SERVICE LIFE ESTIMATION

INSULATIONS AND SHEATHS OF ELECTRICAL CABLE

1. Introduction: Life expectancy of any product used in defence services is very

important and in the same way when any cable and its accessories are used in defence
services, it is always planned for 10 - 20 years of life and the material is also selected
accordingly. The service life of cables life mainly depends upon life of insulating and /or sheath
material. Estimation of service life is carried out on Insulation and sheathing material with the
help of Thermal Endurance test and evaluation thereafter i.a.w. IEC 60216-1:2013 and
respective technical specification of product. Insulation and sheathing material of electrical
cables are subjected to thermal endurance test before introduction of cable into use as part of
product development test.

2. Concept of Testing: Sample of the Insulation and sheathing material is aged at

extrapolated temperatures for different durations and properties like tensile strength,
elongation, stress applied, loss of mass etc is measured on completion of each time interval,
which is then evaluated and plotted on graph to know the approximate service life. The plot
thus achieved is called Arrhenius-plot. The extrapolated temperature is decided based on
maximum operating temperature of cable which is known as Temperature Index.

Thermal endurance test is the only method by which the life of a material can be
determined. It has been observed that material deteriorates faster in mechanical parameter
(tensile strength & Elongation at break) compared to electrical parameters like breakdown
voltage test. In mechanical parameter, deterioration was found to be much faster in elongation
at break compared to tensile strength. Hence, elongation at break is generally selected for
property measurement during life cycle of cables.

3. Important Terms used in Testing:

Temperature Index : Maximum operating Temperature specified for desired service life
Desired Service Life / Time to end Point: As given in respective specification
End of Life point: Value of measured property at the end of desired life time.
Temperature Oven : The equipment in which samples are exposed for set temperature
and time.
Temperature Group : No of specimen being exposed on same temperature.
Test group : No of specimen removed together from a temperature group to check
property.

4. Types and Procedure:

(a) Types:

Proof Test : In this test specimen under test undergoes for a specified stress
and further ageing cycle on passed specimen is conducted on till it fails.
 Non Destructive Test: In this test property of specimen is measured at each
time interval and same specimen again undergoes for further aging till we reach
the desired value. For example loss of mass.

Destructive Test: In this test specimen under test is stressed till it get
broken/destroyed. For example elongnation at break or tensile strength.

(b) Procedure :

Cyclic Test : In this procedure Specimen are evaluated at each interval of time
till obtaining the desired result.

Continuous Test : In this procedure samples are aged continuousely till

specified period and thereafter result is evaluated.

5. Selection of end points: Either of following two ways may be selected:-

(a) Percentage increase or decrease in the measured value from the original level.
(b) Fixed value of property. In case of proof test fixed value of property is chosen.
However, all three types of testing can be undertaken by any of above procedure

6. Exposure Time and Temperature: Minimum three preferably at four different

temperatures specimen should go under test to achieve better estimation. Minimum four to five
specimen should be selected at each temperature and time (each cycle in case cyclic
tests).Temperature group should be selected in such a way that a linear relationship between
time to end point and reciprocal thermodynamic (absolute) temperature can be demonstrated.
Following Table (as per table 1 of EC 60216-1: 2013) illustrates making initial selection of
temperature for end of life point for time of 20,000 Hrs. Cyclic duration can be re-appropriated
in same ratio for other given time.

Estimated Exposure 120 130 140 150 160 170 180 190 200 210
Value of Temperature
Temperature
Index in ºC
Exposure Time in Days for each Cycle
95-104 28 14 7 3 1
105-114 28 14 7 3 1
115-124 28 14 7 3
125-134 28 14 7 3

The above table is for illustrative purpose during initial selection. However, successive
measurement of property can be taken at suitable intermittent time considering trend of result
being obtained in preceding readings and end of life point.
 7. Typical Example TI of 120 and service life of 20000 Hrs considering End
Point 50% elongation at break, Destructive Test

The mean value of group of samples and percent elongation are recorded in above
table and thereafter the same is plotted for further evaluation on graph as follows:
follows

Taking into the linear region of measurement at each temperature from above graph a
hypothetical value of time to end point (50% in present case) is calculated which is further
evaluated on plotting graph between logarithm of time to end point and reciprocal of
thermodynamics (temperature in ºK). The table below illustrates calculation for value of x and y
plotting the life estimation graph:
graph:-
 Temp ºC Temp Actual Hours Required X axis 1/K (x) Y axis ln (t)
absolute ºK (t) Hours as per (y)
(ºC+273.15) specs
(K)

120 393.15 NA 40000 0.00254 9.9034

(Specified TI)
140 413.15 5250 >5000 0.00242 8.5659
160 433.15 1275 NA 0.00231 7.1507
180 453.15 420 NA 0.00221 6.0402
200 473.15 120 100 to 500 0.00211 4.7874

The value of x and y is plotted on graph paper to get the inception trend. Based on
inception trend, regression analysis is carried and regression co-efficient (a and b) is put in
formula y = ax +b where y would be calculated and the same would be equivalent to estimated
service life at given Temperature Index (TI). Here x has been taken of 1/k value at 120ºC. The
value of (a) and (b) in above example was calculated as (a) ≈ 11379 and (b) ≈ -19.03 after
regression analysis.

10.0000
y = 11379x – 19.03
Lograthim of time (t)

= 12088 * 0.00254 -19.03

8.0000 =9.99352
Anti ln 9.99352 = 21884
Hence estimated service life is :
6.0000
21884 Hrs

4.0000

2.0000

0.0026 0.0025 0.0024 0.0023 0.0022 0.0021 0.0020

Reciprocal of Temp (K)

8. Conclusion: In this way service life of insulating or sheathing material can be estimated
even if tests are not being conducted at exact period of service life. It can be estimated after
taking measurements at extrapolated temperatures and reduced duration. The technical study
carried out above is based on author’s understanding of IEC 60216-1:2013 for academic
purpose only and the same may not be treated for reference.

----------end -----------