Non-Destructive , Non Invasive

Condition Assessment of Transmission

Cable Systems
By:
Nagu N. Srinivas
IEEE Life Fellow
Vice President, UTILX Corporation
Presented at ICC Spring 2009 meeting in Orlando, Florida

In the Beginning

Early version of the technology was experimented on 120-kV

XLPE terminations and splices at Detroit Edison.
The program ran from 1984 to 1990, and successfully prioritized
the replacement of a first generation termination installed on all
DECO 120-kV XLPE cables.
In 1997 online PD measurements were performed on specific
splices of the 345-kV pipe-type cable system. The signals were
measured at splices which were suspected of having thermomechanical bending insulation damage. The readings correlated
to prior DGA measurements.

TYPICAL HV EXTRUDED CABLE SYSTEM LAYOUT

TERMINATIONS

MANHOLES & SPICES

CABLE ELECTRIC FIELD STRESS

Maximum Average Stresses in
Power Cables*
Partial discharge occurs inside
voids or cavities filled with gases
within the insulation media.

FIELD STRESS (V/mil)

SYSTEM
VOLTAGE (KV) PAPER
EXTRUDED

PD occurs when the electric stress

exceeds the ionization level of
these gases.

15

76

40-50

25

108

49-56

35

121

49-59

For air, this is about 70 V/mil

69

142

62-93

138

160

97-101

230

178

159-173

345

196

500

219

* T.Tanaka and A. Greenwood, Advanced Power Cable

Technology, CRC press, Boca Raton, FL, 1983

TYPICAL HV EXTRUDED CABLE DESIGN

LEAD SHEATH

Large conductor
XLPE insulation - maximum stress design
Insulation operates at much higher stress
than distribution cable
Metallic sheath, moisture barrier
Overall jacket

CORRUGATED
COPPER SHEATH

CABLE: WHAT CAN BE DETECTED

Voids in insulation
Voids between extruded layers
Inclusions & contaminants
Effects of moisture in insulation (treeing)

CABLE END PREPARATION

TRAIN & STRAIGHTEN CABLE ENDS
Affects general performance as cable system ages.

Cable and joint/termination must be straightened with application

of heat and well supported so that:
Cable insulation does not shrink back and pull out of joint
insulation or termination stress cone
Accessory is not bent by cable more important at higher
voltages
Cable does not move within accessory during load cycling
Accessory shape does not distort during load cycling more
important at higher voltages

CABLE END PREPARATION

Remove cable jacket.

Take care not to cut into underlying metallic shield, neutral
& water block system.

CABLE END PREPARATION

This is a critical area in cable end
preparation

Remove cable insulation shield

CABLE END PREPARATION

Potential problems when removing semi-conducting insulation shield

semicon
insulation

semicon

Cut into insulation

insulation

torn semi-con shield

insulation

Tearing semi-con shield can also tear

out cable insulation

semicon

CABLE END PREPARATION

Splice/termination design can remedy some craftsmanship problems

semicon
insulation

semicon

Cut into insulation

insulation

torn semi-con shield

insulation

Tearing semi-con shield can also tear

out cable insulation

semicon

CABLE END PREPARATION

The exposed cable insulation must be clean, dry, and free of contaminants

Dirt
Metal
Contaminant
Water

TYPICAL HV EXTRUDED CABLE TERMINATION

Porcelain or polymer
housing
Filled with fluid dielectric
Pre-molded stress cone

TERMINATION: WHAT CAN BE DETECTED

Proper installation of connector
Specified die & compression
Specified seal to prevent moisture
entry at top of termination
Loss of dielectric fluid
Proper size & position of
stress cone
Contaminants & voids in
stress cone polymer

Dirt, metal, contaminant,

water on insulation surface

Proper connection
between termination and
cable metallic shield

TYPICAL HV EXTRUDED CABLE SPLICE

PRE-MOLDED SPLICE INSULATION
& INTEGRAL STRESS CONTROL
METALLIC HOUSING
OVERALL MECHANICAL
PROTECTIVE HOUSING

CONNECTOR

HEAT SINK

CABLE SPLICE: WHAT CAN BE DETECTED

Proper installation of splice
insulation/stress control.
Correct size & position
Voids & contaminants in splice
insulation

Install connector as specified

Insulation cutback
Proper die & compression technique
Proper installation of metallic heat
sink/shield
Electrical connection between metallic
heat sink & connector

Potential problems during accessory installation

insulation shield removal

is out of specification

insulation removal is out of specification

Potential problems during accessory installation

Bore of pre-molded joint

housing is too large

Potential problems during accessory installation

The joint insulation must be centered on the joint

Potential problems during accessory installation

Heat shrink splice cable end preparation

Potential problems during accessory installation

Improper installation of heat-shrink component

Potential problems during accessory installation

uniform heat:
Heat-shrink layers must shrink tightly and uniformly against cable core.

Potential problems during accessory installation

Insufficient heat:
Heat-shrink layers do not shrink tightly against cable core.

Potential problems during accessory installation

Non-uniform heat:
Layers may shrink off-center. Over heating may
crack layers.

CABLE X-BOND SYSTEM: WHAT CAN BE DETECTED

Defective surge
arrester

Proper connection pattern

to link box
Proper installation of X-bond lead
connectors

Purpose of Diagnostic Testing

To avoid failures in service
To reduce cost
To target replacement money

Diagnostic Technique
CableWISE Technique (Frequency Resolved)

No need to de-energize the cable system

Testing cable at systems operating conditions
Non-destructive (will not active dormant PD sites)

CableWISE Condition Assessment

Frequency Resolved

No need to de-energize the cable system

Testing cable at systems operating conditions
Non-destructive (will not activate dormant PD sites)
Will measure micro-discharge and discharge signals.
Assessment results indicate the condition of cable, splices &
terminations.

Cable|wise On-Line Signal Detection

Custom sensors can detect low energy (<1 pC), high frequency
(300 MHz) signals.

Signals are analyzed in the frequency and time domains,

unique to this technology.

Noise rejection is made through signal processing in the

frequency domain.

Not limited by cable length, operating voltage, insulation type,

construction or circuit configuration (branching)

TP #1 at Riser Pole

TP #3 at Halfway Manhole

TP #2 at Substation

Condition Level Definitions for Pipe type Cable Systems

Level 1
Level 2

Component has no detectable deterioration. No action is necessary.

Level 3

Component has a low level of deterioration. Recommend re-assessment after one

year to look for changes in deterioration. If there is no change, then no additional reassessment is necessary.

Level 4

Component has moderate deterioration and a medium probability of failure within

two years.

Level 5

Component is at the end of economic life and has a high probability of failure within
two years. Recommend immediate attention.

Condition levels for Extruded Cable systems

Level 1:
Level 2 :
Level 3:

Level 4 :

Level 5:

The system is not degraded. No immediate action needs

to be taken.
There is a small amount of ageing related signals.
Retesting is recommended in five years
Component has a low level of deterioration. System has
low probability of failure within the next two years.
Retesting is recommended in two years.
System has medium probability of failure. It is
recommended to replace within two years.
For new system, installation is defective. For the old
system it is at the end of economic life. Immediate
replacement is recommended.

Typical data from transmission ( Extruded) cables

APPICATION OF CONDITION ASSESSMENT

New Installation :
Step 1 : Assess when the cable system is installed and energized
To look for proper assembly of splice and termination
To Look for gross defects in cable insulation and dielectric interface
Step 2 : Assess when the cable is loaded and operating for a month
To look for proper assembly of splice and termination after the system
is settled, and voids (if any) at cable insulation/accessory interfaces
Side benefit : Detect any improper connections to the overhead
system And correct them before failure in the field.
Aged System :
Assess when the cable is operating for a period of 1 to 40+ years
To determine whether defects, expanded during service aging in the field,
have caused significant deterioration or about to progress to a service failure
To look for deteriorated components in the cable such as water trees,

Sensor Placement: Extruded Cable

MANHOLE
SUBSTATION

Extruded Cables Sensors Setup

Extruded Cables Sensors Setup

Extruded Cables Sensors Setup

Extruded Cables Sensors Setup

Case History: 69 kV XLPE Cable

69 kV rated, XLPE insulated, 2,250 kcmil/ Al
conductor, PVC jacketed, 3,500 ft long single
conductor

20
(A)

Signals (mV

July 1999
10

Data acquired from both ends of the circuit.

High level signals observed at around 200 feet in

the first 700 ft of all three phases.

0.0
0.0

Signal patterns suggested water-tree type

deterioration.

20

Condition assessment measurements repeated six

months later.

A 3X increase in signal severity was found at one

location while other sites exhibited little or no
increase at all

A lightning strike failed the cable at the above site

before the customer could replace the cable.

(B)

January 2000

Signals(mV)

800

400
Distance (ft)

10

0.0
0.0

400
Distance (ft)

800

Signal data of the first 800 ft of phase C

Case History: 138 kV XLPE Cable System Splices

pre-molded
replacement splices
Field-molded splices

3.5 circuit miles, new 138 kV XLPE cable circuit with eight fieldmolded joints per phase.
Joint failures within 2 months from being energized. The joints in first
manhole were replaced with pre-molded splices.

Case History: 138 kV XLPE Cable System Splices

Condition Assessment Results
ed
d
l
mo es
e
pr plic
s

Condition Levels

1 2 3 4 5
Field-molded splices

Re
pla
ce
d

PD (mV)

12.0

0.0

Splice, PD level 2
1.0

PD (mV)

Splice, PD level 5

0.0

After repairs, CableWISE assessed the circuit as follows: one Level 5 joint, 6
Level 4 joints and 3 Level 3 joints. No activity was detected in the cable and
terminations (Level 1).
Examination of the Level 5 joint by an independent laboratory revealed
voids within one inch of the area where the Level 5 reading was measured
in the field.

Splice Problem in New 60-kV XLPE Cable Installation

New installation
1.5 mile 60 kV XLPE 1/C
4 x 3 splices
Single point bonding at both ends
Cross bonding for center joints

Splice Problem in New 60-kV XLPE Cable Installation

Splice Problem in New 60-kV XLPE Cable Installation

Splice Problem in New 60-kV XLPE Cable Installation

Cable energized for testing, no load

Exceedingly intense discharge activity from all splices
Noise was radiated to terminations, although these seemed OK
Noise from splices was confirmed with acoustic probes with contact sensors
One splice was opened to perform a visual inspection and check insulation shield
connections, some modifications were made. Test after re-assembling showed absolutely
no improvement

Splice Problem in New 60-kV XLPE Cable Installation

Splice Problem in New 60-kV XLPE Cable Installation

Inspection by joint manufacturer revealed a problem with the connection

between the cable conductor shield and the cable connector
Since the problem was confirmed by the manufacturer, all splices are being
replaced with new splices of a different design
Retesting to be scheduled

Case Study: 69 kV transmission cable system

5 ns/div
Est. VOP = 2 ns/ft

A
View of joints in vault TV-127.
Phase A joint (bottom) is
showing significant level signals.
View A, shows two sensors
placed at equal distance from
possible source location as
detected with time trace as
shown in view B. View C,
further pinpoints most likely
longitudinal location of source in
joint structure

VAULT TV-127

APRIL 2004 SPECTRUM

JULY 2004 SPECTRUM

(SIZED VERTICALLY TO
SCALE WITH APRIL 2004)

APRIL 2004 ZERO SPAN

VAULT TV-127
JULY 2004 SPECTRUM
(ENLARGED)

Case Study: Splice Problem in New 60-kV XLPE Cable

10 ns/div

Est. VOP = 2 ns/ft

Joints in vault TV137. Phase A

(bottom) showing
strong signals from
the right side end
of the joint as
depicted by the
series of pictures

VAULT TV-137
APRIL 2004
SPECTRUM

JULY 2004 SPECTRUM

(SIZED VERTICALLY TO
SCALE WITH APRIL 2004)

APRIL 2004
ZERO SPAN

VAULT TV-137
JULY 2004 SPECTRUM
(ENLARGED)

What is Unique about this technology

Data acquired while circuit is in service
On-line, non-destructive, technique avoids shut down
Short set-up time
No over-voltage applied
Custom sensors that can detect high-frequency, low-energy signals
Utilize frequency and time domain traces to determine
Type of defect ( in cable, joint, termination)
Defect location
Extruded, Oil filled cable circuits
Can assess all circuit configurations (branching)
Sample data at every two or three manholes
Simultaneous assessment of other gear connected to the cable system

Summary
The online technology described here is a non-destructive
diagnostic technique that can:
Check the new cable system installation
Increase electrical system reliability
Avoid unplanned outages
Reduce maintenance costs
Prioritize cable system maintenance
Assess entire cable system & components,
regardless of insulation or circuit configuration

HV CABLE SYSTEM OPTIONS

CROSS-BONDING OF METALLIC SHIELDS FOR LONG, LARGE

CONDUCTOR CABLE SYSTEMS.
SHEATH CONNECTIONS
SURGE ARRESTERS

FIBER OPTIC DISTRIBUTED TEMPERATURE SYSTEM

EMBEDDED DISCHARGE SENSORS ATSPLICES & TERMINATIONS

Cross-bonding of High Voltage XLPE insulated cable

It is necessary to cross-bond long, high load current single conductor
cables operating as a three phase circuit to maximize the load current
capability of the cable circuit.
If the shields of single conductor cables operating as a three phase circuit
are short circuited, a large induced current flows in the shield. The shield
current significantly reduces the load current capacity of the cable.
Cross bonding interconnection of the cable shield minimizes the induced
shield currents in the phase cables, and thus, increases the current
carrying ability of the cable.

NOTE:
Pipe type cable does not require cross-bonding
because the metallic shields of the phase cables
are in continuous contact with each other and the
induced shield voltages are continuously canceled.

The shield of a high voltage cable must be grounded.

Uniform field in shielded cable
All high voltage cable is shielded. The semiconducting insulation shield and metallic shield
are grounded to keep the electric field uniform
inside the cable insulation.
semi-conducting
insulation shield
metallic shield

Electrostatic flux
lines

overall jacket

Equal potential lines

Semi-conducting
bedding tape

Non-uniform field in non-shielded cable

If the cable were non-shielded, the electric
field would concentrate near ground, and
eventually fail there. Also, the cable surface
could rise to line voltage.

Electrostatic Flux Lines

Equipotential Lines

If the cable shield is grounded at one end

only, a voltage proportional to conductor
current & cable length is magnetically
induced on the shield. The induced
voltage is proportional to the load current,
and is independent of the conductor
voltage.

SHEILD VOLTAGE (V)

Cable shield grounding

ELD
SHI TAGE
E
L
L
CAB ED VO
C
U
IND

Cable shield

Conductor load current

Cable length

Cable shield
Conductor load current

If the shield is grounded at both ends of a

cable section, a current proportional to
conductor current & cable length is induced
in the shield. The induced current is
independent of the conductor voltage. The
current can be high enough to heat the cable
insulation, thereby reducing the current
carrying capacity of the cable.

Induced shield current

Cable ampacity and heat flow out of cable: Effect of shield current

He
a
cur t from
ren
t (la load
rge
)

Conductor
temperature

Insulation
thermal
resistance

Shield
temperature

Ri

Tc
Wc

Heat
fr
diele om insula
ctric
losse tion
s (sm
a

Jacket
thermal
resistance

Rj

Ts
Wd

Composite
thermal
resistance
from jacket
Cable jacket to earth
temperature
Earth ambient
temperature

Tj

Re

Ta

Ws

ll)

shield
inducted
Heat from e)
arg
current (l

Short circuited shield

Grounding the cable shield at both ends results in an induced
current that significantly raises the temperature of the cable
metallic shield. Cable insulation is heated by both the conductor
and shield. As a result, the allowable conductor temperature
must be lowered to compensate for the shield temperature.
Thus, load current capability is reduced.

Ri

Tc
Wc

Rj

Ts
Wd

Tj

Re

Ta

Ws

Cross-bonded shield
Connecting the cable shield in a cross-bonded pattern significantly reduces
the heat losses in the shield and allows a higher conductor temperature.
Thus, load current can be increased.

Shield connections & voltages for tri-section cross bonding.

CABLE SHIELD
INDUCED VOLTAGE
WITHOUT CROSS
BONDING

VOLTS

CABLE SHIELD
INDUCED VOLTAGE
with CROSS
BONDING
CABLE
LENGTH

0
The lengths of the minor
sections must be equal to
completely cancel shield
voltages.

CABLE
CONDUCTOR

MINOR SECTION

MINOR SECTION

MINOR SECTION

MAJOR TRI-SECTION

CABLE SHIELD

MANHOLE

MANHOLE

MANHOLE

MANHOLE

Over-voltage protection for shield gaps

Ungrounded gap must be protected from over voltages
gap
shield
Conductor load current

Induced shield voltage

Arrester

Both sides of each gap are protected by an arrester.

Shield connections & voltages for tri-section cross bonding.

CABLE X-BOND SYSTEM: WHAT CAN BE DETECTED

Defective surge
arrester

Proper connection pattern

to link box
Proper installation of X-bond lead
connectors

Sources of RF signals in HPFF Cable

HPFF cable systems have some internal partial discharge, even under
normal operating conditions.
Significant sources of partial discharge are not necessarily an immediate
problem to the cable system

METAL TO METAL CONTACT (LOOSE/BROKEN CONNECTIONS)

Sources of RF signals in HPFF Cable

TERMINATION
COMPONENTS

CABLE PULL-IN
DAMAGE

Sensor Placement: HPFF Cable

SENSOR PLACEMENT

SUBSTATION

MANHOLE

Typical data acquisition setup

Typical sensor placement on a splice in a manhole.