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Cables / Testing and Commissioning

Test On 110kV Power Cable After Installation (1)

By Zafar Iqbal December, 22nd 2014

Home / Technical Articles / Test On 110kV Power Cable After Installation (1)

General description of site test procedure

Site test procedure covers all necessary electrical testing for the 110 kV cable and accessories to be carried out during and after installation of
the cable system. This procedure is in line with the requirements of the contract suitable for 110 kV, XLPE cables and accessories and the
tests are in accordance with TCSP-104.08, IEC 229, IEC 540 and IEC 840.

Test
Test On
On 110kV
110kV Power
Power Cable
Cable After
After Installation
Installation –– Part
Part 11 (on
(on photo:
photo: Kyoritsu
Kyoritsu 4102A
4102A digital
digital earth
earth resistance
resistance tester)
tester)

110 kV, 115 kV and 132 kV XLPE Cables

(Standard Reference is IEC 60840 and relevant SEC Transmission Specifications 11-TMSS-02, Rev. 0 and TCS-P-104.02, TCS-P-104.03,
TCS-P-104.06 and TCS-P-104.08)

1. Mechanical Check and visual Inspection

ITEM Description Remark

1 Inspection for physical damage or defects
2 Check tightness of all bolted connections (torque wrench method)
3 Check for proper cable bolted connections
4 Check cable bends to ensure that bending radius is equal to or greater than the minimum bending radius
specified
5 Check for proper cable support, clamping, trays arrangements
6 Link box tightness check
7 Verify that shields are terminated as specified (through link box or directly grounded)
8 Verify the exact route length as per approved drawings from terminations to terminations
9 Check that all grounding points are securely connected to ground grid as specified
10 Check that phases are identified and color coded
11 Single core cable connected between power transformer and switchgear shall be single point earthed as
switchgear side and at floating side SVL (sheath voltage limiter) should be installed
12 Check single point or both ends, via voltage limiter as per approved design
13 Inspection of label inside link boxes and water proofing
14 Check cable entry path trench as ducts are properly sealed
15 Check irregularities of outer jacket formed by non-uniform shield wire distribution
16 Check/inspect the transposition of cable phases
17 Check the cable outer jacket for any physical damage during and after installation
18 Check for the cross connection of cable metallic sheath in cross bonding system
19 Check the rubber seal in cable clamps to avoid any damage to cable outer jacket
20 Check the insulating shrouds are installed at the base of the cable terminations
21 For accessories (sealing terminations, instrument panels and link boxes) check the following:
a. Name plates installed and data is correct
b. Danger signs
c. Bolt tightness check and paint work conditions

2. Electrical Test

(Standards Reference is IEC 60840, and relevant SEC Transmission specifications 11-TMSS-02, TCS-P-104.08).

ITEM Description Remark

1 Check Phasing for Conductor and sheath bonding
2 Sheath DC high voltage test (10 kV DC for 1 min.) and 5 kV DC insulation test before and after high
voltage/24 hour soaking test
3 Conductor resistance, capacitance and inductance measurement test
4 Conductor insulation resistance test
5 Cross-bonding verification test The sheath current should
be <3% the current due to
induction neighboring
circuits should be
considered and limit should
be 3%+current due to
external circuits
6 Zero and positive sequence impedance measurement
7 SVL (Sheath/Surge voltage Limiter) test by 2.5 kV DC insulation tester
8 Measure the ground resistance at all link box positions as per SEC standards TES-P-104.08)
9 Contact resistance test on link boxes (less than 20 μΩ)
10 Metallic sheath continuity test
11 Cable profile test- during jointing
12 In case of Double Circuit (110 kV and above), check the separate grounding pit
13 AC High voltage test for all new cables, but if old portion are involved then soaking for 24 hours at rated
voltage

1. Phase indication test

After complete installation, the cables are to be identified with respect to their phases and are to be reconfirmed whether they are correctly
marked or not.

Phase
Phase Identification
Identification Test
Test diagram
diagram

Equipment / Instruments Used

Battery operated KYORITSU, High Voltage Insulation Resistance Tester, and MODEL-3125

Kyoritsu
Kyoritsu 4105A
4105A –– Digital
Digital Earth
Earth resistance
resistance tester
tester

Instructions

1. The screens of all cables at one end are to be shorted and grounded.
2. The conductor of the cable under test is to be connected to the negative pole of the meter.
3. The positive pole of the meter is to be grounded.
4. Through a switch ground the other end of this conductor of the cable under test and measure the resistance.
5. If the resistance becomes zero, the phase identification is ok and checks whether the correct color coding is applied or not.
6. To cross check, open the switch, the meter shall read high resistance (Tending to infinity).
7. Similarly repeat the test for other phases and verify the correctness of color coding.

2. DC Conductor Resistance Measurement

The DC resistance of conductors of the cables, to be measured at ambient temperature before conducting any other test, and the values are to
be computed for 20ºC.

Schematic
Schematic layout
layout for
for measurement
measurement of
of DC
DC resistance
resistance for
for long
long cable
cable

Reference

IEC 60228 – Conductors of insulated cables

Equipment / Instruments used

1. Any wheatson bridge, micro Ohm-Meter.

2. Any industrial type thermometer to measure the ambient temperature.

Instructions

1. The conductors are short circuited at the far end by minimum 95 mm2 cable.
2. The other ends of the cable are connected to the bridge according to equipment instructions.
3. Note down the measured value.
4. The resistance of conductor at 20ºC/km is obtained by substituting the measured value in the formula.

Formula for Temperature Correction:

For Copper R20 = R/L (1 + 0.00393*(T-20)) Ω/KM

Where,

R20 – Conductor resistance at 20ºC *(ohm/km

R – Measured resistance of one phase (ohm)
L – Exact length (km)
0.00393 – Temperature coefficient at 20ºC for copper (K)
T – Temperature of conductor when measured in ºC

3. Capacitance Test
The capacitance shall be measured between conductor and metallic screen. According to IEC, the measured value shall not sxceed the
normal value specified by the manufacturer by more than 8%.

Schematic
Schematic layout
layout for
for capacitance
capacitance measurement
measurement

Reference

IEC 60840 – Applies to cable voltage ratings between 30 kV and 150 kV. It includes a regular type test sequence for cables and a
separate sequence for the cable accessories.

Equipment / Instruments used

Any RLC bridge capable of measuring capacitance up to 0.01 micro-farad (μF)

Omicron
Omicron –– for
for zero
zero positive
positive sequence
sequence test
test and
and capacitance
capacitance measurements
measurements

Instructions

Connections are made as per below schematic.

Connect the instrument cable between conductors and metallic screen and take the measurements.
The capacitance is measured between each individual conductor and sheath. A capacitance bridge is used for this measurement.
The value obtained can be converted to μF/km

Formula for Capacitance:

C = Cm/L (μF/km)

Where:

C – Capacitance in μF/k
Cm – Measured Capacitance in μF
L – Length of Cable in km.

To be continued soon…

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Zafar Iqbal

Electrical engineer with more then 5 year experience in Electrical Transmission and Distribution Field. Highly specialized
for design, installation and testing of HV/MV T&D lines and Power Substations.

27 Comments

Mohamed Mahdi
OCT 22, 2018

Dear Eng. Zafar

I really thank you for providing us with these information of HV cables site tests and we have learnt from them well.
we are waiting to learn more from you in the field of electrical power transmission
thank you

Reply

Shaik Sulthan
APR 02, 2018

Dear Eng.Zafar,

You are really doing a good job by providing necessary information regarding field testing of power cable.I would like to
suggest, please mention the specific standard of each testing, clear connection drawing of testing and achievable values of
testing.it would be even better if you please provide this information.

Anyhow, the overall article was so good and keep up the good work.

Best of luck for the rest of your life.

Reply

Hadi Salih
JAN 14, 2018

Dear Sirs,
what differ between shield and screen in medium voltage armored cable where I need to do test between continuity test
between shield and screen.

Thank you,
Hadi

Reply

Ahmed Zubair
JUL 16, 2015

Nice work ! keep it up .. Why there is earth tester in the picture instead of HV insulation tester ? (3124 ….)

Reply

A K Jawahire
MAR 18, 2015

Why earthing one end only for single core cable

Reply

Nadhim
APR 25, 2015

That is to avoid making the cable screen (Grounding) a part of the Grounding system of the Network (or Substation), if not
then a huge earth fault will be induced in it and may damage the cable (because it is not made for this purpose).

Reply

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Cables / Testing and Commissioning

Test On 110kV Power Cable After Installation (2)

By Zafar Iqbal December, 26th 2014

Home / Technical Articles / Test On 110kV Power Cable After Installation (2)

Test
Test On
On 110kV
110kV Power
Power Cable
Cable After
After Installation
Installation (Part
(Part 2)
2)

General description of site test procedure

In previous part of this technical article first three procedures were explained. Now the rest will be explained in details:

1. Phase indication test (previous part)

2. DC conductor resistance measurement (previous part)
3. Capacitance test (previous part)
4. DC Sheath test on outher sheath
5. Insulation resistance measurement
6. Cross bonding check
7. Zero sequence and positive sequence impedance test (next part)
8. Earth resistance measurement at link boxes (next part)
9. Link box contact resistance measurement (next part)

4. DC sheath test on outher sheath

The test is applied when the cable sheath can be isolated from the earth to permit a voltage to be applied to the over-sheath to check the
integrity of the covering.

This testing is generally applied at certain stages of cable system installation at specified parameter as follows:

1. When the cable is still on reel. The applied test voltage is 10 kV for 10 seconds, if a proper test lead is provided.
2. Once the cable are laid, dressed and tied together in trefoil configuration a test voltage of 10 kV for 30 seconds is applied.
3. Following backfilling sand beddind-2, a test voltage of 10 kV is applied for 1 minute on each cable. This is a formal testing with test
records and signed by representatives of the responsible parties as witnesses.
4. Following completion of jointing activities between two cable sections in a joint bay and after backfilling of the joint bay, the jointed cable
sections are then tested by applying 10 kV for 30 seconds.
5. Following the completion of cable system installation and prior to acceptance testing, as a pre-check testing a test voltage of 10 kV is
applied for 1 minute.

Note – All above mentioned testing will be conducted in presence of project consultant.

References

IEC 60840 – Power cables with extruded insulation and their accessories for rated voltages above 30 kV
IEC 60229 – Electric cables // Tests on extruded oversheaths with a special protective function
TES-P-104.08 – Bonding and grounding of insulated metallic sheath of power cable system

Equipment / Instruments used

The DC HV 25kV Tester, Model No. PGK 25 manufactured by BAUR Germany. The test is applied only to cables covered with conductive
layer over outer sheath. (Read more about Hipo Testing)

DC
DC Hipo
Hipo Tester,
Tester, BAUR
BAUR PGK
PGK 25
25

Instructions

1. The covering under sheath is exposed about 2 cm length at one end of the cable so that the negative polarity shall be applied to it.
2. The conductive layer on outer sheath shall be removed about 20 cm wide at a distance of 30 cm from both ends of the cable.
3. The positive terminal of the DC source is connected to a copper band wound on the conductive layer of the sheath at one end of the
cable (60 cm away from the end).
4. The 25 kV tester can be operated by choice either from the power supply source of 220/110 v- 50/60 Hz supply or can be charging its in-
built battery set-up.
5. Switch on the timer in clockwise direction, a lamp indicator will be indicated ‘ON’ position to a desired test period.
6. Select the voltage selector switch to 5 kV or 25 kV.
7. Select the range of current measurement to position corresponding to the current value intended for charging the test cable.
8. Slowly rotate the voltage selector to the desired voltage value on the scale (1 kV per second in intervals). Watch carefully the voltmeter
while charging. If required re-adjust voltage selector before the desire test voltage is reached.
9. Set range switch for current measurement to the desire range after charging has been completed.
10. After the time has elapsed the high voltage bring down to zero, switch off the timer and discharge the cable through ground wire.

DC
DC Sheath
Sheath Test
Test diagram
diagram

Requirements

The cable is considered to have passed if it withstands the required voltage (10 kV) during the test for 1 minute without break down. During
the test, the leakage current shall be recorded. During the testing, safety regulations on electric hazards should be strictly observed. The
measurements / reading are recorded in the available format in company.

Go back to Index ↑

5. Insulation resistance measurement

The insulation resistance shall be measured between conductor and metallic screen according to IEC 60840.

References

IEC 60229 – Electric cables – Tests on extruded oversheaths with a special protective function
TES-P-104.08 – Bonding and grounding of insulated metallic sheath of power cable system

Equipment / instruments used

Battery operated -KYORITSU High Voltage Insulation Resistance Tester, and MODEL-3125.

KYORITSU
KYORITSU High
High Voltage
Voltage Insulation
Insulation Resistance
Resistance Tester
Tester

Instructions

1. Cable should be free from all system connections

2. Connect the cables between conductor and metal sheath.
3. Measure the resistance at the required voltage and charging time (1 minute).

Insulation
Insulation resistance
resistance test
test diagram
diagram

The insulation resistance (Ri) measured between each individual conductor and metal sheath. The insulation resistance per kilometer is
calculated from:

Rl = Ri x L (GΩ Km)

Where:

Rl – Insulation resistance in GΩ Km.

Ri – Measured insulation resistance in GΩ.
L – cable length in Km.

Go back to Index ↑

6. Cross bonding check

With the cross bonding checks, the right connection of the cables can be checked and when correctly bonded, no current may flow in the
metal sheath of the cable in case of an ideal situation.

Ideal case is only the case when all cable sections have the same length and the spacing between the cables is constant along the
cable route. But in practice, some induction current will always flow as the configuration of the cable system is never ideal.

The actual site requirements and situation dictate what the actual cable section lengths that may differ from section to section.

Equipment / Instruments used

380 V Generator
3-Phase Current Transformer
Clamp Meter

Instructions

1. Screen is to be grounded at both ends.

2. The conductors are short circuited at the far end firmly by minimum 95 mm2 cable.
3. The conductors under test are connected as shown in figure below.
4. Increase the current gradually insteps by balancing the phases individually to desired value.
5. Note down the current induced in all the link boxes.
6. Reduce the current gradually and switch off the breaker.

Cross
Cross bonding
bonding check
check diagram
diagram

Go back to Index ↑

Will be continued soon…

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Premium Membership

Get access to premium HV/MV/LV technical articles, electrical engineering guides, research studies and much more! It helps you to shape up
your technical skills in your everyday life as an electrical engineer.

MORE INFORMATION

Zafar Iqbal

Electrical engineer with more then 5 year experience in Electrical Transmission and Distribution Field. Highly specialized
for design, installation and testing of HV/MV T&D lines and Power Substations.

One Comment

Abdullah
JAN 07, 2021

Hi Zafar,

Hope you are doing well,

How can I connect you sir? I have some questions regarding cable system?

Your kind and earliest reply shall be highly appreciated.

Reply

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