PROCEDURES IN TESTING OF POWER CABLES

I. SCOPE:
This methods covers the routine procedures for testing newly installed and in
serviced 36 KV and below, cross linked polyethylene, XLPE power cables or similar
type in substation.

II. OBJECTIVE:

To determine the integrity of the insulation condition by measuring the

leakage current of the main insulation by high voltage methods.

III. SIGNIFICANCE:

Very low frequency (VLF) hi-pot testing is the latest IEEE approved
standards for testing shielded power cable cables. Although excessive test voltage using
DC hi-pot can cause service – aged cables with solid dielectric insulation to fail after they
return to service DC high potential has been an important tool in determining the
condition of insulation in cables and termination. Properly conducted test will indicate
such faults as cracks, excessive moisture or dirt, faulty splices, faulty potheads etc.

IV. TESTING EQUIPMENT:

DC Hi-Pot Test Set Digital Low Resistance Ohmmeter

Make: Biddle Inst. Make: Biddle Inst.
Catalog Nos. 220070 CatalogNos. 247001
Doble Insulation Power Factor Test Set

Model: M4000
V. TEST SET-UP DIAGRAM:

VI. SAFETY PRECAUTION:

DO NOT CONNECT THIS INSTRUMENT

TO ENERGIZED CIRCUITS.
 Before making any tests, isolate, take out of service or disconnect all
apparatus that is the subject of the test and any adjacent circuit or
apparatus that may induce any voltage into the circuit under test. Be
sure that the specimen is grounded before making any connection.
Make certain that no person can come in contact with the HV module,
the HV output terminal or any material energized by the output. Use
protective barriers if necessary.

The test set and the specimen to which it is connected are a source of
high voltage electrical energy and all person making or assisting in the
tests must use all practical safety precautions to prevent contact with
energized parts of the test equipment and associated circuit.

A.) DIELECTRIC TEST OF MAIN INSULATION

DC Hi-Pot Test Set-Up Procedures:

1. Position the HV module on the flat surface at least 3 feet(90 cm) away from the cable
to be tested, as well as any other structure.
2. Connect the wing thumb- nut GROUND terminal of the HV module to a low
impedance earth ground using one of the 15 feet ground cables supplied with the test
set.
3. Connect the wing thumb-nut GROUND terminal of the HV module to the test sample
ground terminal and main conductor using the second ground cable supplied with the
test set.
4. Position the control unit at least 6 feet away from the HV module.
5. Connect the control unit to the HV module with the interconnection cable. The plug
shells should be fully screwed down on the receptacles.
6. Remove the protective cap from the HV terminal on the HV module, then connect the
HV output cable to this terminal. Screw down the plug shell fully on the receptacle.
7. Insert the external internal plug into the receptacle marked EXT INTERLOCK.
8. With the MAIN BREAKER switched off, plug input power cord into control panel
receptacle and into 3 wire grounded power outlet.

TESTING PROCEDURES

1. Connect the alligator clip of the HV cable to the main conductor of phase A power
cable to be tested.
2. Remove the safety ground of phase A power cable.
3. Energize the test set by closing the MAIN BREAKER switch. The green AC ON
lamp and the two digital panel meters should light.
4. Initially set the current RANGE switch to the 5mA range.
5. Close the external interlock switch, if used.
6. Set the VOLTAGE CONTROL to “0” (Reset), then depress the HV ON pushbutton
switch. The HV ON lamp should light.
7. Advance the VOLTAGE CONTROL slowly until the initial test voltage in
accordance with table 1 is read on the OUTPUT VOLTAGE kilovoltmeter.
8. Set the current RANGE switch to the desired current range.
9. Maintain the test voltage for three(3) seconds. The OUTPUT CURRENT meter
indicates the leakage current of the sample under test.
10. Read and record the leakage current in the OUTPUT CURRENT meter.
11. Repeat step 7 to 9 and raised the test voltage in accordance with table 1 for newly
installed power cables and for in-serviced power cables.
12. Advance the VOLTAGE CONTROL slowly until 70 KV test voltage is read on the
OUTPUT VOLTAGE kilovoltmeter.
13. Maintain the test voltage for three(3) minutes.
14. Read and record the leakage current in the OUTPUT CURRENT meter.
15. After maintaining the test voltage for the desired time, turn the VOLTAGE
CONTROL slowly in the counterclockwise direction to “0”(RESET).
16. Depress the HV OFF pushbutton switch, or open the external interlock switch.
17. Allow sufficient time for the test sample charge to bleed off, which is indicated when
the kilovoltmeter reading returns to zero.
18. Switch the MAIN BREAKER off. The green AC ON lamp and the two digital panel
meters should now be out.
19. Connect the alligator clip of the HV cable to the main conductor of phase B power
cable to be tested.
20. Remove the safety ground of phase B power cable and connect it to phase A.
21. Repeat step 3 to 18.
22. Connect the alligator clip of the HV cable to the main conductor of phase C power
cable to be tested.
23. Remove the safety ground of phase C power cable and connect it to phase B.
24. Repeat step 3 to 18.
25. The test is complete.

Table 1: Test Voltage

Rated Cable Utilization Voltage, Applied DC Voltage Applied Dc Voltage
Voltage,KV KV KV(Used) KV(New)
6 6.24 & below 5 15
15 13.8 delta 20 30
15 7.62KVY 11 30
35 20 28 70

Insulation Power Factor Test Set-Up Procedures:

1. Connect the clip end of the twist-lock ground lead of the test instrument to the station
ground, preferably on the equipment to be tested.
2. Insert the other end of the ground leads into the test set ground receptacle on the right
side of the transformer case.
3. Lock the lead in place by rotating the connector one-half revolution clockwise.
4. Insert the inboard pothead of the high voltage test cable into the receptacle on the
right side of the transformer case until the grooved metal ground ferrule can be
engaged by the tongue latch.
5. Insert the control cable from the transformer case to the instrument control console.
6. Set the VOLTAGE control to zero voltage , the counterclockwise stop.]
7. Set the reversing switch to the “ON” position
8. Set the CURRENT multiplier switch to the highest multiplier(100 milli-Amperes).
9. Set the WATTS multiplier switch to the highest multiplier(1K)
10. Set the current interference switch Icc to OFF position.
11. The SELECTOR switch is set to CHECK.
12. Connect the polarized supply lead to a 240 Vac source to the test set receptacle
located on the front of the transformer case panel. The green power pilot light on the
panel indicates when the supply voltage is connected.

TESTING PROCEDURES

1. Hook the high voltage test cable of the test instrument to the main conductor terminal
of phase A power cable under test.
2. Ground the main conductor terminals of phase B & C using no. 12 AWG wires.
3. Connect the shield ends of the power cables under test to system ground.
4. Turn the circuit breaker to “ON” position.
5. Press the high voltage push button switch to energized the test specimen, a red light
labeled HIGH VOLTAGE light.
6. While watching the KILOVOLT meter, gradually turn the voltage control clockwise
until the desired voltage(5 or 10 KV) is obtained.
7. Set the CURRENT & WATTS meter to 100 division by turning the METER
ADJUST control.
8. The selector switch is set to the CURRENT multiplier position.
9. Select the multiplier that gives the largest on scale meter reading on the CURRENT
& WATTS meter.

10. Read and record the current and multiplier readings in the CURRENT & WATTS
meter scale.
11. The selector switch is set to CHECK position.
12. Check if the CURRENT & WATTS meter is still in the 100 division, turn the
METER ADJUST control if necessary.
13. The SELECTOR switch is set to the WATTS MULTIPLIER position.
14. The WATTS ADJUST control is rotated in the direction which produces a decreasing
reading until a minimum meter reading is obtained on the CURRENT & WATTS
meter.
15. The WATTS multiplier switch is reduced successively to the smallest multiplier
which gives an on scale meter reading.
16. Re-adjust the WATTS ADJUST control for the minimum watts reading. The
minimum watts reading should be obtained on the smallest WATTS MULTIPLIER
for the particular CURRENT MULTIPLIER in use.
17. Turn the POLARITY control switch slowly in a clockwise direction while carefully
noting the initial change in the deflection of the pointer of the CURRENT & WATTS
meter. A down scale movement indicates a positive polarity while an up scale
movement indicates a negative WATTS.
18. Read and record the watts reading in the CURRENT & WATTS meter scale taking
into accounts the polarity.
19. Turn the REVERSING switch to the other “on” position.
20. Re-adjust the WATTS ADJUST control for the minimum watts reading. The
minimum watts reading should be obtained on the smallest WATTS MULTIPLIER
for the particular CURRENT MULTIPLIER in use.
21. Turn the POLARITY control switch slowly in a clockwise direction while carefully
noting the initial change in the deflection of the pointer of the CURRENT & WATTS
meter. A down scale movement indicates a positive polarity while an up scale
movement indicates a negative WATTS.
22. Read and record the watts reading in the CURRENT & WATTS meter scale taking
into accounts the polarity.
23. Compute and record the average of the two watts reading in step 16 and 20, taking
into account the signs.
24. The computed watts reading in step 23 is the measured watts loss dissipation of
phase A power cable under test.
25. Repeat step 1 to 22 to determine the current and watts loss dissipation of phase B & C
power cables.
26. Compute for the percent insulation power factor at 10 KV in each bushing using the
formula:

%IPF = 10xW x100%

mA

where: W is the average watts loss reading

mA is the current reading

27. The test is completed.

B.) MAIN CONDUCTOR RESISTANCE MEASUREMENT

1. Connect the main conductor of one end of phase A power cable to the other end of
phase B power cable using #12 AWG jumper wire.
2. Set the selector switch of the multi meter to the lowest resistance range.
3. Connect the positive test lead of the multi meter to the main conductor of phase A
power cable and the negative lead to phase B power cable.
4. Read and record the measured conductor resistance A+B = X
5. Connect the main conductor of one end of phase B power cable to the other end of
phase C power cable using #12 AWG jumper wire.
6. Set the selector switch of the multi meter to the lowest resistance range.
7. Connect the positive test lead of the multi meter to the main conductor of phase B
power cable and the negative lead to phase C power cable.
8. Read and record the measured conductor resistance B+C = Y
9. Connect the main conductor of one end of phase C power cable to the other end of
phase A power cable using #12 AWG jumper wire.
10. Set the selector switch of the multi meter to the lowest resistance range.
11. Connect the positive test lead of the multi meter to the main conductor of phase C
power cable and the negative lead to phase A power cable.
12. Read and record the measured conductor resistance C+A = Z
13. Compute the value of the conductor resistance of power cable A, B & C using the
following formula:

C = (Z-X+Y)/2 , ohms
A = Z-C, ohms
B = Y-C, ohms

C.) SHIELD RESISTANCE MEASUREMENT

14. Connect the shield and main conductor together using #12 AWG jumper wire in
one end of phase A power cable.
15. Set the selector switch of the ducter or low resistance ohmmeter(DLRO) to the
lowest resistance range.
16. Connect the P1C1 test lead of the ducter to the main conductor and the C2P2 test
lead to the shield in the other end of phase A power cable.
17. Read and record the measured total shield and conductor resistance of phase A
power cable.
18. Determine the actual value of the shield resistance by subtracting the computed
resistance of the main conductor in phase A obtain in step 13 to the value obtain in
step 17.
19. Record the shield resistance of phase A power cable.
20. Connect the shield and main conductor together using #12 AWG jumper wire in
one end of phase B power cable.
21. Set the selector switch of the ducter or low resistance ohmmeter(DLRO) to the
lowest resistance range.
22. Connect the P1C1 test lead of the ducter to the main conductor and the C2P2 test
lead to the shield in the other end of phase B power cable.
23. Read and record the measured total shield and conductor resistance of phase B
power cable.
24. Determine the actual value of the shield resistance by subtracting the computed
resistance of the main conductor in phase B obtain in step 13 to the value obtain in
step 17.
25. Record the shield resistance of phase B power cable.
26. Connect the shield and main conductor together using #12 AWG jumper wire in
one end of phase C power cable.
27. Set the selector switch of the ducter or low resistance ohmmeter(DLRO) to the
lowest resistance range.
28. Connect the P1C1 test lead of the ducter to the main conductor and the C2P2 test
lead to the shield in the other end of phase C power cable.
29. Read and record the measured total shield and conductor resistance of phase C
power cable.
30. Determine the actual value of the shield resistance by subtracting the computed
resistance of the main conductor in phase C obtain in step 13 to the value obtain in
step 17.
31. Record the shield resistance of phase C power cable.
32. The test is now complete.