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230k V Cable Test Process

The document outlines the testing procedures for cable jointing and termination, categorized into pre-jointing, internal, and post-installation tests, each with specific processes and acceptance criteria based on IEC standards. Key tests include visual inspections, insulation resistance tests, partial discharge tests, and high voltage AC tests, all aimed at ensuring cable integrity and safety. The final check before energization confirms that all tests meet standards and that there are no insulation failures or excessive temperature rises.

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rajatdubey16.rd
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104 views6 pages

230k V Cable Test Process

The document outlines the testing procedures for cable jointing and termination, categorized into pre-jointing, internal, and post-installation tests, each with specific processes and acceptance criteria based on IEC standards. Key tests include visual inspections, insulation resistance tests, partial discharge tests, and high voltage AC tests, all aimed at ensuring cable integrity and safety. The final check before energization confirms that all tests meet standards and that there are no insulation failures or excessive temperature rises.

Uploaded by

rajatdubey16.rd
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
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1.

Pre-Jointing Tests (Before Jointing & Termination)

These tests are conducted before starting jointing to ensure the cable and
accessories are in good condition.

1.1 Visual Inspection

📌 IEC Standard: IEC 60840, IEC 60229


✅ Process:

1. Inspect for physical damage, cracks, contamination, or moisture.

2. Verify correct cable alignment, bending radius, and no sharp edges


in the trench.

3. Check the presence of manufacturer markings and sheath integrity.


✅ Acceptance Criteria:

 No physical damage, dirt, or moisture

 Correct cable laying & bending radius as per manufacturer


guidelines

1.2 Insulation Resistance (IR) Test (Megger Test)

📌 IEC Standard: IEC 60502-2, IEC 60840


✅ Process:

1. Connect a megohmmeter (Megger) between the conductor and


the metallic sheath/earth.

2. Apply a test voltage of 5kV DC for 1 minute.

3. Measure insulation resistance values.


✅ Acceptance Criteria:

 Insulation Resistance: Should be ≥ 5000 MΩ (5 GΩ)

 Any drop in resistance indicates insulation failure.

1.3 Sheath Continuity & Fault Test

📌 IEC Standard: IEC 60229


✅ Process:

1. Apply a low-voltage continuity tester between sheath points.

2. Check for electrical continuity and locate sheath breaks if any.


✅ Acceptance Criteria:
 Sheath resistance: < 1Ω/km

 No open circuit detected

1.4 Conductor Resistance Test

📌 IEC Standard: IEC 60287


✅ Process:

1. Use a micro-ohmmeter to measure DC resistance of the conductor.

2. Compare resistance values with manufacturer data.


✅ Acceptance Criteria:

 DC resistance at 20°C: As per IEC 60287 (e.g., 0.01724 Ω/km for


copper).

1.5 Partial Discharge (PD) Test

📌 IEC Standard: IEC 60270, IEC 60885-3


✅ Process:

1. Apply a voltage of 1.5 × U0 (Nominal Voltage Phase-to-


Ground).

2. Use a PD detector to measure discharge activity.


✅ Acceptance Criteria:

 PD Level: ≤ 5 pC (picoCoulombs) for XLPE cables

 No significant increase in PD over time

2. Internal Tests During Jointing

2.1 Graphite Coating Test

📌 IEC Standard: IEC 60840


✅ Process:

1. Apply a thin graphite paint layer on the semi-conductive screen.

2. Ensure uniform coverage and let it dry completely.


✅ Acceptance Criteria:

 Even, smooth coating without excessive thickness.

2.2 Crimping/Conductor Joint Test


📌 IEC Standard: IEC 61238-1
✅ Process:

1. Strip insulation carefully without damaging the conductor.

2. Insert the conductor into the jointing sleeve.

3. Use a hydraulic press to crimp at specified pressure.

4. Verify correct compression using a crimp gauge.


✅ Acceptance Criteria:

 No conductor damage or misalignment.

 Compression should meet manufacturer specifications.

2.3 Shielding & Stress Control Layer Test

📌 IEC Standard: IEC 60840


✅ Process:

1. Apply stress control tubes over the jointing area.

2. Heat uniformly with a heat gun for even shrinkage.


✅ Acceptance Criteria:

 No air gaps or loose connections in shielding layers.

3. Post-Installation Tests (After Jointing & Termination)

3.1 Insulation Resistance (IR) Test (Repeated)

📌 IEC Standard: IEC 60502-2, IEC 60840


✅ Process:

1. Perform the Megger test again after jointing.


✅ Acceptance Criteria:

 Resistance should remain ≥ 5000 MΩ (5 GΩ)

 No sudden drop in insulation resistance.

3.2 High Voltage AC Test (HV Withstand Test)

📌 IEC Standard: IEC 60060-1, IEC 60840


✅ Process:

1. Apply a test voltage of 1.7 × U0 (phase-to-ground voltage).


2. Hold for 15 minutes while monitoring leakage current.
✅ Acceptance Criteria:

 No breakdown or insulation failure.

🔹 Example for 230kV Cable:

 Nominal U0 = 133kV

 Test Voltage = 1.7 × 133kV = 226kV AC

3.3 Sheath Fault Location Test

📌 IEC Standard: IEC 60229


✅ Process:

1. Apply a DC voltage to the metallic sheath and check for


continuity.

2. Use a sheath fault locator to detect breaks.


✅ Acceptance Criteria:

 No interruptions in sheath continuity.

3.4 Partial Discharge (PD) Test (Repeated)

📌 IEC Standard: IEC 60270, IEC 60885-3


✅ Process:

1. Apply a voltage ≥ 1.5 × U0 again and measure PD levels.


✅ Acceptance Criteria:

 PD levels should be ≤ 5 pC

 No new PD detected after installation.

3.5 Tan Delta (Dissipation Factor) Test

📌 IEC Standard: IEC 60840


✅ Process:

1. Apply test voltage and measure dielectric losses.


✅ Acceptance Criteria:

 Tan δ ≤ 0.002 for XLPE cables.

3.6 Thermal Imaging (After Energization)


📌 IEC Standard: IEC 60840
✅ Process:

1. Use an infrared thermal camera to scan joint areas.

2. Identify hotspots that indicate poor jointing or insulation damage.


✅ Acceptance Criteria:

 No hotspots (>5°C difference) in joints and terminations.

Final Check Before Energization

📌 IEC Standard: IEC 60840, IEC 62067


✅ Process:

1. Verify all test results are within standard limits.

2. Gradually energize the cable in stages while monitoring voltage


balance.

3. Conduct final inspections with thermal imaging.


✅ Acceptance Criteria:

 All tests passed

 No PD, insulation failure, or excessive temperature rise

📌 Summary of IEC Testing Standards & Values

Test Acceptance
Test IEC Standard
Voltage/Value Criteria

Insulation IEC 60502-2, IEC 5kV DC for 1 ≥ 5000 MΩ (5


Resistance (IR Test) 60840 min GΩ)

DC voltage
Sheath Fault Test IEC 60229 No discontinuity
injection

Partial Discharge IEC 60270, IEC


1.5 × U0 ≤ 5 pC
Test 60885-3

HV AC Withstand IEC 60060-1, IEC


1.7 × U0 No breakdown
Test 60840

Tan Delta Test IEC 60840 Applied voltage Tan δ ≤ 0.002

No hotspots
Thermal Imaging IEC 60840 Infrared camera
(>5°C)

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