded. The result is expressed as percentage of light
transmitted. The specimen is deemed to pass this test
(IEC61034-1 & 2) if the value is greater than 60%. The higher the
light transmittance, the less smoke emitted during a fire.
◎ISO4589-2/BS2863 (Oxygen Index LOI)
This is a test for assessing the oxygen index of the material

in accordance with the test method specified in ASTM D2863-
95 (Measuring the minimum oxygen concentration to support
candle-like combustion of plastics). At room temperature when the
oxygen content in the air exceeds the oxygen index, the material
will burn by itself automatically. The higher the oxygen index, the
more retardant the cable will be. For example, if the oxygen index
of a material is 21%, it means that the material will burn by itself
even at room temperature because at room temperature the normal
oxygen content is 21%. In general, the oxygen index of a LSZH
cables ranges from 33% to 42%.
◎ISO4589-3/BS2782.1 (Temperature Index TI)
This is a test for assessing the performance of a material when

it is tested in accordance with BS2782 Part 1 Method 143A and 143B.
The oxygen index of a material will drop when the temperature rises.
When the temperature rises and the oxygen index drops to 21%, the
material will burn automatically. This temperature is defined as
temperature index. For example, the temperature index of coal is
50%. When the temperature climbs to 150℃, its oxygen Index drop to
21% and the coal will burn by itself automatically.
The temperature index of the coal will then be defined as 150 ℃.
In general, the temperature index of LSZH cables ranges from 250 ℃
to 300℃.
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◎ES713 (Toxicity Index)
This is a test defined by Naval Engineering Standard which is a directed

at the analysis of a specified set of gaseous species which are commonly
present in the combustion products of materials used in military application
and which may cause lethality at the time of a fire. In this test, a 1g cable
specimen is completely burnt inside a sealed chambers of volume 0.7-1m3
using a burner fed with air and gas to give a non-luminous flame. The resulting
chamber atmosphere is quantitatively analyzed for a specified set of gases.
For each gas, the measured concentration (Ci) is scaled up for 100g and the
concentration is recalculated as though the combustion products is diffused
into a volume of exactly 1m3. The resulting concentration (C8) is expressed
as the ratio of critical factor (Cf) which is equal to the concentration of this
gas considered fatal to human for 30 minutes exposure. The ratio C8/Cf is
summed for all gases detected to give the toxicity index. The higher the
toxicity index, the more toxic the cable materials is. In general, the toxicity
index of LSZH materials are less than 5. LSZH cable will also emit toxic CO
and if the cable materials contains P, N and S, the toxic gases generated
will even be greater. Thus LSZH cables cannot be categorized as toxic free.
CM, CMR and CMP cables in general contains halogen elements which are
essential for passing the strict fire retardancy testing. For example, CMP
cables are made from FEP which contains Fluorine and are much toxic than
normal LSZH cables.
SMOKE DENSITY, IEC 60754 – IEC 61034

Fan, 7 m3/min to
• It measures the density of smoke emitted by 13 m3/min
the cable during the fire. Door Photocell, height
• Cable is laid inside room of dimensions 2.15 m
3m x 3m x3 m.
• The cable will be subjected to fire.
• A light beam from light source is passed
through the smoke and received on the Draught
opposite side ona photo cell. Screen, height
1.0 m
• The intensity of light passing through the
smoke is measured to evaluate the
percentage that has passed through smoke.
• Acceptable percentage is not less than 60%.
IEC 60754 – IEC 61034
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Cable Sheath Fault Location Using Bridge Methods
Cable Fault Location

Cable sheath faults are defects in the outer protective sheath of cables, such as PVC jackets. These
type of faults do not necessarily influence the electrical performance of a shielded cable initially, but do
have a negative side effect on the medium to long-term operation of the cable. Damages to the outer
sheath can allow soil and moisture to penetrate into the cable, which facilitates corrosion of the cable
sheath, or of the neutral wires (neutral corrosion), and may lead to the development of water trees that
could lead to breakdown of the cable in the future. As a result it is important to test the integrity of a
cable sheath and repair any faults that may be present to ensure the long-term performance of a power
cable.
When cable faults occur between two defined cores, such as cable conductor and cable screen,
methods using time domain reflectometry (TDR) can be used to pre-locate the fault position. However,
in some cases and in certain cable structures, faults can happen between core to the cable sheath or
surrounding soil. This is especially the case in unshielded cables such as high voltage DC cables used
for railway power supply, low voltage cables, and signal or pilot cables. Since the soil or surrounding
medium cannot be accessed like a grounded metal sheath or screen, TDR can no longer be used. A
TDR pulse can only travel along a path as long as two parallel conductive paths are given. Therefore,
pre-location for cable sheath faults is conducted using measuring bridge techniques. HV
TECHNOLOGIES, Inc. offers this solution with the Shirla Sheath Test and Fault Location Device,
which uses the measuring bridge principle according to Murray and Glaser.
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The Bridge Principle - Wheatstone Bridge
The Murray and Glaser measuring bridge principles used in the Shirla Sheath Test and Fault
Location Device are based upon the simple Wheatstone Bridge measuring principle. This bridge
consists of two voltage dividers, which when balanced, have a ratio of R 1/R2 = R3/RX and the meter
reads zero. In order to determine the fault resistance (RX) of the faulted cable, R2 must be adjusted until
the measuring device reads zero. In this case, RX = (R2/R1) * R3
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Murray Loop Bridge
The measuring bridge circuit according to Murray is applied when only one additional healthy conductor
(auxiliary line) is present. Ideally this additional conductor has the same diameter and conductor
material so as to not have different resistance values affect the measurement. The resistance of the
loop bridge at the cable ends is also included in the measurement, and therefore, this must be of very
low resistance. In this case RX = (R2/R1) * (R3 + RLoop Bridge + R3b), where R3 is the resistance of the
auxiliary line, RLoop Bridge is the resistance of the loop bridge, and R3b is the resistance of the cable to
the fault from the loop bridge. The distance to the fault can then be calculated.
Using the Shirla, the Murray measuring bridge is connected to the cable in the following way. It is
important to remember that when trying to force a current flow from the sheath to earth through the fault
only, both ends of the cable sheath need to be disconnected from earth.
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Glaser Bridge
The bridge measurement according to Glaser requires operation via two auxiliary lines. The advantage
is that different parameters of the conductors, such as material, cross-section and length, will not affect
the accuracy of the measurement. The major difference to the Murray method is that the forward path
defined via the two auxiliary lines is compensated and the remaining effective external circuit is the
sheath only. The influence of the R3 auxiliary line is eliminated and the bridge only sees the ratio of the
voltage divider in the cable. This compensation is very helpful, as the sheath is always of different
diameter compared to the core. In this case RX = (R2/R1 + RH) * R3b
Using the Shirla, the Glaser measuring bridge is connected to the cable in the following way. It is
important to remember that when trying to force a current flow from the sheath to earth through the fault
only, both ends of the cable sheath need to be disconnected from earth.
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Advantages of Bridge Measuring Techniques using Shirla

The main advantage of using bridge measuring techniques when determining sheath faults is the simple
fact that the resistance of the actual fault has no influence on the measurement and only the resistances
of the cable conductors (core, sheath, auxiliary lines, etc.) are taken into account. Therefore, an
unstable resistance behavior in the earth is negligible. This is contrary to the voltage drop method, in
which the resistance of the fault has a full effect on the measurement as it is part of the entire
measurement loop. If the earth loop value alternates during a measurement, the resulting calculated
resistance ratio will alter as well. Furthermore, if the sheath fault is located within 5-10% of either cable
end, the voltage drop method becomes extremely inaccurate.
Features of the Shirla Sheath Test and Fault Location Device:
• Automatic zero balancing and evaluation of the fault distance

• Ideal for locating sheath faults and areas of neutral corrosion
• Ability to enter various conductor materials, cross-sections and lengths, increasing the accuracy
of the measurements
• Supplied with high quality, very low resistive test leads and linking bridges to ensure accurate
measurements
• Lightweight and portable device
• Operation via mains power or with internal rechargeable battery
• Cable sheath testing up to 10 kV
• Simple operation and intuitive user interface
• Data export via USB interface
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High potential “Hi-Pot” DC testing

This provides general guidelines for high potential “Hi-Pot” DC testing of MV power cables.
All tests made following cable installation and during the warranty period must be performed in
accordance with the applicable specifications.
High potential (Hi-Pot) DC testing guidelines for medium voltage cables
Testing should be performed by qualified personnel taking all appropriate safety precautions. The
responsible safety officer should be consulted regarding the equipment and the appropriate personnel
protection requirements.
IMPORTANT NOTE: The significance of performing DC high voltage tests on non-shielded, non-metallic
sheathed cable is dependent upon the environment in which it is installed because the characteristics
of the return circuits are unknown. The environment must be carefully considered or the test results
may not be significant.
In fact, these tests can result in damage to the cable insulation.
Humidity, condensation and actual precipitation on the surface of a cable termination can increase the
leakage current by several orders of magnitude.
Humidity also increases the corona current, which is included in the total leakage current. Wind prevents
the accumulation of space charges at all bare energized terminals. This results in an increase of corona.
It is desirable to reduce or eliminate corona current at the bare metal extremities of cable or terminations.
This may be accomplished by covering these areas with plastic envelopes, plastic or glass containers,
plastic wrap, or suitable electrical putty.
Let’s see now the general guidelines for high potential (Hi-Pot) DC testing of medium
voltage cables:
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1. Pre-test Guidelines
a. Testing equipment
Direct current test equipment is commercially available with a wide range of voltages. The Operator’s
Manual for the particular test set being used should be read and well understood.
Accessory equipment necessary to safely conduct high voltage tests such as safety barriers,
rubber gloves, non-conducting hard hats, and, where necessary, arc ash protection must be used.
b. Recommended testing procedures

Acceptable procedures for conducting Hi-Pot testing, although varying slightly in technique, have been
standardized as either a “withstand test” or a “time-leaking current test”. IEEE Std 400 provides
additional information on DC testing and evaluation of the insulation of shielded power cable systems.
c. Preparation for testing

Before conducting any Hi-Pot testing, the following steps should be taken.
All equipment, such as transformers, switches, taps, motors, circuit breakers, surge arrestors, etc., must
be disconnected from the cable circuit to prevent damage to equipment and will prevent test
interruptions due to flashovers or trip-outs resulting from excessive leakage current.
Provide adequate clearance (about 2.5 ft) between the circuit test ends and any grounded object,
and to other equipment not under test.
Ground all circuit conductors not under test including the cable shields and nearby equipment.
Test equipment should be supplied from a stable, constant voltage power source. Do not use the same
source that is supplying arc welders or other equipment that may cause line voltage
fluctuations! The output voltage of the test set must be filtered and regulated. The use of a portable,
motor driven alternator to provide power to the test set is recommended.
2. Hi-pot testing procedures

The DC test voltage may be applied either continuously or in predetermined steps up to the
maximum value in accordance with the applicable specifications.
a. Continuous method
The test voltage is applied at an approximate rise rate of 1 kV per second or 75% of the rated
current output of the equipment , whichever is less. Some equipment will take longer to reach the
maximum test voltage because of the amount of charging current.
b. Step method
The test voltage is applied slowly in 5 to 7 increments of equal value up to the maximum specified. Allow
sufficient time at each step for the leakage current to stabilize.
c. Recommended testing procedure
Maintain the test voltage at the prescribed value for the time specified in the applicable specifications. At
the end of the test period, set the test set voltage to zero, allow the residual voltage on the circuit to
decay, disconnect the power supply and then ground and “drain” the conductor just tested.
After testing, maintain solid grounds on the cable for at least 4 times the duration of the test since
DC charges can build up on the cable to potentially dangerous levels if grounds are removed too quickly.
On exceptionally long cable lengths, it may be necessary the increase the grounding time.
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It is also advantageous to maintain these grounds longer and while reconnecting circuit components.
Acceptance testing is performed to detect any defects in cable insulation and
terminations which may have resulted from poor workmanship or mechanical damage. This proof test
confirms the integrity of the insulation and accessories before the cable is placed into service.
After installation and before the cable is placed in regular service, the test voltages specified in Table c.1.
should be applied for 15 consecutive minutes. Record the leakage current at one minute intervals for the
duration of the test.
Table c.1. – ICEA dc Field Test Voltages
ICEA S-97-682 Utility Shielded Power Cables Rated 5,000-46,000 Volts
Table – ICEA dc Field Test Voltages (ICEA S-97-682 Utility Shielded Power Cables Rated 5,000-46,000 Volts)
c.2. Maintenance testing
At any time during the warranty period, the cable circuit may be removed from service and tested at a
reduced voltage (normally 65% of the original acceptance value) for 5 consecutive minutes. Record
the leakage current at one minute intervals for the duration of the test.
Routine periodic DC maintenance testing of cables for the evaluation of the insulation strength is
not a common practice.
Some power cable users, particularly in the continuous process industries, have adopted a program of
testing circuits during planned outages, preferring breakdowns during testing rather than experiencing a
service outage during regular operations.
It is nearly impossible to recommend test voltage values for maintenance testing without having a history
of the cable circuit. An arbitrary test voltage level could result in a cable failure in a circuit that would
otherwise have provided long trouble-free service at normal operating ac voltage. Periodic off-line partial
discharge testing at very low frequencies (VLF) is a diagnostic method for monitoring the insulation
degradation of medium voltage cable. This type of testing is discretionary and generally not recommended.
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3. Common testing problems

Some common problems that may be encountered during testing are listed below.
Extra leakage current:
• Failure to guard against corona
• Failure to clean insulation surface
• Failure to keep cable ends dry
• Failure to provide adequate clearance to ground
• Failure to isolate the cable from other equipment
• Improper shield termination
CABLE TESTING
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.
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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.
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.
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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:
• Boom Truck
• Electrical Hand Tools
• High Voltage Module
• Control Unit
• Ground Leads
• High Voltage Output Cable
• Interconnection Cable
• Kilovoltmeter
• Term Shield Conn.
All tools utilized in a classified area should be intrinsically safe and suitable for hazardous areas.
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59
ADVANCED MEASUREMENT OF AC RESISTANCE ON SKIN-EFFECT REDUCED

LARGE CONDUCTOR POWER CABLES
There are a different measurement methods available to perform AC resistance measurements.

1. Electric methods:
• Measurement of conductor AC resistance using the sheath as the return conductor
• Measurement of AC resistance using an AC bridge with a current transformer
• Special methods that could be used to obtain higher accuracy by compensation
2. Thermal measurement methods.
Here is an advanced but still easy to handle measurement procedure to determine the AC resistance
of cable conductors with large cross sections by measurement of conductor AC resistance using the
sheath as the return conductor.
This method eliminates any proximity effect due to possible interaction of magnetic fields produced by
currents flowing in other conductors. The coaxial arrangement prevents from measurement error due
to induced voltages in the leads used to carry out the measurements. The principle is shown in figure 4.
It can be assumed, that an important influence on the repeatability of AC resistance measurements is the
connection to inject the AC test current into the conductor.
The influence of this effect is under consideration. In order to minimize such parasitic effects, the
measurements should be performed on complete production lengths on cable drums as shown in figure
4 and 5.
The used procedure is based on high-accuracy vectorial voltage-current measurement. By performing
the AC resistance measurement with variable frequency it becomes possible to self-check the
measurement data with data from calculations and so to verify the results.
Conventional measurements of the AC resistance are performed at line frequency only (50 or 60 Hz),
taking no advantage from the well-known frequency-dependency of the skin effect.
Besides self-check capability, variable frequency measurements enable integral estimation of the
ks- Factor, minimizing the measurement error compared to single-frequency testing.
Fig. 4: Set up for AC resistance measurement:

using the sheath as the return conductor Fig. 5: AC resistance measurement
on a full-size cable drum
82
Measurements with a frequency close to 0Hz are leading to results according to DC measurements
(ks=0), with higher frequencies the results represent the conductor design described by the ks factor.
It can be assumed that the area of application of the formulae (2) and (3) are limited in terms of the
frequency. In this paper both values have been derived by analytical calculations and compared with
the measured values.
The block diagram of used equipment is given in figure 6.
The voltage taps of the cable conductor impedance and shunt are used for the measurement of the
conductor voltage drop and the injected AC current. The AC source is the combination of a function
generator (to generate sine wave of variable frequency) and a power amplifier (suited for impedances
down to 2 Ohm). The shunt is specially designed for high-accuracy current measurements with very low
phase displacement.
In an on-line measurement following data are processed and calculated:
 Frequency [Hz]
 Voltage [V] and Current [A]
 Phase difference [rad]
 Active Power [W]
 Reactive and apparent power [VA]
 Efficiency factor cos-phi and tan delta
 Serial and parallel resistance [Ohm]
The accuracy of the measured phase difference has been determined to approx.
The phase error uncertainty has been determined to approx. +/- 5 x 10-5, the total measurement
uncertainty was < 0.01% of the actual input range.
Fig. 6: Block diagram of used equipment
An overview of the equipment needed for the AC resistance measurement is shown in figure 7.
83
Fig. 7: Easy and manageable equipment for AC resistance measurement
The measurements have been performed with low current magnitude, any distortion by line frequency
was easily to suppress. The used measurement equipment showed a high sensitivity. Thus, the
measurements can be performed at extremely low current magnitude (e.g. 0.2%
of the rated current) excluding any thermal effects and so enabling the use of a low power AC current
sources.
The measurements have been performed on two different cables:
1. BNC cable type RG58
2. 500kV XLPE cable
• Conductor: 2500mm2 copper conductor, round, segmented, stranded, longitudinal water-tight
• Screen/metallic sheath: copper wire and copper tape cross section 300 mm², longitudinal water-tight.
RESULTS
With variable frequency it becomes possible to fit the measured AC resistance data as a function of AC
frequency to the analytical skin effect function (first-order Bessel function) by parameter identification,
resulting in a precise estimate of the ks factor. Furthermore, this procedure provides a 'built-in' self-check
to verify the results: extrapolating the identified curve for f → 0 should deliver the DC resistance of the
conductor, which can be easily cross-checked by DC resistance measurement.
The result of the measurement of the AC resistance measurement for both measured cables are shown in
figure 8 and 9.
Fig. 8: Measurement of AC resistance over Fig. 9: Measurement of AC resistance over

frequency for a BNC cable type RG58 15m in frequency for a 500kV XLPE cable with
length from 1Hz - 104Hz 2500mm2 cross section from 1Hz - 104Hz
84
Regarding the 500kV XLPE cable 2500mm2 in figure 9 the significant break starts at 20Hz. From here
there is a dependence of the frequency obvious. Compared to the BNC cable the break starts
approximately two dimensions lower.
Up to 100Hz the measurement results are in good accordance with the calculated values of a first-order
Bessel function, but above 100Hz the calculation differs from the measurement. The steepness of the
measured development is much higher than the calculated. It must be assumed, that so far unknown
effects cause this deviation.
85
ELECTRICAL TEST FACILITIES

a- 22,500 KVA AC Test System capable for:
1- Long term High Voltage test
2- System Type Tests
3- Lightning & Switching Impulse Voltage Test
b- Impulse Test System

2,400 KV – 120 KJ Lightning Impulse – 1.540 Switching Impulse.
1- Lightning & Switching Impulse Tests.
c- 500 KV – 20,000 KVA AC Resonant Test System

1- Partial Discharge Detector
2- High Voltage Test
3- Partial Discharge Test
d- 350 KV – 4,000 KVA, AC Resonant Test System

1- Partial Discharge Detector
2- High Voltage Test
3- Partial Discharge Test
e- Impulse Test System

1,400 KV – 42 KJ Lightning Impulse
1- Lightning Impulse Tests.
f- 150 KV – 125 KVA, AC Dielectric Test Set

1- Long Term Voltage Tests
2- Type Tests
86
g- 525 KV – 3 KW Test System

1- DC Voltage Test
2- Site Test
h- Schering Bridge
1- Tan Δ Measurement
2- Capacitance Measurement
i- Cable Heating Test System

1- Heating Cycle Voltage Test
2- Water Penetration Test
Non-Electrical Test Equipment
Moisture Content Measuring Device (Karl-Fischer)

Insulation and SC materials moisture content measurement
Fourier Transform Infrared Spectrometer (FTIR)

Spectral Analysis of Insulation and Sheath materials
87
Thermo-Gravimetric Analyzer (TGA)

Insulation and sheath materials'
By product concentration
Carbon Black Measurements
Thermal Analysis Equipment & DSC

Insulation, sheath and various material
Thermal Analysis
Melting Point Measurements
Digital Micro ohm-meter

DC Resistance Measurement
Optical Thickness Measuring Systems

Thickness Measurement
88
Flame Spread Test Cell

Flame Spread Test
Smoke Density Test Room

Smoke Density Test
Universal Test System

Tensile strength and elongation measurements
Tube Furnace (For Carbon Black Test)
Using for Carbon black content test along
with the air controller and accessories
89
Tan Delta and Capacitance Bridge
For the measurement of the capacitance and
Tangent delta measurement of the Cable.
90

QC &amp; Testing of Power Cables

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Power Cables Handbook

POWER CABLES HANDBOOK

QUALITY CONTROL & CABLE TESTING

What is done during Cable Testing?

1. Persulphate test (for copper)

Physical tests for Insulation and Sheath

1. Tensile strength and elongation at break

Acceptance test: The following shall constitute acceptance test:

1. Annealing test (for copper)

Routine test: The following shall constitute the routine test.

How is Cable Testing Performed?

• The insulation test proceeds as follows:

Insulation Resistance (IR)

IR Value Measurement (Conductor to Earth Insulation)

• Connect conductor under test to the Line terminal of the megger.

Benefits of Cable Testing

QUALITY CONTROL OF POWER CABLES

MOM (Machine Operating Manual)

PES (Process Engineering Specification)

SAMPLE SAMPLING PLAN

RAW MATERIALS SUPPLIERS EVALUATION

Check 10% samples of the total lot.

Check 25% samples of the total

Check 50% samples of the total lot.

RAW-MATERIAL INSPECTION FLOW-CHART

Test & Measure Samples

Fix NCR Tag Not OK Fix Inspected OK Tag

RAW-MATERIALS CHECK PROCEDURES

IN-PROCESS QUALITY CHECK

R.M USED IN PRODUCTION

ISSUE NCR NOT OK TO BE USED IN NEST

• Copper / AL Wires: Sample from each

IN-PROCESS CHECK OF DR / STR

FINISHED GOOD QUALITY PLAN

Thickness Measure & Eccentricity

PRODUCT AT FINAL STAGE

TESTING OF ALL PRODUCTS

Electric Test on 100% of Products

Measure Diam. of Each

CLASSIFICATIONS OF CABLES TESTING

INTERNATIONAL STANDARDS FOR TESTING

▪ Electrical resistance of conductors

Electrical resistance of conductors

DC Resistance Results (DCR)

High Voltage Test

Inprocess Spark Test

Spark Test Voltage Setting

Coils immersed in water -

Test procedure for multicore cables

Routine test voltages

No breakdown of the insulation shall occur.

Number of samples for sample tests

Digital Image Projector

HOT SET Test (IEC 60811-507:2012)

Medium & High Voltage

Hot set test, cont.

▪ Hot set testing is performed on the

▪ The central 20 mm (or 10 mm for smaller samples) is marked by two lines.

▪ Calculate the load in grams using the formula:

CALCULATION ‐ PERMANENT SET

HOT SET Test Requirements

Type tests, non-electrical

• Pressure test at high temperature on insulations and non-metallic sheaths

Insulation resistance measurement at ambient temperature

QC & Testing of Power Cables

QC & Testing of Power Cables