LOW VOLTAGE NON-SHIELDED CABLES: "MEGGER" Test IEEE 400: IEEE Guide for Making High-Direct-Current-Voltage Tests AEIC CS-5-94: Cross-Linked Polyethylene Insulated Shielded Power Cables AEIC CS-6-??: Ethylene Propylene Rubber Insulated Shielded Power Cables Time-Leakage Test: Direct Current Time-Leakage Test
INTRODUCTION
SAFETY
Before conducting tests on a cable system, verify that the cable system is properly de-energized. If the system has been previously energized, follow the prescribed rules for switching necessary to de-energize, lockout, tag, and ground the cable system. The personnel conducting the testing must be qualified to operate the test equipment and be familiar with the cable system and its components. PREPARATION FOR TESTING
Disconnect cables from non-cable system equipment and apparatus. This will reduce the possibility of erroneous test results. In the case of HVDC (High-Voltage-Direct-Current) testing, it will prevent damage to equipment and apparatus. Adequate physical clearances between the cable ends, and other equipment, other energized conductors, and to electrical ground must be checked. During the testing, be sure that unauthorized access to the cable system is maintained. Verify that proper procedures are taken to clear all tap(s) or lateral(s) in the circuit. Remove grounds from the cable phase to be tested. Phases not under test should remain grounded at all ends. CONDUCTING TEST
Conduct test according to prescribed procedures and instructions. Record test results and retain for future reference. -------------------------------------------------------------------------------- LOW VOLTAGE NON-SHIELDED CABLES
"HI-POT": High Voltage Potential DC Test
High potential tests are "go no-go" tests. The cable is required to withstand the specified voltage for the specified time duration. These tests will normally reveal gross imperfections due to improper field handling. Recommended test voltages are given in tables for dc and ac. Alternating current new installation test voltages are 80% of the factory test voltage. Di rect current voltages are two times the ac new installation test voltage. Test duration should not exceed five minutes. Recommended DC Dielectric Test Voltages For New Installations Size XHHW/RHH/RHW USE THHN/THWN 14 4800 --- 3200 12 4800 4800 3200 10 4800 4800 3200 8 - 2 4800 5600 3200 1 - 4/0 6400 6400 4000 250 -500 8000 8000 4800 550 - 1000 9600 9600 5600 1100 - 2000 11200 11200 6400
Recommended AC Dielectric Test Voltages For New Installations Size XHHW/RHH/RHW USE THHN/THWN 14 2400 --- 1600 12 2400 2400 1600 10 2400 2400 1600 8-2 2800 2800 1600 1-4/0 3200 3200 2000 250-500 4000 4000 2400 550-1000 4800 4800 2800 1100-2000 5600 5600 3200
-------------------------------------------------------------------------------- "MEGGER": Insulation Resistance Test
Low voltage, non-shielded cables can be tested using a battery powered ohmmeter or a device called a "megger". Hand held ohmmeters generally have outputs from several volts to 24 volts. They are excellent for detecting direct "shorts" such as bolted faults and low resistant measurements in the kilohm range. A "megger" measures resistance in the megohm range using higher voltages than an ohmmeter. Manual or motor-driven meggers are available for a range of fixed dc voltages. Typical fixed dc voltages are 500, 1000, 2500 and 5000 volts. 2 to 50 Megohm Rule Applied dc potential may be 500 or 1000 volts dc with the insulation resistance reading taken at one minute. A megohm meter reading of less than 50 megohms may be used for deciding when to investigate the cable installation, readings less than two megohms will most likely indicate damaged insulation. Readings of 2 to 50 megohms are usually associated with long circuit lengths, moisture, or contamination. In most cases a 2 to 50 megohm reading does not indicate the insulation quality, therefore 2 to 50 megohms should not be specified as a pass/fail value. Insulation resistance readings should be made and interpreted by experienced testing specialists to determine the condition of the cable's insulation. Note that it is difficult to obtain accurate insulation resistance measurements in the field. Factory tests are done in a controlled environment with the cable submerged in water to provide an electrical ground. Using factory test values are not recommended. -------------------------------------------------------------------------------- MEDIUM VOLTAGE SHIELDED CABLES
IEEE 400
"IEEE Guide for Making High-Direct-Current-Voltage Tests on Power Cable Systems in the Field" With any HVDC testing it is highly recommended that IEEE Standard 400 be understood and that there is concurrence of the manufacturers of the cables, terminals, and splices prior to the performance of any proposed testing. Table 1 is taken from IEEE Std. 400:
IEEE Standard 400 tests are "go no-go" tests. The system is required to withstand the specified voltage for the specified time duration. These tests will normally reveal gross imperfections due to improper field handling such as excessive bending or air gaps between the insulation and shield interfaces. Table 1 Field Test Voltages for Shielded Power Cable Systems 5 kV to 35 kV System Voltage System BIL Acceptance Test Maintenance Test (kV rms) phase-phase (kV) (crest) (cond-gnd) Voltage* (kV dc) (cond-gnd) Voltage** (kV dc) 5 75 28 23 8 95 36 29 15 110 56 46 25 150 75 61 28 170 85 68 35 200 100 75
* Acceptance test voltage duration is normally 15 minutes. ** Maintenance test voltage duration is normally not less than five minutes or more than 15 minutes.
-------------------------------------------------------------------------------- AEIC CS-5-94 "Specifications for Cross-Linked Polyethylene Insulated Shielded Power Cables Rated 5 Through 46 kV"
Tests During and After Installation During Installation. At any time during installation, a dc proof test may be made at a voltage not exceeding the dc test voltage specified for During Installation, applied for five consecutive minutes. After installation. After the cable has been completely installed and placed in service, a dc proof test may be made at any time within the first five years at a voltage not exceeding the dc test voltage specified for the First five Years, applied f or five consecutive minutes. After that time, dc testing is not recommended. DC test voltages are applied to discover gross problems such as improperly installed accessories or mechanical damage. DC testing is not expected to reveal deterioration due to aging in service. There is some evidence that dc testing of aged cross-linked polyethylene cables can lead to early cable failures.
Table 2 DC FIELD TEST VOLTAGES Cross-Linked Polyethylene Insulated Shielded Power Cables
Rated Voltage During First Phase to Phase (kV) Insulation Thickness DC Test Voltages (kV) During Installation ( 5 min) First 5 years (5 min) 5 90 28 9 5 or 8 115 36 11 15 175 56 18 15 220 64 20 25 260 80 25 25 320 96 30 28 280 84 26 35 345 100 31 35 420 124 39 -------------------------------------------------------------------------------- AEIC CS-6-?? ---DO NOT SPECIFY COMPLIANCE--- "Specifications for Ethylene Propylene Rubber Insulated Shielded Power Cables Rated 5 Through 69 kV" This information has not been adopted and is pending review by AEIC!
Tests During and After Installation During Installation. At any time during installation, a dc proof test may be made at a voltage not exceeding the dc test voltage specified for During Installation, applied for five consecutive minutes. After installation. After the cable has been completely installed and placed in service, a dc proof test may be made at any time within the first five years at a voltage not exceeding the dc test voltage specified for the First five Years, applied f or five consecutive minutes. DC test voltages are applied to discover gross problems such as improperly installed accessories or mechanical damage. DC testing is not expected to reveal deterioration due to aging in service.
This information has not been adopted and is pending review by AEIC!
Table 3 DC FIELD TEST VOLTAGES Ethylene Propylene Rubber Insulated Shielded Power Cables Rated Voltage Phase to Phase (kV) Insulation Thickness DC test Voltages (kV) During Installation (5 min) First 5 years (5 min) 5 90 28 22 5 or 8 115 36 29 15 175 56 45 15 220 64 51 25 260 80 64 25 320 96 77 28 280 84 67 35 345 100 80 35 420 124 99 This information has not been adopted and is pending review by AEIC! -------------------------------------------------------------------------------- Time-Leakage Test
For more sophisticated evaluations, it is important to recognize the components of dc "leakage" current. The output current of the test set into the cable is not the true leakage current. The output current is the sum of three currents; geometric capacitance, absorption, and true leakage current. The absolute value of output current is not of primary importance. This value is virtually impossible to predict and is dependent upon the previously mentioned factors which can affect the resultant output current from a few microamperes to hundreds of microamperes. Time-Leakage Test, Components of DC Test Output Current (Diagram not available) It is the shape of the total current curve (it) with respect to time that indicates the condition of the dielectric. A drop-off of current with respect to time is an indication of sound insulation. A rising current is an indication of questionable condition or impending failure. A flat curve is generally due to test conditions. The output current variation with respect to time of voltage application is generally considered more indicative than the absolute value. The characteristic shapes of the time-leakage current curve and probable causes are outlined below. 1. A rising leakage curve at a steady voltage may be indicative of faulty insulation. However, other leakage paths (over porcelain surfaces and through insulating fluids) can contribute to such a result.
2. A falling leakage curve is indicative of good insulation characteristics, especially if at similar levels for all phases. 3. A flat leakage curve at low value is generally indicative of acceptable insulation. Flatness may be influenced by circuit length, cable geometry, and possible presence of moisture or contaminants over terminal surfaces. 4. A flat leakage curve at high value may indicate any of the following conditions: a. presence of moisture b. contaminants over terminal surfaces or other creepage surfaces c. surface leakage greater than volume leakage d. moist laminated insulation e. condition of insulating fluids f. air ionization losses (corona) from projections
5. Dissimilar leakage curves are indicative of nonuniformity of circuit insulation. The characteristic curve of each phase should be analyzed to determine the cause of dissimilarity. Air ionization losses from projections may affect one phase more than the others, dependent upon corona shielding (such as at terminals), temperature and humidity transients, air movement, and the like.
Generally speaking, the increase of current with test voltage is approximately linear for sound insulation. Care should be exercised to prevent terminal corona and minimize terminal surface leakage as these can mask test results.