IEEE Transactions on Electrical Insulation Vol. EI-21 No.

6g December 1986 1t051

TESTING METHODS FOR POWER CABLE INSULATION

S. Hiyama
Fujikura Ltd.,
Tokyo
and Y. Fujiwara
Showa Electric Wire & Cable Co., Ltd.,
Japan

ABSTRACT
Testing methods for power cable insulation depend basically
on type and material of cable insulation. Cross-linked poly-
ethylene (XLPE) is now spreading widely for power cable in-
sulation at the rated voltage of 66 to 154 kV world-wide, and
especially in Japan many 275 kV lines have already been put in
service. Typical conventional power cable insulation is oil-
impregnated paper which is used mainly for oil-filled cable
above 66 kV in many countries, including Japan. Testing methods
for both of these types of power cables in Japan are introduced
here in comparison with those prevailing in the USA together
with the reason for each testing method or condition. In gen-
eral, there is no fundamental difference between testing methods
in Japan and in the USA. However, test voltages are decided
by the insulation thickness and the specified stress in the
USA, while test voltages in Japan are given directly by the
rated voltage. Tests described here cover factory tests to be
made at the time of delivery, acceptance tests after instal-
lation at site, and maintenance tests to be made during
operation.

TESTING METHODS FOR POWER CABLE INSULATION such a high voltage should not be applied often, in
order not to damage and shorten the life of the cable.
Tests on power cables are roughly divided into three The test shall be made at ambient temperature using al-
groups, that is, factory tests to be made at the time ternating voltage at power frequency.
of delivery, acceptance tests after installation at
site, and maintenance tests to be made during operation. The test voltage shall be raised gradually to the
specified value which shall be then maintained for 10
Testing methods of these tests in Japan compared with minutes between the conductor and metallic screen. The
those in the USA are introduced for oil-filled and XLPE test voltage is summarized on Table 1 and is
insulated power cable respectively.
V = E, K1 K2 K3 (1)
FACTORY TESTS V/3.
TESTS ON XLPE CABLE AND ACCESSORIES Table 1
(a) Routine Tests ac withstand test voltage (in Japan)
The following tests shall be carried out on all manu-
factured lengths to check that the whole of every length
complies with the requirements.
(al) Withstand Tests
This test is carried out to check that the cable is
capable to endure fully commercial-frequency overvolt-
age which might be applied during operation. However,

0018-9367/86/1200-1051$01.00 @ 1986 IEEE

1052z IEEE Transactions on Electrical Insulation Vol. EI-21 No.6, December 1986

Where, Eo is the maximum rated voltage (kV), K1 the PC = 5 + (Vt/Vg - 2.0) 22.5 (2)
commercial frequency overvoltage multiple; K1=2.0 for
resistance grounded neutral system, K1=0.88 for direct where PC is the partial discharge (pC), Vt the test
grounded neutral system; K2 is the tolerance (1.1) for voltage (kV), and Vg the phase-to-ground voltage (kV).
uncertain factors such as delivery and installation,
and K3 is the temperature coefficient (1.1). Table 3
While in accordance with AEIC standards, withstand Applying voltage for partial discharge test (in Japan)
tests in the USA shall be carried out at the voltage
shown in Table 2 for five or fifteen minutes.
Rated voltage (kV) 22 33 66 77 154 275
Table 2
ac withstand test voltage (USA) 1st stage (kV) (17) (26) 52 61 120 220

2nd stage (kV) (33) (49) 97 115 225 310

3rd stage (kV) (17) (26) 52 61 120 220

For example, in case of Vt/Vg=2, the allowable magni-

tude of the partial discharge is 5 pC and the test volt-
age is shown in Table 4 for each rated voltage.

Table 4
(a2) Partial Discharge Test
Applying voltage for partial discharge test (USA)
Partial discharge test is performed to check on local
defects, for example, voids in insulation which might
develop during manufacture. The test is performed by Rated Voltage 25 28 35 46 69 115 138
applying voltage in three stages as shown in Fig. 1. (kV)

Test Voltage 29.0 32.5 40.5 53.0 80 135 160

(kV)

Furthermore, the testing time is decided after the

insulating process, the test shall not be performed
earlier than 7 days for 25 to 35 kV, 10 days for 46 kV
and 20 days for 69 to 138 kV cables.
(b) SamrpZe Test
Time
The following typical tests shall be made, if requir-
ed by the purchaser, on samples of cable taken to repre-
Fig. 1: Partial discharge measurement by 3 stage sent batches.
voltage (in Japan). Voltage applied 1 min/step.
(bl) HV Time Test
The first stage is designed to check that no partial This test is performed to check that the XLPE cable
discharge occurs in connection with operating voltage, can withstand both normal voltage and commercial fre-
the second to check that no abnormality is caused by quency overvoltage over 30 years' operation. This 1 h
commercial frequency overvoltage anticipated during ac- test is made at a voltage, equivalent to 30 yr condi-
tual operation in this case, the same test voltage
--
tioning according to the Vt characteristics of XLPE
in withstand HV test is applied, followed by the third cable. The test voltage is shown in Table S. In view
stage which is made to check that cable is not damaged of mechanical stress which might be incurred during in-
by application of voltage in the second stage test -- stallation, this test is carried out after bending the
voltage in this case is the same as in the first stage. cable twice. Following this test, breakdown voltage is
Thus, the test voltage for the second stage equals the usually obtained by raising applied voltage is steps of
test voltage of withstand test. 10 to 15 kV per hour.
The allowable magnitude of the discharge is different On the other hand, in case of the AEIC standard, there
in each voltage class, for example, 10 pC for 22 to 33 are some differences among the rated voltages, i.e. the
kV class and 5 pC for 66 to 77 kV class. test voltage for 25 to 46 kV cables is determined by
electrical stress and insulation thickness while that
Whereas the maximum partial discharge in pC is given for 69 to 138 kV cables is simply given as shown in
by Eq. 2 when the quantity in parenthesis is not less Table 6.
than zero, according to AEIC standards.
Hiyama and Fujiwara: Testing methods for power cable insulation 1 053

Table 5 Table 8
Applying test voltage for high voltage time test Test voltage for Impulse test (USA)
(in Japan)

Rated 25 28 35 46 69 115 138

Rated voltage (kV) 22 33 66 77 154 275 voltage
(kV)
Test voltage (kV) 80 110 195 225 400 kV* 805
BIL (kV) 150 150 200 250350 550 650
*Duration of ac withstand test is 3 h.
Test First = BIL voltage First: BIL voltage
Voltage x (+) 3 shots x (+) 3 shots
Table 6 and (at 130°C) (at 130°C)
Shots
Applying test voltage for high voltage time test (USA) Second= 1.25xBIL Second: BIL voltage
voltage x (-) x (+) 3 shots
3 shots (at 90°C)
Rated Test Voltage Period (at 90°C)
Voltage Third : 1.25xBIL
(kV) voltage x (-)
3 shots
(at 90°C)
25-46 First : 100 (V/mil) x One hour
Insulation
thickness (mil) = Vt

Second: Vt + 40(V/mil) 1/2 hour (b3) Void, Contaminants and Projection Detection Tests
Step up to 420 V/mil
In this test, 20 wafers 0.50+0.25 mm in thickness are
cut off from the cable insulation and are observed by
69-138 First : 2.5 Vg 4 hour means of a microscope to check for detrimental voids,
Second: 3.75 Vg 1 hour contaminants, and projections in the insulation. The
allowable levels for voids, contaminants, and projec-
tions are shown in Table 9.
Table 9
(b2) Lightning Impulse Voltage-withstand Test
Allowable value for voids, contaminants and
This test is performed at room temperature on the projections (in Japan)
sample with the test voltage taking into account BIL
values. Negative polarity is used for lightning im-
pulse voltage to ground because more than 90% of direct Rated voltage 22 33 66 77 154 275
lightning stroke hitting transmission lines is nega- (kV)
tive, and because positive inductive lightning surge
for 66 kV class is lower than BIL and mostly negative Voids (pm) (70) (70) 70 70 50 30
surge. The cable must withstand three negative shots
of the appropriate value in Table 7. In view of me- Contaminants
chanical stress which might be incurred during instal- Amber (ipm) (250) (250) 250 250 250 250
lation, this test is made after bending the cable twice. Black (pm) (250) (250) 100 100 100 100
Following this test, breakdown voltage is usually ob-
tained by raising the applied voltage in steps of 20 to
30 kV per three shots. Projection (jjm) (250) (250) 250 250 250 250
Table 7
Applying voltage for lightning impulse
voltage-withstand test (in Japan) As in contaminants, the shape of a projection was sup-
posed to be a rotary oval and maximum local electrical
stress around a projection are calculated to set criti-
cal conditions at 1:2 as the ratio of height to width,
with a sufficient safety factor against electrical tree
generating field.
In accordance with AEIC standards, void, contaminants
and projection are specified for each rated voltage
cable.
The test voltage in accordance with AEIC standards is The insulation of the completed cable shall be free
shown in Table 8. from the following value given in Table 10.
1 054 IEEE Transactions on Electrical Insulation Vol. EI-21 No.6, December 1986

Table 10 for the test voltage, which is 0.69 for Vm=500 kV,
0.88 for Vm=187 to 275 kV, 1.1 for Vm=66 to 154 kV, and
Allowable value for voids, contaminants where C2=1.1 is the allowance for deterioration of
and projections (in USA) characteristics of cable by shipment and installation.
Rated The test voltages for the typical rated voltate in
voltage Voids Contaminants Proj ections each country are shown in Table 11.
(kV)
Table 11
1) Any void 1) Any contami- 1) More than
larger than nants larger 5 mils toward Test voltage for HV test
3 mils than 7 mils the insulaton
(A.'76 vm) ('.'178 pm) or Rated
161 230 345 500
voltage 69 115
2) 10 mils (kV)
25-46 2) The number 2) The number
of voids of contami- away from the U.S.A.
1000 2250 1000 1500 2000 2500
insulation (ASIC Conductor 4/D 350 800 750 1000
larger than nants of CS4-79) size (AWG to to to to to to to to to to to
for the con- Kcmil) 4000 4000 900 4000 2000 4000 1250 4000 2500 4000
2 mils sizes between or 750

(-.S51 pm) 2 and 7 mils ductor shield

shall not shall not or + 10 mils Test
85.5 130.5 117.0 177.0 159.0 228.0 186.0 310.5 276.0 402.0 375.0
voltage
exceed 30 per exceed 15 per for the insu- (kV)
cubic inch cubic inch lation shield
Rated
I 69-138 1) Any void 1) Any contami- voltage 66 77 154 220 275 500
larger than nants larger JAPAN (kV)
than 7 mils (JEC
3 mils 3401) -

Teat
2) The number 2) The number ditto voltage 90.0 100.0 200.0 240.0 280.0 420.0
of contami- (kV)
of voids
larger than nants of sizes above
2 mils and between 2 mentioned
less than or and 7 mils
equal to shall not
3 mils shall exceed 10 per (a2) Ionization Factor Test
not exceed cubic inch
30 per cubic The ionization factor is defined as the difference of
inch
dielectric power factor between specified voltage.
I
In USA, the specified voltage is determined by the
specified average stress for insulation thickness as
stated in Table 12 and the stress of 0.79 MV/m.
(c) Tests on Accessories
Table 12
The basic concept of the tests for accessories are
the same as in the case of cable, but the accessories Specificated Average Stress for Ionization
Factor Test
have the following different features. Structure and
materials of accessories are of many types and are Rated Voltage The Specified Average Stress
complicated. Heat cycle during operation has a serious kV in volts per mil (MV/m)
effect, which depends on the individual structure. As- (Phase to Phase) of Specified Insulation
sembling at site is of great significance. Thickness
15 to 68 175 (6.89)
Considering these features, direct voltage-withstand
tests and accelerated aging tests are introduced which 69 to 115 185 (7.28)
are not carried out in the case of the test for cable
only. 120 to 165 190 (7.48)
TESTS ON OIL-IMPREGNATED PAPER CABLES AND ACCESSORIES 230
230 210 (8.
c
27) s

Routine Tests 345 & 500

(a)
The following tests are for completed cables and com-
pare between USA and Japan as follows. In Japan, for rated voltage Eo (conductor to earth)
not exceeding 89 kV, the measurements shall be made at
(al) High Voltage Test rated voltage Eo and 2EO, for rated values of Eo ex-
ceeding 89 kV, the measurements shall be made at rated
In USA the test voltage, which is based on the speci- voltage Eo and 1.75 Eo.
fied thickness of insulation shall be corresponding to
11.8 MV/m. The measured ionization factor shall not exceed 0.1%
in each country. Moreover, the dielectric power factor
On the other hand, in Japan the test voltage is deter- measured at specified voltage stated above shall not ex-
mined considering the abnormal voltage expected in the ceed the appropriate values shown in Table 13 in Japan.
cable. The test voltage is set at VmClC2, where Vm is
the maximum line-to-line voltage (kV), C1 the factor
Hiyama and Fujiwara: Testing methods for power cable insulation 1055

Table 13 Table 15
Specification of Dielectric Power Factor Maximum Power Factor for Dielectric
(in Japan) Power Factor Test
Temperature Maximum Power Factor, Percent
of Cable
Degrees C 15 to 161 kV 230 kV 345 and 500 kV

20 to 40 0.35 0.30 0.25

0.4>0.4> 0. 25> 0.22> 0. 22> 0. 20>
Di- at at at at at at 70 0.30 0.25 0.23
elec- 38kV, 44kV, 89kV, (127kV) (159kV) (318kV)
tr ic 76 kV 89 kV 0. 30> 0.25> 0.25> 0. 22> 90 0.35 0.28 0.25
power at at at at
factor 178 kV (240kV) (28OkV) (420kV)
(b3) Lightning Impulse Voltage Test
This test shall be made on the sample for the same
(b) Sample Tests reason as the XLPE cable. The cable must withstand
three negative polarity lightning impulses as shown in
The following tests are made on components taken from Table 16. The test voltage is BIL K1 K2, where,
completed cables and on components of accessories as K1=1.1 is the safety factor for uncertainty, and
sample tests in order to verify that the finished prod- K2=1.1 is the temperature coefficient corresponding to
uct meets the design specification. the ratio of impulse breakdown stress at room tempera-
ture to that at maximum conductor temperature.
(bi) High-voltage Time Test
Table 16
This test is made to verify that cables and accessor-
ies can maintain stable insulation characteristics suf- Lightning Impulse Voltage on Oil-filled Cable
ficiently against working voltage and anticipated com- (in Japan)
mercial frequency overvoltage through cable life and
also enhance operating performance quaranteed. Rated voltage 66 77 154 220 275 500
(kV)-
In USA, the test voltage corresponding to 16.9 MV/m, Room
is applied for 6 h and then raised to 20.5 MV/m for Lightning temp. 420/3 480/3 900/3 1080/3 1260/3 1860/3
3 h. In Japan, the test voltages are basically decided -impulse (kV/
considering V-t characteristics of oil-impregnated pa- tests shots)
per insulation. The test voltages for the typical (negative 80°C
rated voltage in each country are shown in Table 14. oolarity) (kV/ 385/3 440/3 825/3 990/3 1155/3 1705/3
__ _ _ _
shots),_ _ _ _ _ _ _ _ _ _ _ _ _ _

Table 14
Test Voltage for HV Time Test ACCEPTANCE TEST AT SITE
Rated A HV test must be made after installation and before
Voltage 69 115 161 230 345 500 the cable is placed in regular service.
(kV)
In USA, the test field is 7.48 MV/m ac, applied for 4,
U.S.A. Test voltage or 10.04 MV/m applied for 15 min.
for 6 hours 122.5 187.0 254.0 326.8 445.0 576.2
(AEIC (kV) -
The HV tests may be made with dc instead of ac, in
CS4-79) Test voltage
for 3 hours 148.2 226.2 306.8 395.2 538.2 696.8 which case the test voltage for the cable shall be 2.4
(kV) times the prescribed alternating potential.
JAPAN Rated 66 77 154 220 275 500
voltage (kV) In Japan, the test is made with dc, and the test volt-
(JEC Test voltage age is shown in Table 17. The test voltage after in-
-3401) for 3 hours 130 150 300 280 350 660 stallation is given in Table 18 in accordance with AEIC
(kV) - standard.
MAINTENANCE TESTS
(b2) Dielectric Power Factor Test
Maintenance tests are performed to ensure stable power
In USA, this test is made with rated voltage at not transmission through reasonable maintenance, improvement
less than four temperatures. One temperature is room and effieicnt operation of underground transmission
temperature and the others are 70, 90, and 105°C. The lines and generally consist of patrolling, inspection,
measurement at 105°C is for engineering information checking, testing, and repairing. Maintenance tests,
only. The measured value shall not exceed the allow- intended to make sure that cables can be put to contin-
able value shown in Table 15. ued use safely, are made periodically or occasionally to
prevent them from insulation damage during power trans-
In Japan, the test is made with rated voltage Eo and mission.
2Eo at six temperatures, that is, room temperature, 40,
60, 70, 85, and 950C. Maximum allowable values at each
temperature are as stated in Table 13.
1056Ei IEEE Transactions on Electrical Insulation Vol. EI-21 Noc6, December 1986

Table 17 (a) Maintenance Test on XLPE Cables

dc Test Voltage After Installation The maintenance test method currently adopted by
electric power companies is the so-called dc HV test in
Rated dc Test Description which dc voltage is applied to the installed cable to
voltage voltage measure leakage current and partial discharge, and the
measurement of tan6 at line frequency.
66 kV 10 min. Rated voltage x 11 x 2.5
177 kVn 1.15 A special committee for Establishment of HV XLPE Cable
Insulation Measurement Method was organized and reviewed
77 kV 177 kV Rated voltage x 1.15 x 2.2 the measuring method, including the newly developed
methods from 1978 to 1980. Recommended measuring meth-
154 kV 410mk. (Grounded neutral system) ods by this special committee are leakage current meas-
urement, tan6 measurement and partial discharge measure-
331 kV ment.
220 kV 10 min. 1.1 xx14
Rated voltage x 1.15 1.44
There are new methods, independent of the above ones,
i.e. residual voltage measurement, absorption current
275 kV 414 kV (Grounded neutral system) measurement, and measurement of dc transient current.
Recently, a new maintenance test was introduced for on-
500 kV 10 min. line operation.
(b) Maintenance Test on Oil-filled Cables
Table 18
The following factors are deemed to accelerate deter-
dc Test Voltage After Installation (USA) ioration of oil-filled cables: oxidation, heating, and
energi zing.
Rated Insulation deterioration of oil-filled cable is apt
voltage 25 28 35 46 69 115 138 to occur from a combination of oxidation and heating.
(kV)_
The following measurements are made on the insulating
Test 80 84 100 132 208 256 272 oil samples from the cable sealing-end and splices:
Voltage electrical characteristics (power factor, resistivity),
dc (kV moisture content, and gas analysis.
15 min.

Manuscript was received on 5 September 1986, in

revised form 12 November 1986.