DWG Insulator Polymer

KEMA INSPECTION REPORT
3174-15
Object Power cable system consisting of 3-core submarine optical fiber composite
power cable including a factory joint, 3 porcelain outdoor terminations and
3 composite outdoor terminations
87/150 (170) kV – 3x800 mm2 – Cu – XLPE
Client Zhongtian Technology Submarine Cable Co., Ltd.,

Nantong, China
Manufacturer Cable Zhongtian Technology Submarine Cable Co., Ltd.,
Nantong, China
Accessories Changlan Electric Technology Co., Ltd
Changsha, China
Inspected by KEMA Nederland B.V.,

Arnhem, The Netherlands
Test location Zhongtian Technology Submarine Cable Co., Ltd.,
Nantong, China
Testing Center of Shanghai Electric Cable Research Institute (TICW),

Shanghai, China
Date of tests 22 January to 29 June 2015
Test specification The type tests have been carried out in accordance with Cigré 490 (2012).
Remarks The object passed the tests.
This report applies only to the object tested. The responsibility for conformity of any object having the
same type references as that tested rests with the Manufacturer.
This report consists of 60 pages in total.
KEMA Nederland B.V.
J.P. Fonteijne
Executive Vice President
KEMA Laboratories
Arnhem, 27 October 2015
Copyright: Only integral reproduction of this report is permitted without written permission from DNV GL. Electronic copies as PDF or scan of this report
may be available and have the status “for information only”. The sealed and bound version of the report is the only valid version.
KEMA Laboratories -2- 3174-15
TABLE OF CONTENTS
1 IDENTIFICATION OF THE OBJECT TESTED ...................................................................... 4

1.1 Ratings/characteristics of the object tested 4
1.1.1 Characteristics of the cable system 4
1.1.2 Characteristics of the cable 4
1.1.3 Characteristics of the accessories 8
1.2 List of drawings 10
2 GENERAL INFORMATION ............................................................................................ 11

2.1 Persons attending the inspection 11
2.2 The inspection was carried out by 11
2.3 Purpose of the tests 11
2.4 Inspection of the test set-up 11
3 ELECTRICAL TYPE TESTS ON COMPLETE CABLE SYSTEM ................................................ 12

3.1 Test arrangement 12
3.1.1 Determination of the cable conductor temperature 12
3.1.2 Test set-up 12
3.2 Tensile bending test 13
3.3 Test voltage values 15
3.4 Partial discharge test at ambient temperature 16
3.5 Tan δ measurement 18
3.6 Heating cycle voltage test 19
3.7 Partial discharge test at ambient temperature 20
3.8 Partial discharge test at high temperature 21
3.9 Lightning impulse voltage test 22
3.10 Power frequency voltage test 34
3.11 Examination 35
3.11.1 Examination of cable and accessories 35
3.11.2 Photographs 36
3.12 Resistivity of semi-conducting screens 39
4 NON-ELECTRICAL TYPE TESTS ON CABLE COMPONENTS AND ON COMPLETE CABLE .......... 40

4.1 Check of cable construction 40
4.2 Tests for determining the mechanical properties of insulation before and after
ageing 43
4.3 Tests for determining the mechanical properties non-metal sheaths before and after
ageing 44
4.4 Ageing test on pieces of complete cable 45
4.5 Pressure test at high temperature on oversheath 46
4.6 Hot set test for XLPE insulation 47
4.7 Shrinkage test for XLPE insulation 48
4.8 Shrinkage test for PE oversheaths 49

4.9 Measurement of carbon black content of black PE oversheaths 50
4.10 Water penetration test on conductor (including optical fiber unit) 51
4.11 Water penetration test on metal sheath 53
4.12 Radial water penetration test for joints 55
5 DRAWINGS............................................................................................................... 57
1 IDENTIFICATION OF THE OBJECT TESTED
1.1 Ratings/characteristics of the object tested

1.1.1 Characteristics of the cable system
Rated voltage, U0/U (Um) 87/150 (170) kV

Rated maximum conductor temperature 90 °C
Rated conductor cross-section 3x800 mm2
Composition of the cable system:
· cable One piece of submarine cable of type HYJQF41-
F 87/150 kV 3x800+24B1 including a factory joint
· accessory 1 three pieces of YJZWC4-87/150 kV
· accessory 2 three pieces of YJZWCF4-87/150 kV
The test voltages and calculated nominal field stresses were based on U0 test = 87 kV.
1.1.2 Characteristics of the cable
Standard IEC 60840, Clause 6
Manufacturer (as stated by the client) Zhongtian Technology Submarine Cable Co., Ltd.,
Nantong, China
Type U0 = 87 kV 3x800 mm2 XLPE Submarine Cable
Manufacturing year November 2014
Overall diameter (D) 220,4 mm
Calculated nominal electrical stress at 6,7 kV/mm
conductor screen at U0 = 87 kV (Ei)
Calculated nominal electrical stress at 3,4 kV/mm
insulation screen at U0 = 87 kV (Eo)
No. of cores 3
Core identification core 1 = red
core 2 = yellow
core 3 = blue
Nominal capacitance between conductor 0,192 µF/km
and metal screen
Marking on the oversheath 中天科技海缆有限公司 HYJQF41-F 87/150kV 3×
800+24B1 2014/08　xxxx m
Construction see list of drawings
Conductor
· material copper
· cross-section 800 mm2
· nominal diameter (d) 34,0 mm
· type compacted circular
· maximum conductor temperature in 90 °C
normal operation
· presence and nature of measures to yes
achieve longitudinal watertightness swelling tape applied between layers of the
conductor wires
· swelling material swelling tape
· material designation known in KEMA's files
· manufacturer of the material known in KEMA's files
Semi-conducting tape outside the conductor

· material semi-conducting swelling tape
· number of swelling tapes 2
· nominal thickness and width 0,27 x 40 mm (overlap: 25%)
Conductor screen
· material semi-conducting shield compound
· nominal thickness 1,5 mm
Insulation
· material XLPE
· nominal inner diameter of the insulation 38,1 mm
· nominal outer diameter of the insulation 75,1 mm
· material designation known in KEMA's file
Insulation (core) screen

· material semi-conducting shield compound
Longitudinally watertightness
· presence and nature of measures to yes
achieve longitudinal watertightness along semi-conducting swelling tape
insulation screen
· number of swelling tapes 2
· nominal thickness and width 0,5 x 70 mm
(overlap: 10%)
Metal screen
· material lead alloy
· nominal thickness of sheath 3 mm
· type plain extruded
PE sheath
· material semi-conductive PE, type ST7
· colour black
Fillers
· material PE fillers
Binder tape
· material rubber coated cloth tape
· number of tapes 1
· nominal thickness and width 0,3 x70 mm (overlap: 30%)
Teredo protection
· material copper tape
· number of tapes 2
· nominal thickness and width 0,10 x 60mm (overlap: 20%)
Armour bedding
· material PP yarns
Metal armour
· material galvanized steel wires
· number of wires 100 ± 2
· nominal diameter of wires 6 mm
Out serving
· material PP yarns
· nominal overall diameter of the cable (D) 220,4 mm
· colour black and yellow
· graphite coating applied no
Fire retardant no
(acc. IEC 60332-1)
Manufacturing details insulation system

· location of manufacturing Nantong, China
· type of extrusion line VCV
· type of extrusion triple common extrusion
· factory identification of extrusion line ZTT/HL-SC032
· manufacturer of the extrusion line known in KEMA's files
· identification of production batch 201408
· curing means nitrogen
· cooling means nitrogen
Optical fiber cable

· number of fibers 2×12 G. 652D
· single mode fibers 2×12 G. 652D
· material designation G. 652D
· material of tubes outside the fibers Stainless steel

· number of tubes 1
· nominal diameter of the tube 2,7 mm
· nominal thickness of the tube 0,2 mm
· material of innersheath HDPE

· nominal diameter of innersheath 4,7 mm
· material of steel wires galvanized steel wire　

· number of steel wires 14
· nominal diameter of steel wires 1,23 mm
· material of oversheath HDPE

· nominal diameter of oversheath 14,6 mm
1.1.3 Characteristics of the accessories
Accessory 1
Outdoor termination with porcelain insulator for polymeric extruded power cable
Manufacturer (as stated by the client) Changlan Electric Technology Co., Ltd.,
Changsha, China
Type prefabricated
Type designation YJZWC4-87/150 kV
Manufacturing year January 2015
Creepage distance 5590 mm
Flashover distance 1620 mm
Number of sheds 37 (19 big and 18 small)
Insulator
· type of insulator porcelain
· type designation known in KEMA's files
· manufacturer known in KEMA's files
· colour of insulator brown
· pedestal insulators known in KEMA's files
Conductor connector
· type, reference number known in KEMA's files
· assembly technique compressed
· tooling, dies and necessary setting Die width 52 mm
· details of the type test approval known in KEMA's files
Stress cone
· type of stress cone moulded EPDM
Insulating medium
· insulating medium silicon oil
Installation instruction see list of drawings

Accessory 2
Outdoor termination with composite insulator for polymeric extruded power cable
Manufacturer (as stated by the client) Changlan Electric Technology Co., Ltd.,
Changsha, China
Type prefabricated
Type designation YJZWCF4-87/150 kV
Manufacturing year January 2015
Creepage distance 5525 mm
Flashover distance 1570 mm
Number of sheds 30 (15 big and 15 small)
Insulator
· type of insulator composite
· colour of insulator grey
· pedestal insulators known in KEMA's files
Conductor connector
· type, reference number known in KEMA's files
· assembly technique compressed
· tooling, dies and necessary setting die width 52 mm
· details of the type test approval known in KEMA's files
Stress cone
· type of stress cone moulded EPDM
Insulating medium
· insulating medium silicon oil
Installation instruction see list of drawings

1.2 List of drawings
The manufacturer has guaranteed that the object submitted for tests has been manufactured in
accordance with the following drawings and/or documents. KEMA has verified that these drawings
and/or documents adequately represent the object tested. The manufacturer is responsible for the
correctness of these drawings and/or documents and the technical data presented.
The following drawings and/or documents have been included in this report:
Drawing no./document no. Revision
201408-05 01
YJZWC4-87/150 kV -
YJZWCF4-87/150 kV -
KEMA Laboratories-11- 3174-15
2 GENERAL INFORMATION
2.1 Persons attending the inspection
Name Company
Zhang Jianmin Zhongtian Technology Submarine Cable Co., Ltd.,
Nantong, China
Fan Yujun Testing Center of Shanghai Electric Cable Research

Institute (TICW),
Shanghai, China
2.2 The inspection was carried out by
Name Company
Gu Bin KEMA Nederland B.V.,
Li Song Arnhem, The Netherlands
2.3 Purpose of the tests
Purpose of the tests was to verify whether the material complies with the specified requirements.
2.4 Inspection of the test set-up
The tests were carried out in the laboratory of the manufacturer and in the laboratory of Testing
Center of Shanghai Electric Cable Research Institute (TICW), Shanghai, China, who are therefore
jointly responsible for the correctness of the results obtained. The measuring devices and the test set-
up were checked by KEMA and were calibrated when necessary.
Result
The inspection did not give rise to remarks.
3 ELECTRICAL TYPE TESTS ON COMPLETE CABLE SYSTEM
3.1 Test arrangement

3.1.1 Determination of the cable conductor temperature
Standard
Standard IEC 60840, Annex A, Subclause A.3.1
For the tests with the cable system at elevated temperature, a reference loop for temperature control
of the conductor was installed and conductor current was used for heating. The reference cable was
cut from the total cable length intended for the type test. This reference loop was installed close to the
test loop in order to create the same environmental conditions as for the test loop.
The heating currents in the reference loop and the test loop were kept equal at all times, thus the
conductor temperature of the reference loop is representative for the conductor temperature of the
test loop. Annex A was used as a guide and Subclause A.3.1, method 1 was applied.
The tests at elevated temperature are carried out after the conductor temperature has been within the
stated limit for at least 2 hours.
3.1.2 Test set-up
In order to perform the test, the following test loop was prepared by the manufacturer’s
representatives in the manner specified by the manufacturer’s instructions:
· one piece of submarine cable type CU/XLPE/PE, 38,5 meters long.
· six outdoor terminations (three with porcelain insulator and three with composite insulator).
· one factory joint (with one flexible joint on one core of the three cores cable)
3.2 Tensile bending test
Standard and date

Standard Cigré 490, Subclause 8.6.1
Test date 30 January 2015
Environmental conditions
Ambient temperature 8 °C
Characteristic test data

Temperature of test object 8 °C
Laying depth 100 m
Weight of 1 m cable 98,9 kg
Diameter of cable 218 mm
Tensile load 112 kN
Diameter of drum 4,4 m
Times of bending 3 times
Length of cable 48 m
Distance from cable end to flexible joint 17 m
Lay-length of the armour 2,3 m
Procedure
This test shall be made on a sample from the cable tested according to sub-clause 2.1 including at
least one flexible joint. By means of suitable equipment, the cable sample including possible joints
shall be wound and unwound on the drum for 3 times consecutively without changing the direction of
bending.
After the tensile bending test, the 24 optical fibers were checked individually. One end of the each
fiber was connected with red optical power source, the light was checked visually from the other end.
Result
The test was carried out successfully. The results are for information only.
All 24 optical fibers were not broken by visual checking.
Photograph of test set-up

3.3 Test voltage values
Standard and date

Standard Cigré 490, Subclause 8.5

Length of cable sample 0,5 m
Core Nominal insulation Measured average Deviation of measured average

thickness insulation thickness insulation thickness from
(mm) (mm) nominal insulation thickness
(%)
1 18,5 18,599 0,5
2 18,5 18,526 0,1
3 18,5 18,553 0,3
Procedure
Prior to the electrical tests, the insulation thickness was measured by the method specified in
Subclause 8.1 of IEC 60811-1-1 on a cable sample with a length of approximately 0,5 m, to check
that the thickness is not excessive compared with the nominal value.
Requirement
If the average thickness of the insulation does not exceed the nominal value by more than 5%, the
test voltages shall be the values specified in Table 4 for the rated voltage of the cable.
If the average thickness of the insulation exceeds the nominal value by more than 5% but by not
more than 15%, the test voltage shall be adjusted to give an electrical stress at the conductor screen
equal to that applying when the average thickness of the insulation is equal to the nominal value, and
the test voltages are the normal values specified for the rated voltage of the cable.
The cable length used for the electrical type tests shall not have an average thickness exceeding the
nominal value by more than 15%.
Result
The measured average insulation thickness did not exceed the nominal value by more than 5%. The
voltage tests can be performed with the values specified before.
3.4 Partial discharge test at ambient temperature
Standard and date

Standard Cigré 490, Subclause 8.8 a
Test date 11 February 2015

Temperature of test object 9 °C
Circuit direct
Calibration 5 pC
Noise level < 2,5 pC
Declared sensitivity 5 pC
Required sensitivity £ 5 pC
Centre frequency 200 kHz
Bandwidth (Df) 50 – 350 kHz
Test frequency 50 Hz
Coupling capacitor 2000 pF
Assembly Voltage applied, 50 Hz Duration Partial discharge level

... x U0 (kV) (s) (pC)
Cable system 1,75 152,3 10 -
(Core 1, 2 and 3) 1,5 - Not detectable
130,5
Procedure
After the bending test the partial discharge test was performed in accordance with IEC 60885-3 at
ambient temperature. The sensitivity of the measuring circuit was checked with a calibrator.
The voltage was raised gradually to and held at 1,75 U0 for 10 s and then slowly reduced to 1,5 U0. At
this voltage the partial discharges were measured.
Requirement
There shall be no detectable discharge exceeding the declared sensitivity from the test object at
1,5 U0.
Result
The object passed the test.

3.5 Tan δ measurement
Standard and date

Standard Cigré 490, Subclause 8.8 b

Temperature of conductor 99 °C
Length of test object 39,5 m
Standard capacitor 49,84 pF
1)
Core Voltage applied, 50 Hz Capacitance of main loop Tan δ
(kV) (µF/km)
1 87 0,204 5,04 x 10-4
2 87 0,198 5,04 x 10-4
3 87 0,200 5,04 x 10-4
1)
for information only
Procedure
The measurement was performed on a different sample.
The cable sample was heated by conductor current, until the conductor reached a temperature of 5 K
to 10 K above the maximum conductor temperature in normal operation The tan δ was measured at a
power frequency voltage of U0 at the temperature specified above.
Requirement
The measured value shall not be higher than 10 x 10-4 at U0.
Result
3.6 Heating cycle voltage test
Standard and date

Standard Cigré 490, Subclause 8.8. c
Test date 13 February to 4 March 2015
Ambient temperature 7-14 °C

Heating method conductor current
Stabilized temperature 99 °C
Diameter of U-bend 5,3 mm
No. of Required Heating Heating cycle Voltage

heating steady current during Heating Cooling
cycles conductor steady
temperature condition Total Duration of Total Total Voltage
duration conductor at duration duration applied
steady 2 U0
temperature
(°C) (A) (h) (h) (h) (h) (kV)
20 95-100 approx. 1180 ≥8 ≥2 ≥ 16 480 174
Procedure
The assembly was heated by conductor current, until the cable conductor reached a steady
temperature 5 K to 10 K above the maximum conductor temperature in normal operation. The heating
was applied for at least 8 h. The conductor temperature was maintained within the stated temperature
limits for 2 h of each heating period. This was followed by at least 16 h of natural cooling to a
conductor temperature less than or equal to 30 °C or within 15 K of ambient temperature, whichever
is the higher. The conductor current during the last 2 h of each heating period was recorded.
The cycle of heating and cooling was carried out 20 times.
During the whole of the test period a voltage of 2 U0 was applied to the assembly.
Requirement
No breakdown shall occur.
Result
3.7 Partial discharge test at ambient temperature
Standard and date

Standard Cigré 490, Subclause 8.8 d
Test date 5 March 2015

Circuit direct
Calibration 5 pC
Noise level at 1,5 U0 <,5 pC
Required sensitivity ≤ 5 pC
Bandwidth (Df) 50-350 kHz

... x U0 (kV) (s) (pC)
Cable system 1,75 152,3 10 -
1,5 130,5 - Not detectable
Procedure
After the heating cycle voltage test the partial discharge test was performed in accordance with
IEC 60885-3 at ambient temperature. The sensitivity of the measuring circuit was checked with a
calibrator.
Requirement
1,5 U0.
Result
3.8 Partial discharge test at high temperature
Standard and date

Standard Cigré 490, Subclause 8.8 d

Circuit direct
Calibration 5 pC
Noise level at 1,5 U0 <,5 pC
Required sensitivity ≤ 5 pC
Bandwidth (Df) 50-350 kHz

... x U0 (kV) (s) (pC)
Cable system 1,75 152,25 10 -
1,5 130,5 - Not detectable
Procedure
After the heating cycle voltage test the partial discharge test was performed in accordance with
IEC 60885-3 at high temperature. The conductor was heated by conductor current. During the last 2 h
of the heating period the conductor was at a temperature of at least 5 K to 10 K above the maximum
cable conductor temperature in normal operation. The sensitivity of the measuring circuit was checked
with a calibrator.
Requirement
1,5 U0.
Result
3.9 Lightning impulse voltage test
Standard and date

Standard Cigré 490, Subclause 8.8 f

Specified test voltage 750 kV
Testing arrangement Polarity Voltage applied No. of See figure on

impulses next pages
Voltage applied to Earthed (% of test voltage)
Conductor Metal Positive 50 1 28 (waveshape)
screens 65 1 28
80 1 28
100 10 29-32
Conductor Metal Negative 50 1 33 (waveshape)
screens 65 1 33
80 1 33
100 10 34-37
Procedure
The test set-up was tested with a lightning impulse voltage while the conductor was heated by
conductor current. The conductor was heated at a temperature of 5 K to 10 K above the maximum
conductor temperature in normal operation and was maintained within the stated temperature limits
for at least 2 h.
The test was applied according to the procedure given in IEC 60230.
The three cable cores were tested simultaneously.
Requirement
The assembly shall withstand without failure or flashover 10 positive and 10 negative voltage impulses.
Result
Lightning impulse test with positive voltage
Fig. 1
Ch1: 1
Up = 372.99 kV
T1 = 3.8911 µs
T2 = 52.382 µs
Figure 1: +50% of test voltage
Fig. 2
Ch1: 1
Up = 488.75 kV
T1 = 3.9064 µs
T2 = 52.902 µs
Fig. 3
Ch1: 1
Up = 600.26 kV
T1 = 3.8913 µs
T2 = 53.768 µs

Fig. 4
Ch1: 1
Up = 748.51 kV
T1 = 3.8914 µs
T2 = 53.882 µs
Fig. 5
Ch1: 1
Up = 747.97 kV
T1 = 3.8763 µs
T2 = 53.885 µs
Fig. 6
Ch1: 1
Up = 750.29 kV
T1 = 3.8748 µs
T2 = 53.870 µs

Fig. 7
Ch1: 1
Up = 750.29 kV
T1 = 3.8844 µs
T2 = 53.821 µs
Fig. 8
Ch1: 1
Up = 749.40 kV
T1 = 3.8805 µs
T2 = 53.729 µs
Fig. 9
Ch1: 1
Up = 748.36 kV
T1 = 3.8685 µs
T2 = 54.076 µs

Fig. 10
Ch1: 1
Up = 749.60 kV
T1 = 3.8623 µs
T2 = 53.906 µs
Fig. 11
Ch1: 1
Up = 749.99 kV
T1 = 3.8700 µs
T2 = 54.036 µs
Fig. 12
Ch1: 1
Up = 750.85 kV
T1 = 3.8749 µs
T2 = 53.884 µs

Fig. 13
Ch1: 1
Up = 750.32 kV
T1 = 3.8695 µs
T2 = 54.069 µs

Lightning impulse test with negative voltage
Fig. 14
Ch1: 1
Up = -373.11 kV
T1 = 3.9458 µs
T2 = 52.996 µs
Figure 14: -50% of test voltage
Fig. 15
Ch1: 1
Up = -487.89 kV
T1 = 3.9064 µs
T2 = 52.858 µs
Fig. 16
Ch1: 1
Up = -599.52 kV
T1 = 3.8819 µs
T2 = 53.360 µs

Fig. 17
Ch1: 1
Up = -743.31 kV
T1 = 3.8974 µs
T2 = 53.601 µs
Fig. 18
Ch1: 1
Up = -751.47 kV
T1 = 3.8912 µs
T2 = 53.603 µs
Fig. 19
Ch1: 1
Up = -751.50 kV
T1 = 3.9009 µs
T2 = 53.590 µs

Fig. 20
Ch1: 1
Up = -754.50 kV
T1 = 3.8848 µs
T2 = 53.201 µs
Fig. 21
Ch1: 1
Up = -750.85 kV
T1 = 3.8867 µs
T2 = 53.751 µs
Fig. 22
Ch1: 1
Up = -752.84 kV
T1 = 3.9090 µs
T2 = 53.506 µs

Fig. 23
Ch1: 1
Up = -751.18 kV
T1 = 3.8973 µs
T2 = 53.795 µs
Fig. 24
Ch1: 1
Up = -751.27 kV
T1 = 3.9004 µs
T2 = 53.719 µs
Fig. 25
Ch1: 1
Up = -751.92 kV
T1 = 3.8995 µs
T2 = 53.730 µs

Fig. 26
Ch1: 1
Up = -752.07 kV
T1 = 3.9101 µs
T2 = 53.610 µs


3.10 Power frequency voltage test
Standard and date

Standard Cigré 490, Subclause 8.8 f

Testing arrangement Voltage applied, 50 Hz Duration

Voltage applied to Earth connected to … x U0 (kV) (min)
Conductors Metal screens 2,5 217,5 15
Procedure
After the lightning impulse voltage test, the assembly was subjected to a power frequency voltage test
at 2,5 U0 for 15 min. The test was carried out during the cooling period.
Requirement
No breakdown of the insulation shall occur.
Result
3.11 Examination
3.11.1 Examination of cable and accessories
Standard and date

Standard Cigré 490, Subclause 8.8 i
Termination Item Unit Nominal value Measured/determined

Porcelain Creepage distance mm 5500 5590
outdoor Flashover distance mm 1600 1620
termination Number of sheds - 37 (19 big and 18 37 (19 big and 18
small) small)
Composite Creepage distance mm 5500 5525
outdoor Flashover distance mm 1560 1570
termination Number of sheds - 30 (15 big and 15 30 (15 big and 15
small) small)
Procedure
Upon completion of all tests the cable and the accessories were dismantled and examined, with
normal or corrected vision without magnification, for signs of deterioration (e.g. electrical degradation,
leakage, corrosion or harmful shrinkage).
Requirement
Examination of the cable and accessories shall reveal no signs of deterioration (e.g. electrical
degradation, leakage, corrosion or harmful shrinkage) which could affect the system in service
operation.
Result
No signs of electrical degradation, leakage, corrosion or harmful shrinkage which could affect the
system in service operation were detected.
3.11.2 Photographs
Cable
Outdoor termination with porcelain insulator

Outdoor termination with porcelain insulator

3.12 Resistivity of semi-conducting screens
Standard and date

Standard Cigré 490, Subclause 8.8 j

Temperature during ageing 100 °C
Duration 7 x 24 h
Resistivity measured at 90 ± 2 °C
Item Unit Requirement Measured/determined

Conductor screen
· without ageing Ωm ≤ 1000 67,0
· after ageing Ωm ≤ 1000 45,4
Insulation screen
Oversheath
Procedure
The measurement of resistivity of the cable semi-conducting screens was made on a separate sample.
The resistivity of the extruded semi-conducting screens applied over the conductor and over the
insulation was determined by measurements on test pieces taken from the core of a sample of cable
as manufactured, and from a sample of cable which had been subjected to the ageing treatment, to
test the compatibility of component materials as specified in Subclause 12.5.4.
The test procedure was in accordance with Annex D.
The measurement was made at a temperature within ± 2 K of the maximum conductor temperature in
normal operation.
Result
4 NON-ELECTRICAL TYPE TESTS ON CABLE COMPONENTS

AND ON COMPLETE CABLE
4.1 Check of cable construction
Standard and date

Item Unit Requirement Specified Measured/determined

Core 1 Core 2 Core 3
Conductor
Diameter of conductor mm 34,0 34,92 34,76 34,83
Number of segments - - -
Number of wires ≥ 91 121 121 121 121
Diameter of wires mm - Φ3,05 compacted
Semi-conducting water
blocking layer
Number of layers - - 2 2
Thickness of layers mm - 0,27 0,24
Width of layers mm - 40 (25% 80 (40% overlapping)
overlapping)
Semi-conducting conductor
screen
Nominal thickness mm - 1,5 -
Average thickness mm - 1,5 1,8 1,9 1,9
Minimum thickness mm - - 1,8 1,9 1,8
Outer diameter of conductor mm - - 34,5 34,4 34,5
screen
Insulation
Minimum thickness [tmin] mm ≥ 16,65 - 18,2 18,1 18,1
Maximum thickness [tmax] mm - - 18,8 18,9 18,7
(tmax – tmin) / tmax - ≤ 0,15 - 0,03 0,04 0,03
Semi-conducting insulation
screen
Minimum thickness mm - - 1,2 1,3 1,3
Outer diameter of insulation screen mm - - 78,0 78,1 78,3
Semi-conducting water
blocking layer
Number of layers - - 2 2
overlapping
Item Unit Requirement Specified Measured/determined

Lead
Minimum thickness mm ≥ 2.75 - 3,2 3,0 3,2
Innersheath
Minimum thickness - ≥ 2,45 - 2,9 3,0 3,3
Colour of the innersheath - - black black
Marking on innersheath 中天科技海缆有限公司 HYJQF41-F 87/150kV 3×800+24B1
2014/08　xxxx m
Fillers
Outer diameter mm - 197,2 192,9
Teredo protective tape
Number of copper tape - 2 2
overlapping)
Armor
Number of galvanized steel wires - 100 100
Diameter of galvanized steel wires mm - Φ 6,0 Φ 5,8
Bitumen layer
Average thickness - 0,1 0,1
Outer serving
Optic fiber cable
Diameter over the PE oversheath mm - 14,6 15,3
Thickness of the PE oversheath mm - - 3,7
Number of steel wires - - 14 14
Diameter of steel wires - - 1,23 1,26
Diameter over the steel wires mm - - 7,7
Diameter over the PE innersheath mm - - 5,0
Thickness of the PE innersheath mm - 1,0 1,1
Diameter of stainless steel tube mm - 2,7 2,7
Thickness of the stainless steel mm - 0,2 0,2
tube
Number of optical fibers - - 24 24
Procedure
The examination of the conductor and measurement of insulation, oversheath and metal sheath
thickness were carried out in accordance with Subclauses 10.4, 10.6 and 10.7.
At a sample of approximately 0,5 m the dimensions of the completed cable were measured.
The conductor construction was checked by inspection and measurement.
The test method was in accordance with IEC 60811-201, IEC 60811-202 and IEC 60811-203.
The thickness of the semi-conducting screens on the conductor and over the insulation was not
included in the thickness of the insulation.
The thickness of the lead sheath was measured by the strip method with a specified micrometer.
Result
4.2 Tests for determining the mechanical properties of

insulation before and after ageing
Standard and date


Temperature during ageing 135 ± 3 °C
Ageing duration 7 x 24 h (22 to 29 January 2015)

Without ageing Core 1 Core 2 Core 3
Tensile strength N/mm2 ≥ 12,5 23,3 26,9 24,5
Elongation at break % ≥ 200 560 570 560
After ageing in air oven
Tensile strength
· value after ageing N/mm2 - 24,2 22,4 22,7
· variation % ± 25 max. 3,9 -16,7 -7,3
Elongation at break
· value after ageing % - 570 560 540
· variation % ± 25 max. 1,8 -1,8 -3,6
Procedure
The sampling and preparation of the test pieces were carried out in accordance with IEC 60811-501.
The ageing treatment was carried out in accordance with IEC 60811-401, under the conditions given
in Table 6.
Result
4.3 Tests for determining the mechanical properties non-

metal sheaths before and after ageing
Standard and date


Ageing duration 10 x 24 h (22 January to 1 February 2015)

Tensile strength N/mm2 - 12,8 12,7 14,0
Elongation at break % - 410 350 350
Tensile strength
· variation % - 21,1 17,3 4,3
Elongation at break

· variation % - -19,5 -11,4 -14,3
Procedure
The sampling and preparation of the test pieces were carried out in accordance with IEC 60811-501.
The ageing treatment was carried out in accordance with IEC 60811-401, under the conditions given
in Table 7.
Result
The material of the sheath is semi-conducting polyethylene. The requirements in the standard are not
applicable. The results listed are only for information.
4.4 Ageing test on pieces of complete cable
Standard and date


Ageing duration 7 x 24 h (22 to 29 January 2015)
Insulation
2
Tensile strength N/mm ≥ 12,5 23,3 26,9 24,5
Elongation at break % ≥ 200 560 570 560
Tensile strength
· variation % ± 25 max. -7,3 -16,0 -4,1
Elongation at break
· variation % ± 25 max. 3,6 1,8 3,6
Innersheath
2
Tensile strength N/mm - 12,8 12,7 14,0
Elongation at break % - 410 350 350
Tensile strength
· variation % - 3,9 0,8 -8,6
Elongation at break
· variation % - -29,3 -14,3 -20,0
Procedure
The samples for the tests were taken from the complete cable as described in IEC 60811-401. The
test pieces of insulation and oversheath from the aged pieces of cable were prepared and subjected to
mechanical tests as described in EC 60811-401.
The ageing treatment of the pieces of cable was carried out in an air oven as described in
IEC 60811-401.
Result
The insulation material passed the test.
The material of the sheath is semi-conducting polyethylene. The requirements in the standard are not
applicable. The results listed for the sheath are only for information.
4.5 Pressure test at high temperature on oversheath
Standard and date


Temperature 110 ± 2 °C
Heating time 6 hours

Depth of indentation % - Core 1 Core 2 Core 3
>50 >50 >50
Procedure
The test was carried out as described in IEC 60811-508, employing the test conditions given in the
test method in Table 7.
The loaded test pieces were heated for the following times:
· 4 h for test pieces with an outer diameter not exceeding 15 mm.
· 6 h for test pieces with an outer diameter exceeding 15 mm.
Result
The material of sheath is semi-conducting polyethylene. The requirements in the standard are not
applicable. The results listed are for information only.
4.6 Hot set test for XLPE insulation
Standard and date


Air temperature 200 ± 3 °C
Time under load 15 min
Mechanical stress 20 N/cm2

Elongation under load % ≤ 175 70 63 65
Permanent elongation after % ≤ 15 0 0 0
cooling
Procedure
The sampling and the test procedure were carried out in accordance with IEC 60811-507, employing
the test conditions given in Tables 19 and 23.
Result
4.7 Shrinkage test for XLPE insulation
Standard and date

Standard IEC 60840, Subclause 12.5.16

Length of cable sample 300 mm
Duration 6h

Shrinkage % ≤ 4,5 3,5 4,0 4,5
Procedure
The sampling and test procedure were in accordance with IEC 60811-502.
Result
4.8 Shrinkage test for PE oversheaths
Standard and date

Standard IEC 60840, Subclause 12.5.17

Length of cable sample 500 ± 5 mm
Duration 5h
Number of heating cycles 5
PE of ST7 Unit Requirement Measured/determined

Shrinkage allowed % - 1,4 2,0 1,6
Procedure
A 500 mm sample was taken at least 2 m away from the end of the cable length. The shrinkage test
was carried out on PE oversheath of ST7 using the sampling and test procedure described in of IEC
60811-502 and the conditions specified in Table 7.
Result
4.9 Measurement of carbon black content of black PE

oversheaths
Standard and date


Carbon black content % - 27,8 27,7 27,8
Procedure
The carbon black content was measured using the sampling and test procedure described in
IEC 60811-605.
Result
4.10 Water penetration test on conductor (including optical

fiber unit)
Standard and date

Test date 29 April to 11 May 2015

Length of cable sample 9m
d1 6,5 m
Water temperature 16-22 °C
Water pressure 1 MPa

Water penetration under cm ≤ 5,5 0,9
conductor
Water penetration under optical cm ≤ 5,5 2,0
fiber unit
Procedure
The cable sample has taken from the cable subjected to mechanical test 3.2.
The conductor penetration test was performed on one cable core. The optical fiber unit penetration
test was performed on one unit.
The test object was taken from the cable sample which has passed electrical type tests. The test
object has been preconditioned by more than three heating cycles. Each heating cycle consisted 8
hours of heating followed by 16 hours of cooling. Current heating was used to give the declared
maximum conductor temperature + (5 - 10)˚C. The temperature was kept at the stated value at least
2 hours in the end of each heating cycle.
After preconditioning, approximately 50 mm of the conductor was exposed. The ring comprised all
layers external to the conductor, thus exposing the conductor to water. The other end of the test
sample was sealed. The optical fiber unit sample was cut to 9 m long with one end opened and the
other end sealed. The test sample was placed inside a pressure vessel.
The test object was pressurised while submerged in water with a water pressured corresponding to
the specified maximum laying depth. The pressure was raised as fast as is practically possible. The
test continued for 10 days with a water temperature of 5 - 35˚C.
Result

4.11 Water penetration test on metal sheath
Standard and date

Test date 17 June to 29 June 2015

d2 4,5 m
Water pressure 0,3 MPa
No. of Required Heating Heating cycle Cooling cycle

heating steady current during Total duration Duration at Total duration
cycles conductor steady steady temperature
temperature condition
(°C) (A) (h) (h) (h)
10 95-100 approx. 2050 ≥ 8 ≥2 ≥ 16

Water penetration under lead sheath m ≤ 5,5 0,1
Procedure
The test was performed on one cable core. The test object was taken from the cable sample which has
passed the electrical type tests The test object has been preconditioned by more than three heating
cycles. Each heating cycle consisted 8 hours of heating followed by 16 hours of cooling. Current
heating was used to give the declared maximum conductor temperature + (5 - 10)˚C. The
temperature was kept at the stated value at least 2 hours in the end of each heating cycle.
After preconditioning, a ring approximately 50 mm wide was removed from one meter from the end of
the sample. The ring comprised all layers external to the outer semi-conducting screen, thus exposing
the outer semi-conducting layer to water. The test sample and dummy cable was placed inside a
pressure vessel.
The temperature of the conductor was measured inside the pressure vessel. The test object was
pressurised with a water pressure corresponding to a water depth of 30 metres.
The cable sample was subjected to 10 heating cycles while pressurised at a water temperature of 5 -
35 ˚C. Each heating cycle consisted 8 hours of heating followed by 16 hours of cooling. Current
heating was used to give the declared maximum conductor temperature + (5 - 10)˚C. The
temperature was kept at the stated value at least 2 hours in the end of each heating cycle.
Result

4.12 Radial water penetration test for joints
Standard and date

Test date 8 June to 2 July 2015

Water pressure 1 MPa
No. of Required Heating Heating cycle Cooling cycle

heating steady current during Total duration Duration at Total duration
cycles conductor steady steady temperature
temperature condition
(°C) (A) (h) (h) (h)
10 95-100 approx. 1180 ≥ 8 ≥2 ≥ 16
Procedure
The factory flexible joint sample has taken from the cable subjected to mechanical test 3.2 and 10
heating cycles was applied. Each heating cycle consisted 8 hours of heating followed by 16 hours of
cooling. Current heating was used to give the declared maximum conductor temperature (5 - 10)˚C.
The temperature was kept at the stated value at least 2 hours in the end of each heating cycle.
The test was performed on one core joint. The joint sample was sealed at the cable ends by means of
caps. The test sample was placed inside a pressure vessel.
The test object is submerged in pressurised water corresponding to the specified maximum laying
depth. The test continued for 48 hours with a water temperature 5 – 35 ˚C.
Result
When the test time has elapsed, the test object is removed from the water. No water ingress under
the water blocking barrier and no appreciable shape irregularity in the metal sheath were found.

5 DRAWINGS

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KEMA INSPECTION REPORT

87/150 (170) kV – 3x800 mm2 – Cu – XLPE

Client Zhongtian Technology Submarine Cable Co., Ltd.,

Inspected by KEMA Nederland B.V.,

Testing Center of Shanghai Electric Cable Research Institute (TICW),

Remarks The object passed the tests.

This report consists of 60 pages in total.

KEMA Nederland B.V.

Arnhem, 27 October 2015

1 IDENTIFICATION OF THE OBJECT TESTED ...................................................................... 4

2 GENERAL INFORMATION ............................................................................................ 11

3 ELECTRICAL TYPE TESTS ON COMPLETE CABLE SYSTEM ................................................ 12

4 NON-ELECTRICAL TYPE TESTS ON CABLE COMPONENTS AND ON COMPLETE CABLE .......... 40

4.8 Shrinkage test for PE oversheaths 49

1 IDENTIFICATION OF THE OBJECT TESTED

1.1 Ratings/characteristics of the object tested

Rated voltage, U0/U (Um) 87/150 (170) kV

1.1.2 Characteristics of the cable

Standard IEC 60840, Clause 6

Semi-conducting tape outside the conductor

Insulation (core) screen

Manufacturing details insulation system

Optical fiber cable

· material of tubes outside the fibers Stainless steel

· material of innersheath HDPE

· material of steel wires galvanized steel wire

· material of oversheath HDPE

1.1.3 Characteristics of the accessories

Standard IEC 60840, Clause 7

Installation instruction see list of drawings

Standard IEC 60840, Clause 7

Installation instruction see list of drawings

1.2 List of drawings

2.1 Persons attending the inspection

Fan Yujun Testing Center of Shanghai Electric Cable Research

2.2 The inspection was carried out by

2.3 Purpose of the tests

2.4 Inspection of the test set-up

3 ELECTRICAL TYPE TESTS ON COMPLETE CABLE SYSTEM

3.1 Test arrangement

3.1.2 Test set-up

3.2 Tensile bending test

Standard and date

Characteristic test data

Photograph of test set-up

3.3 Test voltage values

Standard and date

Characteristic test data

Core Nominal insulation Measured average Deviation of measured average

3.4 Partial discharge test at ambient temperature

Standard and date

Characteristic test data

Assembly Voltage applied, 50 Hz Duration Partial discharge level

Photograph of test set-up

3.5 Tan δ measurement

Standard and date

Characteristic test data

3.6 Heating cycle voltage test

Standard and date

Characteristic test data

No. of Required Heating Heating cycle Voltage

3.7 Partial discharge test at ambient temperature

Standard and date

· material of steel wires galvanized steel wire　