Cable Testing

Definitions concerning the tests

1- Routine tests
Tests made by the manufacturer on each manufactured length of cable to check
that each length meets the specified requirements
2- Sample tests
Tests made by the manufacturer on samples of completed cable or components
taken from a completed cable, 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 the performance characteristics .
4- electrical tests after installation
tests made to demonstrate the integrity of the cable and its accessories as
installed
 Voltage Designation
In the voltage designation of cables U0/U (Um):
U0 is the rated power frequency voltage between
conductor and earth or metallic screen for which the cable
is designed ( Phase Voltage);

U is the rated power frequency voltage between

conductors for which the cable is designed ( Line to Line
Voltage);
Um is the maximum value of the "highest system
voltage’’ for which the equipment may be used
 Routine test

MADE IN
Ethiopia

CONDUCTOR VOLTAGE
TEST
CONDUCTOR RESISTANCE
3
1-Voltage test
The voltage test shall be made at ambient temperature, using
either alternating voltage at power frequency or direct voltage,
at the manufacturer’s option.
1.1 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 test voltage then applied for 5
min between the conductor and the water.

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1.2 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
metallic layers, if any.
The conductors may be suitably connected for successive
applications of the test voltage to limit the total testing
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 conductor and the metallic
layers, if any.
 Alternatively, three-core cables
may be tested in a single operation
by using a three-phase transformer.
 Test Voltage
KV 0.6/1 V 450/750 V 300/500 V 300/300 Rated voltage U0/U

KV 3.5 KV 2.5 KV 2 KV 2 Test voltage

IEC IEC 60227 IEC 60227 IEC 60227 Reference Standard

60502-1
2 Electrical resistance of conductors
Resistance measurements shall be made on all conductors of
each cable length submitted to the routine tests, including the
concentric conductor, if any.
The complete cable length, or a sample from it, shall be placed
in the test room, which shall be maintained at a reasonably
constant temperature, for at least 12 h before the test. In case
of doubt as to whether the conductor temperature is 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 can be measured on a sample of conductor
conditioned for at least 1 h in a temperature controlled liquid
bath.
The measured value of resistance shall be corrected to a
temperature of 20 °C and 1 km length in accordance with the
formulae and factors given in IEC 60228.
The d.c. resistance of each conductor at 20 °C shall not exceed
the appropriate maximum value specified in IEC 60228. For
concentric conductors, the resistance shall comply with national
regulations and/or standards.
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 Table of Resistance for Conductors
Maximum Resistance of Conductor at 20°C Nominal Cross
Flexible CU conductor Al Conductor CU Conductor
Sectional Area
Rm/rmc/sm/re Rm/rmc/sm/re (mm²)
(Ohm/Km) )Ohm/Km( (Ohm/Km)

39 ---------- 36 0.5

26 --------- 24.5 0.75

19.5 --------- 18.1 1

13.3 18.1 12.1 1.5

7.98 12.1 7.41 2.5

4.95 7.41 4.61 4

3.30 4.61 3.08 6

1.91 3.08 1.83 10

1.21 1.91 1.15 16

0.780 1.2 0.727 25

0.554 0.868 0.524 35

0.386 0.641 0.387 50

0.272 0.443 0.268 70

0.206 0.320 0.193 95

0.161 0.253 0.153 120

0.129 0.206 0.124 150

0.106 0.164 0.0991 185

0.0801 0.125 0.0754 240

0.0641 0.100 0.0601 300

 Recommendations for storage and
transportation
Basic Requirements Terms
2X cable diameter but at least 5 Distance between the outer cable
cm layer and the head of the flange
The cable ends have to be sealed Cable sealing end
during transport storage and
laying to prevent ingress of water

The cable ends should be Transport

tightened properly
Only suitable carriers shall be Carriers
used
Cable drums with flange Drum axis position
diameters exceeding 1 m have to
be transported with horizontal
drum axis
Only suitable carriers shall be Loading and unloading
used
 Recommendations for storage and
transportation

Basic requirements Terms

Filled-up cable drums shall be Rolling the cable drums
rolled on short distances over
plain solid ground in the direction
indicated

Short cable lengths may be coiled Cable rings

to rings and transported and
stored horizontally taking into
consideration the the min
bending radius
Recommendations for cable Laying
Basic requirements Terms
The cable route, the laying method and the Selection of cables
operating conditions shall be taken into
account
Cables shall be laid and operated in such a Laying and operating
way that their prosperities are not
endangered.
a) Operating conditions
- Concentration of cables
- Influence of external heat
- Specific earth resistance
- Protection against radiation of sunlight
b) Leakage of stray currents and corrosion
c) Movements of soil, vibrations and
shakes
d) The method of laying and the bedding
material have to be selected in respect
of the outer cable sheath
Recommendations for cable Laying
Basic requirements Terms
Cables shall be protected against mechanical Protection of
damages occurring after installation. cables
Cables laid in ground are sufficiently protected
against mechanical damages.
A laying depth of at least 0.6 m respectively 0.8 m
below road-surface is recommended. In case of lower
laying depths the cables shall be protected by other
means.

Inner diameter of ducts and pipes ≥ 1.5 times cable Dimensions

diameter of ducts
In case of several cables within one pipe the diameter
of the pipe has to be so width that the cables do not
block themselves.
When steel pipes are used single-core cables
belonging to a three-phase system have to pass
through the same steel pipe.
Recommendations for cable Laying
Basic requirements Item
The lowest allowed temperature of the cables during Lower
installation and mounting of accessories is -5 OC temperatures
This temperature is valid for the cable itself and not for cable
for the surroundings. In case the cables have a lower laying
temperature than permitted they must be warmed
up. Care has to be taken that the temperature
remains above the permitted temperature during
laying.
Pulling force
a) Pulling
head
Recommendations for cable Laying

Basic requirements Items

It is assumed that the cable route is well Preparation of
designed for the laying procedure with well- cable route
established curves and a sufficient number of
cable rollers. Special attention shall be paid to
the requirement bending radius
The pulling force shall be permanently
supervised the pull-in procedure.

During installation Bending radius

-Single-core cables : 15 times the cable
diameter
-- multi-core cables: 12 times the cable
diameter
Storage
Transport
De-reeling
Rewinding
 Thanks
 Eng/ Ashraf Abd El-Raouf

 Elsewedy Cables Ethiopia PLC