Inspection Procedure For Electrical Cables

Introduction:

A cable is two or more wires running side by side and bonded, twisted or braided together to form
a single assembly. Electrical cables may be made more flexible by stranding the wires. In this
process, smaller individual wires are twisted or braided together to produce larger wires that are
more flexible than solid wires of similar size. Bunching small wires before concentric stranding adds
the most flexibility. Copper wires in a cable may be bare.

Types of Electrical Cables:

1. LV Cables.
2. MV Cables.
3. HV Cables.

Construction Requirement:
- LHS/RHS: conductor/insulation/armouring/outer sheathing.

Cable Types:
1. Armoured/unarmoured XLPE insulated cables.
2. Lead sheathed cables / without Lead sheathed cables.
3. Copper or Aluminium PE tape (with drain wire) shielded.

Cable sizes:
- Single core, 2 cores, 3 cores, 4 cores, 5 cores & Multi cores.

Number of cores Identification:

Single - core Brown or blue
Two - core Brown, blue
Three - core Brown, black, grey
Four - core Blue, brown, black, grey
Five - core Green-and-yellow, blue, brown, black, grey

International Reference Standards:

IEC 60332 Tests on electric and optical fiber cables under fire conditions.

IEC 60502-1 Power cables with extruded insulation and their accessories for
rated voltages from 1 kV (Um = 1.2 kV) up to 30 kV (Um = 36 kV).
Part 1: Cables for rated voltages of 1 kV ((Um = 1.2 kV) and 3 kV
(Um = 3.6 kV)

IEC 60228 Conductors of insulated cables

BS 5467 Electric cables —Thermosetting insulated, armoured cables for

voltages of 600 /1000 V and 1900 / 3300 V

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 Inspection Procedure For Electrical Cables

IEC 60227 Polyvinyl chloride insulated cables of rated voltages up to and

including 450/750 V

IEC 60245 Rubber insulated cables – Rated voltages up to and including

450/750 V

IEC 60811 Common test methods for insulating and sheathing materials of
electric cables and optical cables

Types of Inspection:

1. Routine Test.
2. Sample Test.
3. Type Test.

1. Routine test

a) Measurement of the electrical resistance of conductors.

- Resistance measurements shall be made on all conductors of each cable length
submitted to the routine tests, including the concentric conductor, if any.
- The measured value of resistance shall be corrected to a temperature of 20 °C and
1 km length in accordance with the formulae and factors given in IEC 60228.
b) Voltage test.
- Single-core & Multicore with individually screened cables; the test voltage shall be
applied for 5 min between the conductor and the metallic screen.
- Single-core unscreened cables shall be immersed in water at room temperature for
1 h and the test voltage then applied for 5 min between the conductor and the
water.
- Routine test voltages

Rated voltage U0 kV 0.6 1.8

Test voltage kV 3.5 6.5

2. Sample Test

a) Conductor Examination.
- Measurement of the thickness of insulation and sheath
- Measurement of the overall conductor diameter
- Selection of cable samples shall be made on one length from each manufacturing
series of the same type and nominal cross-section of cable, but shall be limited to
not more than 10 % of the number of lengths in any contract.
b) Check of dimensions.
- Thickness of Lead sheath
- Thickness of bedding sheath
- Measurement of armour wires

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- Measurement of overall diameter

c) Hot set test for EPR, HEPR, and XLPE insulations and elastomeric sheaths.

3. Type Test

a) Insulation resistance measurement at ambient temperature.

b) Insulation resistance measurement at maximum conductor temperature in normal
operation.
c) Voltage test for 4 h.
- The cores of the cable sample shall be immersed in water at ambient temperature
for at least 1 h before the test.
- A power frequency voltage equal to 4 U0 shall then be gradually applied and
maintained continuously for 4 h between each conductor and the water.

Note: Cables of rated voltage 1.8 /3 (3,6) kV shall also be subjected to an impulse test on a separate
sample of completed cable, 10 m to 15 m in length. The tests shall be limited to not more than three
cores.

4. Type tests (non-electrical)

a) Measurement of thickness of insulation

b) Measurement of thickness of non-metallic sheaths (including extruded separation
sheaths, but excluding inner coverings)
c) Tests for determining the mechanical properties of insulation before and after ageing
d) Tests for determining the mechanical properties of non-metallic sheaths before and after
ageing
e) Additional ageing test on pieces of completed cables
f) Loss of mass test on PVC sheaths of type ST2
g) Pressure test at high temperature on insulations and non-metallic sheaths
h) Test on PVC insulation and sheaths and halogen free sheaths at low temperatures
i) Test for resistance of PVC insulation and sheaths to cracking (heat shock test)
j) Ozone resistance test for EPR and HEPR insulations
k) Hot set test for EPR, HEPR and XLPE insulations and elastomeric sheaths
l) Oil immersion test for elastomeric sheaths
m) Water absorption test on insulation
n) Fire tests
o) Measurement of carbon black content of black PE over sheaths
p) Shrinkage test for XLPE insulation
q) Special bending test
r) Determination of hardness of HEPR insulation
s) Determination of the elastic modulus of HEPR insulation
t) Shrinkage test for PE over sheaths
u) Additional mechanical tests on halogen free over sheaths

5. Electrical tests after installation

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