Kinectrics Presentation - HV Cable Testing

GENERATING SUCCESS --- FOR 100 YEARS
Transmission & Distribution Technologies

Hassan Younes
Transmission Cable & Substations ,
Service Line Lead
2014 / 2015
life cycle management solutions
Copyright 2014 Kinectrics Inc. All rights reserved.
Page 1
Kinectrics - Proprietary and Confidential
Transmission Cable Testing

GENERATING SUCCESS --- FOR 100 YEARS

Page 2
Manufacturing
Transportation
Repairs / Upgrade
Effect of Aging
Environment
Installation Mistakes
Methods / Experience
Damage During
Transport
Raw Materials
Manufacturing
Mistakes
Testing Philosophy / Why Test ?
Installation
Operation @ 50/60 Hz.
Tested at 50/60 Hz.
Maintenance
Testing
Acceptance
Testing
Commissioning
Factory Type
Testing
Power Cable Life Cycle

Page 3
Basic tests available in the industry

After Laying Field Tests
24 Hr. Soak Test

DC Hipot Test
AC Hipot Test
VLF Test (0.1Hz)
VLF CR Test (0.1Hz)
DAC /OSW Test
Partial Discharge Test

Dielectric Spectroscopy
4
Page 4
Test methods
Soak Test Method
Energize Cable System at Uo for 24 or 48 hours
Withstand Testing (Hipot)

DC HiPot Testing
Not for XPLE type cable systems (Space Charge).
AC HiPot Testing
Recommended in combination with PD monitoring (IEC Standard).
VLF Testing
Limited to Transmission cables up to 69KV (IEEE 400.2).
Very limited data on VLF withstand and nearly no data on PD diagnosis.
Diagnostic Testing
Damped AC or Oscillating Wave
Partial Discharge Testing

Page 5
Factory Testing at Kinectrics Laboratory

Type Test
Electrical and Material Testing is performed per
IEC 60840, 62067, 60229, 230, IEEE 404, IEEE
48, AEIC, and ICEA standards.
Kinectrics performs an independent third

party Laboratory testing for most cable
manufacturers:
Electrical Testing
Partial Discharge
Tan Delta at Uo @ 100C
Heating Cycle @ 2Uo for 20 days / 100C Partial
Discharge at Ambient & 100C
Switching Impulse @ 100C
Lightning Impulse at 100C
AC Withstand
Resistance of semi-conducting screen
Cable
Termination
Cable
Termination
PD Sensitivity of 5pC or better for cable sections

and accessories
HV Source
CHV
CLV
Cable
Section
No PD activity should be detected above 1.5Uo
Cable
Section
Joint
Joint
HV Divider +
PD Sensor
Vref
VPD
Cable
Section
Grounding
Measurement
Location

Page 6
Onsite Testing
(Commissioning & Maintenance Testing)
Electrical testing is performed Onsite by
Kinectrics in compliance with various testing
standards.
Kinectrics performs an independent

third party onsite testing service
worldwide:
AC Withstand with Partial Discharge

Online Partial Discharge
Tan Delta at Uo
Dielectric Spectroscopy
Surge Voltage Limiter testing (SVL)
Cross bonding contact resistance testing
Sheath potential testing
Positive and Zero sequence impedance
testing
PD Sensitivity of 10pC or better for cable sections and 5pC or better for accessories.
No PD activity should be detected at 1.5 Uo However,
Some clients require NO PD activity at 1.7Uo (During Hipot).
Page 7
AC Hipot (Withstand) using Resonance Circuit
Compliant with IEC 60840 and IEC 62067 international testing standards
Testing at near power frequency from 20 Hz to 300 Hz
Test level range from 1.25Uo to 2Uo but typically 1.7Uo.
Over voltage applied for 60 minute or by Cycles.
Accepted commissioning test methodology for HV & EHV
Pros
Cons
Comparable to factory tests

Requires heavy equipment
Proven test methodology with
Require Technical expertise
decades of experience
Effective in identifying life limiting
defects
Can perform PD testing during
AC HiPot tests
Gets soft failure so meaningful
forensics can be performed
Page 8
Typical single RTS Circuit configuration

260KV / 83 A with an external power supply generator
External filter divider is required to be

setup in the field to protect the RTS,
measure applied voltage and filter out
unwanted P from the RTS.
Outputs pure sinusoidal waveform at a Frequency 20 to 300 Hz.

Page 9
Typical single RTS system configuration

260KV / 83 A with an external power supply generator

Page 10
Resonance Test System units in Parallel

260KV / 249A for testing long cables

Page 11
Resonance Test System 4 unit configuration

520KV / 166A for testing long cables
Four RTS units in series & parallel

configuration to perform testing up to
520KV test voltage and 166 A of load.

Page 12
Multiplexed Daisy Chain System

Daisy Chained Multiplexer Systems, A Kinectrics designed partial
discharge monitoring multiplexer system that allows us to connect a large
number of cable joints into a network that can be remotely and
individually controlled via fiber optics from test site.
This product is used exclusively by Kinectrics to offer in lieu of the Joint

hopping which requires many extra activities such as additional staff,
traffic diversion, police escort, barricades, etc This translates to a more
expensive process.

Page 13
Multiplexed Daisy Chain PD Systems
Installed prior to testing, removed following completion of testing

Constant PD monitoring of all accessories simultaneously
Does not require access to joints during test No joint hoping
Requires pre-installation of PD sensors and Fiber optic cable
Water proof and 3 months battery life
Can remotely switch between phases and joints
Page 14

Page 15

Page 16
Sheath Sensors
Partial Discharge Sheath Sensors: A Kinectrics Designed Sheath type
sensor to be used on cable system where cable joints have no cross
bond links for a standard type HFCT (High Frequency Current
Transformer type PD sensor).
Sheath Sensors are typically used near a joint or before and after a joint
to detect PD activity with high accuracy in or near the accessory.
Sheath (Voltage) PD Sensor

Page 17
Sheath Sensor (Voltage)

Sheath sensors are a unique type sensor designed and built by Kinectrics
for special straight thru joints without bond lead. They are designed to
sense voltage variations in the sheath.
Typically use ultra wideband PD monitors

10kHz to 30 MHz
10kHz to 50 MHz
10kHz to 400 MHz

Page 18
High Frequency CTs.

Kinectrics designed HFCT partial discharge
sensors to be utilized in cable systems where cable
joints have exposed and accessible cross bond
links.
Higher frequency bandwidth compared to other
sensors on the market provides a much better
overall performance.
HFCT PD Sensor

Page 19
Power Frequency CTs.
Kinectrics uses power frequency partial

discharge sensors to be utilized in cable
systems where online Partial Discharge
sensitivity is used to synchronize with
applied voltage zero crossing. These
sensors are left on cable systems for
future online PD monitoring.
PFCT Power Frequency Current

Transformer

Page 20
Sensitivity Assessment
Inject 2,000 pC
Cable
Termination
Cable
Termination
HV Source
CHV
CLV
Cable
Section
Cable
Section
Joint
Joint
HV Divider +
PD Sensor
Vref
VPD
Cable
Section
Grounding
0 Measurement
Location

Page 21
Typical Installation Problems

Transportation Damage 2%
o
o
o
o
Workmanship 88%
o
o
o
o
o
o
o
Improper Lifting
Improper Transportation
Improper Reel Orientation
Manufacturing
Protrusions/dents at inner conductor

Knife cuts
Lack of cleanliness
Flat spots
Misalignment of components
Inadequate use of materials
Lack of Experience
Pulling Damage 10%

o
o
o
o
Dents in sheath
Exceeding bending radius
High Pulling Tension
Torqueing cable

Page 22
Variable Frequency Resonance Test System (RTS)

22MVA
83A / 260KV / 1650nF (20-300Hz)
Control Room
1
2 LC
Reactor
Exciting Transformer
Tarp System
HV Filter
Meets IEC 60840 & 62067 standards for cable testing (up to 500KV cable class).
RTS testing combined with Partial Discharge monitoring, provides the ultimate
diagnostic tools in the industry to determine the health condition of your cable system.

Page 23
Applied Test Typical Voltage Profile

60 minutes Hipot Typically at 1.7Uo
PD monitoring
Voltage Dwell & Frequency Sweeps (1Mhz to 20Mhz)

Page 24
IEC 60840 Standard, for HV Cable (30KV to 150KV):

Page 25
IEC 62067 Standard, for EHV Cable (150KV to 500KV)
133 KV
226 KV
166 KV
282 KV
203 KV
339 KV
289 KV
491 KV
289 KV
491 KV
Requested Test Voltage is typically 1.7Uo of the HIGHEST voltage rating in a cable class
Page 26
Competing Technologies
Soak Test (24 Hr. or 48 Hr. at Uo)
Allowed by some specifications as an alternative test

No test equipment required: quick and cheap, but how effective ?
Low Risk of a failure during test
No overvoltage stress, thus no accelerated ageing of defects
Can be combined with PD diagnosis
Kinectrics successfully performed PD diagnosis during 24 hr Soak
test on a Cable System in Wisconsin for ATC.
Not a diagnostic tool

Page 27
Oscillating Wave / Damped AC / DAC / OSW
OSW / DAC Circuit
IEEE 400.4 Guide for Field testing of Shielded Power

Cable Systems.
50+ Excitation Shots

Not a continuous AC test
20 to 300 Hz. Oscillations
Meets & Exceeds 1.7 Uo test voltage levels
Applicable for withstand testing with PD diagnosis
Applicable for cable class 5KV and higher

Page 28
Oscillating Wave / Damped AC / DAC / OSW
Long DC Charging Time up to 100s for each shot.

Oscillations occur at 20-300Hz. for 10ms per shot.
High risk of spare charges due to DC charging, especially in HV/EHV Cables.
Damping factor ~ 5% to 40%, capacitance dependent.
50+ excitations yield ~ 2 seconds of AC stress, not a suitable withstand test.
Risk of small but critical voids do not initiate PD activity due to inadequate AC Stress, thus weak
points may not be detected.
IEEE 400.4 is a Guide NOT AN IEC STANDARD, thus DAC is not a viable withstand solution.
Page 29
Other Technologies
VLF Very Low Frequency (0.01 Hz. To 0.1 Hz.)
IEEE 400.2 Standard for cable class 69KV and below, used for lower voltage cable
class.
Hipotential Testing very few zero crossings compared to 20 to 300 Hz test.
Possible formation of space charges on HV and EHV class cable
Very limited potential of electrical tree growth, thus requiring much longer test time.
Portable with low power requirement, smaller test sets, however how effective on HV
& EHV ?
May be combined with PD or tan, not comparable to 20-300 Hz. test method.

Page 30
Formation of Electrical Trees

Effects of Frequency and Test Time on Tree Shape Formation.
Sine wave @ 2Uo (0.1Hz to 500Hz)
Sinewave at 2 Uo
Few Branches / Less discharge

ducts
Note the long test time
VLF
Sinewave at 2 Uo
@ 10 50 Hz
More Branches / More discharge
ducts
Less test time
RTS
Sinewave at 2 Uo
@ 100 500Hz.
Numerous Branching / lots of
discharge ducts

Page 31
Total PD pulses collected @ Sine Wave 2Uo.

From 0.1 Hz. (VLF) to 20-300 Hz. (NPF) test frequency
Time (hrs)
# of PD pulses
20Hz
300Hz
# of PD pulses collected at NPF is

at 1/3 of the VLF time
VLF requires much longer test time interval until breakdown

VLF shows significantly less PD pulses as compared to NPF
VLF test time has to be active much longer to achieve same # of PD pulses as NPF
Page 32
What is Partial Discharge?

IEC defines PD as: Localized electrical discharge that only partially bridges the insulation
between conductors and which can or cannot occur adjacent to a conductor.
Partial Discharge measurement is a very important diagnostic tool in assessing the
overall health condition of the insulation in power cable systems.
In XLPE
In OIL
In AIR

Page 33
Partial Discharge
PD is a Diagnostic tool to detect signs of distress in distribution
and Transmission cable systems.
PD gives us the opportunity to detect defects BEFORE failure
Can be performed on-line or off-line
Can use multiple types of power supplies, we prefer NPF.
PD testing is a non destructive test to an insulation system.
PD is typically measured during the Hipot test.
PD is performed at near power frequency and at elevated voltages
to accelerate aging of defects
PD ACTIVITY RELATES DIRECTLY TO INSULATION INTEGRITY

Page 34
Partial Discharge (Equivalent Circuit)

Page 35
Partial Discharge
20
Voltage/Electric Field
Electrical Field Conditions
15
10
Initial
Discharge
Return
Discharge
Second
Discharge
5
Phase Angle
0
0
45
90
135
180
225
270
315
360
-5
-10
-15
Appl. Voltage [kV]

Background Field [kV/mm]
Void Breakdown Strength
Void Field [kV/mm]
-20

Page 36
Terminal vs. Distributed PD measurements
Terminal PD Measurement
No Joints
Distributed PD Measurement
Jointed System

Page 37
Typical Partial Discharge Pattern
Phase Resolved PD Pattern (doble / Lemke, HPMT 03-06)

Page 38
PD Testing Online vs Offline

On-Line
Off-Line
Non-invasive test
Requires cable system to be

disconnected
Done at rated voltage Uo
PDIV and PDEV cannot be measured Guiding criteria is that the cable
system should be PD free at the
Assess individual PD sources
separately
specified test voltage
Often, multiple PD sources from
Requires external power source
various types of HV equipment are
Done at elevated voltages usually
detected
at 1.7Uo.
Can only detect sources present at
Measures PDIV, PDEV, PD level.
the time of testing
Localizes PD Source & Intensity

Page 39
PD Attenuation with Cable Length
Corresponding Attenuation (Normalized)
0.1
Length [feet]
0.01
0
1000
2000
3000
4000
5000
6000
7000

Page 40
Water Tree Formation

High electrical field caused by voltage transients result in power dissipation in the micro
water channels that exist in the XLPE insulation. This raises the temperature of the water
and increases pressure in the water tree channel, generating cavities to support PD.
Water migration into the insulation leads to water trees which in turn decreases insulation
resistance and increases leakage current
Water Trees form and with time convert to electrical trees producing partial discharge and
ultimately lead to failure
Insulation Failure
Water Trees

Page 41
Water Trees (XLPE)

Insulation Shield
Vented Water
Tree (VWT)
Electrical
Tree
Lowers the AC breakdown voltage Increased DC leakage current

Can only be detected via Dielectric
Increase in dielectric loss Tan
Spectroscopy ( Tan Delta at 0.01 to
Delta
60 Hz. )
Page 42
Why test at 1.7Uo ?

(Constant PD Monitoring Only)
Distribution
of PDIV
During
HV Hipot
Comm.
Testing
Distribution
of PDEV
during
Test
0.90
Percentile
1.00
0.75
50% to 90% of PDEV occur at or above

1.7Uo
0.50
Some go as high as 2Uo depending on

cable class
0.25
0.00
0.50 0.60 0.70 0.80 0.90 1.00 1.10 1.20 1.30 1.40 1.50 1.60 1.70 1.80 1.90 2.00
Partial Discharge Inception Voltage (PDIV) [U 0 ]
IEC Standards 60840 & 62067 adopted 1.7Uo due to its higher confidence level and over
30 years of testing experience; if PD source is present, it will ignite at or above 1.7Uo.
But wait, in what time frame

Page 44
Why test for 60 minutes ?

(Constant PD Monitoring Only)
On-Set of PD During HV Commissioning Testing

1.00
0.90
Percentile
0.75
0.50
75% to 99% of the time PD ignites at or

above 20 minutes
Some increase test time depending on
test frequency, for 20Hz, test time is
180 minutes.
0.25
0.00
0
10
20
30
Time [minutes]
40
50
60
IEC Standards 60840 & 62067 adopted 60 minutes test time due to its higher
confidence level and over 30 years of testing experience; if PD source is present, it
will ignite at or above 1.7Uo when applied between 25 min to 60 min.
Page 45
Case Study Feb. 2014

AC Hipot with Daisy Chained PD system
Using 2 RTS units in series to be

able to successfully test and PD
diagnose a 345KV class cable.
* 4 major issues were found.

Page 46
345KV Cable System Tested at 1.7Uo with PD

17 splices per phase (Feb 2014)
Joint was replaced & retested, no PD

present
PD was detected at 339KV at Joint 6

via PD sensor

Page 47

XC Phase / Joint failed during testing (Feb 2014)
PD pulses started igniting a 318KV,
then few seconds later the joint
failed.
Joint was replaced & retested

Page 48

Cascade System / Joint failed during testing (Mar 2014)

Page 49

Termination showed PD activity near IGBT Pulse

Page 50

6 Cables no splices per phase (Jun 2013)
PD was detected on all 3 phases near GIS termination

via Kinectrics HFCT type PD sensor.
Cable section had to be replaced and

retested to be PD Free

Page 51

3 Cables no splices per phase (Mar 2013)
PD was detected on phase A open air termination via
Kinectrics HFCT type PD sensor.
Orientation of PD Sensors allowed the location of the
PD activity to be located Note reversed polarity of A
phase.
All 3 phase were being tested simultaneously.

Workmanship issues while installing stress cone.
Termination had to be
replaced and retested to
be PD Free

Page 52
Cable Class
Total
Accessories
Failures
Failure Rate
Sample of failures from 2012 - 2014
December
2014
138 kV
18
5.5%
October
2014
230
12
8.3%
March
February
June
April
March
December
2014
38
7.9%
2012
102
48
18
12
18
18
4
4
1
1
1
1
3.9%
8.3%
December
138 kV
345 kV
72 kV
115 kV
72 kV
138 kV
138 kV
284
17
5.99%
Test Date
2014
2013
2013
2013
2012
Totals:
5.6%
8.3%
5.6%
5.6%
Selected few Jobs with actual failures due to Hipot and/or PD, shows a steady
failure rate of 4% to 8% on the average Failed components were replaced by
cable manufacturers to ensure long term operation of PD free cable systems.

Page 53
Summary
Many IEC Studies and experiences prove a combination of AC HV
(Hipot) & PD is the Ultimate Diagnosis Tool in determining the
health of underground cable systems.
Test levels must be at 1.7Uo to provide higher confidence level that
all possible PD sources are addressed.
Test duration likely need to be adjusted when testing at lower
frequencies Cigre Workgroup B1.38. Test Duration by cycles.
Trends going towards constant monitoring via daisy chained PD
Systems for commissioning testing.
Testing with Near Power Frequency (20Hz. 300 Hz.) @ 1.7Uo
subjects the cable to similar stresses as operating frequency at
elevated voltages to locate all possible PD sources, after all, the
cable system will live the rest of its life at 50/60 Hz.

Page 54
Contact Information:
HASSAN YOUNES
Service Line Leader
Transmission Cables & Stations
800 Kipling Avenue, Toronto Ontario M8Z-5G5

hassan.younes@kinectrics.com
Mobile: 416.206.7528
Office: 416.207.6000 xtn 6347
Responsible for all HV & EHV Cable testing and Partial

Discharge diagnosis in North America and Europe
Page 55
Questions?

Page 56
Thank you for your attention

Page 57

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GENERATING SUCCESS --- FOR 100 YEARS

Transmission & Distribution Technologies

Kinectrics - Proprietary and Confidential

Transmission Cable Testing

life cycle management solutions

Kinectrics - Proprietary and Confidential

Testing Philosophy / Why Test ?

Operation @ 50/60 Hz.

Tested at 50/60 Hz.

Power Cable Life Cycle

life cycle management solutions

Kinectrics - Proprietary and Confidential

Basic tests available in the industry

24 Hr. Soak Test

Partial Discharge Test

life cycle management solutions

Copyright 2014 Kinectrics Inc. All rights reserved.

Kinectrics - Proprietary and Confidential

Energize Cable System at Uo for 24 or 48 hours

Withstand Testing (Hipot)

Not for XPLE type cable systems (Space Charge).

life cycle management solutions

Kinectrics - Proprietary and Confidential

Factory Testing at Kinectrics Laboratory

Kinectrics performs an independent third

PD Sensitivity of 5pC or better for cable sections

No PD activity should be detected above 1.5Uo

life cycle management solutions

Kinectrics - Proprietary and Confidential

Kinectrics performs an independent

AC Withstand with Partial Discharge

Kinectrics - Proprietary and Confidential

AC Hipot (Withstand) using Resonance Circuit

Comparable to factory tests

Kinectrics - Proprietary and Confidential

Typical single RTS Circuit configuration

External filter divider is required to be

Outputs pure sinusoidal waveform at a Frequency 20 to 300 Hz.

Kinectrics - Proprietary and Confidential

Typical single RTS system configuration

life cycle management solutions

Kinectrics - Proprietary and Confidential

Resonance Test System units in Parallel

life cycle management solutions

Kinectrics - Proprietary and Confidential

Resonance Test System 4 unit configuration

Four RTS units in series & parallel

life cycle management solutions

Kinectrics - Proprietary and Confidential

Multiplexed Daisy Chain System

This product is used exclusively by Kinectrics to offer in lieu of the Joint

life cycle management solutions

Kinectrics - Proprietary and Confidential

Multiplexed Daisy Chain PD Systems

Installed prior to testing, removed following completion of testing

Copyright 2014 Kinectrics Inc. All rights reserved.

Kinectrics - Proprietary and Confidential

life cycle management solutions

Kinectrics - Proprietary and Confidential

life cycle management solutions

Kinectrics - Proprietary and Confidential

life cycle management solutions

Kinectrics - Proprietary and Confidential