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Accessories For HV and EHV Extr - Pierre Argaut
Accessories For HV and EHV Extr - Pierre Argaut
Accessories For HV and EHV Extr - Pierre Argaut
CIGRE
Study Committee B1: Insulated Cables
Accessories for
HV and EHV
Extruded Cables
Volume 1: Components
CIGRE Green Books
Series Editor
CIGRE
International Council on Large Electric Systems (CIGRE)
Paris, France
CIGRE presents their expertise in unique reference books on electrical power
networks. These books are of a self-contained handbook character covering the
entire knowledge of the subject within power engineering. The books are created
by CIGRE experts within their study committees and are recognized by the engi-
neering community as the top reference books in their fields.
This Springer imprint is published by the registered company Springer Nature Switzerland AG.
The registered company address is: Gewerbestrasse 11, 6330 Cham, Switzerland
Message from the President
CIGRE is the global expert community for electric power systems. It is a nonprofit
organization based in Paris. It consists of members from over 100 countries
representing 61 national committees. It functions as a virtual organization with
members who are experts in their technical field, forming working groups dealing
with issues facing the power delivery industry. In 2019, 230 working groups
including more than 3000 experts were working together to resolve the identified
issues. The output of the working groups is technical brochures. There are over 700
technical brochures, which contain the combined knowledge and practice of engi-
neering experts from all over the world. The brochures are practical in nature
enabling the engineer to plan, design, construct, operate, and maintain the power
delivery systems as required. CIGRE has over 10,000 reference papers and other
documents supporting the brochures and dealing with other relevant technical
matters.
This Green Book on Accessories for HV and EHV Cable Systems, compiled by
Study Committee (SC) B1, “Insulated Cables” provides state of the art in the design
and application of Accessories in HV and EHV Cable Systems. The book comprises
material from published technical peer-reviewed publications and technical experts
in the field. CIGRE is a source of unbiased technical information. Engineers can
refer this book without fear of favoring one supplier or country. It is a compilation of
the combined expertise of many international experts.
Like other CIGRE Green Books this book contains input from several tens of
experts; not only one or two. These international experts have provided technical
information relevant to readers irrespective of where the readers reside. The views
expressed and suggestions made are unbiased objective statements. These can be
used as references for engineers to develop standards such as IEC Standards and
guidelines within their organizations. This book is a reference book for academia,
power transmission engineers, consultants, and users. For each of the chapters of this
book, a tutorial has been prepared by the members of the Working Group who
published the content of the chapter as a technical brochure or a report in Electra to
disseminate this unbiased information.
By collecting the knowledge and experience gained over time in the field of cable
accessories and systems, this book not only explains the know-how but also the
know why.
v
vi Message from the President
I would like to congratulate those involved from SC B1 who have compiled this
book. Many of them have had to work in their spare time for hours to complete this
task, for which they worked as volunteers. I specifically want to address on behalf of
Cigre all my thanks and gratitude to Pierre Argaut, Past Chair of Study Committee
B1 for leading this formidable task. I would recommend this book in forming the
basis for Underground Transmission System design activities now and in the future.
This Green Book on Accessories for HV and EHV cable systems aims at describing
the cumulated experience gained by CIGRE experts in the domain of accessories for
transmission underground systems.
It is well known that the reliability and performance of a cable circuit is dependent
in equal measures on the design of the cable and accessories and on the skill and
experience of the person who is assembling the accessory. The cable insulation is
manufactured in the factory under controlled process conditions using selected
materials of high quality. It is equally important that the same quality measures are
employed for the manufacture of the accessories in the factory and for their assembly
on site onto the specially prepared cable.
It is essential to select the design of accessory to be exactly compatible with the
particular cable type and the particular service application. Compatibility should be
validated by electrical type approval tests and be supported by prequalification tests,
and satisfactory service experience. In particular, the performance of the accessory is
dependent on the quality, skill, and training of the jointing personnel and on the use
of the specialized tools required for a particular accessory.
The chapters of this book form the basis of the information that is needed by the
manufacturer and installer of the cable and accessories. For many applications the
cable manufacturer also manufactures, supplies, and installs the accessories as part
of the complete cable circuit. In the event that the user purchases the accessories
separately from the cable, the Green Book will also provide the basis of the
information (including tests reports) that should be needed to obtain the appropriate
performance of the system, both in the case of a new underground line of “the Power
System of the Future” or in the upgrading process of an existing line “to make the
best use of the existing power system”.
This Green Book has been authored by leading industry, research, and academic
professionals, acting as members of Working Groups within Study Committee B1,
who published technical brochures and prepared tutorials, providing all stakeholders
with high quality and unbiased information.
vii
viii Message from the Chairman of the Technical Council of CIGRE
I take the opportunity to acknowledge the editor, the chapters’ authors, and all the
numerous contributors in working bodies for this contribution from which the entire
global power systems will benefit. Also, I especially acknowledge the leading role of
Study Committee B1 – Marco Marelli on the realization of this Green Book.
Marcio Szechtman
CIGRE Technical Council Chair
In 2014, I had the pleasure to comment on the launching of a new CIGRE publica-
tion collection in an introductory message about the first CIGRE Green Book, the
one on Overhead Lines, the second one being on Accessories for HV Extruded
Cables.
The idea to valorise the collective work of the study committees accumulated
over many decades, by putting together all the technical brochures of a given field in
a single book, was first proposed by Dr. Konstantin Papailiou to the Technical
Committee (now Council) in 2011.
In 2015, cooperation with Springer allowed CIGRE to publish the Green Book on
Overhead Lines again as a “Major Reference Work” distributed through the vast
network of this well-known international publisher. In 2016, the collection was
enriched with a new category of Green Books, the CIGRE “Compact Series,” to
satisfy the needs of the study committees when they want to publish shorter, concise
volumes. The first CIGRE compact Book was prepared by Study Committee D2,
under the title Utility Communication Networks and Services.
The concept of the CIGRE Green Books series has continued to evolve, with the
introduction of a third subcategory of the series, the “CIGRE Green Book Technical
Brochures” (GBTB). CIGRE has published more than 720 technical brochures since
1969, and it is interesting to note that in the first one, on tele-protection, the first
reference was a Springer publication of 1963.
A CIGRE Technical Brochure produced by a CIGRE working group, following
specific Terms of Reference, is published by the CIGRE Central Office and is
available from the CIGRE online library, e-cigre, one of the most comprehensive,
accessible databases of relevant technical literature on power engineering. Between
40 and 50 new technical brochures are published yearly, and these brochures are
announced in Electra, CIGRE’s bimonthly journal, and are available for down-
loading from e-cigre.
In the future, the Technical Council of CIGRE may decide to publish a technical
brochure as a Green Book in addition to the traditional CIGRE Technical Brochure.
The motivation of the Technical Council to make such a decision is to disseminate
the related information beyond the CIGRE community, through the Springer
network.
ix
x Message from the Secretary General
All CIGRE Green Books, are available from e-cigre in electronic format free of
charge for the co-authors of the Book. CIGRE plans to co-publish new Green Books
edited by the different study committees, and the series will grow progressively at a
pace of about one or two volumes per year.
This new Green Book, a Major Reference Work prepared by Study Committee
B1 on Insulated Cables, is an updated version of the Green Book published in 2014,
and is the seventh of this subcategory.
This new edition comprises two additional chapters related to the most recent
work of SC B1. A second volume of the book will address Accessories in submarine
and DC applications. Some chapters will also cover distribution cable systems.
It is important to know that each of the chapters of this book is the topic of a
dedicated Tutorial prepared by the members of the WG who published the content of
the chapter as a Technical Brochure or an Electra Report.
I want to congratulate all the authors, contributors, and reviewers of this book,
which gives the reader a clear, comprehensive, and unbiased vision of the past,
recent, and future developments of Accessories for HV and EHV Cable Systems.
Dear Reader,
This CIGRE Reference Book on Accessories for HV and EHV Extruded Cables is
the first in a series of Reference Books regarding High and Extra High Voltages
Cable Systems.
This first volume of the Book provides information regarding Recommendations
and Guidelines from CIGRE for Design, Installation, and Testing of Accessories for
AC extruded cables. Accessories for HVDC extruded cables will be introduced in a
second volume together with accessories for submarine applications.
The Book compiles the results of the work by several Working Groups and Task
Forces of CIGRE Study Committee 21/B1 and Joint Working Groups and Joint Task
Forces with other Study Committees. Many experts from Study Committees 21/B1
(HV Cables), 15/D1 (Materials and Emerging Test Techniques) and 33/B3 (Sub-
stations) have participated in this work in the last 30 years in order to offer
comprehensive, continuous, and consistent outputs. I would like to express my
deepest thanks to these WG members who made all this possible.
This volume is divided into 11 chapters as follows:
xiii
xiv Preface
useful to help the reader to better understand how to match the thermal perfor-
mance of an accessory with the thermal performance of the cable. This has been
taken into account in the existing IEC Standards (IEC 60840 and 62067) and also
in Chap. ▶ 4, “Qualification Procedures for HV and EHV AC Extruded Under-
ground Cable Systems”.
▶ Chapter 10, “Test Regimes for HV and EHV Cable Connectors” deals with Cable
Connectors. It is the output of TB 758, published in 2019 by WG B1.46 and
convened by M. UZELAC (USA) to cover Test regimes for HV and EHV various
types of cable conductors, both in Copper or Aluminum.
▶ Chapter 11, “Standard Design of a Common, Dry Type Plug-in Interface for GIS
and Power Cables up to 145 kV” is the output of TB 784, published by JWG B1.
B3.49 in 2019 to propose a “Standard Design of a Common, Dry type, Plug-in
Interface for GIS and Power Cable up to 145 kV” as recommended in ▶ Chap. 7,
“Feasibility of a Common, Dry Type Plug-in Interface for GIS and Power Cables
above 52 kV”. This JWG was convened by P. MIREBEAU (France) as JWG B1.
B3.33.
xvii
xviii Contents
xix
Contributors
Contents
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Types of Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2.1 Types of Straight Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2.2 Types of Transition Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.2.3 Types of Y Branch Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.3 Types of Terminations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.3.1 Types of Metal Enclosed GIS Terminations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.3.2 Types of “Oil Immersed Transformer” Terminations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.3.3 Types of Outdoor Terminations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.3.4 Types of Indoor Terminations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1.3.5 Types of Temporary Terminations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Appendix: Glossary of Component Names . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Glossary of Names for Components Used in Accessories for Extruded Cables . . . . . . . . . . . 34
1.1 Introduction
Chapter 1 categorises the types of accessory designs available for use on HV cables
with extruded insulation for ac transmission voltages of 60 kV (75.5 kV) and above.
The typical types of extruded cable insulation being low density polyethylene
(LDPE), high density polyethylene (HDPE), cross-linked polyethylene (XLPE)
and ethylene propylene rubber (EPR).
Z. Iwata (*)
Kamakura, Japan
e-mail: z.iwata@kamakuranet.ne.jp
The contents were compiled by Cigré Working Group 21-06, as part of a survey
into the world-wide usage of accessories up to the year 1992. The purpose of
Chapter 1 is twofold;
• To organise the designs into logical categories based upon their function and
principle of design and
• To provide a glossary of the names of their component parts.
The collection of accessory designs has been compiled from those known to have
been used in service applications or to have been developed in the first thirty year
period since the emergence of the extruded type of HV cable. It is important to note
that the inclusion of an accessory design does not imply that it has technical merit or
is preferred for any particular voltage category, nor does the exclusion of a design
imply any censure. Similarly the details of the designs shown are typical and it is
acknowledged that design variations exist of equal utility.
The Chapter 1 is divided into two parts:
The work has been published as Cigré TB 89 (also included in TB 177) in both
English and French versions, these being the dual languages of Cigré. It has been
additionally translated into the German language for reference. The dual language
versions of the Glossary, cross reference each other, for example, the English version
lists each component name together with its French counterpart.
Sections 1.2 to 1.3.5 is a compendium of the generic types of accessories. The
accessory designs are divided firstly into the main categories of joints and termina-
tions and secondly into sub-categories. For example Type 1.2.1.2, Fig 1.6, is a
“straight joint” of the “prefabricated” type, employing “composite” insulation. A
diagram is provided for each category of design, together with a description of the
accessory and its function. The preferred names of components have been used.
Appendix is a glossary in alphabetic order of the preferred names of the compo-
nent parts. Each preferred name is accompanied by a definition and a list of
alternative names. For completeness the list of each type of accessory name have
been included under the headings for “straight joint”, “transition joint”, “Y joint”,
“metal enclosed GIS termination”, “oil immersed transformer termination”, “out-
door termination”, “indoor termination” and “temporary termination”, together with
a cross reference by item number to the Compendium of Accessory Types in Sects. 1.2
to 1.3.5. For example under the heading of “outdoor termination” can be found the
“stress cone and insulator” type together with its Part I item number 1.3.3.4.
A joint is the insulated and fully protected connection between two or more cables.
Also termed “splice”. The following types exist:
1 Compendium of Accessory Types Used for AC HV Extruded Cables 3
• Straight Joint
• Transition Joint
• Screen Interruption Joint
• Y Branch Joint.
Each of the above joint designs is illustrated by a diagram to show the type of
insulation. For the purpose of clarity other important design details have been
omitted. The design requirements common to each type of joint are:
In the HV voltage class of greater than 60 kV the majority of extruded cables are of
single core construction, thus straight joints of the single core type have been illustrated.
Three core joints employ the same types of insulation and are grouped together in one
housing as illustrated in Sect. 1.2.2 for transition joints to three core paper insulated cable.
Single core joints with screen interruption, Fig. 1.1, have:
The insulated flange can be electrically shorted to make the joint suitable for a
solidly bonded cable system.
Joints without screen interruption have an electrically continuous insulation
screen and continuous joint shell; such joints are used for solidly bonded single
core and three core cable systems (Figs. 1.2, 1.3, 1.4, and 1.5 are examples of taped
joints without screen interruption).
For the purpose of comparison the diagram for each type of joint shows the
insulation contained within a metallic joint shell which is plumbed to the cable
sheaths, as shown in Fig. 1.1. This provides a complete water barrier and a connec-
tion between the cable sheaths. For buried direct installations it is usual to protect
and to insulate the metallic shell within a compound filled joint box as shown in
Fig. 1.3. For indoor installations, such as tunnels, the joint shell can be insulated by
either a) a polymeric sleeve or wrapping, or b) by pedestal insulators as shown in
Fig. 1.4. For cables which do not have a metallic sheath an alternative design of joint
protection is shown in Fig. 1.5. The cable screen wires are connected across the joint
and the joint is protected within either a compound filled waterproof joint box as
shown, by a heat shrink sleeve or by a wrapping of elastomeric or adhesive tape.
Fig. 1.3 Typical protection for a joint with metallic shells for direct burial
1 Compendium of Accessory Types Used for AC HV Extruded Cables 5
Fig. 1.4 Typical protection for a joint with metallic shells for indoor installations
Fig. 1.5 Typical protection for a joint without metallic shells for direct burial and for indoor
installations
A straight joint connects two cables of the same type. Also termed “straight splice”.
• “Taped” Joint
• “Prefabricated” Joint
• “Field Moulded” Joint
• “Heat Shrink Sleeve” Joint
• “Back-to-back” Joint.
“Composite” Type
Two factory premoulded elastomeric stress cones are inserted into a central insulator
of cast thermoset resin, Fig. 1.6. Pressure at the stress cone to central insulator
interface and at the cable core interface is maintained by a compression device which
is usually comprised of metallic springs.
Table 1.1 The Typical Methods Used to Form the Insulation of Field Moulded Joints
Forming Process of Joint
Types of Joint Insulation Diagram
Tape moulded Taping ! Moulding
Crosslinked tape Taping ! Moulding !
moulded Crosslinking
Fig. 1.13 (a) “Back-to-Back” joint with one insulator and fluid insulation. (b) “Back-to-Back”
joint with one insulator and solid insulation
12 Z. Iwata
A transition joint connects two cables of different types, for example a polymeric
extruded cable to a self-contained oil filled cable. Transition joints are sometimes
employed to connect cables of the same type, but with different conductor sizes. In
the latter application they are designed to withstand imbalanced conductor thermo-
mechanical force.
• “Polymeric extruded cable to mass impregnated cable” transition joint.
• “Polymeric extruded cable to oil filled paper cable” transition joint.
• “Polymeric extruded cable to gas pressurised paper cable” transition Joint.
▶ Chapter 8, “Test Procedures for HV Transition Joints for Rated Voltages
30 kV up to 500 kV” of this book is dedicated to tests procedures for HV
Transition Joints for Rated Voltages 30 kV to 500 kV.
Fig. 1.15 “Polymeric extruded cable to mass impregnated cable” transition joint
Fig. 1.16 “Polymeric extruded cable to oil or gas filled paper cable” transition joint, three core type
shrink sleeve etc.). The joint on the paper cable side is usually insulated with either
impregnated plain or crepe paper tapes.
The solid barrier can also be formed, as shown in Figs. 1.12 and 1.13a, by either a)
two sets of three back-to-back GIS terminations, which are connected within a short
length of SF6 gas or oil insulated busbar trunking, or b) one set of three back-to-back
oil immersed terminations within a short length of oil insulated busbar trunking.
For the “oil immersed termination” design of joint, one set of insulators can be
omitted and the cable oil can be used to insulate both the busbar trunking and the
paper insulated cable, as shown in Fig. 1.13a (but with each paper cable termination
of the “open” unscreened type).
Fig. 1.17 “Polymeric extruded cable to oil or gas filled paper cable” transition joint, single core,
‘non-fed’ type
1 Compendium of Accessory Types Used for AC HV Extruded Cables 15
Fig. 1.18 “Polymeric extruded cable to oil or gas filled paper cable” transition joint, single core,
“fed” type
A Y branch joint joins together three cables. In principle any of the types of
insulation employed for the straight joint can be considered, however in practice
this is a specialised application in which the “prefabricated composite” design,
Fig. 1.19, has been the most frequently employed. The three conductor connectors
are plugged into an HV electrode. The HV electrode is embedded in a factory cast
thermoset resin barrier from which protrude three half joints of the “composite type”,
described in 1.2.1.2.
A termination is the connection between a cable and other electrical equipment. Also
termed “pot-head”.
Each of the above termination designs is illustrated by a diagram to show the type
of insulation. For the purpose of clarity other important design details have been
omitted. The design requirements common to each type of termination are:
Some termination designs are filled with either a dielectric liquid or pressurised
SF6 gas to provide insulation. Provision is required in such designs to withstand the
effects of the thermal expansion of these insulants. The incompressible nature of a
dielectric liquid requires that an expansion volume be provided. The expansion
volume can be formed by an air or gas filled space, usually at the HV end of the
insulator, or by either a) an external header tank, b) an external pressurised feed tank,
or c) an internal flexible accumulator containing gas usually at the LV end of the
termination. In the case of an internal air volume these terminations are only suitable
for vertical installation or for max inclined angle or 30 . If they are to be installed
inclined, horizontally or inverted then it is usual to fill the termination completely
with insulating liquid and to provide either external compensation or an internal
flexible accumulator containing gas. An expansion volume is not necessary for
gaseous insulation because of its compressible nature, however the termination
1 Compendium of Accessory Types Used for AC HV Extruded Cables 17
Fig. 1.20 “Stress cone and insulator” metal enclosed GIS termination
Dry Type Plug-in Interface for GIS and Power Cables up to 145 kV” of this book
which are dedicated to this design.
Fig. 1.22 “Capacitor cone and insulator” metal enclosed GIS termination
Pre-shaped rolls of polymeric film are wound onto the cable, with sheets of
conducting film interleaved in the rolls to form a linear longitudinal voltage distri-
bution, Fig. 1.22. Alternatively a) the capacitor cone can be assembled onto a tubular
insulator in the factory and then loosely fitted over the prepared cable core on site, or
b) the capacitor cone can be formed from individual toroidal capacitors as shown in
Fig. 1.32. The prepared cable is housed in an insulator which is filled with either
insulating liquid or SF6 gas.
This is a termination into oil insulated metalclad busbar trunking, which is usually
part of the transformer housing. These closely resemble the types of metal enclosed
GIS terminations shown in Figs. 1.20, 1.21, 1.22 and 1.23. A corona shield larger
than the one of GIS Termination is usually fitted on HV side of Oil Immersed
Transformer Terminations.
Also termed “oil immersed transformer potheads”.
22 Z. Iwata
This is a cable termination which interfaces with air insulated equipment and which
is subjected to full climatic conditions.
Also termed “outdoor pothead” or Outdoor Sealing End.
or a high permittivity filler may be applied over the insulation to control the
longitudinal stress distribution. This terminations are generally not self supporting.
premoulded elastomeric sheds have been fitted or moulded. In Fig. 1.28 an expan-
sion volume is shown above the liquid level. In some cases the termination is
completely filled with liquid and in these terminations external or internal compen-
sation is required for expansion in the form of a pressure tank or a header tank.
permittivity stress control layer applied adjacent to the cable insulation screen
termination.
be assembled onto a tubular insulator in the factory and then loosely fitted over the
prepared core on site.
These are essentially outdoor terminations for which the creepage length and sometimes
the height of the insulator have been reduced for those situations in which the termina-
tion is subjected to neither wet atmospheric conditions nor to air pollution. When sheds
are not required, the insulator is of a simple cylindrical or conical shape. The methods of
stress control are the same as those described for the outdoor termination, item 1.3.3.
Indoor terminations closely resemble the types of outdoor terminations shown in
Figs. 1.24, 1.25, 1.26, 1.27, 1.28, 1.29, 1.30, 1.31, 1.32 and 1.33.
Also known as “indoor potheads” or Sealing Ends.
1 Compendium of Accessory Types Used for AC HV Extruded Cables 29
Fig. 1.31 “Capacitor cone and insulator”, “cylindrical capacitor type” outdoor termination
Fig. 1.33 “Prefabricated composite and capacitor cone and insulator” outdoor termination
Adaptor Moulding
Pièce moulée d’adaptation
A type of “elastomeric moulding” usually of the “stress cone” type employed in
prefabricated accessories such as the “premoulded straight joint” of the two and
three piece types (1.2.1.2, Figs. 1.8 and 1.9) and some types of stress cones for
terminations. These mouldings are designed a) to fit a range of cable sizes, by
having different internal bore diameters and b) to have a constant external
diameter such that an outer elastomeric cylindricai moulding of constant size
can be fitted. The outer moulding is usually designed to be slid back over the
cable sheath during jointing.
Adhesive Tape
Ruban adhésif
Tape that is supplied pre-coated with an adherent layer. The tape is usually a
polymer with insulating or semi-conducting properties.
Anchor Plate
Plaque d’ancrage
The component which rigidly connects the joint shell of an anchor joint to a
concrete or steel structure for the purpose of segregating unequal mechanical
loading between two cables.
Barrier Insulator
Isolateur d’arrêt
A shaped insulator, usually formed from porcelain or cast resin, which is used a)
in a transition joint to prevent the impregnant in the paper cable from entering
the polymeric cable, b) in straight joint designs which employ oil of SF6 insula-
tion and c) in some types of straight joint designs to prevent the migration of
moisture from a damaged polymeric cable to a sound cable.
Barrier Plate
Plaque d’arrêt
A metal plate to which bushing insulators are clamped within a three core
transition joint. Alternatively the thermoset resin plate which is cast integrally
with the three bushing insulators. See “bushing”.
Base Plate
Plaque de base
A metal support plate to which the insulator of a cable termination is rigidly
bolted. The base plate is usually connected to earth potential a) directly by a local
connection or b) by connection to the insulation screen, metallic sheath or shield
wires of the cable. See “bonding lead”.
Bifurcating Joint
Jonction de dérivation
See “Y branch joint”.
Blind-Head Insulator
Isolateur borgne
A cylindrical insulator used in a metal enclosed GIS termination which is perma-
nently sealed at its high voltage end in the factory to prevent SF6 gas from entering
the termination in service. One method is to have a solid high voltage electrode
embedded into an insulator cast in thermoset resin. A plug-in connector is required
to transmit current from the conductor to the high voltage electrode. An external
adaptor is usually employed to transmit current to the off-going busbar. See “metal
enclosed GIS termination”, “busbar adaptor” and “plug-in connector”. Also termed
a “closed-top” insulator and a “plug-in” insulator.
Bonding Lead
a ble de raccordement d’écran
C^
36 Z. Iwata
Busbar
Barre collectrice
The off-going conductor that connects to a) the “conductor stalk” on an outdoor,
indoor or oil immersed transformer termination and b) the “busbar adaptor” on a
GIS termination.
Busbar Adaptor
Pièce de connexion
The off-going current carrying connection on a “metal enclosed GIS termination”
(1.3.1.1–1.3.1.5), which on one face fits to the embedded electrode or to the
conductor stalk, and on the second face fits to the particular design of off-going
busbar.
Bushing
Borne traversée
A type of “barrier insulator” employed in either a three core transition joint, or a
single core transition joint of the non-fed type, to prevent the impregnant in the
paper insulated cable from entering the polymeric cable. It is usually formed from
cast resin into which a solid conductor rod has been embedded. It has a central
flange which is designed to be sealed either to a “barrier plate” or to a “joint shell”
The insulation on each side is normally conical or cylindrical in shape, with
sufficient length to provide the “creepage” distance.
Cable Chamber
Cuve d’extrémité
1 Compendium of Accessory Types Used for AC HV Extruded Cables 37
The metallic “trunking” into which a “metal enclosed GIS termination” is bolted.
The trunking at this position is sometimes of different diameter to the trunking
that screens the rest of the SF6 gas insulated busbar.
Capacitor Cone
Cône à répartition capacitive ou cône condensateur
Insulation which contains a number of capacitors in series. It is designed to
give a linear voltage distribution along either a) the prepared cable core, b) the
surface of an insulator, or c) both. Capacitor cones are usually employed in
terminations (eg 1.3.1.4, 1.3.2.4, 1.3.3.2, 1.3.3.7 and 1.3.3.8). The cylindrical
type of capacitor cone (1.3.3.7, Fig. 1.31) is constructed from metallic or
semiconducting foils, which form a series of overlapping cylinders insulated
from each other by rolls of polymeric film. This type of cylindrical capacitor
cone can be wrapped directly onto the cable core or can be preformed in the
factory. Alternatively the capacitor cone can be formed from discrete toroidal
shaped capacitors (1.3.3.7, Fig. 1.32), which are slipped over the prepared
cable core and stacked one on top of the other. Also termed a “condenser
cone”.
Cast Barrier
Corps isolant en résine thermodurcissable
See “resin casting”.
Central Insulator
Corps isolant en résine thermodurcissable
A type of resin casting used in a prefabricated composite type of joint (1.2.1.2,
Fig. 1.6). See “resin casting” and “prefabricated straight joint”.
Composite Insulator
Isolateur composite
An “insulator” used in cable terminations of the “outdoor” (1.3.3), “indoor”
(1.3.4) and “temporary” (1.3.5) type. The “composite” insulator has a rigid
cylindrical core onto which pre-moulded elastomeric or polymeric “sheds” have
been fitted. The “sheds” are usually formed from silicone rubber. The core is
usually formed from thermoset resin reinforced with glass fibre.
Compression Device
Dispositif de compression
The device employed to compress the elastomeric “stress cone” in prefabricated
designs of joints and terminations of the “composite” type (1.2.1.2, 1.3.1.3,
1.3.3.6 and 1.3.3.8), to achieve an intimate fit with a) the cable core and b) the
38 Z. Iwata
Condenser Cone
Cône condensateur
See “capacitor cone”.
Conductor Rod
Barre conductrice
A metal rod embedded in a thermoset bushing to enable connection to be made
between two cable conductors in a transition joint (1.2.2.2, Fig. 1.16 and 1.2.2.3,
Fig. 1.17). See “bushing”.
Conductor Screen
Ecran sur conducteur
The conducting or semiconducting layer at high voltage, which is applied over
the conductor and upon which the insulation is applied. See “screen”. Also
termed “HV screen”, “HT screen”, “inner screen” and “conductor shield”.
Conductor Stalk
Tige de sortie
A metal connector which terminates the cable conductor to enable a current
carrying connection to be made to a busbar. See “busbar”.
Connector
Connecteur
The generic name for the conducting connection between a) cable conductors, b)
cable screen wires and c) one cable conductor and a conductor stalk at a
termination. The connection can be of the permanent type or of the separable
type. See “ferrule”, “MIG weld”, “thermit weld” and “conductor stalk”.
Connector Screen
Ecran sur connecteur
The conducting or semiconducting layer at high voltage, which is applied over
the conductor connector and upon which the joint insulation is applied. See
“screen”, “connecte” and “ferrule screen”. Also termed “HV screen”, “HT
screen” and “connector shield”.
Corona Shield
Ecran pare-effluves
A shaped conducting component positioned around a conductor or busbar con-
nector in a back-to-back straight joint (1.2.1.5, Figs. 1.12, 1.13 and 1.14) and in a
termination (e.g. 1.3.3.4–1.3.3.8). Its purpose is to control the electrical stress
distribution and thereby prevent the occurrence of corona (partial discharge) in
the surrounding liquid or gaseous insulation.
1 Compendium of Accessory Types Used for AC HV Extruded Cables 39
Creepage Distance
Ligne de fuite ou chemin rampant
The shortest distance measured along an insulating interface between conducting
components at high and Iow voltage.
In a joint the creepage distance is that between the end of the “insulation
screen” and the exposed “conductor screen”, measured along the interface
between the cable core and the applied joint insulation.
For a termination the “external creepage” distance is the distance between the
upper and Iower metalwork of the insulator, which includes the upper and Iower
surfaces of the “sheds”.
For an outdoor termination the “protected creepage” is the cumulative surface
distance of the underside of each shed. The “external” creepage and “protected”
creepage lengths are often specified to meet a particular level of atmospheric pollution.
Crosslinked Insulation
Isolation réticulée
Electrical insulation that has been changed from a thermoplastic to a thermoset
material by a chemical reaction which forms links between adjacent long chain
molecules. Crosslinked insulation has improved mechanical performance at high
operating temperatures because it does not melt. The cross-linked insulation can be
formed from a polymer with a semi-crystalline structure such as polyethylene
(PE) or from an elastomer with an amorphous structure such as ethylene propylene
rubber (EPR). Crosslinking can be achieved by a chemical reaction or by radiation.
In the chemical reaction method, an agent termed a curative is contained within the
insulation to promote the crosslinking process, usually with the application of heat.
Also termed “vulcanised” or “cured” insulation. This process also applies to the
crosslinked screens.
Cured Insulation
Isolation réticulée
See “crosslinked insulation”.
Deflector Cone
Déflecteur
A factory formed “stress control profile” of metal or semi-conducting polymer,
positioned adjacent to the termination of the cable insulation screen to control stress.
it is usually employed in combination with either a liquid or gaseous insulation of
high electric strength in accessories such as terminations of the “deflector and
insulator” type (1.3.3.5) and straight joints of the “back to back” type.
Dielectric
Diélectrique
An insulating material with high electric strength.
Dielectric Fluid
Fluide diélectrique
40 Z. Iwata
Dielectric Gas
Gaz diélectrique
A gas with high insulating properties, such as SF6, N2 or SF6/N2 mixture. These
gases are usually pressurised to achieve the required dielectric strength. N2
requires a significantly higher pressurisation than SF6.
Dielectric Liquid
Liquide diélectrique
A liquid with high insulating properties, eg. silicone liquids, synthetic hydrocar-
bon liquids and minerai oils.
Earth Screen
Ecran de terre
See “insulation screen”.
Elastomeric Moulding
Corps isolant en élastomère
An insulating component that has been premoulded in the factory from an
insulating polymer, which has elastic properties (low modulus of elasticity) in
the working temperature range of the accessory. The component usually has one
or more integral screens formed from a semiconducting elastomer.
Also termed a “rubber moulding” or “synthetic rubber” moulding.
Embedded Electrode
Electrode encastrée
See “HV electrode” and “HT electrode”.
Extruder
Extrudeuse
A powered machine used to prepare a) the cable insulation in the factory and b) the
joint insulation for some types of field moulded joints (1.2.1.3, Table 1.1). The
machine is comprised of a long rotating “screw” with a helical thread-form of
“flights” of varying pitch, which is contained within a heated “barrel”. The polymer
is fed into one end of the barrel, usually in the form of small pellets. The polymer is
melted and compressed into a viscous liquid termed the “melt”, which is homog-
enous and void free. The melt is extruded from the end of the barrel under the
pressure generated by the screw into either a) the cable insulation die tool or b) the
joint mould tool).
Ferrule
Douille de raccordement
A cylindrical metal connector between cable conductors or between cable screen
wires.
1 Compendium of Accessory Types Used for AC HV Extruded Cables 41
Types of ferrule:
Types de douilles de raccordement
• Compression Ferrule
Douille à sertir
A metal tube into which the conductors to be joined are inserted. The tube is then
compressed by a hydraulic press tool.
• Flush Ferrule
Douille équidiamétrale
The ferrule is nominally made flush with the diameter of the conductor, either by
a) compressing, b) removing a layer of wire, or c) welding.
• Mechanical Bolted Ferrule
Douille mécanique à visser
The current carrying connection is made by compressing the conductor inside the
ferrule by tightening threaded bolts. The bolts are finished flush with the surface
of the ferrule.
• Soldered Ferrule
Douille soudée (à basse température)
A metal ferrule is placed around the two conductors. The assembly is then filled
with hot molten solder (a lead alloy).
• Stop Ferrule
Douille borgne
The ferrule has a central internal barrier to segregate the conductors. Used a) in a
transition joint to prevent the flow of impregnant from a paper cable and b) in a
straight joint to prevent the migration of moisture from a damaged cable to a
sound cable.
• Welded Ferrule
Douille soudée (à haute température)
The two conductors are fused together by the application of molten metal. See
“MIG weld”, “TIG weld” and “thermit weld”.
Ferrule Screen
Ecran sur douille
The conducting or semiconducting layer at high voltage which is applied over the
ferrule and upon which the joint insulation is applied. See “screen” and “ferrule”.
Also termed “connector screen”, “HV screen”, “HT screen” and “ferrule shield”.
Filling Compound
Matière de remplissage
An insulating material used to fill some types of accessories. At amblent and at
operating temperatures it is substantially solid. During assembly of the accessory
it is heated to elevated temperature to reduce the viscosity and permit it to be
poured. See “waterproof compound”.
Filling Liquid
Liquide de remplissage
An insulating liquid used to f II some types of accessories, for example straight
joints of the “back-to-back type” and terminations which are protected within
hollow insulators. See “insulating liquid” and “dielectric liquid”.
Filling Oil
Huile de remplissage
An insulating liquid used to fill some types of accessories. The term “oil”
specifically relates to a minerai oil.
Flashover Distance
Ligne de contournement
The shortest distance between high voltage and low voltage metalwork in gaseous
or liquid insulation through which an electric discharge (flashover) can occur.
GIS Termination
Extrémité pour PSEM
A termination into Gas Insulated Switchgear. See “metal enclosed GIS
termination”.
A particular type of “joint box”. The box is placed around the joint shell and is
filled with compound to provide electrical insulation and corrosion protection
(1.2, Fig. 1.3). The box is pre-moulded from a thermoset or thermoplastic resin,
which has been reinforced with glass fibres. See “filling compound” and “water-
proof compound”.
Prefabricated composite and capacitor cone and insulator (1.3.4.8, Fig. 1.33)
A cône déflecteur composite, cône condensateur et isolateur.
1 Compendium of Accessory Types Used for AC HV Extruded Cables 45
Inner Screen
Ecran intérieur
See “conductor screen”.
Insulated Flange
Flasque isolant (1.3.4.8)
The generic name for the cylindrically shaped insulator which electrically sepa-
rates a) the two halves of a metallic joint shell or b) the lower metalwork of a
termination. The insulated flange can be a) an individuel annular ring of porcelain
or thermoset resin (1.2, Fig. 1.1, 1.3.1.5, Fig. 1.23), b) an integral part of a cast
resin barrier in a joint (1.2.2.2, 1.2.2.3, 1.2.2.4, Figs. 1.16, 1.17, 1.18, 1.19 and
1.1.3) or c) an integral part of a cast resin insulator in a termination (1.3.1.1–
1.3.1.4). The insulated flange together with the insulated screen gap are essential
parts of a specially bonded cable system. See “sectionalising ring” and “screen
interruption”. Also termed “insulated ring” and “resin ring”.
Insulated Gap
Interruption d’écran
See “screen interruption”.
Insulating Liquid
Liquide isolant
A liquid with high electrical strength used principally to fill and insulate some
types of terminations and back-to-back joints. Examples are minerai oil, synthetic
hydrocarbons (such as polyisobutene) and silicones. See aise “dielectric liquid”,
“filling liquid” and “filling oil”.
Insulating Tape
Ruban isolant
Tape with high electrical strength can be used to form the insulation or part
insulation of an accessory. It can be of the “adhesive” or “self-amalgamating”
type or simply of the non-adherent type.
Insulation
Isolation
Material of high electric strength which is applied between the conductor screen
and the insulation screen.
Insulation Screen
Ecran sur isolation
The conducting or semiconducting layer at earth potential applied over the
insulation. Also termed “earth screen”, “LV screen”, “ground screen”, “outer
screen” and “insulation shield”.
46 Z. Iwata
Insulator
Isolateur
The generic name for pre-formed solid insulation and particularly of the hollow
insulators used in cable terminations.
In addition to their insulating duty, the “Insulators” employed in cable termina-
tions (1.3.1.1 to 1.3.1.4 and 1.3.3.4 to 1.3.3.8) are designed to a) support the cabie,
b) protect the cable insulation, c) contain oil or gas insulation from leakage, d)
segregate the cable from external atmospheric conditions e) segregate the cable
from the oil or gas insulation used in other manufacturer’s equipment and f)
withstand conductor thermomechanical forces. Insulators employed in cable termi-
nations are usually formed from a thermoset casting or from porcelain, with a
hollow interior and either a cylindrical or a conical exterior shape. The outer surface
of the insulator is often formed in the shape of annuler protrusions termed “sheds”.
Insulator designs of the metal enclosed GIS and transformer termination types
are sometimes employed in transition joints and straight joints of the “back-to-
back” type (1.2.1.5). See also “porcelain”, “composite insulator”, “pedestal
insulator”, “resin casting”, “shed”, “barrier insulator” and “bushing”.
Joint (1.2)
Jonction
The generic name for the insulated and fully protected connection between two or
more cables. It provides an insulated path for the flow of current between the
conductors. Also termed a “splice”.
Types of Joints
See:
• “Straight joints” (1.2.1)
Jonctions droites
• “Transition joints” (1.2.2)
Jonctions de transition
• “Y branch joints” (1.2.3)
Jonctions en Y ou en T – Jonction de dérivation.
Joint Box
Boı̂te de jonction
The generic name for the waterproof housing which is fitted around the joint as
part of the “joint protection” (1.2, Figs. 1.3 and 1.5). The box is normally formed
from a moulding of thermoplastic polymer or thermoset resin, the latter usually
being reinforced with glass fibre (termed a “glass fibre box”). After being
assembled around the joint, the box is usually filled with a waterproof insulating
compound, such as bitumen, or thermoset resin. See also “joint protection”,
“glass fibre box” and “waterproof compound”.
Joint Protection
Protection de jonction
1 Compendium of Accessory Types Used for AC HV Extruded Cables 47
The generic name given to the outer coverings of the joint which, depending upon
the particular application, a) protect the joint metalwork from corrosion, b)
prevent water from entering the joint and c) electrically insulate from earth
potential the insulation screens, shield wires and joint shell. Types of protection
are “joint shell protection”, “joint” be and “glass fibre box”. Protection can also
be formed from tape and heat shrink sleeves.
Joint Shell
Enveloppe de jonction ou enveloppe métallique
The metal tube which contains the joint insulation (1.0, Fig. 1.1), to a) provide
electrical continuity between sheaths, b) contain short circuit current within the
cable system, c) form an impervious water tight barrier and d) contain the filling
of liquid or gas.
Lower Metalwork
Pot d’entrée
The metal tube or gland connected to the base of a termination insulator which a)
seals the cable and b) enables electrical connection to be made to the metal sheath
or wire screen. Also termed “bottom” metalwork, “end bell”, “plumbing gland”
and “wiping gland”.
MIG Weld
Soudure MIG
A weld made by the Metal Inert Gas process in which a consumable wire
electrode, usually aluminium, is fed continuously into an electric arc under a
shield of inert gas, where it is melted and propelled to fuse into the conductor.
Off-Going Connector
Raccordement de sortie
The device that connects the “conductor staik” in a termination to an off-going
busbar. Also termed a “busbar connector”.
A manchon thermorétractable
-stress control sleeve (1.3.3.2, Fig. 1.25)
avec manchon de contrôle du champ
-capacitor cone stress control (1.3.3.2, Fig. 1.26)
avec cône condensateur
• Elastomeric sleeve (1.3.3.3, Fig. 1.27)
A manchon élastomère
• Stress cone and insulator (1.3.3.4, Fig. 1.28)
A cône déflecteur et isolateur
• Deflector and insulator (1.3.3.5, Fig. 1.29)
A déflecteur et isolateur
• Prefabricated composite and insulator (1.3.3.6)
A cône déflecteur composite et isolateur
• Capacitor cone and insulator (1.3.3.7)
A cône condensateur et isolateur
-cylindrical capacitor cone (1.3.3.7)
avec condensateurs cylindriques
-toroidal capacitor (1.3.3.7)
avec condensateurs toroïdaux
• Prefabricated composite and capacitor cone and insulator (1.3.3.8)
A cône déflecteur composite, cône condensateur et isolateur.
Painted Screen
Ecran graphité
A semiconducting screen normally formed by brushing Iiquid paint onto poly-
meric insulation. The paint is loaded with a conducting filler, usually dispersed in
a resin binder and rendered liquid by a solvent, which subsequently evaporates.
See “screen”. Also termed “painted shield”.
Pedestal Insulator
Isolateur support
A short insulator of porcelain or thermoset resin which is used to insulate either
a termination baseplate (1.3.3.4–1.3.3.8) or a joint shell (1.2, Fig. 1.4) from
earth potential. Also termed “stand-off” insulator and “post” insulator. See
“insulator”.
Pencil
Cône
The conical shape into which the insulation of the cable core is formed in a joint
(1.2, Fig. 1.1) or termination. Pencils are usually employed in taped joints and
in field moulded joints. They are designed to withstand the electrical stresses at
the interface between the insulation of the cable and joint. Pencils of shorter
Iength are often employed in a cable termination adjacent to the conductor
connector to facilitate the application of either a sealing tape or a heat shrink
sleeve.
50 Z. Iwata
Plug-In Connector
Connecteur embrochable
A metal connector which terminates the conductor. It is inserted into a mating
electrode usually embedded in a thermoset casting. Current carrying contact is
made by sprung connectors or by elasticity of the component. See “blind-head
insulator”.
Plug-In Insulator
Isolateur borgne
See “blind head insulator”.
Plumb
Soudure au plomb lissé
A conducting connection and seal which is formed between the metal sheath and
a) the joint shell, or b) the termination lower metalwork, by the hand application
of a hot lead alloy. Also termed a “wipe”.
Porcelain
Porcelaine
Solid insulation formed from vitrified clay, used primarily for outdoor termination
insulators and “pedestal insulators”. The name is sometimes used in the abbrevi-
ated foret for “porcelain insulator”. See “insulator”.
Pothead
Extrémité
See “termination”.
Resin Barrier
Corps isolant en résine thermodurcissable
See “resin casting”.
1 Compendium of Accessory Types Used for AC HV Extruded Cables 51
Resin Casting
Corps isolant en résine thermodurcissable
A rigid insulating component manufactured from a thermoset resin (usually
epoxy resin), used to form a) the central insulator in joints of the prefabricated
composite type (1.2.1.2), b) the barriers in some types of transition joints (1.3.2
and 1.3.3) and c) the insulator in metal enclosed terminations (1.3.1.1–1.3.1.4).
Also termed “resin barrier” and “cast barrier”. See “barrier insulator” and “central
barrier”.
Rubber Moulding
Corps isolant en élastomère
See “elastomeric moulding” and “synthetic rubber moulding”.
Screen
Ecran semi-conducteur
A smooth conducting layer in intimate contact with the insulation. It is designed
to a) contain the electric field within the insulation and b) minimise the magnitude
of the electric stress by the elimination of irregularities in the surface, (termed
“stress raisers”). Also termed a “shield”.
Screen Interruption
Interruption d’écran
The “insulated gap” formed in the insulation screen of a joint, which together with
the “insulated flange” in the joint sheil, electrically separates the cable screen on
one side of the joint from that on the other. Screen interruption joints are
necessary for specially bonded cable systems, which together with “bonding
leads” and link boxes permit the metallic sheaths or screening wires to be
transposed for cross bonding. See “bonding leads”. Also termed “insulated
gap”, “sheath interruption” and “sheath segregation”.
Screen Termination
Arrêt d’écran
The name given during jointing to the end position of the cable insulation screen
during jointing, after the screen has been removed from the core and the insula-
tion prepared. See “screen”.
Sealing End
Extrémité
See “termination”.
Sectionalizing Ring
Anneau de sectionnement
A type of “insulated flange”. An insulating ring which electrically separates two
halves of a) a metal joint shell (1.0, Fig. 1.1) or b) the lower metalwork of a
termination (2.1.1, inset and 2.1.5). The ring can be made from a thermoset
52 Z. Iwata
Semiconducting Screen
Ecran semi-conducteur
A polymeric or elastomeric resin that has been loaded with an electrically
conducting filler to give it sufficient conductivity to act as a screen, whilst
exhibiting similar thermomechanical properties to the cable and joint insulation.
It has a significantly lower conductivity than a metallic screen. The semiconduct-
ing screening material can be extruded, moulded or applied in tape form. See
“screen”. Also termed “semiconducting shield”.
Sheath Closure
Etanchéité de gaine
The generic name for the seal between the metallic sheath of the cable and either
the joint shell or termination lower metalwork. See “plumb”.
Sheath Interruption
Interruption d’écran
See “screen interruption”.
Sheath Segregation
Interruption d’écran
See “screen interruption”.
Shed
Ailette, Jupe
One of the disc shaped protrusions on the outer surface of a termination (1.3.1.1–
1.3.1.5) which increases the effective surface length of the insulator without
increasing its height. These are mainly used on outdoor terminations, which are
exposed to rain, ice, fog, salt, mist and to atmospheric pollution. Small sheds are
sometimes used on indoor, oil immersed transformer and GIS terminations. See
“creepage distance”. Also termed a “weather” shed.
Shield
Écran
See “screen”.
Splice
Jonction
See “joint”.
1 Compendium of Accessory Types Used for AC HV Extruded Cables 53
Stress Cone
Cône déflecteur
A shaped insulating component with a screened “stress control profile”. It is used
for stress control at the end of either the low voltage insulation screen or the high
voltage electrode (1.3.1.1, 1.2.2.4, 1.3, 1.3.1.3, 1.3.1.5, 1.3.3.1, 1.3.3.4, 1.3.3.6
and 1.3.3.8). It is usually formed from a moulded or machined polymer, elastomer
or thermoset resin.
Termination (1.3)
Extrémité
The generic name for the connection between a cable and other electrical equip-
ment. Also termed “sealing end” and “pothead”.
Types of Terminations
• Metal Enclosed GIS Terminations (1.3.1)
Extrémités pour PSEM
• Oil Immersed Transformer Terminations (1.3.2)
Extrémités pour transformateur
• Outdoor Terminations (1.3.3)
Extrémités extérieures
• Indoor Terminations (1.3.4)
Extrémités intérieures
• Temporary Terminations (1.3.5)
Extrémités temporaires
Thermit Weld
Soudure aluminothermique
A weld formed by igniting a mixture of combustible material and powdered metal
that melts and fuses to connect two cable conductors.
TIG Weld
Soudure TIG
A weld made by the Tungsten Inert Gas process in which an electric arc is struck
between a tungsten electrode and the conductor under a shield of inert gas. A
consumable hand held welding rod, usually aluminium, is fed into the arc where it
is melted and fused to connect the conductors.
Trunking
Enveloppe d’extrémité
The metallic cylinder that contains a) the SF6 gas in metal enclosed GIS (1.3.1) or
b) the oil in a transformer termination. The trunking also forms a) the insulation
screen and b) the return conductor for short circuit current. The trunking adjacent
to a GIS termination is termed a “cable chamber”. The short length of trunking
used to contain the SF6 gas or oil in a joint, of the “back-to-back insulator” type
(1.2.1.5) is termed the “joint shell”.
Upper Metalwork
Tête d’extrémité
The high voltage metal components at the top end of a cable termination, which
are normally comprised of the top sealing plate, the clamp ring and the corona
shield.
Vulcanized Insulation
Isolation vulcanisée
See “crosslinked insulation”.
Waterproof Compound
Matière d’étanchéité
The generic name for the viscous liquid used to fill a) the joint box and b) the
metallic joint shell of some types of joint (1.2, Fig. 1.3). The compound conforms
and adheres to the joint components (ie joint shell or screened insulation). It
provides electrical insulation and sealing against moisture ingress. Bitumen is one
form of compound, this is normally poured hot and cools to a high viscosity
liquid. Thermosetting resin is another form of compound, which upon curing
forms an adherent solid or elastic mass. See “joint box”, “glass fibre box” and
“joint protection” and “filling compound”.
Waterproof Seal
Etanchéité extérieure
1 Compendium of Accessory Types Used for AC HV Extruded Cables 57
The seal between the “joint box” and the cable oversheath. It is usually formed
from a) thermoset resin putty, b) fibre glass reinforced resin, c) heat shrink sleeve,
or d) waterproof tape. The seal is required to contain the compound filling and to
prevent the ingress of water.
Weather Shed
Ailette, jupe
See “shed”.
Wipe
Soudure au plomb lissé
See “plumb”.
Contents
2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
2.2 Compatibility of the Accessory with the Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
2.2.1 Number of Cable Cores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
2.2.2 Cable Constructional Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
2.2.3 Conductor Area and Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
2.2.4 Operating Temperature of the Cable Conductor and Sheath under Continuous,
Short Term Overload and Short Circuit Current Loading . . . . . . . . . . . . . . . . . . . . . . . 63
2.2.5 Compatibility of the Accessory with the Type of Cable Insulation
and Semiconducting Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
2.2.6 Cable Electrical Design Stresses to be Withstood by the Accessory . . . . . . . . . . . . 64
2.2.7 Mechanical Forces and Movements Generated by the Cable on the Accessory . . . 64
2.2.8 Short Circuit Forces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
2.3 Compatibility of the Accessory Performance with that of the Cable System . . . . . . . . . . . 65
2.3.1 Circuit Performance Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
2.3.2 Circuit Life Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
2.3.3 Metallic Screen Bonding Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
2.3.4 Earth Fault Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
2.4 Compatibility of the Accessory with the Cable System Design and Operating
Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
2.4.1 Type of Cable Installation Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
2.4.2 Standard Dimensions for Cable Termination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Z. Iwata (*)
Kamakura, Japan
e-mail: z.iwata@kamakuranet.ne.jp
2.1 Introduction
The user should determine whether the cable construction is of single, three core or
triplex construction (i.e. three single core cables twisted together). The design of the
accessory and the method of assembly is dependent upon the number of cable cores;
however it is unusual for three core extruded cables to be employed above 60 kV.
For satisfactory service performance it is most important that the correct size of
accessory is selected to suit the particular cable. The outer diameter of the cable
insulation, its tolerance and shape are particularly important in the selection of an
accessory employing a pre-moulded component, such as an elastomeric stress cone
or an elastomeric joint moulding. Such components are designed to fit a specific
range of diameters of prepared cable insulation (that is with the insulation screen
removed and the insulation smoothed and shaped). The components must not be
62 Z. Iwata
used outside this range. The minimum diameter is determined by the need to achieve
sufficient pressure to eliminate voids at the interface with the cable insulation. The
maximum diameter is determined by such considerations as a) preventing damage by
over stretching during assembly and b) limiting the maximum pressure at the
interface such that compression set of the cable insulation and moulded insulation
is minimised.
The diameter and tolerance ratio of the conductor and of its compaction (the radio
of the effective cross sectional area of the metal to the total area occupied) are needed
in selecting a connector that will exhibit stable conductivity and high mechanical
strength.
The diameters and tolerances of the cable metallic barrier and over sheath are
needed to ensure that accessory metallic flanges and other components can be passed
back over the cable during assembly.
The following dimensional and constructional details should be obtained by the
user to ensure compatibility of the accessory with the cable:
The detailed cable construction should be obtained from the cable manufacturer,
which includes the following information as a minimum requirement. Diameters,
maximum and minimum tolerances, eccentricity dimensions, construction and mate-
rial need to be obtained for each of the following cable components:
The user should ensure that the accessory has been designed and tested for the
particular cable conductor size. The electrical performance of an accessory design
can become critical on large conductor cables because of the high cable insulation
screen stress.
The user should ensure that the conductor connections in the complete kit of
components are supplied to suit the particular conductor construction. The conductor
connection must be capable of carrying the same current as the cable conductor and
must be capable of withstanding the cable longitudinal thermomechanical forces,
these being proportional to the cross sectional area.
2 A Guide to the Selection of Accessories 63
cable can result in swelling and modification of the electrical characteristics of the
semi-conducting screens and insulation of both the cable and accessory components,
thereby reducing their electrical performance. Loss of the impregnating fluid into the
polymeric cable can result in eventual electrical failure of the paper cable.
The user is advised to obtain the magnitude of the cable stresses at the conductor and
insulation screens, or obtain the dimensions of the cable, thereby permitting the stresses
to be calculated. The unit of stress is kV/mm calculated at Uo voltage. There are
significant differences in the magnitude of the electrical design stress employed in
cables, these being dependent upon the type and thickness of insulation, the conductor
size, the system voltage and the lightning impulse voltage. It is essential that the
accessory has been designed and tested to operate at the particular cable design stress.
The stress at the cable insulation screen is of particular significance because this
normally determines the maximum design stress in the accessory. The insulation
screen stress is usually of higher magnitude in those cables designed for high system
voltages and large conductor diameters.
The magnitude of the forces and movements generated by the cable on the accessory
depends upon the cable materials, the method of cable manufacture and the type of
cable installation design (i.e. rigid or flexible installation).
The following mechanical strains are dependent on the cable construction:
The following forces are dependent upon the cable construction, current loading,
operating temperature, method and type of cable constraint and accessory design:
Electromagnetic forces are present during a short circuit between the individual
conducting components of the accessory and between the adjacent cables and the
accessory. The following information is applicable:
2 A Guide to the Selection of Accessories 65
The current rating and optimum circuit economics are dictated by the cable conduc-
tor size, cable material costs and the method of installation. To achieve the optimum
economical solution it is important that the accessory design is not allowed to limit
the performance of the cable. The accessory must therefore match the following
cable performance:
The accessory should match the design life specified for the particular cable circuit.
This is typically requested to be from 20 to 40 years, however some cable circuits are
installed as temporary links, for example in an overhead line circuit. Such accesso-
ries may be designed to be suitable for quick assembly with a reduction in perfor-
mance and service life.
• Magnitude of induced sheath or screen wire voltage under normal and short
circuit current.
• Magnitude of circulating sheath or screen wire current under normal loading.
• Magnitude of short circuit current.
• Magnitude of specified over sheath lightning withstand voltage and dc withstand
voltage, (ELECTRA 128; E.R. C.55/4 1989; ANSI/IEEE 575-1988 1988).
It is important that the accessory design incorporates means of connecting the cable
screen wires, metallic tapes or sheath and joint shell to the insulation screen.
Some Utilities require that short circuit currents be returned within the cable system.
The user should ensure that the accessory is also able to contain this current.
The user is advised to ensure that accessory design is a) compatible with the
particular cable installation design, as this determines the mechanical loading
applied, b) capable of being assembled in the site environmental conditions and c)
capable of a satisfactory service performance under adverse climatic conditions.
pressure) and the design of the support structure (fixing arrangements for the
particular cable constraint selected) (IEC 859 1986).
• Space limitations
• Time limitations (for example arising from road or rail traffic influences)
• Tolerance limitations of assembly personnel (for example arising from extremes
of temperature, humidity, vibration, noise and induced voltage).
• Thermomechanical forces
• Earthquake
• Vibration
• Off-going bus bar at terminations
• Wind loading on bus bars at terminations
• Ice loading on bus bars at terminations
• Short circuit loading on bus bars at terminations
• GIS pressure
• Angle of installation of terminations
• Hydraulic or pneumatic pressure forces at transition joints.
If an applicable type test specification is available for the accessory, then these tests
should be undertaken or a type test report provided. A list of world wide test
specifications is given in the References.
If a type test specification for the accessory does not exist, then it is recommended to
use the type test specification for the cable.
2 A Guide to the Selection of Accessories 69
The type test report should be obtained, this will give details of the accessory
together with the cable size, performance levels and test specification reference.
The type test usually includes elevated high voltage testing and load cycle testing of
a comparatively short duration (e.g. 20 daily load cycles).
The cable size recorded in the type test report should be compared to the required
cable for the particular application. The radial design stress of the test cable should
be equal to or higher than that of the required service cable. The conductor area
recorded in the type test report should be equal to or larger than that of the required
cable. If the conductor size of the particular cable has not been tested it is permitted
to accept tests already performed on a larger conductor (for example on the largest
conductor size in the range). Some specifications require the testing of both the
largest and smallest conductor sizes in the range, (IEC 840 1988).
The pre-qualification test is an endurance test of extended duration (for example one
year). If a recognised pre-qualification test specification does not exist then the user
is recommended to ask for confirmation that long term development tests have been
undertaken. For pre-qualification tests on accessories for use at system voltages
above 150 kV see (ELECTRA 151 1993a, b).
Although not essential if the cable and accessories have passed recognized type
approval tests and pre-qualification tests it is advisable to check that the accessories
have a satisfactory service experience.
Type approval reports should be provided to demonstrate the adequacy of the electrical
insulation of a) the joint protection and b) the screen interruption. These tests are usually
required to be undertaken on the complete accessory together with the cable. The
exception is for discrete components, such as pedestal insulators, which for some
applications may be tested individually. The tests usually require a combination of
lightning impulse, ac and dc voltage withstand tests (ELECTRA 128; E.R. C.66/1 1979).
70 Z. Iwata
Type approval reports should be provided for those joints required to operate
partially or fully submerged under water. Typical applications being installation in
water logged ground or in jointing chambers or tunnels which are liable to flood.
These tests are usually undertaken on the completed joint together with the cable and
should require the application of either temperature cycles or current loading cycles
whilst under water immersion.
For installation in the ground, the test specification may also require the addition
of mechanical tests to demonstrate the ability to withstand forces imposed by soil
loading and by heavy vehicles, (E.R. C.66/1 1979).
For joints in specially bonded cable circuits, installed in the ground, it is usual to
provide a type test report which demonstrates performance when subjected to a
combination of mechanical loading, water immersion, temperature cycling and
elevated voltage withstand tests (item 2.5.7) (E.R. C.66/1 1979).
In addition to the basic electrical type approval test report, the user is advised to seek
confirmation of test performance for the following items:
If the accessory contains fluid under pressure or is connected to GIS metal clad
trunking it is advisable to check the requirements of National Regulations, if they
exist, concerning approval of the design, routine test and type test.
Type approval testing is intended to verify that the design has met the specified
performance. To ensure consistent manufacturing quality, the user should verify the
following items.
The user should ensure that the accessory supplier or manufacturer provides evi-
dence of an approved Quality Assurance system for design, manufacture, routine test
and traceability complying with an internationally recognised standard, e.g. (BS EN
ISO 9001:1994 1994).
It is strongly recommended that the user specifies that each factory moulded
insulating component be subjected, as a minimum requirement, to a routine test
comprising an ac voltage withstand test and a partial discharge measurement test.
Consideration should also be given to the application of additional routine tests, for
example, dielectric loss angle measurement, X-ray examination and ultrasonic
examination (KEMA S10-2; ENEL spec. DJ 4585).
72 Z. Iwata
Assembly of the accessories onto cable with extruded insulation is the most vulnerable
part of a project involving the manufacture and installation of a new cable circuit.
Accessories and cables are manufactured and tested under controlled factory conditions,
whereas the in-service performance of the accessory is dependent upon the training, skill
and reliability of the personnel, who are often required to work under adverse site
conditions.
For many project applications one company will manufacture the cable and acces-
sories and undertake to complete the installation of the circuit. In other applications the
installer may complete the circuit using cable and accessories supplied by different
manufacturers. In some applications the installer may only assemble the accessories. For
each application the requirements of the QA system are equally rigorous.
The user should ensure that the installer provides evidence of an approved quality
assurance system for installation to an internationally recognised standard (BS EN
ISO 9001:1994 1994).
The installer is required to produce a Quality Plan for each project, this includes the
project time schedule together with the requirements for suitably qualified personnel,
training, on-site storage of components and accessories, tools, testing equipment,
constructing materials, assembly instructions, preparation of the jointing environment
and records of the assembly work. It is important that the records of assembly are
traceable to the location of each accessory in the cable circuit. If purchasing separately,
the user is advised to ensure that, for the purposes of traceability, the quality systems of
the cable manufacturer, accessory manufacturer and installer are compatible.
When selecting the designs of accessories the user should ensure that training courses are
available for the jointing and supervisory personnel. It is strongly advised that personnel
receive training on the particular designs of accessories and cable.
2 A Guide to the Selection of Accessories 73
• General training at specific system voltages with the standard range of accessories
required by the user
• Repeat training after a defined period for those personnel who have completed
general training
• Specified training on a new accessory or cable design for those personnel who
have completed general training.
At the end of the training course the proficiency of the assembly personnel is
normally assessed, for example, by a verbal or written examination, by a practical
test and preferably by performing on the assembled accessories an electrical partial
discharge test and voltage withstand test.
Proficiency is recognised at the completion of training by the issue of a certificate,
which should be checked by the user as part of the quality plan for a specific project. In
many instances a kit of general jointing tools and a set of general assembly instructions
is also issued to the personnel following satisfactory completion of training.
It is strongly recommended that the assembly area for both joints and termination to
be enclosed within a tent or temporary building, with the objective of providing a
74 Z. Iwata
clean and dry environment. The enclosure should be a) well lit to facilitate accurate
preparation of the cable insulation, b) provided with a sound floor and c) lined with
sealed materials to facilitate cleanliness. In extremes of climate it is good practice
to provide control of temperature and humidity to ensure a) consistent performance
of the personnel and b) consistent properties of the polymeric materials.
When the installation of the cable and accessories has been completed it is standard
practice to perform electrical tests to demonstrate that the assembly of the accesso-
ries is of satisfactory quality and that mechanical damage to the cable and accessories
has not occurred during installation.
The following tests can be performed. It is important to ensure that the accessory
design is suitable for the particular test:
DC tests have been traditionally applied to transmission circuits, however their use
on cable with extruded polymeric insulation is not recommended. Experience has
shown that the dc voltage test is not always sufficiently sensitive to detect damaged
cable insulation or incorrectly assembled accessories and hence prevent them from
entering service. In particular the electrical stress distribution under dc voltage in an
accessory is usually significantly different from that under ac voltage in normal
service. The application of an ac voltage is now under evaluation as an after laying
test, either by the application of service voltage from the transmission system or by
the application of test voltage from mobile test equipment (ELECTRA 173 1997).
Partial discharge detection techniques are at present being developed for some cable
and accessory applications to check for the absence of damage to the cable during
installation and incorrect assembly of the accessories. Methods are not yet available
for this to be done in a simple manner as a routine commissioning test on normal
cable circuits (ELECTRA 173 1997).
2 A Guide to the Selection of Accessories 75
2.8.3 Voltage Withstand Test on the Cable over Sheath and Joint
Protection
The user should ensure that adequate maintenance tests and checks have been
recommended by the cable and accessory suppliers, for example:
Liquid and gas levels: some types of termination, straight joints and transition joints
are filled with insulating liquid or gas and may require to be regularly inspected or
monitored in service to ensure that neither the liquid or gas have escaped.
These tests are similar to the after laying tests, but are usually performed at reduced
voltage levels (ELECTRA 128; E.R. C.55/4 1989).
The user should ensure that information is provided on the shelf life of the compo-
nents in an accessory for long term storage as these may vary according to the type of
material, the way they are packed and the appropriate temperature and humidity
conditions of storage.
76 Z. Iwata
A comparison of the relative costs of different designs of accessory kits should not
be undertaken without giving due consideration to the total costs of installation and
assembly. The following are the main items of cost.
The accessory design should be checked to ensure that it is a complete kit and will be
supplied with all the components and assembly instructions for the particular applica-
tion. Some components that may not necessarily be supplied by all accessory manufac-
turers are for example a) conductor connections and anti-corrosion protection for joints
and b) bus bar take-off connectors and support metalwork for termination.
At the higher system voltages it is more usual for the cable and accessories to be
supplied, installed and guaranteed as a “turn-key” project. Under such circumstances
the guarantee will usually extend to a specified number of years in service. If the user
decides to divide the supply and installation of accessories between companies, it is
recommended that the cost of financial self insurance be considered, because the
responsibility for an accessory failure in service can be difficult to apportion between
the accessory manufacturer, the cable manufacturer and the installer.
The jointing time required to assemble accessories can differ dependent on their
design. Similarly the time required to assemble the anti-corrosion protection and the
final mechanical support to the accessory can be the over-riding factors in determin-
ing the jointing time.
2 A Guide to the Selection of Accessories 77
There may be significant differences in purchase cost and hiring charges of the tools
required for different accessories.
Qualified jointers who are trained to assemble the particular accessory should always
be employed. The user should decide whether it will be more cost effective to a)
employ qualified and experienced personnel to assemble the accessories, or b)
employ qualified and experienced personnel to install the cable and assemble the
accessories as part of a turn-key contract, or c) incur the on-going costs of training
and regular repeat training for his own personnel.
The design of the cable can influence the cost of the accessory design. Thus a
reduction in the cost of the cable construction may result in an increase in the cost
of the accessories. Similarly an increase in the cost of installation by laying longer
lengths of cable may achieve a reduction in overall costs by requiring fewer joints.
78 Z. Iwata
If a type test report is not available for the particular cable and accessory in
combination then the user is advised to allow for the cost of performing a type
approval test. This cost may be born by the supplier, in the case of a turn-key project,
but this is less usually so in the case of separately supplied cable and accessories.
References
ANSI/IEEE 575-1988.: Guide for the application of sheath-bonding methods for single-conductor
cables and the calculation of induced voltages and currents in cable sheaths (1988)
BS EN 50069:1991.: Specification for welded composite enclosures of cast and wrought aluminium
alloys for gas filled high voltage switch gear and control gear (1991)
BS EN ISO 9001:1994.: Quality Systems: Model for Quality Assurance in design, development,
production, installation and servicing (1994)
E.R. C.55/4.: Insulated sheath power cable systems (1989)
E.R. C.66/1.: Type approval testing procedure: protective boxes for use with buried accessories
employed on 33kV–400 kV insulated sheath power cable (and for sheath sectionalising insula-
tion embodied in such accessories) (1979)
EATS 09-10.: Porcelain insulators for 33, 66, 132, 275 and 400 kV pressure assisted cable outdoor
sealing ends (1976)
ELECTRA 128.: Guide to the protection of specially bonded cable systems against sheath over
voltages (Report of WG 21.07)
ELECTRA 151.: Recommendations for electrical tests pre qualification and development on
extruded cables and accessories at voltages > 150 (170) kV and 400 kV (420) kV. (December
1993 pp. 15–19: WG 21.03) (1993a)
ELECTRA 151.: Recommendations for electrical tests, type, sample and routine on extruded cables
and accessories at voltages > 150 (170) kV and 400 kV (420) kV. (December 1993 pp. 21–
29: WG 21.03) (1993b)
ELECTRA 173.: After laying tests on high voltage extruded insulation cable systems (Report of
WG 21-09) (1997)
ENEL spec. DJ 4585.: Prescrizioni per il collaudo di giunti e terminali unipolari cavi isolati con
gomma etilenpropilenica
IEC 1463.: Bushings – Seismic Qualification
IEC 229.: Test on cable over sheaths which have a special protective function and are applied by
extrusion (1982)
IEC 71.: Insulation Coordination. Part 1 (1993): Definitions, principles and rules. Part 2 (1976):
Application guide
IEC 815.: Guide for the selection of insulators in respect of polluted conditions (1986)
IEC 840.: Tests for power cables with extruded insulation for rated voltages above 30 kV (Um ¼
36 kV) up to 150 kV (Um ¼ 170 kV)) (1988)
IEC 859.: Cable connections for gas-insulated metal-enclosed switch gear for rated voltages of
72.5 kV and above (1986)
IEC 986.: Guide to the short-circuit temperature limits of electric cables with a rated voltage from
1.8/3 (3.6)kV to 18/30 (36)kV (1989)
IEEE 48-1990.: Test procedures and requirements for high-voltage AC cable terminations (1990)
KEMA S10-2.: KEMA specification of requirements to be met by accessories for single-phase
power cables with extruded insulation for rated voltages between 50 and 220 kV
Section 3.: Summary of world wide usage of accessories for HV extruded cables (Chapter 4.1)
(Report of WG 21-06)
2 A Guide to the Selection of Accessories 79
Contents
3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
3.1.1 Terms of Reference of JTF 21/15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
3.1.2 Interfaces to be Studied . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
3.1.3 Materials Involved . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
3.2 Interface Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
3.2.1 Smoothness of the Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
3.2.2 Contact Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
3.2.3 Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
3.2.4 Electrical Field Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
3.2.5 Temperature and Temperature Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
3.2.6 Quality of Accessory Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
3.3 Long Term Performance of Interfaces in Cable Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
3.3.1 Migration of the Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
3.3.2 Movements in the Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
3.3.3 Reduction of the Interface Pressure due to Relaxation of Materials . . . . . . . . . . . . . . 91
3.3.4 Electrical Ageing of Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
3.4 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
3.5 Recommendations and Conclusions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
3.1 Introduction
H. Geene (*)
Prysmian Group, Product Management HV Accessories, The Hague Area, Netherlands
e-mail: henk.geene@prysmiangroup.com
accessories for HV and EHV extruded cables. The scope was limited to non-bonded
interfaces between solid insulating materials, but included the applied lubricants.
The Joint task force 21/15 (JTF21/15) was installed by Study Committee SC21
(Insulated Cables now SC B1) and SC15 (Materials now SC D1) and called
“Interfaces in accessories for extruded HV and EHV cables” The members of the
task force were cable systems and/or material experts. The report of the work has
been published as Cigré TB 210.
Within Cigré, interfaces was also subject of study for WG15.10. This working
group was concentrating on the material aspects of interfaces and had developed and
selected interface models for laboratory testing.
The joint task force is reviewed the state of the art regarding the interface behaviour
in accessories for extruded HV and EHV cables.
The targets objectives for JTF 21/15 were:
The task force did not deal with partial discharges and electrical treeing in interfaces,
since these processes are strongly influenced by the type of accessories (materials,
design, etc.).
The focus was on the parameter settings to prevent partial discharges in interfaces
and those phenomena that could lead to partial discharges in service. Partial dis-
charge detection on installed Cable Systems was the subject of Cigré WG 21-16
which published Cigré TB 182 (Cigré WG B1-16 2001).
The interfaces to be studied are those in accessories for extruded HV and EHV cables
between solid insulating materials. Although the cable is an essential part of the
accessory, it will not always be explicitly mentioned (Fig. 3.1).
Interfaces in accessories are between:
• Rubber insulating body and cable insulation, in a liquid or gas filled termination
(a) dry-type termination (b), in a composite joint (c) or joint (d),
• Stress-cone and epoxy joint body, in a dry-type termination (b) or composite
joint (c)
• Adapter sleeve and joint body (e)
3 Interfaces in Accessories for Extruded HV and EHV Cables 83
Interfaces exist between two solid polymer parts. The materials involved in these
interfaces and various related abbreviations are summarized in Table 3.1. The
international standards dealing with symbols and abbreviations of polymers respec-
tively rubber and latex latices appear not to be harmonized yet.
Polyethylene mainly divides into two big families: LDPE (Low Density Poly
Ethylene, density in the range of 0.910-0.925 g/cm3) and HDPE (High Density Poly
Ethylene, density in the range 0.941–0.965). In addition to these two main families,
it is worth mentioning LLDPE (Linear Low Density Poly Ethylene). In cable
manufacturing PE is used both for insulation and for jacketing; the cross-linking
of PE (peroxide or silane) leads to XLPE (Cross Linked Poly Ethylene) and is widely
used both for MV and HV cables, particularly for allowing high operating temper-
atures up to 90 C.
The general term EPR is used as an abbreviation for Ethylene Propylene Rubber
(see Table 3.1). EPR divides into two kinds of polyolefin polymers: EPM and
EPDM. EPM represents an Ethylene Propylene copolymer while EPDM denotes a
84 H. Geene
Interfaces are characterized by the initial or short-term breakdown strength and long-
term ageing properties. In Sect 3.3 the ageing phenomena will be discussed while in
this section the focus will be on the initial breakdown strength.
The electrical withstand strength of interfaces is influenced by a combination of
several parameters. In the design of interfaces the following parameters should be
taken into account:
Most of the parameters mentioned, interact with each other. In the following
paragraphs, the parameters will be discussed separately.
86 H. Geene
Fig. 3.2 Breakdown strength of air gaps, derived from the Paschen Curve (Kreuger 1989)
3 Interfaces in Accessories for Extruded HV and EHV Cables 87
Reading from Fig. 3.2, the cavity size in such case has to be smaller than about
20 μm.
Sanding with grade 400 leads to a roughness Rz ¼ 10 μm (Rz ¼ RmaxRmin).
Assuming that the mould irregularities are significant smaller (order of 1 μm) the
achieved cable insulation smoothness with paper grade 400 is sufficient.
3.2.3 Lubricant
Lubricants are basically used to relieve the friction between rubber parts and the
other insulating materials during installation. Silicone fluids and greases are com-
monly used for this application.
88 H. Geene
→
p y
x z material strength
→
E
XLPE
SIR
electrical interface strength
Rz=const.
electrical
strength of air
transition
zone
Fig. 3.3 Electrical interface strength vs. interface pressure and surface smoothness (Kunze 2000a)
Lubricants also tend to increase the initial breakdown strength (Fig. 3.4). How-
ever it is not recommended to use lubricants for filling cavities. On the long-term,
lubricants probably migrate (at least partly), resulting in a more or less dry interface,
possibly leaving air gaps behind.
The migration rate of the lubricant depends on:
• Type of lubricant
• Type of insulating materials
• Contact pressure
• Temperature.
Another issue regarding lubricants is the presence of air bubbles trapped in the
interface during installation. In particular greases with a high viscosity are more
likely to enclose air bubbles. The design of the accessory or the applied installation
method should prevent the formation of air bubbles (Fig. 3.4).
During operation of the cable system, the interfaces are subjected to electrical
stresses (Fig. 3.5). The following stress characteristics can be distinguished:
• Direction
• Amplitude
• Distribution.
3 Interfaces in Accessories for Extruded HV and EHV Cables 89
Fig. 3.4 Effect of lubricant oil on the breakdown strength of a typical XLPE-SIR interface (Kunze
2000a)
Enorm
E tan
x
The component along the surface of the insulators is called the parallel, longitudinal
or tangential electrical stress and is generally regarded as the most important one.
Also the amplitude (e.g. for inception of partial discharges) and the distribution
(e.g. for electrical treeing) will affect the interface behaviour.
It is preferred that areas with highest electrical stress coincide with highest
interface pressure. In most of the accessory designs the shape of the stress-cones
and embedded electrodes control the electrical field distribution (Fig. 3.5).
90 H. Geene
It is essential that the jointers shall be well trained, to provide the necessary skills.
See ▶ Chaps. 2, ▶ 5 and ▶ 6 of this book for further information.
2000a). More likely, mechanical and thermo-mechanical effects change the interface
parameters. Thermo-mechanical effects can cause formation of cavities and in
extreme situations even gaps between the insulating materials. It is obvious that
gaps or large voids cause partial discharging, followed by electrical treeing or
tracking in the interface.
The formation of cavities and gaps in interfaces can be the result of a combination
of effects, such as:
Interfaces have been shaped carefully in order to obtain a secure fit between the
insulating surfaces. If the insulating surfaces can move in respect to one another, due
to thermal expansion or external forces, the interface pressure can decline locally
causing a weak spot and in some extreme cases even gaps in the interface. The
insulating surfaces shall be shaped in such a way that if movements can occur, this
will not lead to the formation of gaps.
Interface pressure can decrease due to deformation of the cable insulation or due to
relaxation of the rubber.
Deformation of the cable insulation can occur at high temperatures. The acces-
sory design has to prevent unacceptable deformation of the cable insulation.
92 H. Geene
Relaxation of the rubber can occur in those designs where the interface pressure is
achieved by expanding the rubber sleeve onto the cable insulation. To prevent
critical low interfaces pressures, the setting of the rubber should stabilize at a safe
value. Important parameters describing the setting of rubber are the so-called
compression set and tension set.
In the case of interface pressure applied by external means (i.e. springs), their
mechanical design has to secure a sufficient pressure level during the lifetime.
Due to the fact that partial discharge is a symptom of an insulation defect, the
inception and occurrence of partial discharges may accompany the electrical ageing
of interfaces as well.
Because of the different accessory designs on the market, it is impossible to deduce
a single relationship between the magnitude of partial discharges and the remaining
lifetime. However, in individual cases, partial discharge characteristics and its devel-
opment may give indications for the incipient failure (Smit et al. 1997; Smit 1999).
3.4 Testing
There are several ways interfaces in HV accessories can be tested. Roughly speaking
we can distinguish between laboratory testing and on site testing. Laboratory tests
can be performed on many levels:
• Material test
• Model tests on material samples
• System tests on cable and accessories.
As none of these tests can solely represent the characteristics of the interface
completely, the optimum has to found in a combination of these tests.
Regarding an interface, the breakdown strength of the insulation materials itself is
of minor importance, due to the lower electrical stresses in the interface section.
More important for the interface breakdown strength are the mechanical properties
of the materials, i.e.:
• Modulus of elasticity
• Hardness
• Compression set or tension set
• Surface roughness.
the accessories on site (Nagao et al). Testing with DC voltage is not recommended.
The electrical field distribution in the interface for DC voltage can differ completely
from AC voltage (IEC60840 1999).
If there is a need for monitoring accessories in service (e.g. higher failure rate than
normal), the most appropriate test method is on-line partial discharge monitoring.
The partial discharge tests are preferably executed under different environmental
and/or load conditions, in order to determine the thermo-mechanical impact on the
interface. The recommended frequency of testing will highly depend on the nature of
the discharge pattern and accessory type. In high stress accessories (e.g. slip-on
joints for EHV) partial discharges in interfaces in the order of a few pico-coulombs
can lead to breakdown within hours, while for some low stress accessories
(e.g. outdoor termination) partial discharges in interfaces can be withstood some-
times for several years.
Interfaces in HV and EHV cable accessories should be designed in such a way that
under operating conditions always a tight fit between cable and accessory or between
other insulating bodies is secured. Once the insulating surfaces do not adapt care-
fully, cavities will be formed leading to inception of partial discharges.
A proper interface design does not allow partial discharges. Below the inception
level of partial discharge, no detectable ageing will take place. Once discharges have
been ignited, accelerated ageing will start, most probably leading to electrical treeing
in the interface and finally failure of the accessory.
The reliability of interfaces in HV and EHV extruded cable accessories is strongly
dependent on the mechanical and thermo-mechanical design of the accessories and
the interaction with its environment, i.e. way of installation and service conditions.
During the development of cable systems, these circumstances have to be taken into
account. For this reason the long term or prequalification tests of the entire system
(cable and accessories) is of eminent importance.
The quality of the interface depends on the cable surface preparation. This has to
be ensured by clear procedures, adequate quality management systems (e.g. ISO
9001 (1994)) and skilled jointers.
Although there is no general relation between the partial discharges and the
remaining lifetime, trend analyses by means of online partial discharge monitoring
can give indication if risk of failure is involved for the type of PD patterns observed.
References
Cigré WG 21.03.: Recommendations for electrical tests prequalification and development on
extruded cables and accessories at voltages > 150 (170) and 400 (420) kV, Elektra No
151 (December 1993)
Cigré WG B1-16.: Partial Discharge Detection in Installed HV Cable Systems. Cigré Technical
Report 182 (April 2001)
3 Interfaces in Accessories for Extruded HV and EHV Cables 95
Densley, J., Nadolny, Z.: PD characteristics of model interfaces for extruded cable systems –
influence of contaminants, Cigré WG15-10
Fournier, D., Lamarre, L.: Effect of pressure and length on interfacial breakdown between two
dielectric surfaces. In: IEEE International Symposium on Electrical Insulation, Baltimore, June
7–10, 1992, pp. 270–272
Geene, H.T.F., van der Wijk, G.P., Pultrum, E.: Development and qualification of a new 400kV
XLPE cable system with integrated sensors for diagnostics, Cigré 1998, paper 21-103
Gockenbach, E., Kunze, D.: Makroskopische, innere Grenzflächen in Hochspannungskabel-
garnituren, VDE Fachtagung ‘Einfluss von Grenzflächen auf die Lebens-dauer elektrischer
Isolierungen’ (Bad Nauheim, 21–22 Sept 1999)
IEC 62067.: Power cables with extruded insulation and their accessories for rated voltages above
150kV (Um¼170 kV) up to 500kV (Um¼550 kV) – Test methods and requirements
IEC 60840.: Power cables with extruded insulation and their accessories for rated voltages above
30 kV (Um¼36 kV) up to 150 kV (Um¼170 kV)-Tests methods and requirements (1999)
Imai, N., Andoh, K.: Development of pre-fabricated joints for 275 kV XLPE cables, Jicable (1991),
paper A.5.4
ISO 9001.: Quality Systems-Model for quality assurance in design, development, production,
installation and servicing (1994)
Kärner, H., Kodoll, W., Seifert, J., Tanaka, T., Nagao, M.: Interfacial phenomena affecting electrical
insulating properties in composites, Cigré WG15-10
Kreuger, F.H.: Partial Discharge Detection in High-Voltage Equipment. Butterworth & Co, London
(1989)
Kunze, D.: Eine neue Muffengeneration für VPE-isolierte Höchstspannungskabel, Elektrizitäts-
wirtschaft, Jg. 96 (1997), Heft 26
Kunze, D.: Untersuchungen an Grenzflächen zwischen Polymerwerkstoffen unter elektrischer
Hochfeldbeans-pruchung in der Garniturentechnik VPE-isolierter Hochspannungskabel. Dis-
sertation Uni Hannover, Shaker Verlag Aachen (2000a). ISBN 3-8265-7721-3
Kunze, D.: Macroscopic internal interfaces in high voltage cable accessories, Cigré session (2000b),
paper 15-203
Nadolny, Z., Braun, J.M., Densley, R.J.: Effect of mechanical pressure and silicone grease on partial
discharge characteristics for model XLPE transmission cable joint. In: Proceedings of ISH’99
(London, August 1999)
Nagao, M., Ka, S., Murramotto, Y., Tanaka, T.: Model specimens for testing interfacial properties in
EHV extruded cable splices and preliminary results, Cigré WG15-10, 15-10-Nagao-01-98
Nagao, M., Ka, S., Murramotto, Y., Tanaka, T.: Model specimens for testing interfacial properties in
EHV extruded cable splices and preliminary results, Cigré WG15-10, 15-10-Nagao-01-99
Peschke, E., Olshausen, R.V.: Cable Systems for High and Extra-High Voltage. PIRELLI, Publicis
MCD Verlag, Erlangen (1999). ISBN 3-89578-118-5
Report on Internal interfaces of modern electrical insulation systems, Cigré WG 15-10 Meeting
Palais des Congres Paris, France, September 1, 1998
Ross, R.: Dealing with interface problems in polymer cable terminations. IEEE Electr. Insul. Mag.
15(4), 5–9 (1999)
Ross, R.: Investigating and monitoring the reliability of interfaces in polymer cable terminations. In:
Proceedings at IEEJ Kansai Meeting on Insulation Diagnosis
Ross, R., Megens, M.G.M.: Aging of interfaces by discharging. In: Proceedings of ICPADM (2000)
Ross, R., Megens, M.G.M.: An interface testing cell for multi-stress ageing. In: Proceedings ISEIM
98
Smit, J.J.: Life management of electrical infrastructure. In: Cigré SC15-Symposium “Service
Ageing of Materials in HV Equipment”, Sydney (1999), key-note paper
Smit, J.J., Gulski, E., Pultrum, E.: Partial discharge fault analysis of SIR-based cable terminations.
In: Proceedings of International Symposium on High Voltage Engineering, Montreal, vol.
4, p. 513 (1997)
Strassberger, W.: Silicone Elastomers for Transmission and Distribution
Strassberger W., Winter H.-J.: Silikonelastomere in der Mittel- und Hochspannungstechnik. ETG
Fachbericht Nr. 68, pp. 7–14. VDE-Verlag GmbH, Berlin, Offenbach (1997)
96 H. Geene
Contents
4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
4.1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
4.1.2 Scope and Terms of Reference of WG B1.06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
4.1.3 Experience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
4.2 Long Duration Test on EHV Cable Systems (170 < Um < 550 kV) . . . . . . . . . . . . . . . . . . . 107
4.2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
4.2.2 Revision of the Present Prequalification Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . 110
4.2.3 Changes in a Prequalified Cable System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
4.2.4 Recommendations to IEC 62067 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
4.3 Long Duration Test on HV Cable Systems (36 < Um 170 kV) . . . . . . . . . . . . . . . . . . . . . . 122
4.3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
4.3.2 Prequalification Test for HV Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
4.3.3 Exchanges and Modifications in a Prequalified HV Cable System . . . . . . . . . . . . . 127
4.3.4 Recommendations to IEC 60840 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
4.4 Conclusions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
4.5 Annexes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
4.5.1 Terms of Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
4.5.2 Sensitivity of Partial Discharges in XLPE Cable Insulation to Change
of Electrical Stress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
4.5.3 Functional Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
4.5.4 Tests From Functional Analysis not in IEC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
4.6 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
J. Becker (*)
Charleroi, Belgium
Summary
IEC test requirements have evolved over the years from the component-based approach
in IEC 840 to the system based approach. Accessories are considered together with the
cable, in IEC 62067 Ed.1 and in the most recent edition of IEC 60840 Ed.3.
In its meeting in Madrid of 2001, Study Committee B1 decided to install a Task
Force TF 21.11 to get SC B1 prepared to issue future recommendations for evolu-
tions of IEC 62067 taking into account the expected innovations in cable technology,
the need to reduce the time-to-market and the overall cost to introduce new evolu-
tions as well as service experience collected by the Cable Industry.
TF 21.11 issued in 2002 a proposal of Terms of Reference and Scope of Work for
a new Working Group which was launched as WG B1.06 in Paris Study Committee
meeting in 2002.
In July 2005 WG B1.06 circulated its final draft of report for approval by SC B1.
Comments were received from France, Japan, The Netherlands and Italy.
As time schedule for issuing the new Edition of IEC 62067 Ed.1 was critical, SC
B1 agreed to go in more detailed recommendations and decided in its meeting of
Rosenön (SE), September 2005 to launch a Task Force to finalise the report and write
clear and practical recommendations for appropriate changes in IEC 62067 Ed.1 and
IEC 60 840 Ed.3.
This chapter published as Cigré TB 303 is the result of the Work of WG B1.06
and of the Task Force.
Section 4.1 of this chapter is an Introduction, which recalls and details the Scope
of Work and the Terms of Reference and gives an overview of the service experience
of HV and EHV cable systems so far as well as a survey of experience obtained by
testing EHV cable systems.
At voltages up to and including 150 kV extruded insulation has largely super-
seded paper-insulated cables for new installations.
Much of the service experience with HV XLPE cable systems is based on cables
with moderate design stresses. A new generation of “slim-design” HV cables is being
developed, with similar technology and design stresses to those seen in EHV XLPE
systems. Hence historical service experience with HV cable systems is not necessarily
a good guide to the likely future service experience of these novel systems.
XLPE has only recently become the insulation of choice for many utilities for
EHV transmission circuits. The introduction of XLPE for longer transmission
circuits has been facilitated by the use of a one-year heat cycle voltage test called
Prequalification (PQ) test, which was recommended by Cigré in 1993 and afterwards
specified in IEC 62067 Ed.1 in 2001.
Following the successful completion of a number of PQ programmes, some large
400 and 500 kV cable circuits have been installed and commissioned.
There is still limited experience with EHV XLPE cable systems. The designs,
manufacturing methods and materials employed in joints and terminations differ
significantly amongst manufacturers. Thus the service experience from any particular
system cannot necessarily be taken as a guide to the likely service experience of other
systems. The long term behaviour of an EHV system has to be demonstrated by a well
specified PQ test.
4 Qualification Procedures for HV and EHV AC Extruded Underground Cable. . . 99
Section 4.2 covers long duration tests on EHV cable systems and the different
features, which are examined:
• Design concept
• Electrical performance of cable and accessories
• Performance of a cable system under prolonged heat cycling
• Aspects of installation design and practice
• Ability of the Installer to joint in realistic conditions rather than laboratory
conditions.
From the existing service experience in both long duration tests and in operation
as mentioned in Sect. 4.1, it is confirmed that a Prequalification test (PQ test) is still
necessary to demonstrate the long-term reliability. Improvements of this test are
proposed such as measurement of partial discharges as a mean to provide early
warning and offer possibility of repair before failure.
A procedure to be adopted in case of failure of a component during the PQ test is
introduced and a modification to the final impulse test is proposed.
Then changes in an already prequalified cable system are evaluated. A procedure of
extension of qualification is recommended and a table is given to indicate in main
cases of changes the test sequence to adopt, instead of repeating the complete PQ test.
A new test called Extension of Qualification Test (EQ test) is proposed mainly in
case of changes of or in accessories. This test shall be performed in a laboratory on
one or more samples of complete cable of the already prequalified cable system. At
least two accessories of each type that need the extension of qualification shall be
tested. A total of 80 heating cycles shall be carried out of which the last 20 cycles
shall be under a voltage of 2 U0.
As a summary and conclusion from its reflections WG B1.06 makes the following
recommendations to IEC for further consideration in future editions of IEC 62067:
• To maintain a Prequalification (PQ) test for the basic qualification of a new cable
system.
• To allow in case of a failure of an accessory the continuation and completion of
the PQ test for the undisturbed components of the loop.
• To introduce in case of less significant changes/modifications at prequalified
components a simplified long-term test (80 cycles) called “Extension of Pre-
qualification (EQ) test”.
• To perform the lightning impulse test at the end of the PQ test at the complete test
loop or, in case of practical problems with test equipment, in any other test
arrangements, which include the accessories.
• To include sample tests at accessories in IEC 62067 Ed.1 as in IEC 60840 Ed.3.
These tests are intended to check not only the intrinsic quality of the accessory,
but also the quality of the installation, which is critical at the EHV level.
to higher dielectric stresses nearly as high as in the EHV field not only at main
insulation but also at the interfaces between cables and accessories.
In the meantime, new types of accessories are appearing on the market, of
course with no earlier experience. These accessories should be able to fit to the
older types of cables with thicker insulation and the newer types of cables with
reduced insulation (changes of an existing HV link with a new cable type or repair
of an older link).
Taking into account that service experience collected so far on HV cable systems
working at usual stresses was rather good, the Working Group recommend that cable
systems should be considered rather than cables or accessories alone when higher
stresses are adopted.
After giving detailed examples of calculated stresses (AC and impulse) in differ-
ent types of accessories, the WG recommends to adopt a prequalification procedure
when electrical stresses are above given limits.
A Prequalification (PQ) test shall be performed only on cable systems where the
calculated nominal electrical stresses at the conductor screen will be higher than
8 kV/mm and/or at the insulation screen higher than 4 kV/mm. This Prequalification
test can be omitted in some special cases listed in Sect. 4.3.
Contrary to the Prequalification test for EHV systems, in this case the test is
simplified because it can be performed in a laboratory and 180 cycles are
required.
The proposed layout of cable system is described as well as the test sequence.
Then changes in a prequalified cable system are addressed. The Extension of
Prequalification test (EQ) is proposed to be the same as for EHV systems.
As a summary and conclusion from its reflections WG B1.06 makes the following
recommendations to IEC for further consideration in future editions of IEC 60840:
• To introduce a Prequalification (PQ) test for those HV cable systems where the
calculated nominal electrical stress at the conductor screen will be higher than
8 kV/mm and/or at the insulation screen higher than 4 kV/mm. This test needs not
to be performed if
– Cable systems with the same constructions and accessories of the same family
have been prequalified for higher rated voltages
– Equivalent long term tests have been already successfully carried out
– Good service experience at cable systems with equal or higher stresses can be
demonstrated
• To allow in case of a failure of an accessory the continuation and the completion
of the PQ test for the undisturbed components of the test loop.
• To introduce in case of less significant changes/modifications at prequalified
components a simplified long-term test (80 cycles) called “Extension of Pre-
qualification (EQ) test”.
• To perform the lightning impulse test at the end of the PQ test at the complete test
loop or, in case of practical problems with test equipment, in any other test
arrangements, which include the accessories.
4 Qualification Procedures for HV and EHV AC Extruded Underground Cable. . . 101
Section 4.4 lists the conclusions of the Working Group. Main ones are:
• EHV Cable systems: there is not sufficient service experience on EHV cable
systems collected so far to introduce major changes to the existing
initial Prequalification test. This PQ test has to be repeated in case of
extension of the range of approval. Within the range of approval, a new
test called Extension of Qualification test is proposed to control changes in
already prequalified cable systems instead of repeating the complete PQ test.
This new test can be carried out on a laboratory loop and will comprise
80 heating cycles combined with voltage application at 2 U0 for the last
20 cycles.
• HV Cable systems: a Prequalification test is recommended for design stresses
above 8 kV/mm on the conductor or 4 kV/mm over insulation. This test can be
carried out on a laboratory loop and will comprise 180 heating cycles combined
with voltage application at 1.7 U0. This PQ test has to be repeated in case of
extension of the range of approval.
4.1 Introduction
4.1.1 General
Extra high voltage (EHV) cable systems are designed and built to transmit bulk
electrical power. For this reason, it is imperative that they attain the highest possible
reliability. At the same time, the transmission capacity of the high voltage (HV) cable
links is continuously increasing. This is why reliability considerations of cable
installations in this category are also becoming very important.
Accessories are an integral part of a cable system. Their performance together
with that of the cable determines the overall reliability of the circuit. Accessories are
installed by hand, and therefore their reliability is determined by a combination of
good design, clear instructions, quality assurance (QA) and the skill of the fitters.
The long-term Prequalification (PQ) test was developed to build confidence in the
operation of XLPE cable at EHV levels. A PQ test demonstrates the quality of the
overall design of the system together with the quality of assembly.
IEC test requirements have evolved over the years from the component based
approach in IEC 840 to the system based approach, where accessories are considered
together with the cable, in IEC 62067 Ed.1 and the most recent edition of IEC 60840
Ed.3.
The IEC has published series of test specifications for HV and EHV cables,
accessories and cable systems:
• In 1988, the first specification was published. IEC 840 (renamed later as IEC
60840) is for cables up to 150 kV (Um ¼ 170 kV) [1]. In this specification, type
tests, routine and sample tests were prescribed for cables only.
• In 1999 IEC revised this specification and IEC 60840 Ed.2 was published, in
which accessories were included in type testing [2].
• In 2004 IEC published a third edition, IEC 60840 Ed.3, in which type tests on cable
system and routine and sample tests on prefabricated accessories were introduced [2].
• In December 1993 Cigré Working Group 21.03 published in Electra recommenda-
tions for PQ tests, type tests, sample and routine tests for extruded cables and their
accessories for voltages above 150 kV (Um ¼ 170 kV) up to 400 kV (Um ¼ 420 kV)
[3, 4]. In 1997, the voltage range was extended to 500 kV (Um ¼ 525 kV) [5, 6]. In
these recommendations, type tests, routine and sample test procedures were based on
those from IEC 840. Long term AC stressing together with heat cycles up to the
maximum operating temperature followed by impulse tests were prescribed to
demonstrate the long-term electrical and thermo-mechanical performance of the
system (PQ test). It was considered to be imperative that the test set-up reflected
real installation conditions. Test specifications recommended by WG 21.03 were then
implemented in IEC 62067 Ed.1 [7] published in October 2001.
The PQ tests recommended by Cigré and incorporated into IEC 62067 Ed.1 have
been accepted worldwide. As a result, only those manufacturers whose products
have passed long-term PQ tests have been allowed to participate in subsequent EHV
cable projects.
4 Qualification Procedures for HV and EHV AC Extruded Underground Cable. . . 103
It is inevitable that over a period of time an approved cable system undergoes some
changes, such as modifications to the cable construction, higher stress, new type of
accessories, new manufacturing processes, etc. However, there is little incentive to
the manufacturer to make incremental improvements to the product, since these
might invalidate the previous “approval” and require the long and expensive PQ test
to be repeated. Reducing the amount of testing needed would encourage manufac-
turers to introduce design improvements or measures to reduce cost. For this reason,
Cigré Study Committee B1 launched Working Group WG B1.06 with the task of
revising the qualification procedures for underground high voltage cable systems.
The WG was asked to examine how it might be possible to qualify a modification
to a cable system without making the full set of tests which are presently
recommended or specified in standards. All tests, PQ and type tests were to be
reviewed, although the PQ test has received greatest attention, as it is the most costly
and the longest.
The full scope and terms of reference of the WG are given in Annex 4.5.1.
4.1.3 Experience
contaminants from external sources, e.g. water, oil and sulphur are avoided. For
accessories the same may be stated.”
In order to evaluate, to some extent, the electrical ageing aspects of a cable
system, a type test is prescribed in IEC 60840 Ed.3. In IEC 62067 Ed.1, the PQ
test is supposed to evaluate the long-term electrical, thermal and mechanical behav-
iour of the cable system in an environment near to the conditions in the field.
pffiffiffi
3 U0, while Belgium adopted a 100-cycles test at 2 U0. Japan used a half-year test
at relatively low electrical stress based on the degradation factor of the insulation
system.
Plans to install major 400 kV cable systems led Cigré to set up a working Group
to consider an international test specification. The tests were developed to give
confidence that cable systems passing the tests would have a fault rate in service
lower than 0.2 faults/100 km/year. In 1993 Cigré WG 21.03 published a test program
for cable systems above 150 (170) kV [3, 4] and IEC published a specification based
on these documents IEC 62067 Ed.1 in 2001 [7].
In IEC 62067 Ed.1 the definition of the PQ test is as follows: “a test made before
supplying on a general commercial basis a type of cable system covered by this
standard, in order to demonstrate satisfactory long term performance of the complete
cable system. The PQ test need only be carried out once unless there is a substantial
change in the cable system with respect to material, manufacturing process, design
and design levels”.
It is useful to examine some of the early French experience of prequalification
testing. The French (EDF) specification required a long-term test of duration
6000 hours, p although
ffiffiffi many of the tests were continued beyond this. The specified
voltage was 3 U0 for 250 heat cycles (167 cycles at maximum service temperature
and 83 cycles at emergency temperature).
Figure 4.1 summarizes long-term test results on 220 kV cable at the EDF
laboratories. Design stresses for the cables (at U0) were 8.5 kV/mm at the conductor
screen and 4.2 kV/mm at the insulation screen.
12
10
8
Number of failures
0
<100 100- 300- 400- 500- 1200- 1450- 2500- 3000- 4000- 5000- 6000- 7000- 11000- 1200- 14000- 16000- >
300 400 500 1200 1450 2500 3000 4000 5000 6000 7000 11000 12000 14000 16000 30000 30000
Time (hours)
The defects causing breakdown in less than 10 hours were mounting errors in
accessories (5 in joints and 2 in terminations). Eight of the test lengths that failed
prematurely contained artificial defects in their terminations. These tests were to
simulate a defect found in the field. They showed that this type of PQ test is effective
in distinguishing between defective and well-made accessories.
The tests are all from the early stages of development of 220 kV cable systems
(pre 1980). Only 2 breakdowns occurred on cables themselves (150 h and 36000 h).
All the other breakdowns were in the accessories. This indicates the important role of
accessories in determining the overall reliability of the cable system and the impor-
tance of carrying out tests on the cable and accessories as a system.
Some of the tests carried out by connecting the cable between phase and earth of
the 400 kV network highlighted the problems associated with this approach. Four of
breakdowns occurring after about 6000 hours happened during a thunderstorm with
lightning strikes falling on the adjacent overhead line. The defects responsible for the
cable failures could not be determined because the cables had experienced the full
short circuit current of the 400 kV network and suffered significant local damage at
the failure site. The use of a dedicated test transformer provides far better control of
the test voltage (avoiding system disturbances) and limiting the short circuit current
allows better forensic examination of the failure site.
The occurrences of failures over a wide range of times (up to 16000 hours)
suggests that it is not advisable to reduce the duration of the 8760 hours PQ test.
In 2001 Parpal [22] summarized the early experience from a number of PQ tests
[23–30]. Subsequently, most of the major EHV cable makers have successfully
completed PQ tests on 400 or 500 kV XLPE cables often with large conductors
(2000 and 2500 mm2).
Although the service experience is limited, all the EHV installed systems sub-
jected to the IEC 62067 Ed.1 PQ procedures have, to date, demonstrated satisfactory
behaviour. A more precise picture about the service experience of these cable
systems became available when WG B1.10 “Update of service experience on
underground and submarine cables” concluded his task in 2009. See Cigré TB
379 [19 bis].
4.2.1 General
The prequalification (PQ) test was introduced to compensate for the lack of service
experience with XLPE insulated cables above 150 kV (Um ¼ 170 kV).
The PQ test checks the performance of the cable/accessory system under realistic
conditions. Features examined include:
• Design concept (for example, some early PQ tests at CESI Laboratory showed
that a number of taped joints designs did not perform well in long-term tests).
• Electrical long-term performance of accessories and cable.
• Performance of the cable system under prolonged heat cycling (e.g. thermal-
mechanical aspects, shrinkage). The 20 thermal cycles specified in the type test
are not sufficient to test for the effect of cable insulation shrink-back within the
assembled accessories.
• Aspects of installation design and practice. For example, PQ tests have shown
that insufficient attention was paid by some installers to arrangements for
clamping the cable adjacent to the joint.
108
Table 4.1 Major XLPE cable systems at 400 kV and above. (Data supplied by Cigré WG B1.07, March 2006-TB 338)
Conductor cross-
Rated section/
(ϕ–ϕ) Number of Route Number Transmission
voltage Type of Number outdoor/SF6 Type of length of capacity in Winter Commissioning
Country (kV) joints(1) of joints terminations installation(2) (km) circuits Mm2/(MVA) year
Denmark 400 CPFJ 72 3/3 DB 22 1 1600 Cu/975 1997
(Copenhagen:
Southern cable
route) [54]
Denmark 400 PMJ 42 3/3 DB 12 1 1600 Cu/800 1999
(Copenhagen:
Northern cable
route
Germany (Berlin/ 400 CPFJ+ 48 0/12 (double T 6.3 2 1600 Cu/1100 1998
BEWAG Mitte- PMJ systems)
Friedrichshain)
Germany (Berlin/ 400 CPFJ+ 30 0/12 (double T 5.5 2 1600 Cu/1100 2000
BEWAG PMJ systems)
Friedrichshain-
Marzahn)
Japan (Tokyo)(3) 500 EMJ 264 0/12 T 39.8 2 2500 Cu/2400 (4) 2000
[55]
J. Becker
4
United Arab 400 PMJ 12 12/12 D&M 1.3(5) 4 800 Cu/not available 2000
Emirates (Abu
Dhabi)
Spain (Madrid) 400 CPFJ 96 12/0 T 12.8 2 2500 Cu/1720 2004
+PMJ
Denmark (Jutland) 400 PMJ 96 36/0 DB&D 14.5 2 1200 Al/1200 2004
United kingdom 400 CPFJ 60 0/6 T 20 1 2500 Cu/1600 2005
(London)
The Netherlands 400 PMJ 3 6/0 DB&D 2.25 1 1600 CU/1000 2005
(Rotterdam)
Austria 380 PMJ 30 6/6 DB&T&M 5.2 2 1200 Cu/1400 2005
(Wienstrom)
Italy (Milan) 380 PMJ 66 12/0 8.4 2 2000 Cu/2100 2006
CPFJ ¼ Composite prefabricated joint, PMJ ¼ premoulded joint and EMJ ¼ extruded moulded joint
(2) T ¼ tunnel, DB ¼ directly buried, D ¼ ducts, D&M ¼ ducts and manhole
(3) Cable system prequalified following Japanese Specifications [48]
(4) 1200 MVA/circuit with forced cooling in the future. 900 MVA/circuit now
(5) 15 core kms/4 circuits X3 phases ¼ 1.3 km
Qualification Procedures for HV and EHV AC Extruded Underground Cable. . .
109
110 J. Becker
• The ability of the installer to mount accessories under realistic conditions rather
than in the test laboratory. In some cases, this has highlighted the need for
improvements in jointer training. Although not every aspect of the work is tested,
the PQ process gives a good indication of the overall competence of the supplier
of the cable system.
Although some manufacturers have learnt rapidly from problems in the early PQ
tests, this knowledge has not been widely shared. Accessories (and sometimes
cables) are still experiencing problems during PQ and type testing and sometimes
also in service. The WG has the opinion that the state of the art of XLPE cable
technology is not sufficiently advanced that the competence of every manufacturer
can be assumed without evidence. Until such time that a significant body of service
experience has built up, the WG feels that a PQ test is still necessary.
The prequalification test procedure detailed in IEC 62067 Ed.1 has been reviewed by
the WG.
The main items addressed in order to look for a possible simplification/optimi-
zation were:
• The range of Type and PQ approval in relation with the calculated nominal
electrical stresses
• The duration of the heating cycle voltage test
• The procedure in case of a component failure during the test
• The voltage control at the end of the test.
surrounding. Thus the actual duration of the test could vary from 6 months for a
cable system installed in a tunnel to one year for large conductor cables installed in
the ground.
In order to avoid a significant difference in duration of the prequalification test as
a function of the cable construction and installation conditions, WG B1.06 suggests
for the heating cycle voltage test of the prequalification test the duration of one year.
In addition, the practical experience detailed at Sect. 4.1.3.3 has shown that the
duration of the voltage application is an important factor, because failures in
accessories during PQ testing have occurred throughout the one-year test period
[22, 23, 28, 29, 49, 50, 52]. This is another reason why the one-year heat cycle test
with AC voltage on the system is needed to check the long-term electrical behaviour
of the system under test.
Because of these two reasons, it is recommended to maintain the present one-year
duration (8760 hours).
Where partial discharge (PD) tests have been performed at regular intervals
during the long-term test, it was noted that PD activity could initiate at any moment
during the test. For this reason it is recommended to perform partial discharge
measurements on the test assembly to provide an early warning of possible degra-
dation and to enable the possibility of a repair before failure.
The WG considers that it is not easy to specify a PD test on the whole loop as
compulsory, because it can be difficult to achieve an adequate sensitivity when
carrying out a PD test at an unscreened location. This makes it currently difficult
to define a level of background noise that can be achieved in practice.
The failure of the component already prequalified (which in this case acts as a
laboratory test component) does not violate its prequalification and should not be
mentioned in the test report.
1()
Note: If the energy of the impulse generator is not sufficient to test the whole cable length, the test
loop could be cut, without moving the accessories, into appropriate sections, which then are
available to be tested with auxiliary terminations.
4 Qualification Procedures for HV and EHV AC Extruded Underground Cable. . . 113
However it was realized that some of these changes do not require the repetition
of a full Prequalification test, but a simplified long-term test called “Extension of
Prequalification (EQ) test” could be adopted (see Sects 4.2.3.2 and 4.2.3.3).
The Working Group considers that allowing a shorter laboratory based long-term test
rather than requiring the cable/accessory maker to repeat the full PQ test, will encourage
incremental improvements in technology, whilst reducing the risk to the customer.
The main situations of changes that can be found in practice are:
Table 4.3 Test procedures in case of an exchange of a cable and/or accessory in a prequalified
cable system
Already qualified on another cable Already qualified on another cable
Cable and/or system within the same or higher system with a lower insulation screen
accessory insulation screen stress stress or not qualified
cable 12.5 + XX2) 12 + 13.2
(non electrical TT + EQ1) (electrical and non electrical TT + PQ)
Joint XX2) 12 + 13.2
(EQ) (TT + PQ)
Metal XX2) 12 + 13.2
enclosed
Termination (EQ) (TT + PQ)
Outdoor XX2) 12 + 13.2
Termination (EQ) (TT + PQ)
The numbers given refer to the respective clauses in IEC 62067 Ed.1
1)
EQ consists of the bending test, 60 heat cycles without voltage and the electrical type tests
2)
(XX) Clause to be added in the standard
4
Table 4.4 Guide to the selection of tests because of modifications to a cable in a prequalified EHV cable system
IEC 62067 Ed.1 Clause
Modification number
PQ- EQ-
Component Type of modification M P D DL T-test test test
Cable Conductor Larger cross-section ✓ ✓ ✓ 12 13.21) –
Copper to Aluminium ✓ ✓ 12 – –
Insulated wires (enamelled or oxidized...) ✓ ✓ ✓ 12.5 – (xx)
Stranded to solid conductor ✓ 12.5 – (xx)
Water tightness ✓ ✓ ✓ 12.5.14 – –
Cable semi-conductive inner and/or Change of origin (supplier or production plant) ✓ ✓ 123)
outer screen Transfer extrusion line (see cable insulation) ✓ ✓ 2) 2)
Different quality of semicon ✓ 123) – –
Cable Insulation Change of base resin ✓ 123) – –
Change in cross linking package (peroxide/ ✓ 12 – –
antioxidant)
Nature of polymer (XLPE, LDPE, HDPE, EPR) ✓ ✓ ✓ 12 13.2 –
Higher conductor stress, no increase of insulation ✓ 12 – –
screen stress
Increase of insulation screen stress ✓ 12 13.2 –
Qualification Procedures for HV and EHV AC Extruded Underground Cable. . .
(continued)
115
116
Table 4.5 Guide to the selection of tests because of modifications to an accessory within the same
family in a prequalified EHV cable system
IEC 62067
Ed.1 Clause
Modification number
PQ- EQ-
Component Type of modification M P D DL T-test Test test
Joints Higher calculated ✓ – – (xx)
electrical stress
design and
construction
Compound of main ✓ ✓ – – (xx)
insulation body
(same base resin)
Changing nature of ✓ ✓ ✓ – 13.2 –
polymer, (EPR,
Silicone....)
Material of semi-con ✓ – – (xx)
electrodes
Fixation of cable ✓ – – (xx)
ends on either side of
the joint
Screen interruption ✓ Annex – –
D
Outer screen and Annex – –
Protection design, D
(Filling/water
tightness), Outlet of
bonding leads
Terminations: Higher electrical ✓ – – (xx)1)
- outdoor stress design of stress
- indoor cone (or smaller
- metal metal clad for GIS or
enclosed transformer
+ SF6 terminations)
+ oil-immersed Change in nature of ✓ – – (xx)1)
Filling medium
(e.g. oil to gas....)
Change in the ✓ ✓ – – (xx)1)
formulation of the
stress cone
(continued)
118 J. Becker
The selected test procedure depends on the type of modification of the relevant
accessory. The origin of the type of modification may be a change in material,
manufacturing process, design or design level, as indicated for information in
Table 4.5.
35.0
Retraction of
30.0 oversheath
25.0 Retraction of
insulation
20.0
Retraction (mm)
15.0
10.0
5.0 Evelution of
the retraction
0.0
0 10 20 30 40 50 60 70 80
-5.0
Number of heat cycles
Fig. 4.3 Retraction test on a 5-meter long 1000 mm2 500 kV cable with XLPE insulation and PE
sheath
of the accessory. In fact the considerations made at paragraph Sect. 4.1.3.1 and the
TB “Interfaces in accessories for extruded HV and EHV cables” [53], indicate that
thermal cycles stressing is the main failure mechanism in accessories, which typi-
cally include due to their intrinsic construction a number of interfaces.
As shown by Fig. 4.3 the retraction of the XLPE insulation is practically
completed after about 60–80 heat cycles.
In addition the heat cycles are producing a radial expansion and retraction of the
cable insulation and of the accessory components that can also influence the inter-
facial pressure in accessories.
In order to be able to perform the EQ test in a laboratory, limiting the engagement
of the HV test equipment, it has been decided to perform these pre-conditioning
cycles without applied voltage. Being the EQ test performed in a laboratory, i.e. with
well-defined thermal conditions, it is possible to carry out the heat cycles in
approximately one day also with very large cross-section cables.
To prove that the heat cycling has not affected the integrity of the test loop a
complete electrical type test (as defined in IEC62067 Ed.1) is used.
As the installation design conditions can significantly affect the thermo-mechanical
behaviour of the accessories, the test arrangement shall take this into account.
For instance a rigid installation can be simulated by suitably cleating the cable at
each side of a joint. In order to comply with this requirement a minimum length of
10 m of free cable between accessories is specified for the EQ test.
To maintain a similar degree of risk for the shorter duration of the EQ test
compared to the duration of Prequalification test, at least two accessories of the
same type, instead of one, shall be included in the test loop submitted to the
extension of prequalification.
120 J. Becker
Rigid installation
>10 m
Flexible installation
• Check of the insulation thickness of cable for electrical type test to determine the
test voltage values (12.4.1)
• Bending test without final PD test (12.4.4)
• The test assembly may be installed in a laboratory and shall consist of at least
2 accessories of the same type that is to be prequalified. There shall be at least
10 m of cable between accessories. The minimum length of the test loop shall be
at least 30 m. If a joint submitted to EQ has to be used in both flexible and rigid
installations, one joint shall be installed in a flexible configuration, the other rigid.
Where a joint is designed for use only in rigid installations, then both joints shall
be rigidly fixed. Similarly, for a joint intended only for flexible installations, both
joints shall be installed in a flexible test configuration. An example of the test loop
is shown in Fig. 4.4.
• The loop shall have a U bend with a diameter specified in 12.4.4
– The partial discharge test defined in 12.4.5 shall be carried out here to check
the quality of the assembled accessories.
• The thermal preconditioning test consists of 60 heat cycles with no voltage applied.
The heat cycles shall be as given in 12.4.7, i.e. a minimum of 8 hours of heating
followed by at least 16 hours of natural cooling. The steady state conductor temper-
ature shall be between 5 C and 10 C above the maximum cable operating
temperature for at least two hours. At the end of the cooling period the conductor
temperature shall be within 15 C of ambient temperature, with a maximum of 45 C.
• Continue with the partial discharge test (12.4.5) followed by the full sequence of
electrical type test. No failure shall occur.
Note: In case of modification of the cable, in order to cover all the require-
ments of the type test it is necessary to perform also the non-electrical test on
the cable as specified in 12.5.
4 Qualification Procedures for HV and EHV AC Extruded Underground Cable. . . 121
As a summary and conclusion from its reflections WG B1.06 makes the following
recommendations to IEC for further consideration in future editions of IEC 62067:
• To maintain unchanged the present one-year Prequalification (PQ) test for the
basic prequalification of a new cable system (as a check on e.g. the long-term
electrical and thermal-mechanical behaviour).
• To allow in case of a failure of an accessory the continuation and completion of the
PQ test for the undisturbed components (cable and other accessories) of the loop.
• To perform partial discharge measurements on the prequalification test assembly
during the PQ test to provide an early warning of possible degradation and to
enable the possibility of repair before failure.
• To perform the lightning impulse test at the end of the PQ test on the complete test
loop or, in case of practical problems with test equipment, on cable samples
including each type of accessory. The intention is to check the insulation prop-
erties at the interfaces, in the accessories and in the cable.
• To maintain unchanged the present range of Type and PQ approval, see Annex 4.5.2.
• To introduce a simplified long-term test (80 cycles) called “Extension of Pre-
qualification (EQ) test” (see Sect. 4.2.3.3) in case of exchange of prequalified
components (cable and/or accessories) with other components that are already
prequalified in other cable systems with the same or higher calculated electrical
stress at the insulation screen of the subjected system or in case of modification of
a cable or an accessory within the same family in a prequalified cable system (see
Sect. 4.2.3).
• For engineering purposes a “Functional Analysis Method” (see Annex 4.5.3) is
recommended as a mean for a systematic assessment of the significance of
changes/modifications at components (cables and accessories) of a cable system
and thus for the selection of the appropriate test (PQ or EQ test).
• To introduce guides to the selection of appropriate test procedures, based on the
application of that “Functional Analysis Method”, to the most important compo-
nents of actual cable systems, in case of
– Exchange of a cable and/or accessory in a prequalified cable system
(Table 4.3)
– Modification of a cable in a prequalified cable system (Table 4.4)
– Modification of an accessory within the same family in a prequalified cable
system (Table 4.5)
• To include sample tests on accessories, which are presently “under consideration”
within IEC 62067 Ed.1, following the wording of IEC 60840 Ed.3. For accesso-
ries, where the main insulation cannot be routine tested, the partial discharge and
high voltage test should be introduced, but only on one accessory of each type per
contract. These tests are intended to check not only the intrinsic quality of the
accessory (design and materials), but also the quality of the installation (equip-
ment and jointers skill), factors that are very important at the EHV level.
• To align the definition of type tests (sub-clause 3.2.3 of IEC 62067 Ed.1) to the
definition of the prequalification test to ease the potential use of the Tables 4.3,
122 J. Becker
4.4, and 4.5 as a guide for the selection of test procedures in case of changes on
prequalified cable systems.
• It is worth noting that, as a result of the application of the “Functional Analysis
Method” (see Annex 4.5.3), a number of tests have been identified that are not
included in IEC 62067 Ed.1. These tests are generally performed as development
tests and are summarized in Annex 4.5.4 for future consideration by IEC.
4.3.1 General
Traditionally EHV cables are working at a significantly higher stress than HV cables
(see Fig. 4.5).
Due to increased competition and good experience with (very) high AC
stresses (12–15 kV/mm and even more) on EHV cable systems it becomes
more common nowadays to produce cables with reduced insulation thickness
[31–33] at the HV level. This leads to higher dielectric stresses nearly as high as
in the EHV field not only at main insulation, but also at the interfaces between
cables and accessories.
The development of reduced insulation thickness cables at the HV level was
successful due to the experience gained by the major cable makers at the production,
testing, installation and good service of EHV cable systems.
Also new types of accessories are appearing on the market, of course with no
earlier experience [34–40]. These accessories should be able to fit to the older types of
cables with thicker insulation and the newer types of cables with reduced insulation
(changes of an existing HV link with a new cable type or repair of an older link).
The following remarks are of major importance:
100
Impulse stresses
Working stress (kV/mm)
10
AC stresses
1
10 100 1000
Voltage level (kV)
• The new highly stressed cables with reduced insulation thickness are generally
produced by experienced cable makers that are using their know-how from EHV
technology: development and production teams, production equipment and pro-
cess, material handling and control as well as their well trained teams for
installation in the field.
• Failures, if any, during type or after installation tests, tend to occur at the
interfaces between accessories and cables when new systems are tested [41,
42, 45–47]. To assess the reliability of a new HV cable system whose working
stresses are similar to those of the EHV systems, the experienced cable
makers rely on the PQ and type tests they have performed on EHV cable
systems.
• For highly stressed cable systems, type tests are not necessarily sufficient [52].
• The electrical service stresses and mainly lightning impulse stresses at the core
(interface with prefabricated accessories) of HV cables are becoming almost as
high as the stresses of EHV cables.
• Practical shrinkage tests on cable lengths of 5 meters or more have shown that
cable insulation and over-sheath is only stabilized after around 60 to 80 heat
cycles (see Fig. 4.3). This is confirmed by experts and by the outcome of PQ tests
[23, 28, 49, 50]
• New accessory designs are coming to the market
• The countries that have performed long-term tests on new cable systems before
installing them in the network have reported very good service experience
• Test laboratories that conduct type tests for many suppliers have published the
results of their experience: the failure rate of MV and HV type tests is growing
[45]. The reasons for this could be the lack of experience of some manufacturers
with higher dielectric stresses in cables, the lack of experience with new type of
accessories or all these combined
• Breakdowns in service are recorded on recently commissioned systems.
Against:
• The good and sometimes long experience of some cable makers with HV cables
and cable systems (cables with “reasonable” stresses)
• In some countries where long-term tests are not performed on new cable systems
before installing them in the network, service experience is good, as know-how
has been gained during many years in the HV field
• The reluctance of some utilities or other end-users to test entire systems if they
wish to buy their HV cables and accessories separately.
124 J. Becker
Table 4.6 AC and BIL stresses at the insulation screen for different voltage levels
Um (kV) 52 72.5 123 145 170 420
U0 (kV) 26 36 64 76 87 220
BIL (kV) 250 325 550 650 750 1425
Ratio BIL/Uo 9.6 9.0 8.6 8.5 8.6 6.5
Routine Test (kV) 65 90 160 190 218 440
AC-stress for a BIL-stress of 3.74 3.99 4.19 4.21 4.18 5.56
36 kV/mm at insulation surface
(kV/mm)
AC-stress for a BIL-stress of 4.16 4.43 4.65 4.68 4.64 6.17
40 kV/mm at insulation surface
(kV/mm)
4 Qualification Procedures for HV and EHV AC Extruded Underground Cable. . . 125
systems already installed for a long time. Even if most of these cables and accesso-
ries have only been type tested, service experience is generally considered good.
So the prequalification test shall be performed only on cable systems where the
calculated nominal electrical stresses at the conductor screen will be higher than
8 kV/mm and/or at the insulation screen higher than 4 kV/mm. The prequalification
test shall be performed except:
2
() Unfortunately it is difficult to give a specific rule about the evaluation of a good service
experience, but the matter has to be dealt with, case by case, between the supplier and the
purchaser.
126 J. Becker
J1
J3 J2
Fig. 4.7 Possible test layout for cable anchored on the ground
• Tests after long term testing: hot lightning impulse test on the complete loop
• Examination of the test loop after completion of these tests.
Table 4.7 Test procedures in case of an exchange of a cable and/or accessory in a prequalified HV
cable system
Already qualified on another cable Already qualified on another cable
Cable and/or system within the same or higher system with a lower insulation screen
accessory insulation screen stress stress or not qualified
cable 12.4 + YY2 12 + ZZ3
(non electrical TT + EQ1) (electrical and non electrical TT + PQ)
Joint YY2) 12 + ZZ3)
(EQ) (TT + PQ)
Metal YY2) 12 + ZZ3)
enclosed
Termination (EQ) (TT + PQ)
Outdoor YY2) 12 + ZZ3)
Termination (EQ) (TT + PQ)
The numbers indicate the respective clauses in IEC 60840 Ed.3
1
EQ consists of the bending test, 60 heat cycles without voltage and the electrical type tests
2
(YY) Clause to be added in the standard
3
(ZZ) Clause to be added in the standard
Table 4.8 Guide to the selection of tests because of modifications to a cable in a prequalified HV
cable system
IEC 60840 Ed.3 Clause
Modification number
Type of PQ- EQ-
Component modification M P D DL T-test test test
Cable Larger cross- ✓ ✓ ✓ 12 (ZZ)1 –
Conductor section
Copper to ✓ ✓ 12 – –
Aluminium
Insulated wires ✓ ✓ ✓ 12.4 – (YY)
(enamelled or
oxidized....)
Stranded to ✓ 12.4 – (YY)
solid conductor
Water tightness ✓ ✓ ✓ 12.5.14 – –
Cable Change of ✓ ✓ 123
semi- origin (supplier
conductive or production
inner plant)
and/or Transfer ✓ ✓ 2 2
outer extrusion line
screen (see cable
insulation)
(continued)
4 Qualification Procedures for HV and EHV AC Extruded Underground Cable. . . 129
The sequence of tests for the Extension of Prequalification (EQ) test is summa-
rized below. The numbers in brackets refer to clause numbers of IEC 60840 Ed.3.
• Check on the insulation thickness of cable for electrical type test to determine the
test voltage values (12.3.1)
• Bending test without final PD test (12.3.3)
• The test assembly may be installed in a laboratory and shall consist of at least
2 accessories of the same type that is to be prequalified. There shall be at least 10 m
of cable between accessories. The minimum length of the test loop shall be at least
30 m. If a joint submitted to EQ has to be used in both flexible and rigid installations,
one joint shall be installed in a flexible configuration, the other rigid. Where a joint is
designed for use only in rigid installations, then both joints shall be rigidly fixed.
Similarly, for a joint intended only for flexible installations, both joints shall be installed
in a flexible test configuration. An example of the test loop is shown in Fig. 4.4.
• The loop shall have a U bend with a diameter specified in 12.3.3
– The partial discharge test defined in 12.3.4 shall be carried out here to check
the quality of the assembled accessories.
• The thermal preconditioning test consists of 60 heat cycles with no voltage
applied. The heat cycles shall be as given in 12.3.6, i.e. a minimum of 8 hours
of heating by conductor current followed by at least 16 hours of natural cooling.
The steady state conductor temperature shall be between 5 C and 10 C above
the maximum cable operating temperature for at least two hours. At the end of the
cooling period the conductor temperature shall be within 15 C of ambient
temperature, with a maximum of 45 C.
4
Table 4.9 Guide to the selection of tests because of modifications to an accessory within the same family in a prequalified HV cable system
IEC 60840
Modification Clause number
PQ- EQ-
Component Type of modification M P D DL T-test Test test
Joints Higher calculated electrical stress design and construction ✓ – – (ZZ)
Compound of main insulation body (same base resin) ✓ ✓ – – (ZZ)
Changing nature of polymer, (EPR, Silicone....) ✓ ✓ ✓ – (YY) –
Material of semi-con electrodes ✓ – – (ZZ)
Fixation of cable ends on either side of the joint ✓ – – (ZZ)
Screen interruption ✓ Annex – –
D
Outer screen and Protection design, (Filling/water tightness), Outlet of bonding Annex – –
leads D
Terminations: Higher electrical stress design of stress cone (or smaller metal clad for GIS or ✓ – – (ZZ)1
- outdoor transformer terminations)
- indoor Change in nature of Filling medium (e.g. oil to gas....) ✓ – – (ZZ)1
- metal Change in the formulation of the stress cone compound but with the same base ✓ ✓ – – (ZZ)1
enclosed polymer
+ SF6
Change of the base polymer (EPR, Silicone, . . .) of the stress cone ✓ ✓ ✓ – – (ZZ)
+
2 2
oil-immersed
Change of insulator material for indoor or outdoor terminations. ✓ v 12 – –
2 2
Change of insulator design or manufacturer of GIS/Transformer insulator ✓ 12 – –
NOTE: (YY) and (ZZ) Clauses to be added in the standard
Qualification Procedures for HV and EHV AC Extruded Underground Cable. . .
M: change in material; P: change in manufacturing process; D: change in design (construction); DL: change in electrical design stress level
1
When can be demonstrated that the thermo mechanical aspects have no significant influence on the performances of the termination a Type Test may be
sufficient
2
In case of elastomeric insulators (“silicone” or “EPR”) climatic and pollution test according to IEC 61109 Annex C should be considered.
131
132 J. Becker
• Continue with the partial discharge test (12.3.4) followed by the full sequence of
the electrical type test (see 12.3.2 item b to h). No failure shall occur.
Note: In case of modification of the cable, in order to cover all the require-
ments of the type test it is necessary to perform also the non-electrical test on
the cable as specified in 12.4.
As a summary and conclusion from its reflections WG B1.06 makes the following
recommendations to IEC for further consideration in future editions of IEC 60840:
• To introduce a prequalification (PQ) test for those HV cable systems where the
calculated nominal electrical stress at the conductor screen will be higher than
8 kV/mm and/or at the insulation screen higher than 4 kV/mm (see Sect. 4.3.2).
This test need not to be performed if
– Cable systems with the same constructions and accessories of the same family
have been prequalified for higher rated voltages
– If equivalent long term tests have been already successfully carried out on
cable systems with the same construction and accessories of the same family
and a good service experience at cable systems with equal or higher stresses
can be demonstrated
• To allow in case of a failure of an accessory during the test the continuation and
the completion of the PQ test for the undisturbed components (cable and other
accessories) of the test loop.
• To perform partial discharge measurements on the prequalication test assembly
during the PQ test to provide an early warning of possible degradation and to
enable the possibility of repair before failure.
• To perform the lightning impulse test at the end of the PQ test on the complete test
loop or, in case of practical problems with test equipment, on cable samples
including each type of accessory. The intention is to check the insulation prop-
erties at the interfaces, in the accessories and in the cable.
• To maintain unchanged the present range of Type and PQ approval, see Annex 4.5.2
• To introduce a simplified long-term test (80 cycles) called “Extension of
prequalification (EQ) test” (see Sect. 4.3.3.2) in case of exchange of pre-
qualified components (cable and/or accessories) with other components that
are already prequalified in other cable systems with the same or higher
calculated electrical stress at the insulation screen of the subjected system or
in case of modification of a cable or an accessory within the same family in a
prequalified cable system (see Sect. 4.3.3).
• For engineering purposes a “Functional Analysis Method”, see Annex 4.5.3, is
recommended as means for a systematic assessment of the significance of
changes/modifications at components of a HV cable system and thus for the
choice of the appropriate tests (PQ or EQ) or Type Tests (TT).
4 Qualification Procedures for HV and EHV AC Extruded Underground Cable. . . 133
4.4 Conclusions
In this chapter the testing procedures of HV and EHV extruded cables and related
accessories have been reconsidered extensively. Improvements in both effectiveness
(can it be done better) and efficiency (can it be done faster) have been proposed. In
the final proposals the desirable improvement and its practical feasibility are bal-
anced carefully, resulting in a series of well thought practical propositions to
improve extruded cable testing. The main results are summarized below:
sequence of the electrical type tests, with 20 heat cycles combined with voltage
application at 2 U0.
• For both EHV and HV cable systems the PQ test will be completed with an
impulse test on the full loop to check that no degradation in the system, especially
at the interface with accessories, has occurred. (Only in case suitable impulse test
equipment is not available at the test site, the impulse test can be carried out in any
other test arrangement including each type of accessory taken from the loop).
• For both PQ and EQ tests, PD tests are recommended to provide an early warning
of possible degradation and to enable the possibility of a repair before failure.
• Several tables are provided as guides to determine the appropriate test sequence in
case of changes or modifications.
• Functional Analysis is a good tool to help engineers to manage a wide range of
potential changes. Examples are given in Annex 4.5.3.
• In Annex 4.5.4 tests from Functional Analysis, not yet published in IEC stan-
dards, are summarized. This list of tests will be handed to IEC TC 20 for further
consideration.
4.5 Annexes
4.5.1.1 Title
Revision of Qualification Procedures for High Voltage and Extra High Voltage AC
Extruded Underground Cable Systems.
4.5.1.2 Scope
After the official qualification of a cable system, there are possible changes (new cable
construction, higher stress, new extrusion line, new process, new type of accessories. . .)
especially if this cable system is manufactured over several years, and the question
raised is to examine how it is possible to qualify this new system without making the full
set of tests which are presently recommended or specified in standards.
A WG has been launched on this item limited to AC extruded cable systems. All
tests, prequalification and type tests will be reviewed, even if the prequalification test
should be examined first, as it is the most costly and the longest.
• Propose tests where there are lacks e.g. short circuit tests, climatic tests on
terminations. . .
• Evaluate whether in high voltage systems up to 150 kV a long term test has to be
recommended above given dielectric service stresses or where the innovation is
not built on earlier experience
4 Qualification Procedures for HV and EHV AC Extruded Underground Cable. . . 135
Contents
1. Introduction
2. Cable standards and electric stress
3. Sensitivity of electric stress to change of cable dimensions
4. Determination of risk of discharge caused by change of dimensions
5. Effect of change of cable dimensions on discharge free operation
6. Conclusions
4.5.2.1 Introduction
In Cigré WG B1.06, a question was raised whether the range of type approval and of
PQ approval could be widened. This Annex provides details of the analysis made for
this purpose. Dielectric stress level variations specified in relevant sub-clauses of the
current IEC standards were used as a starting point in this work.
As a first step of the process, we can determine the rate of change of electric field
strength inside a radial cable with respect to:
• The change of the insulation inner radius, without changing the insulation thickness
• The change of the insulation thickness, without a change of the inner radius.
• Calculated nominal conductor stress at the conductor screen does not exceed
110% of the tested system
• Calculated nominal insulation stress at the insulation screen does not exceed the
insulation screen stress of the tested system.
U0 1
Ex ¼ ð4:1Þ
x ln Rr
where
We are interested in the field strength at two locations within insulation, namely,
on the inner surface and on the outer surface. Using R ¼ r + w, we get
U0 1
Er ¼ ð4:2Þ
r ln rþw
r
U0 1
ER ¼ ð4:3Þ
r þ w ln rþw
r
dE r U0 kV 1
¼ ð4:6Þ
dw r ðr þ wÞ ln rþw2 mm mm
r
rþw
dER U 0 ln r þ 1 kV 1
¼ 2 ð4:7Þ
dw ðr þ wÞ ln rþw mm mmr
dE r dE =E dE r w 1
¼ r r¼ r ¼ 1 ð4:8Þ
dr PU dr=r dr Er r þ w log rþwr
dE R dER =ER dE R r r w 1
¼ ¼ ¼ 1 ð4:9Þ
dr PU dr=r dr ER r þ w r log rþw r
dEr dE =E dE w w 1
¼ r r¼ r ¼ ð4:10Þ
dw PU dw=w dr Er r þ w log rþwr
dE R dE R =ER dER w w 1
¼ ¼ ¼ þ1 ð4:11Þ
dw PU dw=w dr ER r þ w log rþwr
The obtained expressions can now be used to estimate sensitivity values for a
range of cable designs. The operating voltage will be reflected in the value of the
insulation width, w, while the conductor size will be reflected in the value of the
inner radius r.
0.1
-0.1
-0.2
-0.3
-0.4
20 22 24 26 28 30 32 34 36 38 40
Inner radius (mm)
-0.6
-0,8
-1
-1.2
15 20 25 30 35
Insulation width (mm)
Fig. 4.9 Field strength sensitivity to change of dimension for a range of values of the insulation
inner radius and width
Now, we will consider how these changes of electric field strength affect the risk
of discharge in the interface regions in the presence of voids.
Spherical defects near the conductor screen usually originate from manufacturing
faults and they can be detected by factory quality control tests. Fissure defects at the
interface with accessories pose a greater risk because they can be introduced during
installation and they are not as easily detected.
Both types of defects are found in most practical cable systems in operation. At a
given field strength a discharge free operation is possible if size of defects is
sufficiently small. A discharge free operation may be still possible even under
increased field strength if the defect size is further reduced. The maximum size of
discharge free defects at operating voltage Uo can be estimated from sensitivity of
defect size to a relative increase of the field strength in the insulation, dEins/Eins, at
the defect location. This is done with the help of Paschen curve shown in Fig. 4.10.
In the context of this analysis, the Paschen curve can represent relationship
between breakdown voltage, Ubd, within a defect of given size at given gas pressure
inside the defect (Bar-mm). Instead of breakdown voltage, the breakdown field
strength can be obtained from the curve, as shown in Fig. 4.11.
Ubreakdown [kV]
1000
100
10
0.0
0.001 0.01 0.1 1 10 100
Bar mm
Ubd (kV)
Ebd (kV/mm)
40
35
30
20 Ebd (kV/Barmm)
and (kV/mm, 1B)
15
10
0
0.01 0.0 1
Defect dimension (Barmm)
Fig. 4.11 Breakdown voltage and breakdown field strength as a function of defect dimension in
mm from Paschen curve at p ¼ 1 Bar
U U
εe εi E
Ei E0=U/d d
d Ee
E0=U/d εe
εi
Ei=E013εe/(εi+2εe)
Ei=E0(εe/εi)
(a) Ei=1.23E0 (b)
Ei=2.26E0
Fig. 4.12 Electric field calculations inside a fissure (a) and spherical defect (b)
The field intensity within the defect can be determined from the field strength in
the insulation at the defect location considering also permittivity difference between
the defect (gas, ε ¼ 1) and surrounding insulation (XLPE, ε ¼ 2.26). In a radial field,
such as in the case of fissure at the interface to an accessory, a simple ratio of
dielectric permittivity of insulation material and of gas inside the defect gives the
field increase factor inside the fissure. This is illustrated in Fig. 4.12a. For a gas filled
sphere the field increase factor is equal to 1.23, as shown in Fig. 4.12b.
Taking into account the field increase factors from Fig. 4.12 and the breakdown
field strength of the defect from Fig. 4.11 we can obtain the relationship between
the size of a breakdown free defect and the field strength in the surrounding
dielectric. It is quite clear that nearly twice stronger field is needed to initiate
142 J. Becker
Ei(kV/mm)
15.
sphere
10.
5.
0.
0.0 0. 1
-mm 1B
discharges in a spherical void in comparison with fissure. The related curves are
depicted in Fig. 4.13.
Using Eqs. (4.2) and (4.3) we can calculate partial discharge inception voltage
from field intensity for a defect located on the conductor screen interface and the
insulation screen interface respectively. Typically, we consider a fissure on the
insulation screen and a spherical void at the conductor screen interface.
1 R
U sphere
i ¼ pffiffiffi Er r ln kVrms ð4:12Þ
2 r
1 R
U fissure
i ¼ pffiffiffi ER R ln kVrms ð4:13Þ
2 r
Inception voltage (kV-rms) for a 127/220 (245) kV Inception voltage (kV-rms) for a 127/220 (245) kV
XLPE cable, 2000 mm2, at conductor screen, XLPE cable, 2000 mm2, at insulation screen
sphere
350.00
350.00
Inception voltage (kg-rms)
Ui (kV-rms) spleet
Ui (kV-rms) bol U0 (kV-rms)
U0 (kV-rms)
Fig. 4.14 Partial discharge inception voltage, as a function of the size at p ¼ 1 Bar, in a spherical
void at the conductor screen interface and in a fissure at the insulation screen interface in a
127/220 kV, 2000 mm2 cable
400.00 450.00
350.00 400.00
300.00 350.00
250.00 300.00
250.00
200.00
200.00
150.00
150.00
100.00
100.00
50.00
50.00
0.00 0.00
0.01 0.1 1 10 0.01 0.1 1 10
Bar.mm Bar.mm
Fig. 4.15 Partial discharge inception voltage, as a function of the size at p ¼ 1 Bar, in a spherical
void at the conductor screen interface and in a fissure at the insulation screen interface in a
220/380 kV, 1600 mm2 cable
dðBar mmÞ dEi
¼f ð4:14Þ
Bar mm Ei
These parts of the Paschen curve where Barmm > 0.01 (> 0.01 mm at p ¼ 1 Bar)
can be modelled in sections as an exponential function of the following form
Ebd ¼ εi Ei
ð4:17Þ
dE bd ¼ εi dEi
Substituting (4.17) to (4.16) and rearranging gives the desired form of sensitivity
dðBar mmÞ 1 dE i
¼ ð4:18Þ
Bar mm a Ei
in which a is the exponent coefficient of the exponential function modelling the
Paschen curve.
Equation (4.18) allows us to obtain sensitivity values from estimating the value of
exponent a from the Paschen curve. Taking the logarithm of both sides of (4.15)
gives
Now, the values of a and b can be found from the curve Ebd ¼ f(Barmm) in
Fig. 4.11. The obtained results are shown in Tables 4.12 and 4.13.
Values of 1/a shown in Table 4.13 indicate that within the pd. area of 0.03–
0.1 mm at p ¼ 1 Bar a 1% increase of the electric field strength will require a 2%
reduction of the defect size for a discharge free operation of the cable. Within the
pd. area of 0.1–0.3 mm at p ¼ 1 Bar the corresponding reduction of the defect size is
3.8%. For the range of 0.1–3 mm, the reduction of the defect size is stated to be 3.5%
in case of a 1% increase of the electric field strength.
4.5.2.6 Conclusions
The effect of change of insulation dimensions on the size of discharge free defects in
high voltage cables was analyzed in this Annex. The following results were obtained
for the two types of design considered.
146 J. Becker
4.5.2.6.3 Conclusion
The above results show that widening the current range of type approval described
by IEC 60840 and IEC 62067 will lead to an unacceptable increase of risk of partial
discharge in operating cable systems. Therefore, it can be concluded from this study
that the range of type approval in relevant IEC standards ought not to be changed.
4.5.3.1 Introduction
International Standards provide plant manufacturers with a consistent set of tests that
allows them to demonstrate that their equipment meets certain minimum criteria. For
the purchaser, testing to International Standards provides a degree of assurance that
the plant or equipment can be operated safely and reliably. Although testing to
International Standards is often time consuming and expensive, once a manufacturer
and purchaser have agreed that the test requirements have been met, the product is
“approved” and further purchases of the same product are relatively simple. One
advantage of testing to International Standards is that many purchasers worldwide
will accept the test evidence, without the tests having to be repeated.
A significant disadvantage of International Standards is that once a product is
“approved” there is little incentive to the manufacturer to make incremental
improvements to the product, since these would invalidate the “approval” and
require the type approval tests to be repeated.
This Annex sets out a process whereby the significance of any change can be
evaluated and the need for further testing agreed.
The main changes to cables and accessories in a prequalified cable system, which
require the repetition of the type test (or part of it) or of the prequalification tests or of
the extension of qualification, are summarized in Tables 4.4 and 4.5 in part 4.2 of this
chapter.
The cable supplier and purchaser may use the functional analysis to discuss if any
change to a constituent part might lead to a change in the performance characteristics
or reliability of the cable system. This is particularly useful where the change is
outside the scope of Tables 4.4 and 4.5 of part 4.2.
Table 4.14 Functional Analysis of a High Voltage Cable and cable components (Abbreviations: Routine: R, Sample test: S, Type test: T, Development: D,
148
Prequalification: PQ)
Test to check the functionality
(Relevant paragraphs of IEC 60840
Cable’s Function or Ed.3/62067 Ed. 1 in brackets –IEC
component Property Specification/Threat 62067 Ed. 1 in Italics) Comments
A B C D E
Conductor 1 -a. No overheating with nominal current -a. Resistance measurement a. Measurement to check design
Electrical (S: §10.5/§ 10.5) Verification of AC resistance of large
conductivity conductors with insulated wires or other
special properties: See WG B1-03 –
Large cross-sections and composite
screen designs: For large cross-sections,
AC resistance test should be performed
as type test (see TB TB 272 of Cigré
WG B1-03 from 2005)
-b. Limit temperature with thermal short -b. Calculation of thermal short b. If temperature rise is considered
circuit current circuit temperaturre dangerous, a short circuit test is
proposed as a development test. Check
that there is no degradation of tapes and
extruded semi-con after short circuit
test
2 -a. Satisfy the minimum bending radius -a. Bending before type tests (S:
Mechanical without harmful mechanical §12.3.3/§12.4.4)
properties deformation
-b. Support pulling during installation -b. No test b. Limitation of pulling force to be
given by the manufacturer
3 -a. Prevent longitudinal water -a. Water penetration test (T: a. Test if water blocking properties
Water blocking penetration §12.4.18/§12.5.14) required
4 -a. No corrosion when using Al -a. Examination a. If Al conductor avoid: water ingress
Chemical conductor after type test (IEC60840/ IEC +chemical species (e.g. contaminations,
properties 62067) or long solvents)
term PQ test (IEC 62067)
-b. No degradation due to layers over - b. Compatibility
J. Becker
5 -a. Low interface resistivity with -a. See accessories a. Taken into account in accessories part
Interface with connectors
other components -b. Thermal-mechanical expansion/ -b. Thermal cycles: 20 (T: b. PQ not in IEC 60840 Ed.3
or accessories deformation (Influence of shape of §12.3.6/§12.4.7) or 180 (PQ: §13.2.3
wires on interface of extruded semi-con on cable system)
with insulation)
-c. Avoid water penetration -c. Water penetration test (T: c. Water penetration may lead to
§12.4.18/§12.5) chemical degradation of the insulation
mainly if the conductor metal is
aluminum
Tape over 1 -a. Resistance sufficiently low to avoid -a. PD measurement (R,T; §9.2/§9.2- a. Covered by type tests
conductor Electrical PD and to avoid voltage over semicon §12.3.4/§12.4.5)
(optional) resistance during fast transients +Lightning impulse test (T; 12.3.7/
§12.4.9) + examination (T: §12.3.8/
§12.4.10)
2 -a. Good mechanical properties -a. Bending test (T: §12.3.3/§12.4.4)
Mechanical Examination after completion of the
properties type test
(T: §12.3.8/§12.4.10)
3 -a. No degradation of conductor or -a. Compatibility test on whole cable
Chemical semi-con (T:§12.4.4/§12.5.4)
properties -b. Stability of electrical resistivity after -b. Resistance measurement after b. Can be confirmed by test §12.3.9/
heat cycles heat cycles §12.4.11 on semicon indirectly and its
data should be shown by manufacturer
if required
4 -a. Avoid penetration of semi-con into -a. Visual examination after
Interface with conductor manufacturing in hot oil + impulse
other components test (S; 12.3.7/§12.4.9)
(continued)
Qualification Procedures for HV and EHV AC Extruded Underground Cable. . .
149
150
-c. Compatibility with layers or -c. Compatibility test on whole cable c. PIXE (Particle induced X-ray
conductor below and with insulation (T:§12.4.4/§12.5.4) Emission) measurements have shown
+Resistivity measurement of semicon that there is no ionic migration from the
before and after compatibility test (T: semi-con into the insulation during heat
§12.3.9/§12.4.11) cycling tests or in service. However,
there is some diffusion of the
antioxidant and low molecular weight
species during the curing process and
afterwards Some customers ask to
check the moisture content in the
semicon (<1000 ppm content)
Influence on the dielectric behavior of
the insulation system?
4 -a. Compatibility with conductor or -a. Compatibility
Interface with layers below and with insulation test on whole cable (T:§12.4.4/
conductor and (See above and underneath) §12.5.4)
insulation -b. No degradation of insulation by -b. Type test (T: §12.3/§12.4) or long b. No PQ long term test in IEC 60840
migration of low molecular species term test (PQ: §13.2) Ed.3
-c. Good bonding of extruded semi- -c. Bending + heat cycling (min c. Good bonding of extruded
conducting screen with insulation 80 cycles -D) + PD: ((T: §12.3/§12.4 semiconducting screen with insulation
is generally not a problem but should be
checked at least once with a new
material.
Tests could be performed on model
cables. 20 cycles are not considered
enough to check whether the bonding
with insulation remains correct. When
180 PQ cycles are performed, this
property is indirectly checked
-d. No deformation of semicon surface -d. Examination of surface in hot oil d. Quality control
Qualification Procedures for HV and EHV AC Extruded Underground Cable. . .
(continued)
153
154
3 -a. Same as inner semi-con, but a. See inner semicon a. Some customers ask to check the
Chemical compatibility with outer layers or (and) moisture content in the semicon
properties metal screen (<1000 ppm content) as for the inner
semicon. Influence on the dielectric
behaviour of the insulation system?
-b. Stability of electrical resistivity after b. See inner semicon
heat cycles
4 a. Same as inner semicon, but a. See inner semicon
Interface with compatibility with outer layer or (and)
insulation and metal screen
outer layer or
(and) metal screen
and accesses
Layer over 1 -a. Low resistivity to avoid PD at -a. PD measurement (R: §9.2/§9.2,
Semicon Electrical interface with screen and T:§12.3.4/§ 12.4.5)
(optional) properties
2 -a. Resistance to mechanical bending -a. Bending test before type test (T:
Thermal- during manufacturing and installatn §12.3.3/§12.4.4)
mechanical Examination after completion of the
properties type tests (T:§12.3.8/§12.4.10)
- b. Prevent deformation of the semicon -b. 20 cycles (T: §12.3.6/§12.4.7) + PD
and the insulation... test (§ 12.3.4/§ 12.4.5) + examination
(§12.3.8/§12.4.10)
-c. Water-blocking tapes possibly avoid -c. Water penetration test (T:
the longitudinal water penetration §12.4.18/§12.5.14)
(if required)
3 -a. Compatibility with semi-con and -a. Compatibility test. Ageing on
Chemical screen complete cable (T: §12.4.4/§12.5.4)
properties -b. Stability of electrical resistivity after -b. 20 cycles (T: § 12.3.6/
Qualification Procedures for HV and EHV AC Extruded Underground Cable. . .
-b. Limited deformation of insulation -b. Thermal short-circuit test on b. No official thermal short-circuit test
and outer semicon in case of short screen (D) in IEC specifications concerning HV
circuit temperature rise cables
-c. Supports radial pressure during -c. Thermo-mechanical test with heat c. To be defined: sidewall pressure test
heating cycles as recommended Cigré in ELECTRA
141 and IEC 61901 TR
Only to be performed if needed for a
special application
-d. Radial water tightness in case of -d. Technical Report of IEC (IEC
composite metal foil screen 61901 TR) recommending a long
term test in water (see also Cigré
recommendations from ELECTRA
141): D
-e. Fatigue in case of lead or lead alloy: -e. Check in relevant standards e. Other tests like slow elongation (O.
possible growth of crystals and dealing with lead alloys that the lmm/h) or “cone” test could be
Assuring chosen alloy is well adapted to the proposed to check the quality of the
application in the field: lead extrusion?
EN 12548, EN 50307 or equivalent.
Micrographic tests could be useful to
evaluate the grain size of the
extruded lead (Quality control
during extrusion of lead sheath)
-f. Fatigue in case of composite metal -f. A fatigue test (: repeated bending) f. To be defined: number of bendings,
foil screen when installed in non buried could be recommended as a diameter of bending...
conditions development test D
-g. Side wall pressure in case of -g. Technical Report of IEC(IEC
composite metal foil screen 61901 TR) recommending a side wall
pressure test (see also Cigré
recommendations from ELECTRA
141): D
Qualification Procedures for HV and EHV AC Extruded Underground Cable. . .
(continued)
158
design)
(continued)
159
160
§12.4.10)
4 -a. Compatibility of the possible used -a. Long- term test (D or PQ: § a. Such a PQ test is not prescribed in
Interface additives with the semi-con of the joint 13.2.3 + examination) IEC 60840 ed3
with joint (Grease, mastic, water sealant) Test is also possible on materials: semi-
semi-con con plates in air oven exposed to the
161
additives
(continued)
Table 4.15 (continued)
162
2 -a. Maintenance of good contact with -a. Long term tests + impulse (PQ: a. A long-term PQ test is not
Thermal- cable insulation (good elasticity and §13.2.3 + §13.2.4) prescribed in IEC 60840 ed3. A
mechanical compatible shrinkage of the different development test: “pressure versus
properties layers) with time at ambient and with time of contact of joint insulation to
cycles cable insulation”, would be an
alternative for pre-molded type
insulation
No such test in IEC 62067 ed1 nor in
IEC 60840 ed3
-b. Maintenance of mechanical quality -b. Short circuit test following the
in case of short circuit needs of the network would be useful
as a development test D
-c. Good heat dissipation -c. Development test D: check of
temperature drop in the insulation
during heat cycling
-d. No slipping on cable with pressure -d. Long term test on system installed d. Long term PQ test missing in IEC
from one side (prefabricated: in a test arrangement representative of 60840 ed3
composite or pre-molded joint) installation design (PQ:
§13.2.3 + §13.2.:
3 -a. Maintenance of good contact with -a. Long term tests + impulse +PD a. Long term PQ test missing in IEC
Interface cable insulation (see above) or interface (PQ: §13.2.3+ §13.2.4) 60840 ed3
properties with other joint components
-b. Compatibility with cable insulation, -b. Heat cycles (T: §12.3.6/§72.4.7) b. Long term PQ test missing in IEC
lubricants and joint’s semi-con Long term tests (PQ: §13.2.3 for EHV) 60840 ed3
-c. Shrinkage of cable materials -c. Long term shrinkage test as D on c. The shrinkage test made following
5 m long cable: see French the French specifications shows that the
specification for high voltage and extra insulation and sheath materials shrink
high voltage cables NFC 32 352 or C back during a quite long time:
33 253 80 cycles or even more are often
needed to stabilize the shrink back
Qualification Procedures for HV and EHV AC Extruded Underground Cable. . .
(continued)
163
164
Metal screening, 1 -a. Transfers currents circulating in -a. Thermal cycles with current a. Currents in the screen may be
connection to cable Electrical cable screen, transfers short circuit circulating in the screen:D important and the ability of the screen
screen function current. connection not to overheat during
cycling should be checked (not in
cycling tests in IEC)
Thermal short circuit test following No such short circuit test in IEC 62067
the needs of the network would be ed1 nor IEC 60840 ed3
useful as a development test D (see
IEC 61443)
-b. Current sharing between double -b. Development test D:Thermal
screens if present cycling with current circulating in the
screen and temperature measurement in
the screen area + examinon
2 -a. No hot spot at connection -a. 20 Thermal cycles (T: §12.3.6/§ a. No short circuit test in IEC 62067
Mechanical 12.4.7). ed1 nor in IEC 60840 ed3
properties Thermal short circuit test following the
needs of the network would be useful
as a development test D
-b. No harmful deformation of cable or -b. 20 Thermal cycles (T: §12.3.6/
joint insulation §12.4.7). + Examination
-c. No cracking near the connection in -c. Be sure that the correct lead alloy c. Cracking may need more than
case of lead or lead alloy sheath of for the metal sheath of cable has been 180 cycles to appear (180 cycles: long
cable chosen following EN 50307 and EN 18 term test following IEC 62067 ed1).
Severity depends largely on the
installation environment and
conditions.
3 -a. Compatibility with cable and joint -a. Thermal cycles (T: §12.3.6/§12.4.7)
Chemical materials
properties
4 -a. Withstands dielectric transients -a. AC and impulse tests on outer
Qualification Procedures for HV and EHV AC Extruded Underground Cable. . .
function
4
3 -a. Avoid water ingress into the cable -a. Test in water on outer protection (T:
Water Annex H/Annex D)
tightness
4 -a. Compatibility with inside -a. Long term test (PQ: §13.2.3 for a. Long term PQ tests missing in IEC
Chemical material, resistance against soil EHV) + voltage withstand test on outer 60840 ed3
properties aggression (if cable installed in protection after long term test
ground) or other surroundings
5 - a. Possible shrinkage of cable over- -a. Check the shrinkage of the cable a. May be 20 cycles are not enough to
Interface with sheath and/ or shrinkage of joint sheath and joint protection after heat see the long term behavior of the
cable over- outer protection to be taken into cycling of 20 cycles (T: §12.3.6/§ shrinkage effect Long term PQ tests
sheath consideration when designing the 12.4.7) or 180 cycles (PQ: §13.2.3) missing in IEC 60840 ed3
outer protection
Complete joint 1 -a. No degradation because of -a. Examination after completion of the
Overall interactions between all components type tests (T: §12.3.8/§12.4.10)
properties and of components themselves
-b. No water penetration before and -b. Test in water on outer protection (T: b. Long term PQ tests missing in IEC
after heat cycling into the cable Annex H/Annex D) or better: Long 60840 ed3
system term test (PQ: §13.2.3 for
EHV) + insulation resistance test on
outer protection after long term test
Remarks
- Long-term tests could be performed where necessary as development tests when not prescribed in specifications.
- See the recommendation from the WG in this report (See Table 4.17)
- A short circuit between conductor and metal screen/shield of the cable system may influence most of the functions described by thermal effects and mechanical effects
(thermal expansion and shrinkage of materials). Adherence of layers/screens is also tested with this test. Should this lead to an extension of the test series with a type test or a
development test? After discussion it was concluded that a short circuit test should be recommended as a development test
- In IEC 60840/Ed.3, sample tests on accessories are included. (In the IEC 62067 yet under consideration). They should be included also in the IEC 62067
- General remark: what about checking of skill of the jointers and effectiveness of mounting instructions? People responsible for installation of the accessories shall
consider this in their quality assurance and quality control process. See ▶ Chap. 5, “Cable Accessory Workmanship on Extruded High Voltage Cables”.
Note: to compare the clauses of the IEC specifications IEC 60840 Ed. 3 and IEC 62067 Ed. 1 table with the equivalent clause of IEC Specifications published in
Qualification Procedures for HV and EHV AC Extruded Underground Cable. . .
Table 4.16 Functional analysis of High Voltage terminations and components of terminations (Same as in Table 4.14)
Test to check the functionality
(Relevant paragraphs of IEC 60840
Component of Function or Ed.3/62067 Ed. 1 in brackets IEC
termination Property Specification/Threat 62067 Ed. 1 in Italics) Comments
A B C D E
Metallic connection of 1 -a. Transfers nominal current without -a. Heat cycles on connections Use a. No prescription in IEC 60840 Ed.3
conductor to network Electrical overheating IEC 61238-1 when appropriate (5 or 62067 Ed. 1 Short circuit test
continuity/ not welded): D values could be selected from the
electrical data of IEC 60859
resistivity -b. Supports short-circuit current and -b. Short circuit test (D) following b. No short circuit test prescribed in
temperature the network ds IEC 60840 Ed.3 or 62067 Ed. 1
2 -a. Supports compression/ extension -a. 20 cycles (T) §12.3.6/§ 12.4.7 or a. System aspect
Mechanical efforts during cycling of cable long term test (PQ § 13.2.3 for Long term PQ tests missing in
properties conductor EHV) IEC 60840 Ed.3
-b. Supports the thermal short circuit -b. Short circuit test following the b. No such test in HV IEC
efforts needs of the network would be specifications
useful as a development teD
3 -a. Resistance to corrosion a. Humidity and pollution test as a
Chemical development test D
properties
4 -a. Connection fits with terminal lugs -Matter for engineering of network
Interface with of network interface –(Sliding
network contacts, bimetallic interfaces...)
Electrical field grading 1 -a. Field grading of dielectric stresses -a. Partial discharge (R §9.2) and a. PD after long term test shows that
(stress cones, capacitive Dielectric in order to pass AC and lightning/ voltage test (R §9.3) Lightning adherence between stress relieve
or non linear grading function switching impulses impulse (T §12.3.7/§12.4.9) components is still good Long term
Switching impulse on EHV PQ tests missing in IEC 60840 Ed.3
material (T)§12.4.8) Long term test
(PQ §13.2.3) followed by lightning
impulse (PQ: 13.2.4) and PD
-b. Maintenance of these qualities -b. See above
with ageing
J. Becker
4
-c. Reasonably low tanδ, to avoid too -c. Tanδ test on loop with
high dielectric losses during voltage terminations (T: §12.3.5/§12.)
application
2 -a. Maintenance of good contact with -a. Development test: pressure of a. PD after long term test shows that
Thermal- cable insulation (good elasticity and contact versus time and long term adherence between stress relieve
mechanical compatible shrinkage of the different AC test with cycles, Long term test: components is still good. Long term
properties layers) with time at ambient and with (PQ: §13.2.3) and PD) after long PQ tests missing in IEC 60840 Ed.3
cycles term test
-b. Dissipation of thermal losses -b. b. Calculation. Not measurable
-c. No harmful cable deformation -c. Long term test: (PQ: §13.2.3) c. Long term PQ tests missing in IEC
and PD after long term 60840 Ed.3
test + examinon
3 -a. Resistance to thermal ageing -a. Long term test: (D: §13.2.3) a. Long term test needed if no earlier
Chemical anD experience with a similar product
properties Long term PQ tests missing in IEC
60840 Ed.3
4 -a. Good compatibility with cable -a. Long term test: (PQ: §13.2.3) a. Long term test needed if no earlier
Interface insulation system and lubricants and PD after long term experience with a similar product
quality (between cable insulation and stress test + examination Long term PQ tests missing in IEC
relieve component) if any 60840 Ed.3
-b. Resistance to filling medium -b. Development test D on b. Manufacturers responsibility
(oil...) materials in contact with filling
medium: check of mechanical,
chemical and dielectric properties
of cable materials and termination
materials after ageing in airen
Interface matters 1 -a. The materials used to clean or to -a. Long term tests + impulse + PD a. Long term test followed by PD
including cleaning Electrical lubricate the surfaces of the (PQ: §13.2.3 + §13.2.4 tests will give an indication whether
material, lubricants... properties insulation of the cable or the the contact between the surfaces
Qualification Procedures for HV and EHV AC Extruded Underground Cable. . .
termination shall not degrade the remains correct Long term PQ tests
dielectric properties of the system. missing in IEC 60840 Ed.3
The lubricant is also filling up the
micro-holes between the two
insulating surfaces
169
(continued)
170
-d. Resistance to internal arcing in -d. Short circuit test with internal d. No test in IEC HV specs for cable
case of breakdown in the termination electrical fault: D terminations or similar equipment
(no harmful projections) Internal overpressure test: such as bushings and instrument
transformers
-e. Good heat dissipation e. Engineering problem; depends
very much on surrounding and
protection means
3 -a. Resistance to climatic and -a. Development test D: Climatic
Interface polluting surrounding tests following IEC 61109
quality with -b. Compatibility with filling medium -b. Long term test (PQ b. Long term PQ tests missing in IEC
filling medium §13.2.3) + examination (PQ: 60840 Ed.3
and §13.2.5)
surrounding
4 -a. Resistance to UV, climate, water -a. Development test: Climatic tests
Chemical and pollution following IEC 61109
properties
Filling medium (if any) 1 -a. Good dielectric breakdown values -a. Development test on filling a. Manufacturers responsibility
Electric material: breakdown tests
properties -b. Low dielectric losses -b. Long term test (PQ: b. Long term PQ tests missing in IEC
§13.2.3) + examination (PQ: §13.2 60840 Ed.3
-c. Maintenance of dielectric
properties with ageing
2 -a. No harmful degradation of the -a. Long term test (PQ: a. Long term PQ tests missing in IEC
Thermal material with ageing §13.2.3) + examination (PQ: 60840 Ed.3
properties §13.2.5)
3 -a. Good compatibility with cable -a. Long term test (PQ a. Long term PQ tests missing in IEC
Chemical material in contact (insulation, §13.2.3) + examination (PQ: 60840 Ed.3 Responsibility of the
properties eventually semi-con) and stress §13.2.5) manufacturer
and interface controlling material Development test to check the good
behavior of materials in contact
Qualification Procedures for HV and EHV AC Extruded Underground Cable. . .
(continued)
172
development test? After discussion it was concluded that a short circuit test should be recommended as a development test
- General remark (same as for joints):
- What about checking of skill of the jointers and effectiveness of mounting instructions? People responsible for installation of the accessories shall consider this in their
quality assurance and quality control process. See ▶ Chap. 5, “Cable Accessory Workmanship on Extruded High Voltage Cables”.
Note: to compare the clauses of the IEC specifications IEC 60840 Ed.3 and IEC 62067 Ed.1 table with the equivalent clause of IEC Specifications published in
173
• Column A describes the components from the inner part to the outer part.
• Column B describes per component the functions or properties of the components
such as electrical properties, mechanical properties, etc.
• Column C describes per function or property the specification that has to be taken
into account in the design of the component or the possible threat during operation.
4 Qualification Procedures for HV and EHV AC Extruded Underground Cable. . . 175
• Column D describes per function the test to check the functionality. Where
possible, reference is made to the relevant paragraphs of IEC 60840 Ed. 3 and
IEC 62067 Ed.1.
• Where tests do not exist in these standards, reference is made to other IEC
standards or test recommendations. Distinction has been made between Routine
test (R), Type test (T), Sample tests (S), Development tests (D), and Pre-
qualification tests (PQ).
• Column E gives, when necessary, further comments or clarifications
NO
Haw the risk increased?
YES
No further testing required
NO
Repeat the type test
Perform EQ test
Fig. 4.16 Flowchart showing how functional analysis can be used to determine the extent of
testing required following a change to a component of the cable system
176
Table 4.17 Tests from functional analysis not in IEC 60840 or/and IEC 62067 but recommended by WG B1-06
Test not in IEC 60840 or/and IEC
Item 62067 Function and threat/specification Comment Recommendations
1 Short circuit tests on cable and a) Cable conductor’s conductivity: a. If temperature rise is considered a. – f. Development test
accessories Limit temperature with thermal dangerous, a short circuit test is
short circuit current proposed as a development test
b) Electrical properties of the outer
metal screen: - Satisfy the short-
circuit conditions
c) Short circuit on outer metal screen. c. Short circuit test on screen in
Limited deformation of insulation network conditions as a development
and outer semi conductive layers in test
case of short circuit temperature rise
d) Correct behavior of over-sheath in d. Check that the sensor is not
case of short-circuit on outer screen: destroyed by the short circuit
influence of temperature or temperature and the electromagnetic
mechanical effort forces
e) Short circuit test on screen to check e. Short circuit test following the
thermal monitoring sensors if any network needs
f) Short circuit on metal connections f. Short circuit test following the
(joints and terminations): hot spot? network needs (Such a test is part of
IEC 6123)
g) Check that here is no degradation
of dielectric function with ageing and
during short circuit on outer
protections (oversheath, outer
protection of joints or terminations
h) No degradation of the conductivity
of connections after short circuit tests
J. Becker
4
2 Sheath voltage test combined with a) Check the shrinkage of the cable a. When making pre-qualification Development test
long term prequalification test on sheath versus the accessories long term test this test is indirectly
cable protection and the absence of water done if after long term test a sheath
ingress below the outer protection voltage test is performed
(can be done without voltage
application)
b) Check that there is no degradation
on outer protections
3 Long term heat cycling test (not in a) Cable conductor chemical a. If Al conductor avoid: +water
IEC 60840) on cable or system (With properties: No corrosion when using ingress +chemical species
or without voltage application) Al conductor (e.g. contaminations, Solvents)
b) Cable conductor’s interface with b. Water penetration may lead to b. We propose a PQ test
insulation and accessories: chemical degradation of the and an EQ test for the high
-Thermal- mechanical expansion/ insulation mainly if the conductor stress designs
deformation-Avoid water penetration metal is aluminum
c) Semi-con interface with c. Part of development test
insulation: -No
degradation of insulation by
migration of low molecular species
d) Insulation: Stability of dielectric d. Thermal cycles check mainly the d. We propose a PQ test
properties with thermal and electrical possible deformation of the and an EQ test for the high
ageing insulation. No thermal or electrical stress designs
ageing was ever demonstrated
under normal service conditions.
Some physical-chemical
parameters presented changes
after pre-qualification tests but
they were not correlated to any
Qualification Procedures for HV and EHV AC Extruded Underground Cable. . .
power law
(continued)
Table 4.17 (continued)
Test not in IEC 60840 or/and IEC
178
10 Examination of protrusions and a) Smoothness of interface between a. Some customers or standards Possibly as quality control
contaminants on cable semicon and insulation and prescribe to check on a sample that
cleanness of insulation there are no protrusions, voids or
contaminants. WG has considered
that protrusions and contamination
179
(continued)
180
16 Long term thermal cycling test in a) Radial water tightness in case of a. Radial water tightness in case of Development test where
water on cable metal foil or sheath composite metal foil screen applicable
A technical specification in IEC
recommending a long term test in
water (see also Cigré
recommendations from ELECTRA
141) (also IEC 61901TR)
17 Mechanical impact on oversheath a) Check mechanical behavior of a. Mechanical impact: see ELECTRA Development test
oversheath and metal screen 141 (also IEC 61901TR) for metal
(mainly if metal foil bonded to foils
over-sheath)
18 Accelerated weathering test a) Test of UV behavior of over-sheath Development test
material
19 Test on outer protection to check the a) Mechanical behavior of over a. Special tests depending on type of Development test where
resistance to rodents and termites on sheath termites and rodents applicable
cable N.B. There is no international
standard dealing with criteria of these
kind of resistance.
20 Heat cycles on connections (joints a) Electrical continuity/electrical a. Use IEC 61238-1 when Development test
and terminations) resistivity: -Transports nominal appropriate: D
current without overheating IEC61238-1 is presently only
prescribed for 30 kV connections
and below but could be useful for
HV connections
b) Evaluate how currents are
distributed when a double screen is
applied
Qualification Procedures for HV and EHV AC Extruded Underground Cable. . .
4.5.3.3.1 Remark
A number of tests are identified in the functional analysis tables that are neither
in IEC 62067 Ed.1 nor in IEC 60840 Ed.3. These tests are considered by the WG as
Prequalification tests, Extension of Prequalification tests, Type tests, Sample tests
and development or quality control tests. These tests are enumerated in Annex 4.5.4.
A number of tests are identified in the functional analysis tables, see Annex 4.5.3,
that are neither in IEC 62067 nor in IEC 60840.
Most of these tests are recommended by the WG as development or quality
control tests.
One test, the Long Term Heating Cycling Test, is currently not in IEC 60840
Ed.3. For high stress designs it is proposed to include such a test as a Prequalification
(PQ) test and as an Extension to Prequalification Test.
Another test (item 24) is considered to be a Sample test, namely the Sample Tests
on accessories in the IEC 62067. They are yet under consideration and should follow
the regime of the IEC 60840 Ed.3.
Electrical sample test on cable insulation for IEC 60840 (item 25) is
recommended, see also Table 4.14. It is included in the IEC 62067 and the IEC
60502-2 (Fig. 4.16).
All these tests are enumerated in Table 4.17.
4.6 References
[1] IEC 60840 Ed.1 1998, “Tests for Power Cables with Extruded Insulation of
Rated Voltages above 30 kV (Um ¼ 36 kV) up to 150 kV (Um ¼ 170 kV)”
[2] IEC 60840 Ed.2, February 1999 and Ed.3, April 2004, “Power Cables with
extruded insulation and their accessories for rated voltages above 30 kV (Um ¼
36 kV) up to 150 kV (Um ¼ 170 kV) - Test methods and requirements”
[3] ELECTRA 151, December 1993, Cigré Working Group 21.03 “Recommenda-
tions for electrical tests type, sample and routine, on extruded cables and acces-
sories at voltages >150 (170) kV and 400 (420) kV”
[4] ELECTRA 151, December 1993, Cigré Working Group 21.03 “Recommenda-
tions for electrical tests prequalification and development on extruded cables and
accessories at voltages >150 (170) kV and 400 (420) kV”
[5] Cigré SC21 Website paper Doc 97.08, 1997, Working Group 21.03 “Recom-
mendations for electrical tests (type, special and routine) on extruded cables and
accessories at voltages >150 (170) kV and 500 (525) kV”
[6] Cigré SC21 Website paper Doc 97.07, 1997, Working Group 21.03 “Recom-
mendations for electrical tests prequalification and development on extruded
cables and accessories at voltages >150(170) kV and 500 (525) kV”
[7] IEC 62067 Ed.1, October 2001,” Power Cables with extruded insulation and their
accessories for rated voltages above 150 kV (Um ¼ 170 kV) up to 500 kV (Um ¼
550 kV) – Test methods and requirements”
[8] “Evolution of ac breakdown strength of XLPE HV cable after long term test, and
correlation with physical properties” 4th International Conference on Conduction
and Breakdown in Solid Dielectrics, Sestri Levante, Italia (1992). J. Bezille,
H. Janah, J. Becker and H. Schädlich
[9] “Evolution of ac and impulse breakdown strength of HV cable after long
term test. Correlation with physical properties” C.E.I.D.P., Arlington, Texas,
USA 94, Annual Report, pp. 582–87 (1994). J. Bezille, H. Janah, J. Chan
and M. D. Hartley, See also Jicable 95, Versailles, France, paper A.8.3
(pp. 212–14)
188 J. Becker
[10] “Les limites des études de vieillissement sur le polyéthylène”, Jicable 95, Ver-
sailles, France, paper B.9.1 (pp. 476–80) F. Duchateau et al.
[11] “Optimisation des procédures physico-chimiques d’analyses destinées à l’étude
du vieillissement du polyéthylène, isolant pour c^ables d’énergie” Jicable 95, Ver-
sailles, France, paper B.9.2 (pp. 481–87) F. Duchateau et Co-auteur
[12] “Investigation of XLPE insulations after high stress ageing”, Jicable 95, Ver-
sailles, France, paper B.9.4 (pp. 494–99) H. Schädlich and J. Klass
[13] “AC field ageing of power cables”, Jicable 99, Versailles, France, paper B 3.3
(p405) J. L. Parpal, P. Mirebeau, D. Coelho, H. Janah, F. Gahungu, J. Cardinaels
et D. Meurer
[14] “Assessment under high dielectric field of the long term behaviour of power
polyethylene insulant”, Jicable 99, Versailles, France, paper B 4.2 (pp 424–429)
R. Clavreul, M. H. Luton, J. Berdala, H. Janah and P. Laurenson
[15] “Evaluation of modelling of thermo-electric ageing of XLPE insulated power
cables: the ARTEMIS outcome”, Jicable 03, Versailles, France, paper B.7.5
(pp 525–530) C. Laurent and A. Campus
[16] “Electrical Degradation and Breakdown in Polymers”, IEE Materials and
Devices Series 9, Peter Peregrinus Ltd, 1992, ISBN 0-86341-196-7 Dissado L.
A and Fothergill J.C
[17] ELECTRA 140, February 1992, Working Group 21.09 “Considerations of
ageing factors in extruded insulation cables and accessories”
[18] ELECTRA 139, 1991, Working Group 21-09 “Working Gradient of HV and
EHV Cables with Extruded Insulation and its Effects”
[19] ELECTRA 137, 1991, Working Group 21-10 “Survey of the service perfor-
mance on HV AC cable systems”
[19 bis] Cigre TB 379, April 2009, Working Group B1,10 “Update at Service
Experience of HV Underground and Submarine Cable Systems”
[20] Cigré TB 89, 1994, Working Group 21.06, “Accessories for HV extruded
cables, types of accessories and terminology”
[21] “Development and Installation of Long-Distance 275-kV XLPE Cable Lines in
Japan”, Cigré paper 21-102, Paris 1990. K. Kaminaga, T. Asakura, Y. Ohashi,
Y. Mukaiyama
[22] “Prequalification testing of EHV XLPE cable system”; Understanding and
Managing Underground Transmission and Distribution Cables, CEA Workshop,
June 10–13, 2001. Jean-Luc Parpal.
[23] “New 400kV XLPE Long Distance Cable Systems, Their First Application of
the Power supply of Berlin” Cigré paper 21-109, Paris 1998 Henningsen C. H.,
Muller K. B., Polster K. and Schroth R. G
[24] “Development of High Stress HV and EHV XLPE Cable Systems”, Cigré paper 21–
108, Paris 1998 Attwood J. A., Gregory B., Dickenson M., Hampton R.H. and Svoma R
[25] “Development of a 420 kV XLPE Cable System for the Metropolitan Power
Project in Copenhagen”, Cigré paper 21-201, Paris 1996 P. Andersen,
M. Dam-Andersen, L. Lorensen, O. Kjaer Nielsen, S.H. Poulsen, B.S.Hansen,
T. Tanabe, S. Suzuki
[26] “State of the Art in EHV XLPE Cable Systems”, Jicable 99, Versailles, France,
paper A 2.2 (pp 44–49) A. Bolza, D. Kunze, S. Norman, S. Pöhler
4 Qualification Procedures for HV and EHV AC Extruded Underground Cable. . . 189
[27] “Long term test of 500kV XLPE cables and accessories” Cigré, Paper 21-202,
Paris 1996 Kaminaga K., et al.
[28] “Prequalification Testing of 345kV Extruded Insulation Cable System” Cigré
paper 21-101, Paris 1998 Parpal J.L. et al.
[29] “Prequalification testing of 290/500(525) kV extruded cable system at IREQ”,
Jicable99, Versailles, France, paper A.2.3 (pp 50–55) Parpal J. L. et al.
[30] “Development and Qualification of a new 400 kV Cable System with Integrated
Sensors for Diagnostics”, Cigré paper 21-103, Paris 1998 G.P. Van der Wijk,
E. Pultrum, H.T.F. Geene
[31] “Qualification of a highly electrically and mechanically stressed AC cable
system”; Jicable 03, Versailles, France, paper A.2.1 (pp 38–44) Erisson et al.
[32] “Design of a new 150 kV cable system for the Belgian electrical network”,
Jicable 99, Versailles, France, paper A.1.5 (pp 25–30) Couneson/Argaut et al.
[33] “150 kV underground links in Belgium: A new technical stage for XLPE
insulated cables”; Cigré paper 21–101, Paris 2000 Couneson/Becker et al.
[34] “Development of factory expanded cold shrinkable joint for HV XLPE
cables”; Jicable 03, Versailles, France, paper A.5.1 (pp 148–153)
Kobayashi et al.
[35] “Development of cold shrinkable joints for 110-230 kV XLPE cables”; Jicable
03, Versailles, France, paper A.5.3 (pp 164–169) Nakamura et al.
[36] “Super compact rubber block joint with high dielectric constant layer”; Jicable
03, Versailles, France, paper A.6.1 (pp 175–180). Ninobe et al.
[37] “Micro varistor based field grading elements for HV terminations”; Jicable
03, Versailles, France, paper A.6.3. (pp 186–190) Gramespaker et al.
[38] “Anti explosion protection for HV porcelain & composite terminations”; Jicable
03, Versailles, France, paper A.6.2 (pp 86–190) Gahungu et al.
[39] “New dry outdoor termination for HV extruded cables”; Jicable 03, Versailles,
France, paper A.6.4 (pp 191–196) Dejean et al.
[40] “Plug-in type connection technique using HV-connex on encapsulated compo-
nents in high voltage equipment up to Um ¼ 245 kV”; Jicable 03, Versailles,
France, paper A.6.5 (pp 197–198) Deister et al.
[41] “Type testing of cables and accessories”; Jicable 99, Versailles, France, paper
C.10.1 (pp 880–883) Berlijn et al
[42] “Type testing of cables and their accessories, some statistics”; CIRED May
2003 Pultrum et al.
[43] French specification for HV cables: NF C 32 352 “Insulated or protected cables
for power systems. Single core cables with polymeric insulation of rated voltages
above 30 kV (Um ¼ 36 kV) up to 150 kV (Um ¼ 170 kV)”
[44] French specification for EHV cables: C 33 253 “Insulated cables for power
systems. Single core cables with polymeric insulation of rated voltages above
150 kV (Um ¼ 170 kV) up to 500 kV (Um ¼ 525 kV)”
[45] “Testing of extruded cables: experiences in type testing, PQ testing and test after
installation. What do we learn from it?”; Cigré paper B1-104, Paris 2004
E. Pultrum, S.A.M. Verhoeven
[46] Contribution to the discussion of the Cigré SC B1 session, Paris 2004
E. Dorison
190 J. Becker
[47] ELECTRA 205, December 2002, TF21-05 “Experiences with AC Tests after
installation on the main insulation of polymeric (E) HV cable systems”
[48] JEC-3408-1997, Standard of The Japanese Electrotechnical Committee, “High
Voltage Tests on Cross-Linked Polyethylene Insulated Cables and their Accesso-
ries for Rated Voltage From 11kV up to 275kV”; The institute of Electrical
Engineers of Japan
[49] “Prequalification testing of EHV XLPE cable systems”; CEA Workshop, June
10–13, 2001 J.L Parpal.
[50] “Prequalification testing of 290/500 kV Extruded cable system at IREQ”;
Jicable 99, Versailles, France, paper A 2.3 (pp 50–55) J.L Parpal at al.
[51] “EHV XLPE cable systems up to 400 kV – more than 10 years filed experi-
ence”; Cigré paper B1-102, Paris 2004 W. G. Weissenberg, U. Rengel, R. Scherer
[52] “Prequalification test of 400 kV XLPE cable system “; Jicable 95, Versailles,
France, paper A.1.3 (pp 11–15) Helling K., Henningsen C.G., Polster K., Bosotti
O., Mosca W., Tellarini
[53] Cigré TB 210, 2002, Joint Task Force 21/15 “Interfaces in accessories for
extruded HV and EHV cables”
[54] “Development of a 420kV XLPE Cable System for the Metropolitan Power
Project in Copenhagen”; Cigré paper 21-201, Paris 1996
[55] “Construction of the world’s first long-distance 500kV XLPE cable line”; Cigré
paper 21-106, Paris 2000
Contents
5.1 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
5.2 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
5.3 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
5.3.1 Inclusions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
5.3.2 Exclusions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
5.4 Related Literature and Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
5.4.1 Related Literature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
5.4.2 Additional Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
5.5 General Risks and Skills . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
5.6 Technical Risks and Required Specific Skills . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
5.6.1 Conductors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
5.6.2 Insulation Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
5.6.3 Metallic Sheath . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
5.6.4 Oversheath . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
5.6.5 Installation of Joint Electric Field Control Components . . . . . . . . . . . . . . . . . . . . . . . . . 217
5.6.6 Installation of Termination Electric Field Control Components . . . . . . . . . . . . . . . . . 227
5.6.7 Outer Protection of Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
5.6.8 Filling of Terminations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
5.6.9 Handling of Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
5.7 Skills Assessment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
5.7.1 Aspects to be Tested . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
5.7.2 Methods of Qualification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
5.7.3 Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
5.7.4 Duration of Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
5.7.5 Upskilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
5.7.6 New Accessory Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
K. Leeburn (*)
CBI Electric African Cables, Chief Engineer Process and Product in HV, Vereeniging, South Africa
e-mail: Kieron.leeburn@cbi-electric.com
5.1 Summary
This Chapter 5 (Published as Cigré TB 476) covers workmanship associated with the
jointing and terminating of AC land cables incorporating extruded dielectrics for the
voltage range above 30 kV (Um ¼ 36 kV) up to 500 kV (Um ¼ 550 kV). Cigré TB
476 is a complement of Cigré TB 177 (See ▶ Chaps. 1, “Compendium of Accessory
Types Used for AC HV Extruded Cables” and ▶ 2, “A Guide to the Selection of
Accessories”), the recommendations of which are not questioned in this chapter. A short
section covers general risks and skills, but the bulk of the chapter focuses on the specific
Technical Risks and the associated skills needed to mitigate these risks. This is done for
each installation phase. This Chapter is not an Instruction Manual, but rather gives
guidance to the reader on which aspects needs to be carefully considered in evaluating
the execution of the work at hand. The supplier’s Instruction Manual is considered the
primary source of technical information. A section on skills assessment helps the
qualification of jointers. Finally, attached appendices give samples of a certificate and
QA documentation.
This chapter is intended for a broad range of readers. It is risk mitigation focussed
so the reader can develop his personal use for the document.
5.2 Introduction
High Voltage cable accessories are manufactured using high quality materials and very
sophisticated production equipment. Recent technical and technological developments
in the field in their design, manufacturing and testing have made it possible to have pre
moulded joints and stress cones for terminations up to 500 kV as well as cold shrink
joints for up to 400 kV. One conclusion of Cigré TB 379 – Update of service
experience of Underground and Submarine cables – is that internal failure rates of
accessories, particularly on XLPE cable are higher than other components and are of
great concern. Focus on quality control during jointing operations must be maintained.
Many utilities have adopted the “system approach” by purchasing the cables as
well as the major accessories from same supplier. Some of these utilities would also
5 Cable Accessory Workmanship on Extruded High Voltage Cables 193
request that the link should be installed by the supplier or by a contractor under the
supplier’s supervision in a “turn Key” fashion. The main advantage of this approach
is that the entire responsibility for the materials and workmanship is clearly the
supplier’s.
Some customers have adopted the component approach by purchasing the cables
and the accessories from different suppliers and to entrust the installation to a third
party.
In all cases, it is imperative that, the installation be carried out by qualified
jointers who follow the jointing instructions provided by the supplier.
International standards such as IEC and IEEE provide the necessary guidelines
concerning the interface between cables and accessories. However, it is highly
recommended that the responsible engineer should satisfactorily verify the compat-
ibility of the different components of the link.
It is of vital importance to manage the interface between the cables and the
accessories in order to reduce the potential technical risk.
One of the trends that have been developing in the international cable technology
is the reduction of the cable insulation thickness and the corresponding increase of
electrical stresses. This tendency is based on a better knowledge and an improved
quality of the insulating material and the extrusion process. The cables and acces-
sories are made under well-defined factory conditions. Their quality and reliability
are assured by adherence to well defined specifications. The accessories, however,
are mounted on site, and notwithstanding that this job is done by skilled and trained
jointers, it is often performed in more delicate and undefined conditions than in the
factory.
It is noted that most of the new HV links will be built using XLPE insulated
cables. With the imminent retirement of experienced jointers, a major shortage in this
field has been identified. There are few well structured training programmes and
accreditation processes in place in order to meet demand. Jointer skills are vital in
ensuring the reliability of the new links.
This chapter captures the state of the art of Jointing. It is considered the Best
Practice by the members of the SC B1 Study Committee as of 2009. It is acknowl-
edged that other practices which are not explicitly covered in this brochure are not
necessarily bad practices. Great care should be exercised and the approach agreed
where a departure from this chapter is envisaged. Where alternative techniques are
detailed, no preference is intended nor implied unless specifically mentioned.
Diagrams are provided to illustrate the concept described and should not be
interpreted literally.
Working under induced voltages or currents is not considered in this Chapter. As
mentioned in Sect. 5.8.7, in this case precautions have to be taken to eliminate or
minimize the risk further work is in progress by WG B1.44.
Note: For the range above 36 kV, the risks associated with jointing are
considered significant due to the risk of a Medium 7Voltage (MV) jointing
(continued)
194 K. Leeburn
5.3 Scope
5.3.1 Inclusions
5.3.2 Exclusions
The defined vocabulary can be assumed valid throughout this brochure except
where specific note to the contrary is made.
• Cigré TB 177 –Accessories for HV cables with extruded insulation.
This brochure is still a valid guide to the selection of accessories (▶ Chaps. 1,
“Compendium of Accessory Types Used for AC HV Extruded Cables” and ▶ 2,
“A Guide to the Selection of Accessories”). Annex in ▶ Chap. 1, “Compendium
of Accessory Types Used for AC HV Extruded Cables” concerns the terminology
(update of TB 89). It is adopted in its entirety except where specific note to the
contrary is made.
• Cigré TB 194 – Construction, Laying and installation techniques for
extruded and self contained fluid filled cable systems.
• Cigré TB 210 JTF 21/15 – Interfaces in high voltage accessories (▶ Chap. 3,
“Interfaces in Accessories for Extruded HV and EHV Cables”).
• AEIC CG4-97 Guide for installation of extruded dielectric insulated power
cable system rated 69 kV through 138 kV (2nd ed.)
• TB 379 Update of service experience of HV Underground and Submarine
Cable Systems (2004–2008)
In this brochure tables conclude the general and specific skills and technical risks
related to a work phase.
The quality and performance of any new link or replaced joints and terminations are
highly dependent on the skills and competence of the jointers who need to ensure the
proper installation of these accessories under less than ideal field conditions (Table 5.1).
196 K. Leeburn
• Patience;
• Dexterity;
• Discipline;
5 Cable Accessory Workmanship on Extruded High Voltage Cables 197
• Sense of engagement;
• Responsibility;
• Physical fitness;
• Mental fitness.
5.6.1 Conductors
5.6.1.2 Compression
Deep indentation, hexagonal and other techniques of crimping are considered here.
These techniques include:
conductors usually require longer ferrules and more compression positions than
copper conductors;
• Removing, any sharp edges or marks from the ferrule, after compression, unless it
is screened by a metallic shield (Figs. 5.3, 5.4, and 5.5).
• Cutting the conductor ends diagonally to form a V shape when placed in the
welding jig;
• Avoiding overheating of insulation during welding. Heat sinks or forced coolers
are generally applied on both sides of the exposed conductor and temperature
monitored with thermocouples;
• Removing enamel where enamelled copper wires are MIG/TIG welded, prior to
welding;
• Removing any sharp edges or marks from the connector, after welding.
• Performing trial MIG/TIG Welds on a spare sample of the actual conductor using
the actual jigs and welding equipment.
200 K. Leeburn
Note: A safety and health risk is the high explosive reaction and formation
of gases that prevent this technique being used in confined areas.
to a specified torque. One connector may cover multiple conductor sizes. These
connectors do not require special tools.
This technique includes:
• Restraining the connector while applying tightening torque for small conductor
sizes (Table 5.2).
202 K. Leeburn
Table 5.2 Technical risks and specific skills for conductor connection techniques
Work phase Technical Risks Specific Skills
Conductor Contamination of Cleaning of conductor and filler removal
preparation insulation
Compression and Wrong dies or punch Due care
indentation Wrong press
MIG/TIG Overheating of the Cleaning of conductor and filler removal Specific
welding cable MIG/TIG WeldingTechniques
Thermit weld Moisture Cleaning of conductor and filler removal Thermit
Porosity Welding
Overheating of the
cable insulation
Incorrect gap
Mechanical Bolt too deep Due care
connection
Finishing of Sharp edges Due care
connectors Depressions
The preparation of the cable insulation is considered to be the most critical step in the
installation of accessories on extruded cables.
5 Cable Accessory Workmanship on Extruded High Voltage Cables 203
5.6.2.1 Straightening
In general, accessories require straightness of the cable during preparation. This can
be achieved by either cold straightening or hot straightening techniques. Cable has
the tendency to bend again as a result of the elastic memory of the insulation.
• Heating the insulation to the specified temperature for the specified duration;
• Cooling it down while the cable is fixed in a straight position. The temperature
and duration can vary depending on conductor size as well as, insulation material
and thickness (Table 5.3).
Methods used for removing the screen are peeling, scraping and hot stripping or a
combination of these.
5.6.2.2.1 Peeling
This common technique includes:
Table 5.3 Technical risks and specific skills for cable straightening techniques
Work phase Technical risks Specific skills
Cold Excessive bending Due care
straightening
Hot Overheating due to inadequate temperature control Hot Operation of
straightening core is more prone to mechanical damage heating equipment
204 K. Leeburn
• Moving the peeling tool which contains a specially shaped knife in a circular
direction to remove the screen. It is inevitable that during peeling some core
insulation will be removed too (Figs. 5.10 and 5.11).
5.6.2.2.2 Scraping
In most cases this technique uses glass and includes:
• Moving a fragmented, sharp piece of glass at a shallow angle over the insulation
screen, thereby removing the semiconducting layer until the cable insulation
becomes visible;
• Repeating around the circumference ensuring even removal while avoiding flat
spots, cuts and dents. The scraping method results in a minimum loss of cable
insulation, but requires great skill.
Scraping can be combined with peeling in order to reduce the installation time
(Fig. 5.12).
Table 5.4 Technical risks and specific skills for removing the insulation screen techniques
Work
phase Technical risks Specific skills
Peeling Uneven travel of the peeling tool Blunt tool Removing Appropriate to insulation
too much insulation if the cable is not completely round type
Scraping Flat spots on the insulation surface Cuts/dents in the Glassing
insulation surface
Hot Burning of cable surface Handling the torch on
stripping semiconducting layer
206 K. Leeburn
Irregularities in this area can lead to a mismatch between field control body and
the cable insulation causing field enhancement and reduction of the interface
pressure.
The end of the insulation screen can be chamfered by means of peeling or
scraping. Peeling tools used for this purpose contain a specially angled knife. The
chamfer can also be achieved by carefully scraping with glass.
Sometimes semi-conducting paint is used to achieve a fine tapered transition.
Good practice includes:
• Checking the peeling tool settings by performing a trial on a spare piece of cable.
The methods of smoothing the insulation surface include polishing, melting and a
combination of polishing and melting.
5.6.2.4.1 Polishing
This common technique involves circumferential sanding of the insulation to
remove grooves remaining from the peeling or scraping process. Generally emery
cloth is used with grain sizes ranging from 150 to 400 grit. For EHV accessories, a
grain size finer than 400 grit may be needed to achieve sufficient smoothness.
5.6.2.4.2 Melting
This phase achieves a smooth insulation surface by melting and deforming the cable
insulation surface (Figs. 5.14; Table 5.5).
Melting techniques include:
• Applying a heat shrinkable tube made from fluorine or silicone rubber over the
cable insulation and shrinks it to fit on the insulation surface. The temperature of
the insulation surface is then controlled to above the melting point of the cable
insulation. The smoothness of the inner surface of the tube is transferred to the
insulation surface during the application of heat;
• Applying heat directly to the surface of the insulation. This is usually done with a
hot air gun rather than a flame which could scorch the surface of the insulation
(Table 5.6).
Flat spots in the cable surface should be avoided, as these could result in areas of
low interfacial pressure.
Table 5.5 Technical risks and specific skills for preparing the end of the insulation screen
Work
phase Technical risks Specific skills
Peeling Uneven travel of the peeling tool Blunt tool Handling peeling
Removing too much insulation if the cable is not completely tools
round
Scraping Cuts/dents in the insulation surface Glassing
Painting Thick edge (untapered) Due care
208 K. Leeburn
Table 5.6 Technical risks and specific skills for smoothening the insulation surface
Work phase Technical risks Specific skills
Polishing Surface roughness Incorrect diameter Excessive ovality Due care
(sanding) Eccentric core preparation Flat spots on the insulation surface
Melting Overheating, burning and deformation of cable surface Heating
Damage during removal of heat shrink tube technique Due
care
Table 5.7 Technical risks and specific skills for cleaning the cable insulation surface
Specific
Work phase Technical risk skills
Cleaning with Wrong solvent Too long exposure Dissolving of semiconducting Due care
solvent paint Cross contamination
This is best achieved by using a lint free cloth or tissue wetted with an appropriate
cleaning fluid. Only solvents supplied with the jointing kit, or specifically defined
(full chemical name), should be used due to the risk of incompatibility.
Where semi-conducting paint has been used, be aware that the solvent can
remove the paint.
Water based cleaning fluids are strongly discouraged as they might leave moisture
or residues like soap on the surface.
Good practice includes
• Cleaning from the conductor end towards the semiconducting screen cut and
disposing of the cloth thereby preventing contamination (Table 5.7).
5.6.2.6 Shrinkage
Some insulation has stretch memory introduced into its molecular structure during
the extrusion process. When heated (during load) the insulation may revert to its
relaxed state. This shrinkage can cause a mismatch of the field control components.
Three known methods of mitigating this risk are:
• Locking the insulation e.g. by applying a clamp over the joint connector which
grips into specially peeled grooves in the insulation;
• Pre-shrinking the insulation to ensure all potential shrinkage in the joint has
already taken place;
• Tolerating the anticipated shrinkage in the design of the joint.
5.6.2.7 Lubrication
Lubricants are used to relieve the friction between different surfaces (cable and
accessories) during installation. Lubricants can fill possible gaps and increase the
initial breakdown strength. It is recommended that jointers do not take advantage of
5 Cable Accessory Workmanship on Extruded High Voltage Cables 209
Table 5.8 Technical and specific skills for limitation of the cable insulation shrinkage
Work phase Technical risk Specific skills
Insulation groove Wrong dimensions Due care
Pre-shrinking Overheat the insulation Handling of equipment
Table 5.9 Technical risks and specific skills for lubrication phase
Work phase Technical risk Technical skill
Lubrication Polluting of lubricated surface Due care
The metallic sheath on cables is usually applied as a moisture barrier and mechanical
protection and/or to conduct sheath currents (inductive and capacitive) and fault
currents.
The connection between metallic sheath and accessory casing (joint shell or
wiping bell of the termination) should maintain these characteristics.
• Cutting the welded aluminium sheath and the outer sheath perpendicular to the
cable axis;
• Taking great care to avoid damaging the underlying cable core;
• Using specifically designed tools for these operations;
• Making longitudinal cuts to remove the sheath and facilitate the mechanical and
electrical connections to other metallic components and allowing more room for
subsequent steps.
Plumbing
CABLE CORE
Connecting the WAS to the accessory casing by using the plumbing technique.
• Making longitudinal cuts of the aluminium sheath and the outer sheath;
• Opening out the aluminium sheath bonded to the outer sheath;
• Inserting a connecting piece under the aluminium sheath;
• Ensure an electrical and mechanical contact between the connecting piece and the
aluminium;
• Tinning the accessory casing which is generally in copper or aluminium;
Joining the connecting piece to the accessory casing by using the plumbing
technique or by mechanical assembly.
• Connecting the copper wires directly with the bonding cables. (This can only be
applied if the copper wire screen is rated to handle the sheath currents).
Reinforcement
Glass fibre reinforced epoxy resin may be required over the tin wipes to improve
their mechanical strength (Fig. 5.16; Table 5.10).
Accessory casing
Liaising piece
CABLE CORE
Table 5.10 Technical risks and specific skills for WAS connection
Work phase Technical Risks Specific Skills
Preparation of • Cutting into the underlying • Handling of specific tools for this
cable sheath layers work
Metallic screen • Overheating underlying layers • Removing the glued outer sheath
continuity • Weak metallic screen continuity • Removing glue
Connection on top due to an incomplete cleaning or • Tinning and Plumbing Techniques
of WAS preparation of the aluminium • Controlling the heat of the torch
sheath or/and the metallic
connection before plumbing
Metallic screen • Faulty earth screen continuity • Due care
continuity due to an improper mechanical
Connection under connection
WAS • Damage to underlying layers
Plumbing • Overheating the cable core • Plumbing Techniques
• Melting of the aluminium sheath • Controlling the heat of the torch
• Enclosing voids in the tin wipe,
which could lead to a weak
connection
Copper wire screen • Poor plumbing connection of • Plumbing technique
the wire screen • Crimping techniques
• Poor mechanical connection due
to wrong dies or press
Reinforcement • Uncured resin • Resin mixing and glass-fibre
• Faulty glass-fibre tape application techniques
application
Plumbing
This technique includes:
• Leaving as much metallic sheath on the cable as possible to act as a heat sink
during the plumbing process as well as protecting the underlying layers from
splatter during the wiping process;
• Moving the torch circumferentially to ensure even heat distribution;
• Applying generous amount of tallow will keep the area of the wipe cool.
Note: Making a good, solid and smooth tin wipe, requires specific skills from
the jointers. Jointers that have been used to work with fluid filled accessories
should have the required specific skills.
Soldering
Where the connecting piece is braided tinned copper, this technique includes:
• Leaving as much metallic sheath on the cable as possible to act as a heat sink
during the plumbing process as well as protecting the underlying layers from
splatter during the wiping process;
• Moving the torch circumferentially to ensure even heat distribution;
• Applying generous amount of tallow will keep the area of the wipe cool;
• Cutting the metallic sheath on the crest of the corrugations.
5.6.3.2.4 Reinforcement
Glass fibre reinforced epoxy resin may be required over the tin wipes to improve
their mechanical strength.
• Cutting the lead sheath taking great care to avoid damaging the underlying cable
core. A safe method is to make one shallow (partial) circumferential cut and two
shallow longitudinal cuts toward the end. A tool specifically designed for this
operation should be used;
• Tearing the lead strip between the longitudinal cuts;
• Tearing the sheath along the circumferential cut (Table 5.11).
5.6.3.3.4 Reinforcement
Glass fibre reinforced epoxy resin may be required over the tin wipes to improve
their mechanical strength.
5 Cable Accessory Workmanship on Extruded High Voltage Cables 215
Table 5.11 Technical risks and specific skills for Corrugated Sheath connections
Work phase Technical Risks Specific skills
General Connecting cable screens where not intended Know risks and
function of screen
connections
Cable Overheating the cable core during oversheath Controlling the heat of
Preparation removal the torch
Cutting into underlying layers Handling of specific
tools for this work
Tinning Use of wrong metal Tinning Techniques
Lack of brushing into valleys Controlling the heat of
Uneven circumferential heat (dry joint) the torch
Excessive heat damaging underlying layers
Accidental oxidization of surface by touching or
other material contamination
Use of wrong gas
Platform Wipe Use of wrong metal Due care
(CAS) Excessive heat damaging underlying layers Wipe Plumbing Techniques
exceeds tinned area
Use of wrong gas
Copper wire Poor plumbing connection of the wire screen. Plumbing techniques
screen (CSS) Poor mechanical connection due to wrong dies or Crimping techniques
press
Connection Weak metallic screen continuity due to a bad Tinning and Plumbing
cleaning or preparation of the aluminium sheath Techniques
or/and the metallic connection before plumbing
Cutting of Cutting into underlying layers Handling of specific
metallic sheath tools for this work
Braided tinned Wrong flux Soldering Techniques
copper soldering Overheating underlying layers Due care
Insufficient braided copper pieces
Reinforcement Uncured resin Resin mixing and
Faulty glass-fibre tape application glass-fibre application
techniques
• Connecting the APL/CPL layer directly to the accessories with a roll spring, or
216 K. Leeburn
• Folding the aluminium (APL) or copper (CPL) back over the spring and applying
an additional external connection. Sometimes an additional copper fabric tape is
used under the contact spring on either side. Folding back requires multiple
longitudinal cuts before bending outwards to ensure there is a clean aluminium
surface facing outwards. Where a semiconducting coating is bonded to the inside
of the APL this will need to be removed as well to ensure a good contact.
• Bending the copper wires back and clamping using a roll spring, or
• Collecting the wires together and crimping in a lug or ferrule.
Table 5.12 Technical risks and specific skills for lead sheath connection
Work phase Technical Risks Specific skills
Cable Overheating the cable core during Controlling the heat of the
Preparation oversheath removal torch
Handling of specific tools for
this work
Cutting of lead Cutting into the cable core Handling of specific tools for
sheath this work
Plumbing Overheating the cable core Plumbing Techniques
Melting of the lead sheath Controlling the heat of the
Enclosing voids in the tin wipe, which torch
could lead to a weak connection
Copper wire Poor plumbing connection of the wire Plumbing techniques
screen screen. Crimping techniques
Poor mechanical connection due to wrong
dies or press
Reinforcement Uncured resin Resin mixing and glass-fibre
Faulty glass-fibre tape application application techniques
5 Cable Accessory Workmanship on Extruded High Voltage Cables 217
5.6.4 Oversheath
Prior to work, jointer should be aware about the cable design e.g. extruded semi-
conductive layer or graphite applied on the PVC or Polyethylene oversheath.
• Cleaning the semi-conducting layer for a specified distance from its end;
• Performing an appropriate resistance measurement to confirm effective removal
of any conducting layer.
Check that the body is in good condition and that all surfaces (inside and outside) are
completely clean and free from defects. On joints, the accessory body is temporarily
parked on one cable core before connecting the conductor. Special tools are
218 K. Leeburn
Table 5.13 Technical risks and specific skills for laminated sheath connections
Work phase Technical risks Specific skills
Cutting the cable sheath Damaging the cable core Handling of specific tools
(cutting) for this work
Removing the PE cable sheath Overheating the cable core Controlling the heat of the
by heating Poor contact due to bad torch
cleaning
Damage to thin Aluminium/
Copper layer
Opening the Aluminium/ Damaging the cable core Handling of specific tools
Copper foil (cutting) for this work
Plumbing/soldering Excessive heat damaging Plumbing and soldering
underlying layers techniques
Table 5.14 Technical risks and specific skills for oversheath preparation
Specific
Work phase Technical Risks Skills
Cleaning or removing of the Local overheating and fire risk due to Due
conductive or semiconducting incomplete cleaning which can lead to surface care
layer currents
Removing of the embossed Graphite concentration Due
lettering care
generally required to guide the movement of the accessory body into the final
position and subsequently to align it correctly. The tools may include:
• Movable supports;
• Chain hoists;
• Special clamps;
• Special seals;
• Dry nitrogen;
• Lubricating grease which reduces the friction between cable core and the acces-
sory body. Only use the lubrication specified in the instruction manual
(Tables 5.14 and 5.15).
Table 5.15 Common Technical risks and specific skills for joint field control components
Work
phase Technical risk Specific skill
Core Dimension/tolerance Due care
preparation
Joint Cutting or damaging the joint body Handling of sensitive
parking Damage to conductive varnishes Selection of components
wrong tools
Use of wrong tools
Use of wrong grease
• Lubricating the inner surface of the joint body and the cable core with grease or
other liquids specified by the manufacturer;
• Slipping the joint body on the cable core into a parking position in order to
prepare the conductor connection. It is advisable to temporarily cover the con-
ductor during the positioning phase (Figs. 5.19, 5.20, 5.21, and 5.22);
• Checking for smoothness and cleanliness before the joint body is slipped on to the
prepared cable core;
• Slipping the joint body into the final position after making the conductor
connection;
• Using chain hoists or other auxiliary tools to help move the joint body.
• Good practice includes:
• Special movable supports are used in order to guide the movement of the
accessory body;
• Chain hoists with suitably auxiliary slip-on rings might be used in order to pull
the accessory body;
• The use of reference marks on the cable core to ensure correct positioning of the
joint body;
• Check the correct position of the accessory body which should be in accordance
with the instruction manuals. During positioning the accessory body, any slight
bulging of the body caused by the pulling process may in some cases be smoothed
out by slightly turning the body on the cable;
220 K. Leeburn
• Temporary cover on cable conductor to ensure that the joint body is not damaged
during parking;
• Ensuring that instructions are followed where a specific installation tool is to be
used for locating the accessory body.
Site expanded joints have to be expanded onto a carrier tube in the field, just
before fitting them on the cable. Particular skills and tools are required for making a
field expanded joint or termination. The tools vary with each manufacturer and the
jointer must be trained in their use.
The jointer should ensure that the expanded body is positioned correctly as
specified by the manufacturer (Table 5.16).
Field expansion steps:
Table 5.16 Technical risks and specific skills for the “slip-on” prefabricated joint installation
Work
phase Technical risk Specific skills
Accessory Any damage or cutting into the Due care
pulling body
Preparation Wrong joint body Due care
Mis-alignment of the cable Cleaning with specified solvents and the
Contamination of components prior correct use of grease
to slide on
Incorrect application of lubrication
Wrong preparation dimensions
Parking Damage while positioning in Due care
parking position due to sharp edges
of the conductor
Slipping Incorrect positioning of joint body Due care
on Damage by use of chain hoists Awareness of the behaviour of accessory
Damage of joint body and/or cable bodies with different sizes during
core due to use of wrong tools movement on the cable core
Damage due to improper fixation of Application of formulas or graphs for
the accessory body calculating the premoulded body position
Damage to semi-conductive paint respect to reference marks made on the
cable
Handling of specific tools
222 K. Leeburn
Some tapes are impregnated with silicon oil to fill overlap gaps.
The taped profile and geometry forms the electrical stress control of the joint.
The taping phase includes:
5 Cable Accessory Workmanship on Extruded High Voltage Cables 223
Fig. 5.24 Example of lubrication and fitting of a smooth carrier tube for a stress cone and a
joint body
Fig. 5.25 Removal of helical carrier tube from the joint body
Table 5.17 Technical risks and specific skills for field expansion of premoulded body
Work
phase Technical risks Specific skills
General The risks listed under Table 6.5.1 The skills listed under Table 6.5.1 apply here
apply here
Expansion Presence of defects on the carrier Due care
of the body tube (e.g. sharp edges or cracks)
Presence of defects on the
expansion tooling (e.g. damaged
nose)
Carrier Breaking of the carrier tube during Ability to correctly remove the carrier tube.
tube removal Damage to the cable Knowledge about handling the special tools
removal insulation required for the removal of the smooth
carrier tube Handling of special tools and
equipment
Table 5.18 Technical risks and specific skills for field taped joints
Work
phase Technical risk Specific skills
Preparation Contamination Mis-alignment of Due care
the cable
Taping Wrong tension during taping High skill in hand taping
Wrong stress control profile Knowledge of setting and operating taping
(diameter and length) machines Reading technical drawings and
Wrong settings of taping machine measuring
• Applying the tapes at the right pace, stretch, tension (Table 5.18);
• Ensuring that the correct profile is achieved and that air gaps and voids are
managed. Frequent measurement is required;
• Ensuring that the transition point between the taped insulation and the cable core
semiconducting layer is correctly applied;
• When a tapping machine is used, setting the parameters as per operating and
jointing instruction manuals. These settings include tension, pitch and return
limits;
• Continuing the semiconducting layer over the joint with a semiconducting tape;
• Depending on the instruction, lead tape may be applied over the semi-conducting
tape to ensure continuity (Fig. 5.28).
Stress control B
Rj
profile
dy (x, y)
A dx
Ri
Cable insulation
r
x Conductor
Table 5.19 Technical risks and specific skills for heatshrink joint
Work
phase Technical risk Specific skills
Shrinking Wrong order of tube insertion Change in positioning during Shrinking of thick
shrinking Uneven shrinking Folds in tube wall tubes
• Ensuring the straightness of the cable is within the prescribed limits given in the
instruction manual;
• Parking the joint shells, epoxy and rubber insulators;
• Lubricating the appropriate surfaces with the specified lubricant;
• Connecting the conductors with compression type connector.;
• Fixing the Epoxy insulation unit and Connector completely by fitting the HV
electrode embedded in the Epoxy insulation unit to connector;
226 K. Leeburn
Table 5.20 Technical risks and specific skills for prefabricated composite joint
Work phase Technical risk Specific skills
Insert parts Wrong order of inserting parts Due care
Setting the epoxy unit and Slide of Setting in wrong place Handling of specific
premoulded stress cone Wrong centering of the cable to tools for this work
epoxy insulation unit
Damage to cable insulation Due care
Assemble the spring unit Lack of the designed pressure Due care
• Fitting and compressing with the springs the premoulded stress cones against the
epoxy insulation unit (Fig. 5.29; Table 5.20)
• Wiping the joint shells to the cable sheaths if applicable.
Table 5.21 Technical risks and specific skills for plug-in type joints
Work phase Technical risk Specific skills
Inspection of Damaged plugs Check plug and cable
cable end ends
Inserting cable Mis-alignment of the cable in case of hand driven Due care
ends chain hoists
Locking of the Not locking Pull back check of
plugs cable
In order to successfully install terminations, the jointer must possess certain skills
and abilities. These depend on the following aspects: the technology of the termi-
nations, the voltage levels and the manufacturer of the cable and accessories. The
procedures and skills as detailed in Sect. 0 above apply.
Installation of HV cable terminations present an additional set of challenges. As
most terminations are installed in a vertical position at a few meters from the ground,
special preparation of the work area is needed. Usually, a scaffolding system is built
around each cable (or the three cables) to facilitate access to cable and reduce strain
on the jointers. Some environmental protection against dust, wind, rain and snow is
also advisable.
228 K. Leeburn
Stress profile
Screen connection
Conductor Shrinkable sleeves with
connection moisture barrier
Table 5.22 Technical risks and specific skills for pre-moulded three piece joint
Work phase Technical risk Specific skills
Parking Wrong placing Due care
Core preparation Wrong measures Handling of specific tools for this work
Bad surface
Pushing on of elastomeric parts Wrong position Due care
See also Table 5.16
• Inner Epoxy Cone – based on a rubber stress cone pushed into the epoxy
insulator, achieving the required interface pressure by means of metal springs;
• Outer Epoxy Cone – based on a rubber mould, pushed onto a conical bushing of
the epoxy insulator, achieving the interface pressure by stretching the rubber
mould.
5 Cable Accessory Workmanship on Extruded High Voltage Cables 229
Table 5.23 Technical risks and specific skills for cone plug-in terminations
Work phase Technical risk Specific skills
Installing the epoxy insulator Damaging the insulator Due care Check
Unequal tightening of the bolts torques
Inserting cable ends (with or without Mis-alignment of the cable Due care
stress cone) Damaging the cable and or
stress cone
Locking of the plugs (if applicable) Not locking Check locking
• Parking heat shrink tubes on one or both cable ends, prior to joint installation;
• Moving heat shrink tubes into place after inner joint components have been
applied;
• Shrinking the tubes in position;
• Avoiding excessive heat as it will lead to melting or even burning of the material;
• Ensuring sufficient heat is applied to enable the shrinking process and melting of
the glue;
• Installing an under lying tape layer if the heat shrink is not adequate to withstand
the sheath voltage requirements. A self fusing polymeric tape is often used for this
purpose (Tables 5.24 and 5.25).
5 Cable Accessory Workmanship on Extruded High Voltage Cables 231
Table 5.24 Technical risks and specific skills for taped terminations
Work phase Technical risk Specific skills
Taped Wrong order of material Wrong High skill in taping.
Accessories positioning and diameter of the Operation of taping equipment
(terminations) specified layers as specified by the Dealing with measuring tools such as
manufacturer vernier-callipers Read technical
Wrong positioning of conductive drawings well
layers Lack of cleanliness and dryness
of all components during taping
Inclusion of particles or voids during
taping must be avoided
Vacuum Improper degassing Handling of the equipment and basic
treatment knowledge about the behavior of
fluids and vacuum treatment
Table 5.25 Technical risks and specific skills for polymeric outer protection (taping and/or
heatshrink tubes)
Work phase Technical risks Specific skills
Shrinking Burning the polymeric material in case of too much heat Heat control
Insufficient melting of the hot-melt glue in case of too little heat Taping
Folds in the tubes
Gaps between overlapping layers, resulting in leaks
Wrong amount of tension during taping
In the case where a joint is to be fixed to a support structure this should be done
before the outer protector is filled with compound.
• Taking a sample from each batch or joint in order to ensure that it has cured
properly;
• Considering the physical position of the joint in order to avoid air pockets;
5 Cable Accessory Workmanship on Extruded High Voltage Cables 233
Table 5.26 Technical risks and specific skills for outer protection assembly
Specific
Work phase Technical risks skills
Outer protection Poor sealing of interfaces leading to loss of compound, poor Due care
assembly filling, etc. and leading to water penetration
Over tightening of bolts leading to cracking of outer protection
Incorrect horizontal positioning of outer protector leading to
poor filling
There are types of terminations that are to be filled with insulating compound,
typically they are metal enclosed GIS terminations and outdoor terminations. They
can be filled with insulating liquid or gas. For taped terminations the process is
covered in Sect. 5.6.6.3. In the case where the termination is to be filled with
compound the manufacturers filling instruction is to be followed; filling compound
may include such items as polybutene, silicon oil or other dielectric fluid, gas or
mixed two component resins.
The different filling compounds involves different steps, the main steps in
preparation phase includes:
• Taking a sample from each batch or termination in order to ensure that it has cured
properly (when applicable);
• Considering the physical position of the termination and be aware about the risk
of including air bubbles inside the chamber;
• Preventing contamination to ground and waterways.
• Applying the right amount of torque to the closing screws. Too much torque can
result in deformation of the polymeric jacket, while too little torque will reduce
the friction between cable (and/or joint) with the support structure and give
inadequate support and constraint.
Flame treating the extruded polythene sheath and applying a resin impregnated tape
system, in order to mechanically reinforce the cable/accessory interface where thermo-
mechanical forces and movement might be experienced (Tables 5.28 and 5.29).
Table 5.27 Technical risks and specific skills for filling compounds
Work phase Technical risks Specific skills
Preparation Contamination Due care in cleanliness of equipment
and components
Heating filling Overheating of compound General skills and knowledge in
compound Underheating of compound handling the equipment
Filling of Insufficient hardeners or accelerators The use of special equipment
compounds Premature curing due to heat (e.g. mixer) under clean conditions
(joints) Enclosed air pockets Able to check and verify the correct
position Able to check the status of
the vulcanization.
Check of outer Wrong order of materials General skills and knowledge in
protection May be impossible to visually check handling the equipment
condition the vulcanization status afterwards
Table 5.28 Technical risks and specific skills for filling of terminations
Work phase Technical risk Specific skills
Preparation Contamination Due care in cleanliness of
equipment and components
Heating filling Overheating of oil Handling the equipment
compound Underheating of oil
Evacuating Not evacuated enough Handling of equipment
chamber
Mixing of Incorrect curing of compounds with A Mixing and handling compounds
components and B mixing components and tools
Filling Water or humidity presence during filling Handling the specific tool or
Underfilling or overfilling method required
Air bubbles if the compound is filled or
mixed improperly
Table 5.29 Technical risks and specific skills for installation of supporting of accessory
Work phase Technical risks Specific skills
Closing the clamps Applying the wrong torque on the closing General skills and
on the cable (and screws knowledge in handling
joint) with equipment
Erecting steelwork Steelwork modification or the adjustment General skills
on site may weaken the support or cause
steelwork corrosion at a later date
Mechanical Burning of the PE oversheath Wrong resin Heating techniques
reinforcement of and/or deficient application
accessories
Table 5.30 Technical risks and specific skills for lifting/moving accessory
Work
phase Technical risks Specific skills
Lifting/ Cable damage and displacing the General skills and knowledge in handling
moving internal parts due to bending or twisting with equipment Operator to be trained in
of the cable Broken insulator Cracked relevant aspect of lifting/moving for
Porcelain Scratched polymeric sheds accessory Rigging skills
• Temperature;
• Distributed temperate sensing;
• Pressure (leak);
• Partial discharge;
• G as density, etc.
The kind of sensors used depends on the accessories and the requirements of the
manufacturer or the user. It should not be assumed that the HV cable jointer
automatically has the required sensor connection skills. The specific sensor supplier
should provide input on the suitable skill set needed.
Special care should be taken where insulated sheath systems are employed as the
sensors must not compromise the earth isolation.
5 Cable Accessory Workmanship on Extruded High Voltage Cables 237
Table 5.31 Technical risks and specific skills for special bonding configurations
Work phase Technical risks Specific skills
Connecting bonding lead Sheath bonding connection error Knowledge of
Disturbed seal on bonding lead may bonding design
lead to water ingress Due care
Filling link box with Similar risks as in 0 General skills and
compound e.g. bitumen as 0
Table 5.32 Technical risks and specific skills for sensor connections
Specific
Work phase Technical risks skills
Connecting Sheath bonding connection error Disturbed seal on bonding lead Due Care
sensors may lead to water ingress
Note, these activities can be done by a third party (Tables 5.31 and 5.32).
Since education and training differs for each country, it is not appropriate to dictate
the method of assessment and certification. It is recommended that the certifying
authority, normally the accessory manufacturer, keeps an up to date record of the
jointing competencies tested and certified. The methodology of assessment should
also be stated. Where no formally structured assessment and certification is
238 K. Leeburn
Table 5.33 Technical risks and specific skills for installation of fibre optics
Work phase Technical risks Specific skills
Handling the optical fibre Breaking the optical fibre Fibre splicing Knowledge
in handling optical fibre
Removing the stainless Damaging the cable core with the Due care
steel fibre protection tube steel tube
Short circuiting of the sheath
interruption of the joint with the steel
tube
available, the methodology described in Sects. 5.7.1, 5.7.2, 5.7.3, 5.7.4, 5.7.5, and
5.7.6 should be used.
Modern high voltage accessories often seem fairly simple in design e.g. pre-molded
joints. This may lead to the incorrect assumption that a jointer with a skill-set suitable for
assembling low voltage accessories can be easily up skilled to high voltage accessories.
However, very careful assembly is needed for high voltage accessories, as these
accessories will operate at very high voltage stresses and, as a result, the margin for
error in assembly is very low. Further, the impact of a system outage is very high.
It is essential that the jointer has the skill-set appropriate to the accessory being
assembled or, if a team is assembling the accessory, then the team should have the
full skill-set between them. Of course in the latter case each jointer should be limited
to working only in his area of competency.
In order to determine the jointer’s skill-set he should be tested for relevant
competencies, as outlined in Sect. 5.6 above.
There may be three levels of competence:
5.7.2.1 Theoretical
This test should demonstrate the jointer’s basic understanding of the theoretical
aspects of the assembly processes e.g. importance of smooth surfaces, cleanliness,
avoiding nicks, etc.
5 Cable Accessory Workmanship on Extruded High Voltage Cables 239
5.7.3 Certification
Mechanism used for Certification (Sects. 5.7.2.1, 5.7.2.2, and 5.7.2.3) – if Sect.
5.7.2.3, give test details.
While it is preferable that a jointer keeps his skills up to date by having a continuous
programme of work, it is recognised that this rarely happens. Very often there can be
240 K. Leeburn
long breaks between periods of jointing activity and there may be a possibility that
there would be a reduction in skills. It is for this reason that the concept of a duration
attached to certification is introduced. If the jointer is regularly using his skill-set
then there is no need for re-certification. In the event that there is a significant gap in
the jointer’s work programme, then the jointer may need to be re-certified. The
re-certification should take place in accordance with the relevant parts of Sects. 5.7.2
and 5.7.3 above. The log book described in Sect. 5.7.2.2 above will help in the
evaluation of the need for re-certification.
5.7.5 Upskilling
A case may arise where a jointer has a fairly good skill-set, but needs to gain some
more skills for a new accessory to be installed that is not too different from
accessories he has previously installed. In this case it may be sufficient for the
jointer to be tested and certified for the additional skills required. We would advise
to err on the side of caution.
If the jointer is required to install an accessory, with which he is not familiar, then he
should be fully trained in all of the necessary skills outlined in Sect. 5.6 above, tested
as per Sect. 5.7.2 and certified as per Sect. 5.7.3, as appropriate, before he com-
mences installation.
5.8 Set Up
While, not part of the accessory, set up is complimentary to the accessory, and is thus
covered here. It is recommended the steps outlined below are followed:
Joints are installed in different locations such as, joint bays, manholes, vaults,
tunnels, etc.
The installation crew should ensure that:
• The jointing kits are verified for contents and expiry dates where appropriate;
• The layout of the jointing space is compatible with the required dimensions to
carry out the jointing activities;
• There is adequate space available for tools and equipment as well as the joint
components;
• There is adequate electric power supply, lighting, ventilation and other necessary
services;
• Safety of the personnel is assured through careful planning.
5 Cable Accessory Workmanship on Extruded High Voltage Cables 241
Allowance should also be made for those designs that incorporate rigid joint
designs.
The jointer should ensure that the conditions are suitable with for jointing with
respect to:
• Temperature;
• Humidity;
• Dust;
• Pollution;
• Salt.
Depending on the jointing instruction, the joint bay environmental control may
vary from a simple single skinned jointing tent with no temperature or humidity
control to a double skinned tent or jointing container with careful temperature and
humidity control.
In addition the possibility of the jointer perspiring too much must be considered.
At the commencement of jointing, great care should be exercised to inspect the cable
pulling head and tail. They should be very carefully removed and inspected for
moisture penetration, as should the remaining cable – this can be done visually, but it
is best done by immersing a small sample of conductor in hot oil; if there is moisture
present then the oil will crackle. Cable should not be jointed if there is moisture in the
conductor. This should be the subject of discussions between the Installation Com-
pany and the Client.
In any jointing operation it is vital that considerable attention is paid to the safety and
health of the jointing operatives and their assistants. Amongst the items that should
be considered and precautions taken to eliminate or minimise the risk are:
• Tripping;
• Sunburn/sunstroke;
• Falling from ladder or into joint bay or other;
• Ground Subsidence;
• Electrocution/Earthing;
• Induced voltages from parallel circuits;
• Water, drowning;
• Gas;
• Traffic;
• Attack by animals;
• Attack by people;
• Lifting/handling;
• Noise;
• Handling hazardous substances;
• EMF exposure;
• Explosion/Fire;
• Failure of parallel power circuits;
• Equipment failure;
• Inadequately trained staff and supervision;
• Compliance with local safety laws and Regulations.
All of the above should be the subject of a detailed documented risk assessment.
The quality insurance is treated in TB 177 (see ▶ Chap. 2, “A Guide to the Selection
of Accessories”).
5
Set Up
Organisation of jointing location
Positioning of Joint
Environmental Conditions
Cable End Inspection
Safety and Health
Check cable placed in position with correct bending radius
Check cable serving, sheath, semi-conducting layer and insulation removed in
truction drawing
Check that end bell, etc are passed down the cable, before jointing commences,
so that they are available in the right position for use later in the jointing
installation
Organisation of jointing location
Conductors
Construction and Procedure description
Conductor preparation
Cable Accessory Workmanship on Extruded High Voltage Cables
Insulation Preparation
Straightening
Stripping of semi conductive insulation screen
Preparing the end of the semi conducting insulation screen
Smoothing the insulation surface
Cleaning of insulation
243
Shrinkage
Lubrication
CERTIFICATE
244
Oversheath
Preparation of oversheaths
Extruded PVC
Extruded Polyethylene
Low Smoke, Zero Halogen, Enhanced Flame Performance Sheaths
Mechanical Reinforcement of Accessories
ents
Field expansion
Taped Accessories (Joints)
Field moulding Extrusion or taped
Heatshrink tube insulation.
Coldshrink tube insulation.
Prefabricated composite type joint
Prefabricated composite type termination
Polymeric outer protection by taping and/or heatshrink tubes
K. Leeburn
5
d spring loading, if
necessary, to ensure pressure is maintained
Installation of plug-in types
CERTIFICATE
Special features
Sensor connections
on system
Fibre optics
Cable Accessory Workmanship on Extruded High Voltage Cables
Safety
Environmental Aspects
Signed By
Certifying Authority
Expiry Date
245
CERTIFICATE FILLED IN SAMPLE
246
Set Up
Organisation of jointing location R e q u i re d re q u i re d re q u i re d
Positioning of Joint R e q u i re d re q u i re d re q u i re d
Environmental Conditions R e q u i re d re q u i re d re q u i re d
Cable End Inspection R e q u i re d re q u i re d re q u i re d
Safety and Health R e q u i re d re q u i re d re q u i re d
Check cable placed in position with correct bending radius R e q u i re d re q u i re d re q u i re d
Check cable serving, sheath, semi-conducting layer and insulation removed in
t r u c t i o n d r aw i n g R e q u i re d re q u i re d re q u i re d
Check that end bell, etc are passed down the cable, before jointing commences,
so that they are available in the right position for use later in the jointing installa-
tion R e q u i re d re q u i re d re q u i re d
Organisation of jointing location R e q u i re d re q u i re d re q u i re d
Conductors
Construction and Procedure description R e q u i re d re q u i re d re q u i re d
Conductor preparation R e q u i re d re q u i re d re q u i re d
Round and Hexagonal Compression R e q u i re d re q u i re d re q u i re d
MIG Welding
Deep indentation
Thermit Weld
Mechanical Connection
Insulation Preparation
Straightening required required
Stripping of semi conductive insulation screen required required
Preparing the end of the semi conducting insulation screen required required
Smoothing the insulation surface required required
Cleaning of insulation required required
Shrinkage required required
Lubrication required required
K. Leeburn
5
Oversheath
Preparation of oversheaths R e q u i re d re q u i re d re q u i re d
Extruded PVC
Extruded Polyethylene required required
Low Smoke, Zero Halogen, Enhanced Flame Performance Sheaths
Mechanical Reinforcement of Accessories required required
nts
Field expansion
Cable Accessory Workmanship on Extruded High Voltage Cables
Special features
Sensor connections required to know about required to know about PD
PD
on system required required
Fibre optics
Safety R e q u i re d re q u i re d re q u i re d
Environmental Aspects R e q u i re d re q u i re d re q u i re d
Signed By
Certifying Authority
Expiry Date
K. Leeburn
5
Appendix B: QA Document
QA DOCUMENT
QA Requirement Value QA Signed Date Any
sets required value/description checked by comments
from list by jointer
and ok
Accessory Type/voltage class/number:
Set Up
Organisation of jointing location
Checking that all jointing materials and consumables are on site
Checking that all jointing tools and other required equipment are on
site
Positioning of Joint
Environmental Conditions
Cable End Inspection for no damage /water
d and managed
Check fully detailed jointing instruction supplied covering all items
listed above and below
Check cable placed in position with correct bending radius
Check cable serving, sheath, semi-conducting layer and insulation
ointing
instruction drawing
Check that end bell, etc are passed down the cable, before jointing
commences, so that they are available in the right position for use later
in the jointing installation
Cable Accessory Workmanship on Extruded High Voltage Cables
Conductors
Construction and Procedure description
Conductor preparation
Round and Hexagonal Compression
MIG Welding
Deep indentation
Thermit Weld
Mechanical Connection
Insulation Preparation
Straightening
249
Oversheath
Preparation of oversheaths
Extruded PVC
Extruded Polyethylene
Low Smoke, Zero Halogen, Enhanced Flame Performance Sheaths
Mechanical Reinforcement of Accessories
nts
Field expansion
Taped Accessories (Joints)
High Voltage tape
High Voltage Heat-resistant tape
Field moulding Extrusion or taped
Heatshrink tube insulation.
Coldshrink tube insulation.
Prefabricated composite type joint
preparation
K. Leeburn
5
QA DOCUMENT
QA Requirement Value QA Signed Date Any
sets required value/description checked by comments
from list by jointer
and ok
insert parts
sleeve compression
setting the epoxy unit and slide of premoulded insulator
assemble the spring unit
Prefabricated composite type termination
Polymeric outer protection by taping and/or heatshrink tubes
Filling compounds (joints)
d spring loading,
if necessary, to ensure pressure is maintained
Installation of plug-in types
Taped Accessories (Terminations)
Heatshrink tube insulation
Fitting OD porcelain/cast resin insulator and top metal
rminations
Special features
Sensor connections
on system
Fibre optics
Safety
Environmental Aspects
Signature of Jointer
Set Up
Organisation of jointing location required description to be achieved yes yes xxxx
Checking that all jointing materials and consumables are on required list to be achieved yes yes xxxx
site
Checking that all jointing tools and other required equipment required list to be achieved yes yes xxxx
are on site
Positioning of Joint required dwg to be achieved yes yes xxxx
Environmental Conditions
Cable End Inspection for no damage /water required description to be achieved yes yes xxxx
d and required list to be achieved yes yes xxxx
managed
Check fully detailed jointing instruction supplied covering all required description to be achieved yes yes xxxx
items listed above and below
Check cable placed in position with correct bending radius required value to be achieved yes yes xxxx
Check cable serving, sheath, semi-conducting layer and insula- required values to be achieved yes yes xxxx
in joint-
ing instruction drawing
Check that end bell, etc are passed down the cable, before required description to be achieved yes yes xxxx
jointing commences, so that they are available in the right posi-
tion for use later in the jointing installation
Conductors
Construction and Procedure description required per J.I to be achieved yes yes xxxxx
Conductor preparation required per J.I to be achieved and dimen- yes yes xxxxx
sions checked
Round and Hexagonal Compression required per J.I dimensional value to be yes yes xxxxx
achieved
MIG Welding
Deep indentation
Thermit Weld
K. Leeburn
5
Insulation Preparation
Straightening required per JI description of process and yes yes xxxxx
value to be achieved
Stripping of semi conductive insulation screen required per JI description of process and yes yes xxxxx
value to be achieved
Preparing the end of the semi conducting insulation screen required per JI description of process and yes yes xxxxx
value to be achieved
Smoothing the insulation surface required per JI description of process and yes yes xxxxx
value to be achieved
Cleaning of insulation required per JI description of process and yes yes xxxxx
value to be achieved
Shrinkage reqiuired per JI description yes yes xxxxx
Lubrication required per JI description yes yes xxxxx
Metallic sheath
Welded Aluminium Sheath
Construction and procedure description required per JI description yes yes xxxxx
Preparation of cable sheath required per JI description of process and yes yes xxxxx
value to be achieved
Metallic screen continuity
Copper wire screen
Corrugated Seamless Aluminium (CSA)
Plumbing required per JI description yes yes xxxxx
Tig Welding
Lead Sheath required per JI description of process and yes yes xxxxx
value to be achieved
Aluminium Polyethylene Laminate (APL)
Cable Accessory Workmanship on Extruded High Voltage Cables
Oversheath
Preparation of oversheaths required per JI description of process and yes yes xxxxx
value to be achieved
Extruded PVC
Extruded Polyethylene required per JI description of process and yes yes xxxxx
value to be achieved
Low Smoke, Zero Halogen, Enhanced Flame Performance
Sheaths
253
254
ents
Field expansion
Taped Accessories (Joints)
High Voltage tape
High Voltage Heat-resistant tape
Field moulding Extrusion or taped
Heatshrink tube insulation.
Coldshrink tube insulation.
Prefabricated composite type joint
preparation
insert parts
sleeve compression
setting the epoxy unit and slide of premoulded insulator
assemble the spring unit
Prefabricated composite type termination
Polymeric outer protection by taping and/or heatshrink tubes
Filling compounds (joints)
Special features
Sensor connections required for PD per JI description yes yes xxxxx
detection
on system required per JI description of process and yes yes xxxxx
value to be achieved
Fibre optics
Safety re q u i re d g e n e ra l g e n e ra l ye s ye s xxxxx
Signature of Jointer
References
International Electrotechnical Commission IEC 60050 Chapter 461: electric cables
Cigré TB 89 – Accessories for HV Extruded Cables (Chapter 1)
Cigré TB 177 – Accessories for HV cables with extruded insulation (Chapters 1 and 2)
Cigré TB 194 – Construction, Laying and installation techniques for extruded and self contained
fluid filled cable systems
Cigré TB 210 JTF 21/15 – Interfaces in high voltage accessories (Chapter 3)
Association of Edison Illuminating Companies AEIC CG4-97 Guide for installation of extruded
dielectric insulated power cable system rated 69 kV through 138 kV (2nd ed.)
Cigré TB 272 – Large Cross Sections and Composite Screen Design
Cigré TB 379 – Update of service experience of HV Underground and Submarine Cable Systems
Cigré TB 446 – Advanced Design of Metal Laminated Coverings: Recommendations for Tests.
Guide for Use Operational Feed-Back
Contents
6.1 Review of Recent Experience with Failures of Outdoor and Filled Terminations
and Non-buried Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
6.1.1 Review of Literature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
6.1.2 Review the Consequences of Termination Failures for Cables within Substations
and Outside . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
6.1.3 Survey by B1–29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
6.2 The Role of Improved Materials, Design, Assembly and Quality Control in Mitigating
the Effects of Termination and Non-buried Joint Failures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
6.2.1 Survey Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
6.2.2 Design and Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
6.2.3 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
6.2.4 Quality Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
6.3 The Role of Testing and Condition Monitoring in Minimising the Incidence or Severity
of Termination and Non-buried Joint Failures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
6.3.1 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
6.3.2 Condition Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
6.4 Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
6.4.1 Existing Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
6.4.2 New Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
6.5 Conclusions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
Appendix 1: Terms of Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
Appendix 2: Bibliography/References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
IEC Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
CIGRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
Jicable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
E. Bergin (*)
Dublin, Ireland
Executive Summary
This work was motivated by the occurrence of disruptive failures of cable terminations
and the consequential risks. The original scope of the Working Group (WG) was limited
to land XLPE cable systems 110 kV and above. Although priority was given to outdoor
and oil-immersed terminations, joints that are not directly buried were also included.
The Terms of Reference are attached as 6.Appendix 1. Following discussions
within the Working Group on the terms of reference, it was agreed that:
• Bonding and earthing, including SVL failures, were, in the main, not to be included.
• Any relevant learning points from PE cable accessories were to be included,
although polyethylene (PE) cables are no longer installed.
• There should be no time restriction on assets covered by the survey, as the relative
newness of XLPE cable technology would naturally limit the scope.
• The scope was extended to cover voltage ranges from 60 kV and above, as
relevant failures at these voltage levels have also occurred and designs are similar
to those being used at higher voltages.
• Priority was given to outdoor, oil-immersed and GIS terminations, but joints that
are not directly buried were also to be considered.
Those items that needed to be considered and complied with to minimise the
failure rate for terminations and non-buried joints are listed below, following
detailed analysis by WG B1–29.
Type tests in IEC62067 and IEC 60840 focus mainly on the withstand levels of
cables and accessories with respect to a.c. or impulse stresses. They do not supply
much information on the long-term behaviour of components, as the longest voltage
test in these standards is limited to 20 days or 20 cycles of heating and cooling. The
issue of long term tests (typically 1 year) is dealt with in Prequalification Tests in IEC
60840 and is to be carried out if the electrical stresses at the design voltage Uo
exceed 8.0 kV/mm at the conductor screen and 4.0 kV/mm at the insulation screen.
Fluid leakage is a significant cause of termination breakdown and this concern has to
be addressed e.g. through final examination, as in IEC 62067 and 60840 standards,
which states:
“Examination of the cable system with cable and accessories with unaided vision shall
reveal no signs of deterioration (e.g. electrical degradation, moisture ingress, leakage,
corrosion or harmful shrinkage) which could affect the system in service operation.”
Jointer Certification
As the quality of cable preparation and accessory installation plays a significant part
in the reliability of XLPE accessories, it is critical that cable jointers have sufficient
knowledge and training to carry out the task. It is therefore important that jointers are
continually assessed to ensure competence and to maintain a high standard of
workmanship. These training records and an up-to-date CV of previous works can
be requested for review. Jointers should have valid up-to-date certification, as
contained in Cigré TB 476, for the accessory they intend to assemble.
260 E. Bergin
Tools
The minimum required tools are:
Specific tools and consumables shall be specified by the cable and accessory
supplier/s.
Site Testing
It is strongly recommended that an AC voltage test should be carried out on the
insulation of the cable system in accordance with IEC Standards.
Risk Assessment
The continued use of any accessory should be based on:
In case of a failure in service the first step is to verify if the cable systems (cable
and accessories) has been subjected to the tests (development, prequalification, type,
sample, routine), as requested by the relevant IEC standards or Cigré recommenda-
tions. Following that one should investigate manufacture, delivery, installation and
operation to determine the source of the fault.
In the case of new cable systems, utilities should try to adopt designs that either
do not experience disruptive discharge and/or have been tested to ensure the impact
is kept to a minimum.
The Working Group carried out a review of published literature on the subject and
also carried out a survey of the experience of the Working Group members’ and
Study Committee B1 members’.
The first step taken was to review existing literature and determine what was relevant
to the study of accessory failures. It was agreed reviews should be short and take the
following format:
• Cause of defect
• Consequence of the defect
• Corrective steps taken.
6.1.1.2 Statistics
Cigré TB 379 “Update of Service Experience of HV Underground and Submarine
Cable Systems” supplied the statistics in Table 6.1 below regarding XLPE termina-
tions. There is no information in Cigré TB 379 for non-buried joints. The table below
gives an overview of the number of terminations installed on XLPE cables (includ-
ing PE and EPR) in the period 2001–2005. Later statistics are not available in a Cigré
TB, but the WG addressed this in Sect. 6.1.3 below by gathering up-to-date
experience from those 14 countries that responded to the WG survey enquiry.
The table below (Table 6.2) indicates the failure rates over the same time period
(2000 to 2005):
In Table 6.1, for the period 2001–2005, we can see that for the HV cable systems
(60 to 219 kV) the use of outdoor composite insulators is already a commonly used
technology. For EHV (above 219 kV) this technology is only starting. The same
findings are made with regard to the use of dry type GIS terminations.
From Table 6.2 we can see that the failure rate on terminations for EHV cable systems
(above 219 kV) is around 5 times higher than that for the HV cable systems (60–219 kV).
Table 6.3 gives indicates the failure rate per type of termination and is grouped for
the voltage levels 60–219 and 220–600 kV. For a relatively high number of failures
on terminations, the type of the terminations was not specified. As a result, the reader
must be careful when comparing the different types of terminations.
The information as shown in Tables 6.1, 6.2 and 6.3 is based upon replies
received by WG B1–10 to their questionnaire. For further information regarding
these statistics we refer to Cigré TB 379.
6.1.1.3 Workmanship
Cigré TB 476 “Cable Accessory Workmanship on Extruded High Voltage Cables”
was published in October 2011 and is published in this Book as ▶ Chap. 5, “Cable
Accessory Workmanship on Extruded High Voltage Cables”. This Sect. 6.1.1.3 is
substantially reproduced from that Cigré TB and ▶ Chap. 5, “Cable Accessory
Workmanship on Extruded High Voltage Cables”.
Cigré TB 476 covers workmanship associated with the jointing and terminating
of AC land cables, incorporating extruded dielectrics for the voltage range above
30 kV (Um ¼ 36 kV) and up to 500 kV (Um ¼ 550 kV). This brochure is a
complement of Cigré TB 177 (see ▶ Chaps. 1, “Compendium of Accessory Types
Used for AC HV Extruded Cables” and ▶ 2, “A Guide to the Selection of Acces-
sories” of this book). A short chapter covers general risks and skills, but the bulk of
the document focusses on the specific technical risks and the associated skills needed
to mitigate these risks. This is done for each phase of the installation. This Cigré TB
is not an Instruction Manual, but rather gives guidance to the reader on which aspects
need to be carefully considered in evaluating the execution of the work at hand. High
voltage cable accessories are manufactured using high quality materials and very
sophisticated production equipment. Recent technical and technological develop-
ments in the field of their design, manufacturing and testing have made it possible to
have pre-molded joints and stress cones for terminations up to 500 kV, as well as
cold shrink joints up to 400 kV.
6 Guidelines for Maintaining the Integrity of Extruded Cable Accessories 263
Table 6.1 Terminations installed on XLPE cables (including PE and EPR) in the period 2001–
2005
AC ACCESSORIES
VOLTAGE YEAR OF EXTRUDED CABLES (EPR, PE or XLPE)
RANGE INSTALLATION
kV O u td o o r Outdoor Outdoor Outdoor GIS or GIS or
Termination Termination Termination Termination Transformer Transformer
- Dry - - Dry - Termination Termination
- Porcelain - composite Porcelain Composite - Dry
insulator Insulator
60 to 109 2001 531 27 12 75 0 311
2002 753 15 27 69 6 296
2003 513 21 15 96 5 225
2004 483 24 24 186 2 190
2005 600 21 51 138 3 225
110 to 219 2001 267 131 159 32 116 394
2002 282 128 216 35 77 565
2003 546 163 51 83 130 447
2004 226 190 63 32 98 366
2005 187 285 162 41 106 389
220 to 314 2001 135 0 0 0 54 135
2002 63 0 0 0 30 12
2003 102 6 0 0 0 42
2004 66 9 0 0 3 27
2005 60 3 0 12 3 42
315 to 500 2001 12 0 0 0 0 0
2002 0 0 0 0 0 0
2003 0 0 0 0 0 12
2004 0 0 0 36 0 0
2005 28 12 0 0 12 0
>500 2001 0 0 0 0 0 0
2002 0 0 0 0 0 0
2003 0 0 0 0 0 0
2004 0 0 0 0 0 0
2005 0 0 0 0 0 0
Table 6.2 Failure rates of terminations over the period 2000 to 2005
Failure rates based on all replies
Xlpe cables (AC)
A. Failure Rate – Internal Origin Failures 60– 220– ALL
219 kV 500 kV VOLTAGES
Termination Failure rate [fail./yr. 0,006 0,032 0,007
100 comp.]
B. Failure Rate – External Origin Failures 60– 220– ALL
219 kV 500 kV VOLTAGES
Termination Failure rate [fail./yr. 0,005 0,018 0,006
100 comp.]
C. Failure Rate – All Failures 60– 220– ALL
219 kV 500 kV VOLTAGES
Termination Failure rate [fail./yr. 0,011 0,050 0,013
100 comp.]
264
Table 6.3 Failure rates by type of termination over the period 2000 to 2005
220 to Extruded Outdoor Termination - Fluid 1493 5 0,075 0,030 0,045 0,000
500 (XLPE, PE or filled - Porcelain
EPR) Outdoor Termination - Fluid 61 0 0,000 0,000 0,000 0,000
filled - Composite insulator
Outdoor Termination - Dry - 0 0 0,000 0,000 0,000 0,000
Porcelain
Outdoor Termination - Dry - 53 0 0,000 0,000 0,000 0,000
Composite insulator
Outdoor Termination -Type not 0 18
specified
Outdoor Termination -Total 1607 23 0,330 0,215 0,086 0,029
GIS or Transformer Termination 2447 2 0,016 0,016 0,000 0,000
- Fluid filled
GIS or Transformer Termination 637 2 0,071 0,071 0,000 0,000
- Dry
Guidelines for Maintaining the Integrity of Extruded Cable Accessories
265
266 E. Bergin
One of the conclusions of Cigré TB 476 is that internal failure rates of accesso-
ries, particularly on XLPE cable, are higher than other components and are of great
concern due the larger impact of a failure. Therefore the focus on quality control
during jointing operations must be maintained.
Many utilities have adopted the “system approach” by purchasing the cables as
well as the major accessories from the same supplier. Some utilities also request
that the link should be installed by the supplier or by a contractor under the
supplier’s supervision in a “turnkey” fashion. The main advantage of this approach
is that the entire responsibility for the materials and workmanship is clearly the
supplier’s. Some customers have adopted the component approach by purchasing
cables and accessories from different suppliers and entrusting the installation to a
third party. In all cases, it is imperative that the installation be carried out by
qualified jointers, who follow the jointing instructions provided by the accessory
supplier.
International standards such as IEC and IEEE provide the necessary guidelines
concerning the interface between cables and accessories. However, it is strongly
recommended that the responsible engineer should verify the compatibility of the
different components of the link. It is of vital importance to manage the interface
between the cables and the accessories in order to reduce the potential technical risk,
e.g. cables and pre-molded accessories having non-compatible diameters or other
non-compatible dimensions or characteristics.
One of the international trends in cable technology has been the reduction of
the cable insulation thickness and the corresponding increase in electrical stress.
This tendency is based on better knowledge, increased quality of the insulating
material and improvements in the extrusion process. Cables and accessory
components are made under well-defined factory conditions and their quality
and reliability are assured by adherence to well defined specifications. However,
the accessories are assembled on site and, notwithstanding that this job is carried
out by skilled and trained jointers, it is often performed in more delicate and less
controlled conditions than in the factory. This means that correct assembly is
even more important, because, with the increased stress level due to the reduced
insulation thickness, bad workmanship will, sooner or later, lead to a breakdown
of the accessory.
It is noted that the majority of the new HV cable links being considered will use
XLPE insulated cables.
Cigré TB 476 captured the state of the art of jointing and is considered the best
practice internationally. It is acknowledged that other practices, which are not
explicitly covered in this brochure, are not necessarily bad practices. Great care
should be exercised and the approach agreed when departing from practices
recommended in Cigré TB 476.
While Cigré TB 476 does not directly refer to failures or the consequences of
failures, it is a comprehensive document on the assembly of cable accessories. If
used properly it can provide vital advice on the avoidance of failures due to bad
workmanship.
6 Guidelines for Maintaining the Integrity of Extruded Cable Accessories 267
6.1.2.2 Statistics
From Cigré TB 379, average repair times in days for XLPE systems are set out in the
Table 6.4 below. This average repair time was calculated for all the reported failures
on extruded cables for the corresponding voltage levels. No separate values were
calculated for specific types of accessory.
The definition of repair time as used in the questionnaire by B1–10 is the
following:
Repair time is the cumulative period of time required to mobilize resources, locate
and repair the failure. The repair time associated with a failure is of fundamental
importance since the summation of repair times is required to obtain a measure of
non-availability, which from a reliability viewpoint is of greater significance than
fault rate.
6.1.2.3 Workmanship
Cigré TB 476 does not specifically refer to the consequences of failures, except to
indicate the potential damage in the area, the very serious transmission system
consequences with potential safety implications, loss of load, loss of customers,
poor public relations and potential loss of revenue and additional costs.
• 50–109 kV
• 110–219 kV
• 220–314 kV
• 315–500 kV.
• In only a few cases were maintenance test carried out – varying from a serving
test, DC test and thermovision tests
• The pollution design ranged varied from normal to serious
• The causes of failure were listed as:
– Termination Design
• Moisture ingress due to inadequate sealing.
• Pre-molded component breakdown.
• Breakdown of insulating material.
– Manufacture
• Poor adherence of pre-molded components within stress cone
• Rough surface of metallic parts leading to Partial Discharge
• In one case manufacture was identified, but a reason was not given.
• Poor fluid quality leading to internal discharges.
– Workmanship
• Damage to primary insulation during jointing.
• Poor fluid treatment prior to filling.
• Poor XLPE surface preparation.
• Poor preparation of the outer semi-conducting layer.
• Copper particles between cable and stress cone.
• XLPE shavings left in position between cable and stress cone.
• Incorrect application of stress cone.
• Cable not sufficiently straightened prior to jointing.
– Overload
• No cases reported in the returned survey results.
– Overvoltage
• Four cases due to switching/lightning surge.
– Animals
• No cases reported in the returned survey results.
– Weather Effects
• No cases reported in the returned survey results.
– Cable Insulation Inadequacies
• Two cases, no details supplied.
– Bonding Problems
• Thermal runaway due to a metal sheath being solidly bonded during
installation. This was not in accordance with the specified bonding design,
which was based on single point bonding.
• Poor earth connection due to mechanical movement causing flash-over.
– Fluid/Gas Problems
• Partial discharge caused by solidifying silicon oil.
• Multiple failures due to leaks of insulating oil.
– External Damage /Sabotage
• No cases reported in the returned survey results.
– Others
• Failure of pressure relief system, leading to loss of insulating fluid.
• Consequences of Failure – fire, outage time, collateral damage, reputation
270 E. Bergin
– Most cases resulted in a disruptive failure and some collateral damage that
required a lengthy repair outage (Fig. 6.2).
• Actions Taken
– New Design
• Method for earthing of sheath improved
• Change in specifications for pre-molded parts
– New Tests
• No new tests were specified in the returned surveys.
– New Installation Specification
• Improved termination fluid filling and treatment processes
• Changes made to compounds used during jointing and methods for han-
dling compounds
• Suitable hold and witness points introduced during jointing
• New XLPE shaping techniques implemented
• Improvements made to Jointing Instructions
– Risk Management
• On-Line PD tests introduced.
• Exclusion zones set up around termination, including screening walls.
– Repair/Corrective Action
• Changed whole joint/ termination.
• Changed stress cone only. All faults required some form of repair or
corrective action to be taken.
– Preventative Action
• In many cases sealing ends that were leaking insulating fluid were replaced
or repaired before an electrical failure occurred.
– New Design
• In most cases where joint design was identified as the cause of failure, the
joint was redesigned.
– New Tests
• Post-installation PD testing of joints was introduced in many cases.
– New Installation Specification
• Hold and witness points were introduced including photographic records.
• New guidance on joint protection and waterproofing was introduced.
• Clean room conditions introduced to joint bays.
• Improvements were made to jointing instructions.
– Risk Management
• Joints identified as potential failure candidates were replaced with either
joints of a different design from the same manufacturer or joints from a
different manufacturer.
• Inspection, partial discharge testing and X-Raying of all joints installed
from the same manufacturer were carried out.
– Repair/Corrective Action
• In most cases the affected joints were removed, which required the insertion of
a new piece of cable and 2 joints and the joint bay was extended to fit the new
joints
– Other
• A new reinforced racking design was introduced
This section examines how matters may be improved with respect to materials,
design, assembly and quality control in preventing termination and non-buried joint
failures and mitigating their effects. As part of this process, the results of the survey
are reviewed to identify the causes of faults and steps identified that could be taken to
ensure these faults did not occur. It should be noted that some of the measures
identified in the Survey Results Sect. 6.2.1 below may be repeated to some extent in
the Sections 6.2.2, 6.2.3, and 6.2.4 dealing with Materials, Design, etc. This was
done to ensure the Cigré TB is as complete as possible.
It is of considerable importance that the results of the survey in Sect. 6.1.3 are taken
into account and that, where causes were identified, these are acknowledged and
steps are taken to avoid these causes in the future. The causes and recommended
mitigations are listed below:
6 Guidelines for Maintaining the Integrity of Extruded Cable Accessories 273
6.2.1.1 Terminations
6.2.1.1.1 Design
Cause Mitigation
Unsuitable top O ring seal used leading Use appropriate O ring and fit properly
to moisture ingress
Powder separation of chemical mixture. Ensure correct compounds are used and
installed correctly
Earthing conductors slipping off metal Ensure correct installation. Use checklist
sheath in termination by sliding over PE for installation.
sheath.
Circulating current flowing through Ensure the correct bonding design is
insulator screen causing overheating installed
and damage.
Pre-molded insulation degradation at Ensure design suitable for operating
extremely low temperatures temperatures high and low
Damage due to thermal cycling. Design and test for heat conditions.
(Snaking cable before terminating to
minimise conductor expansion into the
termination)
Interface design. Change components or design
Degradation of components in Use appropriate materials and enhance
stress cone. the interface design Consider extended
Prequalification Tests.
GIS copper corona shield with thin Design corona shield materials for use in
layer having whiskers, leading to PD GIS cable termination box. Inspect all
and breakdown. components prior to fitting.
Stress cone interface contaminants Jointer trained on fitting accessory, as
recommended in 6.Appendix 3 Ensure
clean conditions when jointing
6.2.1.1.2 Manufacture
One case was identified but no details were supplied – no additional mitigation
proposed.
6.2.1.1.3 Workmanship
Cause Mitigation
Jointer damaged insulation Follow 6.Appendix 3 Consider use
of inspection test plans (ITP’s)
Poor XLPE surface shaping – copper Follow 6.Appendix 3 Consider use
contaminants between cable and stress cone- of inspection test plans (ITP’s)
contaminants invasion of oil
Shavings of copper contamination during Follow 6.Appendix 3 Consider use
the insertion of pre-molded insulation of inspection test plans (ITP’s)
274 E. Bergin
Poor surface of outer semi conducting layer- Follow 6.Appendix 3 Consider use
defective position of compression device of inspection test plans (ITP’s)
Void generation between epoxy and stress Follow 6.Appendix 3 Consider use
cone of inspection test plans (ITP’s)
Plastic wrap is used for protection during Follow 6.Appendix 3 Consider use
construction. of inspection test plans (ITP’s)
Void generation at cable/ stress cone
interface by overbending of cable and
shaving cable insulation too much.
Generation of crack in epoxy insulator by
stressing it more than it was designed.
Overbending of cable.
Void generation at cable/ stress cone Follow 6.Appendix 3 Consider use
interface by conductor centering error, when of inspection test plans (ITP’s)
conductor sleeves were compressed Wrong
insert position
6.2.1.1.4 Overvoltage
Cause Mitigation
One case due to switching/ Ensure appropriate design and installation of
lightning surge lightning protection, when required.
Cause Mitigation
Lightning Ensure lightning protection used, when needed
Water entry Follow 6.Appendix 3 and use proper O ring and fit
it properly (it could be a design/material problem)
Connection broken, due to Ensure that not overbend
mechanical overload
Jointing with high relative Use of an enclosed air conditioned work
humidity environment Follow 6.Appendix 3
Cause Mitigation
Metal sheath incorrectly bonded on a Ensure bonding design is followed
single core cable, resulting in a sheath Carry out checks during
circulating current that overheated and commissioning
damaged the termination
Bad connections; poor design of wiping Ensure design suitable for operating
gland leading to mechanical movement, temperatures high and low and
sparking and failure installed properly.
6 Guidelines for Maintaining the Integrity of Extruded Cable Accessories 275
Cause Mitigation
Partial discharge Ensure correct fluid is used and that fluid is properly treated
in fluid and tested and that it is at the right level.
Leaking fluid or Check where fluid or gas is leaking from, repair if necessary,
gas and top up.
Replace termination or component causing the leak.
6.2.1.1.8 Others
Cause Mitigation
Unknown – breakdown just Ensure design is suitable for high and low
above stress cone operating temperatures
Contaminants noticed at the Remove
cable stress cone interface Follow 6.Appendix 3
Moving cables after installation Ensure cables do not exceed their
thermomechanical design limits, are properly
clamped and are not physically disturbed
6.2.1.2.1 Design
Cause Mitigation
Stress cone with incorrect Ensure joint is suitable for use on specified cable after
inner diameter cable is prepared
Shape of embedded Ensure design is compatible
electrode not right
Ensure adequate Prequalification and Type Tests are
carried out
Poor tape design Ensure material used has the right properties and
installation instructions. Consider Prequalification
Testing
6.2.1.2.2 Manufacture
Cause Mitigation
Defective manufacture of stress cone Ensure manufacturer’s QC system is
(voids) adequate Consider Prequalification
testing
Poor material quality Ensure manufacturer’s QC system for
materials is adequate Consider
Prequalification testing
276 E. Bergin
6.2.1.2.3 Workmanship
Cause Mitigation
Jointer mistakes causing damage to Follow 6.Appendix 3 Consider use of
insulation and poor insulation shield inspection test plans (ITP’s)
shaping.
Water penetration, metallic
contaminants, wrong inset position.
Poor adhesion of stress cone Follow 6.Appendix 3 Consider use of
inspection test plans (ITP’s)
Metallic contaminants in the Follow 6.Appendix 3 Consider use of
insulation tape. inspection test plans (ITP’s)
Void generation with poor tape shaping.
Contaminants.
External damage by jointing tool, when
connection box was assembled.
Fibrous contaminant in extruded Follow 6.Appendix 3 Consider use of
insulation. Clamping of screen wires inspection test plans (ITP’s)
caused damage of outer semi-conducting
layer
Loose flakes of applied semiconducting Follow 6.Appendix 3 Ensure proper
coatings in joint assembly. procedures followed, adequate drying
time and care in positioning of the
joint body.
6.2.1.2.4 Overvoltage
Cause Mitigation
In only one case was joint damage attributed to Ensure appropriate lightning
possible lightning strike protection is used.
Cause Mitigation
In only two cases was failure Follow 6.Appendix 3 Consider use of
attributed to weather effects, namely inspection test plans (ITP’s). Adequately
water penetration. designed casing (coffin) filled with
waterproof compound.
6 Guidelines for Maintaining the Integrity of Extruded Cable Accessories 277
for vapour) or through the bonding area between flanges and fibre-reinforced plastic
(FRP) tube. Investigations and service experience indicate that the amount of
moisture ingress due to these mechanisms is below the quantities which can pass
through a good sealing system. Quantities can easily be controlled by internal
desiccants as is usual practice for much of the HV apparatus in the electric power
system. In the case of terminations/ sealing ends this is often accomplished by using
filling compounds. Nevertheless research continues in an attempt to better under-
stand these mechanisms and to derive minimum design requirements on composite
hollow core insulators used for HV apparatus applications.
Most damage in composite insulators can be attribute to errors during transport,
un-packing, re-packing, manipulation and storage of the insulators. These aspects
are dealt in detail in Cigré TB 455 “Aspects for the application of Composite
Insulators to High Voltage (72 kV) Apparatus”, Chap. 9, “Handling and Mainte-
nance”. In this chapter, procedures and rules are given for: unpacking, repacking,
storage, handling and cleaning.
A composite termination has the advantages of a simple structure. Its anti-pollution
capacity depends mainly on the number of sheds and their size and orientation. The
terminal must be installed upright, it cannot be installed inclined or curved.
Porcelain and composite terminations are compared in the Table 6.5 below.
It can be seen that each outer housing material has its advantages and disadvan-
tages. The selection of the appropriate termination body depends on the particular
installation conditions.
The satisfactory performance of composite terminations is dependent on the inner
electrodes and the electric field distribution within and along the termination. This, in
turn, depends on the top electrodes, the insulator material, the inner electrodes,
non-linear coatings, cable make-up; etc. All of these components must be designed,
manufactured and installed to control the operating electrical stresses.
One must also bear in mind the effect of insulation retraction on the termination.
Retraction is a result of the mechanical stress formed in the insulation during the
manufacturing process. When the cable is cut, in order to install the accessory, the
insulation may retract on the accessory and lead to a failure. This must be taken into
account in the accessory design (Fig. 6.6).
GIS and oil immersed terminations have similar construction, except for the use
of a larger top corona shield on the termination in order to reduce the top-end stress.
The electrical stress control for GIS and oil immersed terminations follows the
same approach usually employed for outdoor terminations i.e. it uses a premolded
stress relief cone, which is fitted over the cable insulation. The cable is then
282 E. Bergin
accommodated inside a cast epoxy resin bushing which separates the cable from the
pressurised SF6 or the oil in the termination end box.
The space inside the epoxy bushing can be filled with insulating fluid or SF6 gas.
In order to eliminate any risk of leakage of this fluid or gas from inside the epoxy
bushing, a new generation of dry type SF6 and oil immersed terminations have been
developed. In these dry terminations there is no insulating fluid or gas between the
epoxy insulator and the stress cone, because the latter is in intimate contact with the
inner surface of the bushing; the pressure of the stress-cone at the cable core interface
as well as at the inner epoxy insulator surface can be obtained by means of
compression devices such as springs or by special design of the polymeric part.
It should be noted that currently there is a Joint Working Group B1/B3.33
examining the “Feasibility of a common, dry type interface for GIS and Power
cables of 52 kV and above” (2009–2012) and a Cigré TB is to be issued shortly by
this WG by the end of 2013, ▶ Chaps. 7, “Feasibility of a Common, Dry Type Plug-
in Interface for GIS and Power Cables above 52 kV” and ▶ 11, “Standard Design of
a Common, Dry Type Plug-in Interface for GIS and Power Cables up to 145 kV”.
There are also designs that use SF6 gas as the insulation medium, but this solution
has to bear in mind the environmental concerns of using SF6 gas.
6.2.2.4 Connectors
The connector electrically and mechanically joins the conductors of two cables or the
cable and the top connector of a termination. Thus the connector must exhibit good
electrical conductivity to avoid temperatures higher than that of the conductor in any
operating condition and also present sufficiently high mechanical pull-out (tensile)
strength to withstand thermo mechanical stresses during operation. It should be noted
that WG B1.46 is currently working on Conductor Connectors (Mechanical and
Electrical Testing). The final report of WG B1.46 is reproduced in ▶ Chap. 10, “Test
Regimes for HV And EHV Cable Connectors” of this Book. The following types of
connectors are used for extruded cable connections:-
ignited resulting in a short high temperature reaction, causing the flow of molten
metals to form a localised solid connection.
can be used to anchor the two parts together. Plug-in connectors can easily join
conductors of different materials and cross section.
One of the advantages of a plug-in connection is the shorter length of the joint.
286 E. Bergin
into account electrical and mechanical stresses for both sides of the joint and any
interface locations.
Water can seep into a non buried joint, if any earth or bonding wire connections to
the joint are not sealed properly.
6.2.3 Assembly
Joints and terminations are delivered to site as kits, which in turn are made up of
many components It is vital to have quality control on all components. The main
insulation is either the premolded joint body or premolded stress-cone, and the
testing requirements for these are as defined in IEC60840 and IEC62067. The
manufacturer shall demonstrate or guarantee that the components forming the
accessory are the same as those tested to IEC standards.
Each component has a specific function, whether it is secondary insulation, oil,
gas or air tightness, mechanical protection, conductor or sheath connection, etc. It is
288 E. Bergin
essential that the manufacturer has in place quality control plans that define the tests
to be carried out and their frequency and these should be related to the function of the
component. The inspection or testing may include visual, dimensional, mechanical,
dielectric, pressure, whether as an incoming control from sub-suppliers or as final
control as semi-finished products (insulators for example). Components must be
inspected according to drawings and specifications with given tolerances, and there
must be no deviations outside the given tolerances.
Final checking must be done on delivery to site to ensure the right quantity and
quality of materials has been delivered.
Of course the QC aspects with respect to jointing, as set out in Cigré TB 476, must
also be followed. This applies in particular to the certification/ approval for the
jointers and the site conditions.
6.3.1 Testing
6.3.1.1 General
In order to prove that a cable system meets the expectations of the customer the role
of testing at all stages of design, supply and in-service is clearly important for both
the supplier and end-user. In addition, once a cable system is in service, it may be
beneficial to carry out in-service testing to assess the condition of the system and its
components. This section will examine the types of testing and condition monitoring
6 Guidelines for Maintaining the Integrity of Extruded Cable Accessories 289
that may be carried out, when assessing a cable system. This is not intended to be
exhaustive, but to provide guidance on the areas that should be considered. The level
of testing required for a cable system should be decided on by the customer, based on
risk and performance requirements.
International standards for underground cable systems generally provide design
rules and testing procedures to assess a cable system and to ensure it meets the
requirements for reliable operation during its design life. These generally focus on
prevention of failure, rather than actions that can be taken to mitigate the conse-
quences of a fault. Some National Standards or individual utility specifications have
introduced fault simulation testing and specify requirements for the performance of
the system under these conditions e.g. an internal arc test is carried out by some
utilities to evaluate the consequence of an internal fault – there is a requirement for
this within IEC 62271 requirements for switchgear testing.
It should be noted that a cable system incorporates the cable, terminations, joints,
internal terminations and joint components, filling media, connectors, screen con-
nections, bonding etc., and great care must be exercised in testing to ensure that all of
the components are properly represented and identified in testing regimes.
• Fire and disruptive failure performance, including Internal Power Arc test on
terminations in accordance with 6.Appendix 4.
6.3.1.2.1 Insulators
IEC 61462 “Composite hollow insulators –pressurised and unpressurised insulators
for use in electrical equipment with rated voltage greater than 1000 V” specifies both
design and type test requirements for self supporting composite insulators. The tests
in this IEC standard are designed to provide information on material selection,
manufacturing processes, material thickness and adhesion and end fitting material
selection an attachment.
To complete the project of developing a new accessory, construction drawings
shall be prepared of all components and a full size prototype shall be manufactured
and subjected to tests. If the prototype includes specific components such as pre-
molded parts, composite and epoxy resin insulators, it is necessary to develop the
technology to produce these components.
The tests should show the limit in the performance of the accessory and guarantee
a proper safety margin with respect to test values stated in the relevant IEC standard.
Tests carried out must ensure that the entire family of accessories is able to
withstand the stresses, which they may be subjected to in their operational life
(Fig. 6.14).
The termination may be exposed to a saline solution of a different concentration
depending on the level of pollution it will experience. In this condition it is then
subjected to an AC voltage test. For composite insulators with a polymeric coating,
which are subject to aging of the surface, the pollution test is performed after an
aging of 1000 hours in saline fog or an electrical cycle-environmental of 5000 hours
(see IEC 62 217).
6.3.1.2.2 Connectors
Development testing may also be done for connectors. Thermal cycles are performed
on connectors and contacts used in the accessories following the standards of IEC
61238–1, currently restricted to medium voltage. During the test, measurements of
temperature and electric resistance as a function of time are taken. Short circuit
current tests are also performed on the connectors, Testing of connectors is the topic
of TB 758 which is reproduced in ▶ Chap. 10 “Test Regimes for HV and EHV Cable
Connectors” of this book.
• A low energy external fault. In this case the fault current passes though the
conductor. The fault is external to the accessory.
• A high energy internal fault. In this case the fault is the result of component failure
or arcing inside the accessory.
• AC electrical strength
• Dielectric dissipation factor
• Fourier transform infrared spectroscopy (FTIR)
• Thermal gravimetric analysis (TGA).
As indicated in Cigré TB 420 Generic Guidelines for Life Time Condition Assess-
ment of HV Assets and Related Knowledge Rules, it is recommended that a good
database of information is established for each piece of equipment as it ages. Useful
information on the aging process during the full service life includes loading,
maintenance test results, fault history, general ambient and environmental conditions
and details of any site incidents.
6 Guidelines for Maintaining the Integrity of Extruded Cable Accessories 295
Fig. 6.17 On site Commissioning Test (in this set up three mobile tests sets needed simultaneously,
because of cable length)
methodology is to gather the outputs from this process into a management strategy
which can be used for:
• Preventative maintenance,
• Decisions on equipment change-out
• Improvement in the specification, design or manufacture of new equipment.
6.4 Recommendations
The aim of the WG has been to produce a Cigré TB that could be used by designers,
manufacturers, contractors and utilities to increase the integrity of terminations and
non-buried joints. Many approaches to this subject are possible, depending on the
factors outlined in Sect. 6.3.2 above. Two cases need to be considered:
6 Guidelines for Maintaining the Integrity of Extruded Cable Accessories 297
6.5 Conclusions
The following conclusions resulted from the work carried out by this working group:
• The survey completed by this WG has shown that disruptive discharge has been
experienced in terminations and non-buried joints.
• Utilities are concerned about these discharges.
• In the case of installing new cable systems, utilities should try to adopt designs
that either do not experience disruptive discharge and/or that have been tested to
ensure the impact is kept to a minimum.
• Full quality control procedures should be employed during the manufacture,
delivery, storage and the installation process.
• Jointers should be fully certified, have experience of the accessory to be installed
and their work should be checked/monitored/ inspected.
• All materials and jointing tools used should be appropriate for the work, be in
good condition, have been correctly stored and be within their expiry dates.
• The site conditions should be suitable with respect to space, safety, dust, pollu-
tion, humidity and temperature.
• On-site testing at an elevated voltage level, as prescribed in the IEC standards, is
strongly recommended during commissioning.
• A risk analysis should be done to determine the corrective actions required for
existing accessories, which have experienced disruptive discharge or it is
suspected they may do so in the future. This can vary from leaving the accessory
in service to partial or full replacement. Whether it is decided to go for full or
partial replacement, steps 3 to 8 above should be followed.
• If it is decided to do condition monitoring on existing or new circuits, then the
following items need to be considered
– The importance of the circuit
– The history of the circuit and its accessories
– The potential repair time
– The potential cost of the outage
– Potential cost of the damage
– Effect on reputation
– Potential damage from the failure
– Effectiveness of the monitoring system adopted
– Availability of monitoring tools and trained personnel
– Cost of monitoring
6 Guidelines for Maintaining the Integrity of Extruded Cable Accessories 299
Background:
The work is motivated by the occurrence of disruptive failures of cable end terminations, with consequent risks for personal
and material loss and damage.
Terms of Reference:
The scope shall be limited to land XLPE cable systems at 110 kV and above. Priority shall be given to outdoor and oil-im-
mersed terminations, but also joints (that are not directly buried) shall be considered.
The work shall concentrate on recent incidents, but near misses shall also be included in the analysis.
The WG shall:
Review recent experience with failures of outdoor a
Review the consequences of termination failures for cables within substations and outside.
Examine the role of design, assembly and quality co res
Examine the role of testing (development, type, routine & after-laying) and condition monitoring in minimising the incidence
or severity of termination failures
At the SC B1 meeting in 2010, the WG shall provide recommendations on possible extensions of work into joints (not directly
Deliverables:
An Executive Summary article for Electra
A full report to be published as a TB
A Tutorial
WG members from: AU, BE, BR, CA, FR, DE, IN, IT, JP, KR, NL, NO, ES, CH, UK, US
Appendix 2: Bibliography/References
IEC Standards
IEC 60840 Ed 3 Power cables with extruded insulation and their accessories for rated
voltages above 30 kV (Um ¼ 36 kV) up to 150 kV (Um ¼ 170 kV) –Test
methods and requirements
300 E. Bergin
IEC 62067 Ed 2 Power cables with extruded insulation and their accessories for rated
voltages above 150 kV (Um ¼ 170 kV) up to 500 kV (Um ¼ 550 kV) – Test
methods and requirements
IEC 62217 Ed. 1: Polymeric insulators for indoor and outdoor use with a nominal voltage
greater than 1 000 V – General definitions, test methods and acceptance criteria.
IEC 61462 Ed. 1.0: Composite insulators – Hollow pressurized and unpressurized
insulators for use in electrical equipment with rated voltage greater than 1000 V –
Definitions, test methods, acceptance criteria and design recommendations
IEC 62271:High voltage switchgear and control gear – Part 209: Cable connections for
gas-insulated metal-enclosed switchgear for rated voltages above 52 kV – Fluid-
filled and extruded insulation cables – Fluid-filled and dry-type cable-terminations
IEC 61039: General Classification of insulating liquids
IEC 60815–1 TS Ed. 1.0: Selection and dimensioning of high-voltage insulators for
polluted conditions – Part 1: Definitions, information and general principles
IEC 60836 Ed 2.0 b 2005 Specification for unused silicon insulating liquids for
electrotechnical purposes.
IEC 61109 Ed 2 Insulators for overhead lines – Composite suspension and tension
insulators for AC. systems with a nominal voltage greater than 1 000 V –
Definitions, test methods and acceptance criteria
CIGRE
Jicable
Jicable 2011 paper A.3.7 “Return of Experience of 380 kV Power Cable Failures”
from Sander MEIJER (TenneT TSO), Johan SMIT, Xiaolin CHEN (Delft Uni-
versity of Technology), Wilfried FISCHER (50 Hertz Transmission GmbH),
Luigi COLLA (Terna S.p.A.)
Jicable 2011 paper A.5.4 “Remedial action and further quality assuring measures
after a failure in a 400 kV GIS cable termination” from Frank JAKOB, Frank
KOWALOWSKI, Claus KUHN, Wilfried FISCHER (50 Hertz Transmission
GmbH), Sigurdur A. HANSEN (Südkabel GmbH)
Jicable 2011 paper A.5.3 “Dry terminations for high voltage cable systems” from
Pascal STREIT (NEXANS)
Jicable 2003 paper A.6.2 “Anti-explosion protection for HV porcelain and compos-
ite terminations” from Gahungu, Cardinaels, Streit, Rollier (Nexans)
Jicable 2003 paper A.6.4 “New dry outdoor terminations for HV extruded cables”
from DEJEAN (PIRELLI France), QUAGGIA, PARMIGIANI (PIRELLI Italy),
GOEHLICH (Technical University of Berlin);.
Jicable 1999 paper A.5.4 “Development of synthetic and composite terminations for
HV and EHV extruded cables” (LE PURIANS from EDF R&D and JUNG from
EDF CNIR – RTE
Jicable 1995 paper A.3.2 “Composite EHV terminations for extruded cables”
(ARGAUT, LUTON from SILEC and JOULIE, PARRAUD from SEDIVER.
302 E. Bergin
TB 476 Cable Accessory Workmanship on Extruded High Voltage Cables Oct 2011
Table of Contents
1 Summary 4
2 Introduction 4
3 Scope 6
3.1 Inclusions 6
3.2 Exclusions 6
4 Related Literature and Terminology 6
5 General risks and skills 8
6 Technical risks and required specific skills 10
6.1 Conductors 10
6.1.1 Conductor preparation 10
6.1.2 Compression 11
6.1.3 MIG/TIG Welding 12
6.1.4 Thermit Weld 12
6.1.5 Mechanical Connection 13
6.2 Insulation Preparation 15
6.2.1 Straightening 15
6.2.2 Stripping of insulation screen 16
6.2.3 Preparing the end of the insulation screen 18
6.2.4 Smoothening the insulation surface 19
6.2.5 Cleaning of insulation 20
6.2.6 Shrinkage 21
6.2.7 Lubrication 21
6.3 Metallic sheath 22
6.3.1 Welded Aluminium Sheath (WAS) 22
6.3.2 Corrugated Sheaths: Aluminium (CAS); Copper (CCS); Stainless Steel 25
(CSS)
6.3.3 Lead Sheath 28
6.3.4 Laminated sheaths: Aluminium Polyethylene Laminate (APL); Copper 30
Polyethylene Laminate (CPL)
6.4 Oversheath 32
6.4.1 Case of graphite coating 32
6.4.2 Case of extruded and bonded semiconducting layer 32
6.4.3 Low Smoke, Zero Halogen, Enhanced Flame Performance Sheaths 32
6.5 Installation of joint electric field control components 33
6.5.1 Slip on prefabricated joint 34
6.5.2 Expansion joints 37
6.5.3 Field Taped Joints 40
6.5.4 Field Molded Joints (Extruded or taped) 41
6.5.5 Heatshrink sleeve joint 41
6.5.6 Prefabricated composite type joint 42
6.5.7 Plug-in joint 43
6.5.8 Pre-molded three piece joint 44
6.6 Installation of termination electric field control components 45
6.6.1 Slip-on prefabricated field control components 45
6.6.2 Plug-in terminations 45
6.6.3 Taped Terminations 47
6 Guidelines for Maintaining the Integrity of Extruded Cable Accessories 303
The possibility of two types of fault has to be considered – a fault external to the
accessory and a fault inside the accessory. Both faults will have very different
impacts on the accessory. The external fault may cause rapid heating of the conduc-
tor and result in a build up of pressure, if there is fluid or gas present in the accessory.
The internal fault results in fault current flowing through the insulation of the
accessory with high energy being dissipated in the insulation and filling medium
and this may cause large thermo-mechanical and pressure changes inside the
accessory.
In the case of a system fault in another part of the electrical system external to the
accessory, the fault current passes through the conductor of the termination or joint.
Testing for such a case is carried out on terminations, joints (buried and
non-buried) installed as in service. The test installation shall be in accordance the
requirements of the specification and rules of each System Operator. This test should
be performed on terminations and joints connected by the specified cables, which
have either already gone through a type test or have gone through at least ten thermal
cycles.
The aim is to study the effects of a simulated external fault on the accessories,
including a check that pressure relief devices in terminations do not break during an
external short-circuit.
Requirements
On completion of the test, the pressure relief shall be observed to have operated
correctly. The whole test shall be recorded and filmed with a high-speed camera
6 Guidelines for Maintaining the Integrity of Extruded Cable Accessories 307
(at least 1000 images per second) in order to witness and analyse the behaviour and
reaction of the termination and fixing installation devices.
An internal fault is initiated by drilling a hole in the main insulation of the cable
within the termination or joint. A 1.5 mm2 copper wire shall connect the conductor to
the metallic screen/sheath or to a metallic piece itself connected to the screen/sheath.
Requirements
On completion of the test, no solid debris shall be observed at a distance of more than
3 metres from the termination or joint. The whole test shall be recorded and filmed
with a high-speed camera (at least 1000 images per second) in order to witness and
analyse the behaviour and reaction of the termination or joint and fixing installation
devices.
308 E. Bergin
contamination
of internal
insulation fluid
and/or gas due
to aging or
309
(continued)
Short Circuit Levels at Different Operating Voltages (continued)
310
movement of
cable, cable
clamping,
tracking marks
on outdoor
insulators,
ferrule
retraction,
leakages,
corrosion,
animal attack,
vandalism.
7 Visual Terminations, As with Item On- w U 5 yearly s + ++ CIGRÉ TB
inspection non buried 6 above plus line 279, Table 6.4,
with IR on joints detecting item 8
current possible
carrying hotspots on
components top-connector
and earthing
circuit
8 Leakage Terminations Insulator On- w L Depending s +++ ++ CIGRÉ TB
Guidelines for Maintaining the Integrity of Extruded Cable Accessories
(continued)
312
Link
arrangement
16 Voltage test on Earthing and Failure of SVL Off- W L Depending S + + CIGRÉ TB
SVL cross bonding to operate at line on service 279, Table 6.4,
boxes. rated voltage experience item 10
313
(usually
(continued)
Short Circuit Levels at Different Operating Voltages (continued)
314
Pierre Mirebeau
Contents
7.1 Introduction and Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319
7.1.1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320
7.2 Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
7.2.1 General Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
7.2.2 Definitions and Terms (According to IEC 62271-209) . . . . . . . . . . . . . . . . . . . . . . . . . . 321
7.2.3 Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
7.3 Experience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
7.3.1 GIS Cable Terminations Installation Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
7.3.2 Experience of Dry Type Insulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
7.4 Design of Dry Type GIS Terminations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334
7.4.1 Differences in Design of Barrier Insulator, Inner Cone Type . . . . . . . . . . . . . . . . . . . . 335
7.4.2 Differences in Design of Barrier Insulator, Outer Cone Type . . . . . . . . . . . . . . . . . . . 335
7.4.3 Requirements for Standardization of a Common Interface . . . . . . . . . . . . . . . . . . . . . . 336
7.5 Where the Plug-in Concept Could Be Applicable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339
7.5.1 Geometrical Installation Constraints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339
7.5.2 Safety Practices and Constraints during Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350
7.5.3 Testing Constraints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351
7.5.4 Conclusion Regarding Testing Constraints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353
7.6 Qualification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354
7.6.1 State of the Art . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354
7.6.2 Where the Plug-in Common Interface Could be Applicable . . . . . . . . . . . . . . . . . . . . 362
7.6.3 Qualification of new Insulator or Stress Cone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362
7.7 Feasibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362
7.7.1 Definition Feasibility (Cost Involved) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362
7.7.2 Qualification Feasibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
7.8 Market Acceptance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364
7.8.1 Current Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364
P. Mirebeau (*)
Villebon sur Yvette, France
e-mail: Pierre.mirebeau@sfr.fr
Abstract
Since 1986 the connection between GIS substations and cables has been managed
by a dimensional standard establishing electrical and mechanical interchange-
ability between cable terminations and gas insulated metal enclosed switchgear.
Within this framework termination suppliers design their own components:
insulator, stress cone (for the two available options inner cone and outer cone) and
the connection inside the termination.
The responsibility limit between the switchgear manufacturer and the cable
termination manufacturer is at the interface SF6/insulator.
Considering the large number of substations and planning difficulties due to
the fact that the cable system is not usually defined at the time of switchgear
manufacture, a joint working group has been set up by Cigré within committees
B1 and B3. The group has to investigate the possibility of a standardised common
interface insulator for the dry type and plug-in cable termination, which could be
supplied independently from the remaining termination components.
Starting from review of GIS cable termination designs and actual installation
practices for all voltage levels, the joint working group has studied:
Taking into account all the above, as per the TOR of the group, WG B1-B3.33
advises Study Committees B1 and B3 to set up a new working group with the
following Terms of Reference.
The Working group should recommend a functional design of an insulator
with a common interface with the following scope of work:
• Voltage is 145 kV AC
• Current is 1000A, short circuit 40 kA 1 sec
• Cross sections are 1000 mm2 Cu or 1600 mm2 Al
7 Feasibility of a Common, Dry Type Plug-in Interface for GIS and Power. . . 319
The stress cone design and material, the lubricant and the design of the compression
device should be left to the discretion of the accessory manufacturer within the limits
of the standardised cable terminations properties.
Cigré TB 303 and the work of WG B1.44 and WG B1.46 should be taken into
account.
The interface between High Voltage cable and switchgear is defined by IEC
62271-209.
In particular IEC 62271-209 defines two types of dry-type cable connections for
gas insulated switchgear above 52 kV. The limit of supply of the cable termination
manufacturer is the insulator. Type A connection incorporates elastomeric electrical
stress control component inside the insulating barrier. For type B, the elastomeric
electrical stress control component is located externally. IEC 62271-209 covers
specifically the connection assembly with a separating insulating barrier between
the cable insulation and the gas of the switchgear, which is the case of dry termina-
tions. It does not address specifically the plug in issues.
Regarding Medium Voltage, EN 50181 Standard was published in 1997
describing “Plug-in type bushings above 1 kV up to 36 kV for equipment other
than liquid filled transformers” This document gave full details of bushings
which were fitted to power equipment (such as switchgear) to make a cable
connection to the equipment. The insulator could be customized to suit the design
of the equipment on that side, but was required to have standardized dimensions
on the cable side, such that a “separable connector” (plug in cable/stress cone
assembly as per the definitions of chapter 2.1) could be plugged in on the cable
side. The separable connector could then be supplied by one of several possible
suppliers.
The current version of EN 50181 was published in 2010. In this version the upper
limit of the applicable voltage range was raised to 52 kV.
320 P. Mirebeau
With the above background interest has been raised to extend the principle of a
common insulator interface to higher voltages with the potential benefits that cable
connections from different manufacturers would be interchangeable in a single insulator.
Investigation of this proposal was undertaken within Cigré, by forming a joint
working group (JWG) between Study Committees B1 (cables) and B3 (switchgear).
The working group JWG B1-B3.33 was formed and has produced the current
document.
7.1.1 Scope
The scope of the work of JWG B1-B3.33 is to consider the feasibility of a common
dry-type interface for GIS connections for AC extruded cable systems for voltages
above 52 kV, considering the following aspects:
• Examine the conditions around the switchgear and installation issues, including
the supporting system (also called site issues)
• Consider the impact of large cross sections
• Consider safety prectices during works
• Consider the testing procedures for GIS/Terminations and cables at the factory
and on site (overlapping or missing items).
• Propose measures to reduce the potential consequences of the GIS insulation
failure.
• Propose measures to reduce the potential consequences of the cable termination
insulation failure1
• Review the existing standards addressing the qualifications and extension of
qualification procedures applicable to GIS terminations.
• Define the relevant qualification procedures needed if any.
• Identify the limit of suppliers’ responsibility.
• Estimate the overall technical and practical feasibility of the common design
definition and qualification, insulator manufacturers' qualification and the cable
manufacturers' qualification and the cost involved.
• Once the feasibility window has been determined, survey the market (manufac-
turers and end users)
• Recommend or not to go to a second step with the launching of a new WG B1-B3.
XX to go in detail into the design of the standard components (shape, dimensions,
properties, . . .).
1
A WG “B1.29 Guidelines for maintaining the integrity of XLPE cable accessories” was decided in
2009. The group considered that this question is in B1-29 scope and is not to be addressed here.
Report from B1.29 is TB 560 published in December 2013 and published as ▶ Chap. 6, “Guidelines
for Maintaining the Integrity of Extruded Cable Accessories” of this Book.
7 Feasibility of a Common, Dry Type Plug-in Interface for GIS and Power. . . 321
7.2 Definitions
The general layout of the dry type GIS cable terminations as described in IEC 62271-
209 is shown Figs. 7.1 and 7.2.
The definitions and terms of the different components of the dry type GIS cable
terminations as described in IEC 62271-209 are shown Figs. 7.2, 7.3, and 7.4.
Fig. 7.1 General layout of dry GIS termination (in ref to IEC 62271-209)
322 P. Mirebeau
Fig. 7.2 Dry-type cable connection assembly – Typical arrangement (IEC 62271-209)
Insulator assembly
Insulator
Cable connection enclosure
Cable/stress cone
assembly Stress cone
Cable gland
Cable
Fig. 7.3 Identification of the different parts of GIS termination, inner cone type design
7 Feasibility of a Common, Dry Type Plug-in Interface for GIS and Power. . . 323
Connection interface
Insulator
Stress cone
Cable/stress cone
assembly
Cable gland
Cable
Fig. 7.4 Identification of the different parts of GIS termination, outer cone type design
7.2.2.4 Insulator
Separates insulating fluid (SF6) of GIS enclosure from the cable/stress cone
assembly.
7.2.3 Units
7.2.3.1 Pressure
All pressure values in this document are given in bar as relative pressure.
U0 ¼ the rated r.m.s. power-frequency voltage between each conductor and screen or
sheath for which cables and accessories are designed
U ¼ the rated r.m.s. power-frequency voltage between any two conductors for which
cables and accessories are designed
Um ¼ the maximum r.m.s. power-frequency voltage between any two conductors for
which cables and accessories are designed. It is the highest voltage that can be
sustained under normal operating conditions at any time and at any point in a
system. It excludes temporary voltage variations due to fault conditions and the
sudden disconnection of large loads.
Unless specified differently all voltages mentioned in this brochure are considering
Um values.
7.3 Experience
The following pictures show some examples of installation. They include all kinds
of GIS terminations.
5000
implementation design)
EL. 1523.50
33090
44590
30°
4750
4750
EL. 1522.10
FEEDER 1 FEEDER 2
REACTOR 1 REACTOR 2
Fig. 7.11 245 kV vertical indoor installation, 1400 mm2 (not plug-in)
Fig. 7.14 145 kV horizontal installation 500 mm2 plug-in (compact GIS)
Fig. 7.15 Installation works Plug-in of cable into dry type GIS termination (outer cone model)
• 630 mm2 and 800 mm2 in one city (dimensions fixed as per KG4023
specification),
• 640 mm2 to 1000 mm2 in another city.
7 Feasibility of a Common, Dry Type Plug-in Interface for GIS and Power. . . 333
Cross section/mm2
2500
2010 2008
2000 2004
2000 2002
1000
1996
800
1998
Fig. 7.17 Year of introduction of dry type GIS termination as a function of voltage and cable cross
section in Germany
The electric stress was (and still remains) conservative: 17 mm insulation wall
thickness gives stresses lower than currently used similar cables.
Development History
The goal was to ease the planning of the interface components between the GIS and
cable suppliers though the specification of a standard connection.
Cable manufacturer (A) was giving the insulator to the GIS manufacturer.
Then the cable/stress cone assembly was plugged in on site
As there were only standard cable types (including standard dimensions) the
utility went further to the full standardized termination (insulator and stress cone).
The utility qualified a second cable termination manufacturer (B) for the same
insulator dimensions.
Then a long term test was performed with:
• 4 GIS manufacturers
• 2 cable termination manufacturers (A and B)
334 P. Mirebeau
Cable and GIS manufacturers had met together in the early 80’s to write a technical
specification which establishes electrical and mechanical interchangeability between
cable-terminations and the gas-insulated metal-enclosed switchgear and determines
the limits of supply. This resulted in 1986 in the first edition of the Technical
Specification IEC 859. Now updated and transformed in international standard
IEC 62271-209.
In the frame of this technical specification, each manufacturer developed, with its
own technology and solution, products that comply with the interchangeability
requirements, for the specified inner and outer cone types.
7 Feasibility of a Common, Dry Type Plug-in Interface for GIS and Power. . . 335
All barrier insulators comply with the dimensions and requirements of IEC 62271-
209, however there are differences in the connection part, the plug in connector, the
high voltage screen, the insulator material, geometry, finish and the shield break
design which are represented in Fig. 7.18.
Similar to the inner cone design, all barriers insulators comply with the dimensions
and requirements of IEC 62271-209, however there are differences in the connection
part, the plug in connector, the high voltage screen, the insulator material, geometry,
finish and the shield break design which are represented in Fig. 7.19.
This paragraph deals with the requirements that are to be set in addition to current
standards; they are not intended to replace them.
A common interface implies a common inner surface of the insulator.
If a full interchangeability has to be provided, the connector shielding has to be
common as well because the radius at the bottom of the electrode and the distance to
the interface affects the field distribution at the rubber body interface. As a conse-
quence the minimum epoxy thickness is defined.
To comply with IEC 62271-209, each voltage class requires a specific insulator
(voltage classes are 72.5 to 100 kV, 123 to 170 kV, 245 to 300 kV, and 362 to
550 kV).
For a given voltage class, depending on the cable termination design several
insulator sizes might be needed to cover all cross sections.
7 Feasibility of a Common, Dry Type Plug-in Interface for GIS and Power. . . 337
7.4.3.1 Insulator
For the standardisation of each insulator, the following requirements should be
defined.
The voltage requirements of the insulation shield break are the same as the ones of
the sheath sectionalising insulation of joints in IEC 60840 and IEC 62067 appendix
G. Paragraph G4.3. G.4.3.1 gives the DC voltage level and G.4.3.2 gives the
lightning impulse voltage level in table G.1 column “each part to earth/bonding
leads 3 m”.
• Other standards and specifications may specify higher requirements.
• Resistance to SF6 by-products, if applicable.
Connection and other parts of the termination should be in the supply scope of the
stress cone manufacturer, because they depend strongly on the cable conductor and
screen design.
Solution 1a
• GIS metal enclosure can be factory tested
• Requires a temporary protection around the cable/stress cone assembly (mechan-
ical protection, moisture protection, etc., always required unless metal enclosure
is installed immediately after termination assembly)
• Requires free space above metal enclosure (could require a higher ceiling)
• For safety reasons, reduced pressure inside GIS adjacent gas compartment during
cable termination installation work.
• Needs both installers for final assembly (both of them have major work to do)
• Cable termination enclosure must be disassembled on site.
• Gas operation must be performed prior and after assembly.
340 P. Mirebeau
Solution 1b
• GIS metal enclosure cannot be factory or site tested with the insulator
• Could require a temporary protection around the cable termination (mechanical
protection, moisture protection, . . ., depending of environmental conditions,
stand-by duration and risk of impact during handling)
• Requires free space above metal enclosure (could require a higher ceiling)
• For safety reasons, reduced pressure inside GIS adjacent gas compartment during
cable termination installation work.
7 Feasibility of a Common, Dry Type Plug-in Interface for GIS and Power. . . 341
• Needs both installers for final assembly (cable termination installer has minor
work, which would be to remove eventual protection, adjust cable termination
height, install SVLs)
• Gas operation must be performed after assembly.
Solution 2a
• GIS connection parts could be installed prior cable termination.
• GIS metal enclosure can be factory tested (high voltage + gas tightness test)
including insulator assembly.
• Could require more space under metal enclosure (cable bending for termination
installation)
• For safety reasons, reduced pressure inside metal enclosure during termination
plug-in.
• Does not need both installers at the same time (but GIS installer or customer
would have to come after termination installation to fill the metal enclosure at
rated pressure).
Solution 2b
• GIS metal enclosure cannot be factory or site tested with the insulator
• Could require more space under metal enclosure (cable bending for termination
installation)
• For safety reasons, reduced pressure inside GIS adjacent gas compartment during
cable termination installation work.
• Needs both installers for final assembly
342 P. Mirebeau
All these solutions are presented as vertical installation, but they are also appli-
cable for horizontal installation. In such case only civil work types will be different,
but space constraints will remain the same.
Solution 1a, is not fully satisfactory for the GIS manufacturer as the GIS has to be
opened during installation
Solutions 1b and 2b are not in the scope of the present brochure as they don’t
consider a common interface.
Solutions 1.a and 1.b give much less civil work constraints as the cable termination
can be realised in final position and in such case no room is necessary to move the
cable. As a disadvantage if no free space is available there is no possibility to have
some cable overlength for eventual repair or rerouting of the link in the
switchgear.
height) + the straight length of cable under the termination (at least 1 m where cable
clamps will be installed) + the minimum cable bending radius (20 D) see note2.
Often, it will be worth considering the largest cable size for the minimum
permanent bending radius, as a utility could need to upgrade its substation or install
additional GIS modules with larger cables.
Here is an example (Fig. 7.21):
termination height
straight cable legth
H min (project)
H min (optimal)
D
20
0
10
D=
012
D=
420
2
Installation cable radius based on cable manufacturers recommendation (Nexans catalogue, ERA
technology report) for aluminium or lead sheath
344 P. Mirebeau
7.5.1.2.2 Free Space for Cable Snaking Necessary for Plug-in Operation
Horizontal Cable Snaking – Vertical Plug-in
This drawing shows that in order to allow termination insertion, it is necessary to
have a minimum length available for cable bending (usually horizontal or vertical)
(Fig. 7.23).
Vertical Cable Snaking – Vertical Plug-in
When the cable is laid in ducts the plug-in operation can be applied when the
distance between the base plate and the duct is large enough to make a vertical
snaking (Fig. 7.24).
7 Feasibility of a Common, Dry Type Plug-in Interface for GIS and Power. . . 345
• D: cable diameter
• H bas.: minimum basement height ¼ 20D + D (practically 2 m minimum)
• L bas.: minimum free cable length in basement according to H bas. allowing a
maximum vertical snaking
• Ls: available length due to cable snaking.
The summary Table 7.1 (rounded values), is based on typical cables with an
aluminium foil screen bonded to the outer sheath:
346 P. Mirebeau
Closed ferrous magnetic loops should not be introduced around the single phase
power cables by items such as external steelwork, and concrete reinforcement.
Size of Floor Hole (in Line with the Termination)
When the cable termination can be prepared on the intermediate floor, there is no
additional requirement due to the plug-in concept.
When the cable termination has to be prepared on the lower floor, a larger hole is
needed, depending of the type of termination (3-phase – single phase), and the SVL
position,
For a single phase termination, the hole has to be at least equal to external
diameter of the base of the epoxy insulator + extra space depending on the SVL
position, size and rated voltage (voltage clearance).
Figures 7.28 and 7.29 show an example of floor hole size study for a 72/100 kV
3-phase GIS metal enclosure, with a distance of 150 mm between bottom of metal
enclosure and intermediate floor.
The use of 15 kV SVL requires specific arrangement (SVL are in green).
The two dimensions vertical distance of the bottom of the metal enclosure and
diameter of the floor hole are somehow linked. Whenever the vertical distance gets
narrow (e.g. below 500 mm) the size of the floor hole should be increased in order to
facilitate the mechanical installation and construction during insertion of the cable/
stress cone assembly from below. This leads to additional constraints on the metal
enclosure metallic support structure design.
7 Feasibility of a Common, Dry Type Plug-in Interface for GIS and Power. . . 349
Table 7.3
Type of installation a Type of installation b
Case Strong coordination between Always possible.
1 cable termination and GIS Reduced civil works
installers. Need for coordination
Necessity to disassemble the between cable termination
Cable termination enclosure. and GIS installers.
Increased probability to damage Not plug-in procedure.
the stress cone.
Reduced civil works
No advantage for further No advantage for further
standardization of the insulator standardization of the
insulator
Case Possible with restrictions: Possible with restrictions:
2 Align stress cone and insulator Available space for moving
axis during insertion the cable
Available space for moving the Necessary strength for lifting
cable Necessary strength for the cable.
lifting the cable Not plug-in procedure.
Same civil works as 2a
Further standardization of the No advantage for further
insulator can be evaluated standardization of the
insulator
Table 7.4
Cable type / Uo
63kV 110kV 220 kV 220 kV 500 kV
D (mm) 65 80 100 120 150
Weight (kg/m) 4.5 9.6 17 23 40
H bas. (m) (at least 2 m) 2.00 2.00 2.10 2.52 3.15
L bas. (m) 6.45 7.60 9.1 10.9 13.6
Ls (m) 1.77 1.53 1.43 1.71 2.14
Weight of cable to move (kg) 43 100 190 310 680
*depending *depending
Comments
on site on site
with
- D: cable diameter
- H bas.: minimum basement height = 20D + D (practically 2 m minimum)
- L bas.: minimum free cable length in basement according to H bas. allowing a maximum vertical snaking
- Ls: available length due to cable snaking
nge letters, almost impossible red letters.
These recommendations are specific to GIS plug in cable terminations and come in
addition to normal practices in the electric civil works environment
7 Feasibility of a Common, Dry Type Plug-in Interface for GIS and Power. . . 351
7.5.2.1 Voltage
• DISCONNECT THE VOLTAGE! Two open gaps are needed, for instance circuit
breaker and line disconnector
• Earth the part between the circuit breaker and the outgoing disconnector switch
with the earthing switch.
• Voltage test and PD measurement test according to paragraph 7.1.101 & 7.1.102 of
IEC 62271-203, the pressure being the minimum functional pressure for insulation
as per IEC 62271_209 Fig. 1, with the deviation range of paragraph 8.2.1,
• Tightness test according to paragraph 7.4 of IEC 62271-203,
• Design and visual checks according to Fig. 5 of IEC 62271-209,
• Pressure test according to paragraph 7.104 of IEC 62271-203.
GIS
Without installed cable, test is according to IEC 62271-203 or ANSI C 37.122-2010.
The common interface insulator causes no special issue except the test of the
insulator, which is already prescribed in IEC 62271-209 paragraph 8.1 when it is
pre-installed during GIS manufacturing.
Cable
The cable system shall be tested after installation according to paragraph 8.3 of IEC
62271-209.
When the termination is not plug-in type, it is fitted inside the GIS enclosure.
Different testing arrangements can be implemented:
• A SF6 to air bushing has to be temporarily installed on the GIS after a discon-
nected area. See Fig. 7.30.
• A termination is available at the other end (outdoor termination or SF6/air
bushing). This is used to test the cable without emptying the cable box. If the
GIS busbar is not disconnected, there may be impact on the GIS enclosure in case
of termination failure.
• The GIS has a SF6/air bushing. It can be used for cable after installation test (for
cases above 245 kV – below 245 kV there is usually no bushing as part of the
7 Feasibility of a Common, Dry Type Plug-in Interface for GIS and Power. . . 353
GIS) without emptying the cable box. If the GIS busbar is not disconnected, there
may be impact on the GIS enclosure in case of termination failure.
• A termination is available at the other end (outdoor termination or SF6/air
bushing). This is used to test the cable without emptying the cable box. If the
GIS busbar is not disconnected, there may be impact on the GIS enclosure in case
of termination failure.
• GIS to GIS link or no termination available. The cable box must be open, or use of
a “dummy” accessory before plug in. The final arrangement and the epoxy busbar
cone inside the GIS cable termination are not tested.
• GIS to GIS; as an alternative to the bullet point above, install a voltage lead
outside of the insulator. Depending on the GIS design, it can be a temporary GIS
termination, which is later on removed.
The test of the cable system via GIS should be made in agreement with the GIS
manufacturer.
Due to the weight of the complete cable and the handling issues in the case where
there is no available termination for performing after installation test without moving
the cable, the cross section should be less than 1000 mm2 Cu or 1600 mm2 Al.
354 P. Mirebeau
7.6 Qualification
Introduction
The object of this European Standard is to specify the requirements to ensure
interchangeability of bushings having highest voltages above 1 kV up to 52 kV
and rated currents from 250 A up to 3150 A for insulating liquid filled
transformers.
Scope (Chapter 1)
This European Standard is applicable to ceramic and resin insulated bushings
having highest voltages above 1 kV up to 52 kV, rated currents from 250 A up to
3150 A and frequencies from 15 Hz up to 60 Hz for insulating liquid filled
transformers.
Introduction
The object of this European Standard is to specify the requirements to ensure
interchangeability of bushings for maximum voltages above 1 kV up to 52 kV and
rated currents from 250 A to 2500 A for equipment other than insulating liquid filled
transformers.
Scope (Chapter 1)
This European Standard is applicable to insulated bushings for maximum volt-
ages above 1 kV up to 52 kV, rated currents from 250 A up to 2500 A and
frequencies from 15 Hz up to 60 Hz for equipment other than liquid filled
transformers.
Interface Standards
Table 7.5.
Table 7.5
GIS TERMINATIONS FOR EXTRUDED CABLES
COLLATION OF RELEVANT STANDARDS
Country Standard Title List of Type Tests (TT) List List of PQ
of Extension
PQ Tests
Tests
Country Standard Title Terminations As part As part of cable
alone of cable systems only
systems
International IEC High-voltage This standard is an interface standards gives
and EN 62271- switchgear and recommended arrangements for dielectric tests
209- controlgear on GIS terminations. The dielectric tests for type
2007 -Part and PQ tests are specified in relevant IEC
209: Cable standards for particular type of cable. It makes
connections for reference for insulators to routine tests specified
gas-insulated in IEC 62271-203.
metal-enclosed
switchgear for
rated voltages
above 52 kV.
Fluid filled and
extruded
insulation
cables Fluid-
filled and
dry-type cable-
terminations
USA IEEE Guide for This guide is carbon copy of IEC 62271-209-
1300- Cable 2007 in regard to GIS connections for extruded
2011 Connections cables. In addition it specifies dimensional
for Gas requirements for GIS connections for laminated
Insulated cables.
Substations
7
Table 7.6
GIS TERMINATIONS FOR EXTRUDED CABLES
COLLATION OF RELEVANT STANDARDS
List of PQ
Extension
List of Type Tests (TT) List of PQ Tests Tests
Country Standard Title Terminations alone As part of cable systems As part of cable systems only
International IEC 60840-2011 Power cables with • PD amb • PD amb • 180 cycles at 1.7U0 • PD amb
extruded insulation and • 20 cycles at 2U0 (8 h • 20 cycles at 2U0 (8 h • Hot BIL (if done on •
their accessories for heating, min 2 h @95– heating, min 2 h @ 95– entire test rig) 60 cycles,
rated voltages above 100 C for EPR and 100 C for EPR and • Visual inspection no voltage
30 kV (Um ¼ 36 kV) up XLPE) XLPE) PD amb • 20 cycles
to 150 kV (Um ¼ • PD amb • PD hot at 2U0
170 kV) – Test methods • PD hot • Hot BIL followed by • PD amb
and requirements • Hot BIL followed by 2.5U0 15 min • PD hot
2.5U0 15 min • Visual inspection • Hot BIL
• Visual inspection >4 kV/mm at insulation followed
4 kV/mm at insulation screen. by 2.5U0
screen. 15 min
• Visual
inspection
4 kV/mm at insulation screen.
International IEC 62067-2011 Power cables with Terminations are type • PD amb min 180 cycles at 1.7U0 • PD amb
extruded insulation and tested as part of cable • 20 cycles at 2U0 (8 h (1 year test) •
their accessories for system only. heating, min 2 h @ 95– • Hot BIL (if done on 60 cycles,
Feasibility of a Common, Dry Type Plug-in Interface for GIS and Power. . .
rated voltages above 100 C for EPR and entire test rig) no voltage
150 kV (Um ¼ 170 kV) XLPE) PD amb • Visual inspections • 20 cycles
up to 500 kV (Um ¼ • PD hot at 2U0
550 kV) – Test methods • SIV hot (for Um • PD amb
and requirements 300 kV) • PD hot
• Hot BIL followed by • SIV hot
357
(continued)
Table 7.6 (continued)
358
USA IEEE 48-2009 IEEE Standard for Test • PD amb Not considered Not considered Not
Procedures and • 3.5-3.9U0AC, 1 min considered
Requirements for • DC, 15 min
Alternating- Current • Cold BIL
Cable Terminations • Hot BIL
Used on Shielded • PD amb
Cables Having • 30 cycles at 2U0 (each
Laminated Insulation cycle min 6 h at
Rated 2.5 kV through emergency temp +0/
765 kV oi Extruded 5 C (105 C for
Insulation Rated 2.5 kV XLPE and 130 C for
through 500 kV EPR, cooling process
specific)
• PD amb
• 2.5U0 AC, 6 h
• Cold BIL
• Cold SIL (for 345 kV
and above)
• PD amb
• Visual inspection
USA AEIC-CS9-06 Specification for Per IEEE 48 • For class 170 kV: • For class 170 kV: per Not
Association of Extruded Insulation per IEC60840 IEC60840 (if required considered
Edison Power Cables and their (if required by purchaser by purchaser spec)
Illuminating Accessories Rated spec) • For class >170 kV: per
Companies Above 46 kV • For class >170 kV: per 62067
representting Through 345 kV AC 62067 • Additional 90 cycles at
Feasibility of a Common, Dry Type Plug-in Interface for GIS and Power. . .
(continued)
Table 7.6 (continued)
360
Table 7.7 Guide to the selection of tests because of modifications to an accessory within the same
family in a prequalified EHV cable system
IEC 62067 Ed.1
Modification Clause number
T- PQ- EQ-
Component Type of modification Ma Pa Da DLa test test test
Terminations: Higher electrical stress V – – (xx)1)
Outdoor design of stress cone
Indoor (or smaller metal clad for
Metal GIS or transformer
enclosed terminations)
+ SF6 Change in nature of Filling V – – (xx)1)
+ medium (e.g. oil to gas. . .)
Oil-immersed Change in the formulation V V – – (xx)1)
of the stress cone
compound but with the
same base polymer
Change of the base V2) V2) V – – (xx)
polymer (EPR, Silicone,
...) of the stress cone
Change of insulator V2) V2) 12 – –
material for indoor or
outdoor terminations.
Change of insulator design V 12 – –
or manufacturer of
GIS/Transformer insulator
When can be demonstrated that the thermo mechanical aspects have no significant influence on the
performances of the termination a
Type Test may be sufficient.
In case of elastomeric insulators (“silicone” or “EPR”) climatic and pollution test according to IEC
61109 Annex C should be considered
(xx) Clause to be added in the standard
a
M, change in material; P, change in manufacturing process; D, change in design (construction); DL,
change in electrical design stress level
In every case voltages >170 kV are worth a full system consideration. Voltages
170 kV are either considered as a commodity (example: China, Middle East,
Thailand), or considered as a system (example: France, Italy, some end users in
USA).
parts of the outdated EN 50089 “Cast resin partitions for metal-enclosed gas-filled
high-voltage switchgear and controlgear” (1994) have been included.
Due to the qualification issues and specially the need for prequalification, the
common interface should be restricted to voltages up to and including 170 kV.
The detailed technology and the number of sizes will be defined by the next Cigré
working group.
7.7 Feasibility
In this section, the conclusions from sections 7.6: “the common interface should be
restricted to voltages up to and including 170kV” and 7.5 “Due to the weight of
the complete cable and the handling issues, the cross section should be less than
1000 mm2 Cu or 1600 mm2 Al” are taken into account.
The cost of different development phases are addressed below.
• Design of the geometry: Cigré WG to come (see Terms Of Reference at the end of
the brochure)
• Engineering
• Mould design
• Eachinery
• Prototypes.
• The work needed to design, engineer, prototype stress cones. The cost is between
two to five times more than for the insulator, depending on the stress cone sizes
that are needed per voltage level (according to the core diameters).
Insulator
• Development tests are about 100 k€
• The Type Test of paragraph 7.4.3.2 cost about 200 k€ (test of connector not
included)
• A preliminary Type Test is about 200 k€
Stress Cone
• Development tests are about 100 k€ at the supplier premises
• The Type Test of paragraph 7.4.3.1 is about 200 k€ including laboratory costs,
cable and accessory, installation works.
System
• A type test is needed (no prequalification because of the voltage level) i.e. 200 k€.
• If the cable stresses at the insulation screen is larger than 4 kV/mm (ref. IEC
60840) a prequalification test is required. This cost about 400 k€.
• When a stress cone has been prequalified and the insulator is from a different
manufacturer, a new prequalification test is not necessary as the stresses on
the insulator are not influenced by the insulation screen stress of the cable.
For voltages above 170 kV full qualification of the cable system is required. Each
link is bought as a system (refer to IEC 62067).
For voltages up to 138 kV, There are two opposite trends: some customers move
to the system approach, others go to commodity approach: cable and accessories are
bought separately.
170 kV is a special case where the cable system stresses can be similar to the
245 kV level and the cable cross section is larger. For this voltage, the system
approach prevails.
When the cable termination supplier is not chosen at the time the GIS has to be
delivered (around 70% of cases), the GIS is not pre equipped with the insulator and
the last compartment is not tested. It has to be open at the cable installation time.
There are gas works and risk of pollution.
For voltages lower than 170 kV, if stress cones and insulators are provided by different
manufacturers, there is one more limit of responsibility barrier as compared to the cable
system case. It is the stress cone – insulator interface. In case of failure, the responsi-
bility for the failure is less easy to address than at the insulator/SF6 interface. End users
are concerned by this change as there is no clear limit of responsibility.
All combinations of stress cone/insulator must be tested.
If the cable accessory is installed by a third party contracted by the end user, there
is one more layer of responsibility. Improper cable clamping, contamination, or
pressure spring compression may lead to defect and further complicate allocation
of responsibility in case of a fault.
The end user can limit the complication of responsibility by giving the contract to
a limited number of parties.
The main benefits are that more flexibility is given to the end user and overall
logistics costs are reduced.
Note: The financial balance of common interface benefits versus the design
development and qualification costs was not investigated.
Market acceptance drivers are given in the hereunder table (Table 7.8).
7 Feasibility of a Common, Dry Type Plug-in Interface for GIS and Power. . . 365
Table 7.8
In favour of Detrimental to
interchangeability interchangeability Comment
Qualification Cost of a cross
qualifications of
insulators and stress
cones
Routine test of – –
insulator and
rubber
Routine test of Final termination
termination assembly not routine
assembly tested.
Routine test of Cable enclosure fully
GIS tested. (presently fully
manufacturing tested only when the
termination supplier is
selected together with
GIS)
Planning Engineering of cable More difficult and In practice the cables
and GIS independent. costly logistics for the are ordered later than
Easier logistics for GIS cable accessory GIS.
manufacturer. manufacturer.
Higher flexibility for
the end user
Costs Cable system design: New investments and
Cost less optimised due to qualification to
manufacturing variability perform due to new
(insulator and of components. (ref. design of insulator and
rubber) Vattenfall experience stress cone (paragraph
3.2.2). Cable cost can 7).
be affected.
Cost GIS Less storage – less
manufacturing logistics – easier
planning
Installation on No opening of GIS on The termination can
GIS site and pre-tested (true only be installed when
for any pre-installation the GIS is on site
of insulator, whatever
the interface)
Installation of More space needed to Installation should
cable plug in (see 5.1) as avoid any torsion on
termination compared to 5.1.1 case the cable.
1 situation. This could
impact civil
works cost.
Spare parts Easier logistics
(continued)
366 P. Mirebeau
As coming from the market acceptance drivers the common interface should be
limited to the commodity market:
Taking into account the above considerations and specially the market trend in some
countries towards a commoditisation of the High Voltage cables lower or equal to
145 kV, the working group thinks that there is room in these voltage levels for a
standard design in parallel with the present designs. As per the TOR of the group,
B1.B3-33 recommends Study Committees B1 and B3 to set up a new working group
with the following Terms of Reference.
The Working group should recommend a functional design of an insulator with a
common interface with the following scope of work:
7 Feasibility of a Common, Dry Type Plug-in Interface for GIS and Power. . . 367
The stress cone design and material, the lubricant and the design of the compression
device should be left to the discretion of the accessory manufacturer within the limits
of the standardised insulator properties.
Cigré TB 303 and the work of WG B1.44 and WG B1.46 should be taken into
account.
Acknowledgments The Working Group wishes to thank T. Klein (DE), D. Kunze (DE) and
M. Obst (DE) for their active support.
References
All standards that are in the documents:
Cigré TB 303 (Chapter 4)
Cigré WG B1.29: Guidelines for maintaining the integrity of XLPE cable (Chapter 6)
Cigré WG B1.46: Conductor Connectors: Mechanical and Electrical Test (Chapter 10)
Contents
8.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370
8.1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370
8.1.2 Background . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370
8.1.3 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 371
8.1.4 Condition Assessment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372
8.2 Normative References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372
8.3 Definition of Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373
8.3.1 Development Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373
8.3.2 Routine Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373
8.3.3 Sample Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373
8.3.4 Type Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373
8.3.5 Prequalification Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373
8.3.6 Electrical Test after Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374
8.4 Test Cables and Transition Joint Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374
8.5 Development Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374
8.5.1 Electrical Development Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374
8.5.2 Non-Electrical Development Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374
8.6 Routine Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375
8.6.1 Extruded Cable Side of the Transition Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375
8.6.2 Paper Cable Side of the Transition Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375
8.7 Sample Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375
8.8 Type Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 376
8.8.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 376
8.8.2 Range of Type Test Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 376
8.8.3 Type Test Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 377
8.8.4 Type Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379
8.9 Prequalification Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 382
8.9.1 General and Range of Prequalification Test Approval . . . . . . . . . . . . . . . . . . . . . . . . . 382
8.9.2 Prequalification Test Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383
M. Marelli (*)
Prysmian Group, System Engineering, Land and Submarine HV and EHV AC/DC Power Cable
Systems and Telecom Cable Systems, Milano, Italy
e-mail: marco.marelli@prysmiangroup.com
8.1 Introduction
8.1.1 General
This chapter is the editorial and graphical revision of the Cigré TB 415, prepared by
the WG B1.24 and published in June 2010.
8.1.2 Background
The use of extruded cables is increasing for transmission and distribution circuits in
preference to cables with paper insulation (either kraft paper or polypropylene paper
laminate). The number of manufacturers of paper cable is also decreasing, therefore
the availability of such cables for repair works or re-routing will be very limited in
the near future. Consequently it is becoming more common for a length of extruded
cable to be introduced into a paper cable circuit requiring transition joints for the
interconnection of the two cable types.
Cigré set up WG B1.24 to review this subject and issue a report including:
8.1.3 Scope
The purpose of these new recommendations is to give general guidance for tests on
high voltage transition joints. These recommendations are valid for transition joints
between paper-insulated low pressure oil filled cables and extruded insulation cables
with rated voltage from 30 kV up to 500 kV. Transition joints for single core cables
as well as 3-core cables are covered. The use of these recommendations in relation to
other paper cable types, e.g. high pressure oil filled or gas pressure types is addressed
in Appendix A.
Note: The 30 kV voltage level is included in order to cover the full range of
cables covered by IEC 60141
Tests on joints between cables with similar type of insulation are not considered in
this document, even if they are used between cables with different conductors or
different screens.
Although the application of high voltage transition joints for interconnection of
different cable systems is likely to increase, the quantity of transition joints com-
pared to the quantity of standard accessories required will be low. There will also be
a large variety of cable constructions which have to be connected using transition
joints.
The number of type tests may be limited due to the availability of suitable paper
insulated cables, thus guidance is given about the range of approval.
Comments on the need for a long term prequalification test are also made.
Wherever well known and type tested components are used, for instance sym-
metric back-to-back transition joint designs (e.g. comprising two SF6 terminations in
a common chamber), a type test and prequalification test of the combination may be
omitted.
372 M. Marelli
In many cases the existing oil-filled cable on which a transition joint will be installed
will have been in service for many years and hence diagnostic tests may be advisable
to assess the cable condition. A full review of such procedures is given in reference
(Cigré Electra 1998).
In the event that the cable is found to be in as-new condition then it would
generally be considered unnecessary to carry out any special diagnostic tests after
installation of a transition joint.
Practices for maintenance of HV cable circuits are described in reference (Cigré
TB 279) and are not considered further in this report.
The following documents are indispensable for the application of this document. For
dated references, only the edition cited applies. For undated references, the latest
edition of the referenced document (including any amendments) applies.
• IEC 60141 Test on oil-filled and gas-pressure cables and their accessories.
– Part 1: Oil-filled, paper-insulated, metal-sheathed cables and their accessories
for alternating voltages up to and including 400 kV
– Part 2:Internal gas-pressure cables and their accessories for alternating volt-
ages up to 275 kV
– Part 3: External gas-pressure (gas compression) cables and their accessories
for alternating voltages up to 275 kV
– Part 4: Oil-impregnated paper-insulated high pressure oil-filled pipe-type
cables and their accessories for alternating voltages up to and including
400 kV
• IEC 60229 Electric cables – Tests on extruded oversheaths with a special protec-
tive function
• IEC 60230 Impulse tests on cables and their accessories
• IEC 60840 Power cables with extruded insulation and their accessories for rated
voltages above 30 kV (Um ¼ 36 kV) up to 150 kV (Um ¼ 170 kV) – Test
methods and requirements.
• IEC 60885-3 Electrical test methods for electric cables. Part 3: Test methods for
partial discharge measurements on lengths of extruded power cables
• IEC 62067 Power cables with extruded insulation and their accessories for rated
voltages above 150 kV (Um ¼ 170 kV) up to 500 kV (Um ¼ 550 kV) – Test
methods and requirements.
• EN 50299 Oil-immersed cable connection assemblies for transformers and reac-
tors having highest voltage for equipment Um from 72,5 kV to 550 kV.
8 Test Procedures for HV Transition Joints for Rated Voltages 30 kV up to. . . 373
Internal tests made by the manufacturer before a new transition joint is type tested
and taken into service. Details of such development tests are proprietary and shall be
determined by the manufacturer.
Tests made by the manufacturer on each manufactured component to check that the
component meets the specified requirements.
Note: Once successfully completed, these tests need not be repeated, unless
changes are made in the accessory with respect to materials, manufacturing
process, design or design electrical stress levels, which might adversely
change the performance characteristics.
Note 1: The prequalification test need only be carried out once unless there
is a substantial change in the accessory with respect to material,
manufacturing process, design or design electrical stress levels.
(continued)
374 M. Marelli
For the purpose of carrying out tests described in this document and recording the
results, the cables and accessory shall be identified. The relevant characteristics as
given in IEC 60141-1, IEC 60840 and IEC 62067 shall be known or declared.
Development tests are carried out to prove the main electrical and non-electrical
characteristics of the transition joint.
Details of such development tests shall be at the discretion of the manufacturer,
examples of possible tests are given in the following clauses.
Electrical development tests can be adopted from the type test recommendations of this
document, but may have increased test voltage levels. The duration of withstand tests as
well as the number of impulses during impulse voltage test may be increased, too.
Examples for electrical development tests:
• AC voltage test
• Partial discharge test
• Lightning impulse voltage test.
If new types of conductor connections are used as part of the transition joint design,
the necessity for development tests of such connections should also be considered.
During operation joint housings and barrier insulators are subjected to hydraulic
pressure. Barrier insulators and related sealing systems may also be subjected to
vacuum during the installation process. (Vacuum processing is often used during
assembly work on paper-insulated cable accessories).
Examples for non-electrical development tests:
• Pressure test
• Vacuum leak test
• Thermo-mechanical test.
In cases b) and c) the test voltage shall be selected to obtain electrical stresses at least
the same as those on the component in a complete transition joint when subjected to
the test voltages specified.
The hydraulic tests specified in IEC 60141 shall be made on each accessory to which
the relevant clauses apply.
Due to the small numbers of transition joints which are expected to be supplied under
single orders, sample tests will not normally be appropriate.
376 M. Marelli
8.8.1 General
The tests specified in this clause are intended to demonstrate the satisfactory
performance of transition joints.
The type test may be omitted:
In the case of three-core cables or three-core transition joints then if the cables and
cores within the joint are fully screened then it is permitted to carry out the electrical
type tests on one core only, or on a single core joint of similar electrical design.
Reference to Appendix B may be made to assist in determining the need for type
tests.
A summary of type tests on transition joints is given in Appendix C.
When a type test has been successfully performed on a transition joint for connecting
cables of specific conductor cross-sections, and of the same rated voltage and
construction, the type approval shall be considered as valid for a transition joint
within the scope of these test recommendations with other conductor cross-sections,
rated voltages and with other cables provided that all the conditions of a) to c) are met:
(a) The voltage group is not higher than that of the tested transition joint.
8 Test Procedures for HV Transition Joints for Rated Voltages 30 kV up to. . . 377
Note: In this context, transition joints of the same rated voltage group are
those of rated voltages having a common value of Um, highest voltage for
equipment, and the same test voltage levels as given in Table 8.1.
(b) The transition joint has the same or similar construction to that of the tested
transition joint.
Note: Transition joints of similar construction are those of the same type and
manufacturing process of stress control elements and major insulation
components. Repetition of the electrical type tests is not necessary on
account of the differences of the cable insulation material, of the conductor
or connector type or material, or of the protective outer covering, unless
these are likely to have a significant effect on the results of the test.
(c) The calculated nominal electrical stresses within the main insulation parts of the
transition joint and at the cable and accessory interfaces do not exceed those of
the tested transition joint, or equal or higher electrical stresses at the relevant
locations are well proven in other accessories.
Note: Larger conductor cross-sections than tested are allowed within this
limitation.
The transition joint shall comply with the tests specified in 8.8.4.1 and 8.8.4.2. The
minimum length of free cable between accessories shall be 5 m.
One sample of each transition joint type shall be tested.
The accessory shall be assembled on the cables in the manner specified by the
manufacturer’s instructions, with the grade and quantity of materials supplied,
including lubricants and insulating fluids if any. There should be provision for
measuring internal pressure of insulating fluid in the lapped cable compartment
during the test.
In units that are intended to operate with internal oil pressure, whether such
pressure is from the cable system or a separate source, the maximum pressure during
the test must not exceed the minimum design operating pressure +25%. If the
378
accessory includes an SF6 gas filled compartment then the gas pressure must be set
so that at 20 C the pressure is no greater than the minimal functional pressure for
insulation specified for the accessory +0.02 MPa.
Neither the cables nor the accessories shall be subjected to any form of condi-
tioning not specified in the manufacturer’s instructions which might modify the
electrical, thermal or mechanical performance.
During tests a) to f) of 8.8.4.2, it is advisable to test joints with their outer
protection fitted. If it can be shown that the outer protection does not influence the
performance of the joint insulation, e.g. there are no thermo-mechanical or compat-
ibility effects, the protection need not be fitted.
Note: If suitable oil filled cable of the required insulation thickness is not
available then it is allowed to use a cable with a greater insulation thickness
and to reduce the insulation thickness in the region where the joint is to be
installed to the required level. As an alternative it is also allowed to adjust the
test voltages in order to achieve the required electrical stress values.
The measurements shall be carried out after the final cycle of item b) above or,
alternatively, after the lightning impulse voltage test in item d) below.
(d) Switching impulse voltage test (required for Um 300 kV, see 8.8.4.5).
(e) Lightning impulse voltage test followed by a power frequency voltage test (see
8.8.4.5).
(f) Partial discharge measurements, if not previously carried out in item c) above.
380 M. Marelli
Note: Heating cycles with a conductor temperature higher than 10 K above the
maximum conductor temperature in normal operation are considered valid.
Note: If, for practical reasons, the test temperature cannot be reached,
additional thermal insulation may be applied. The impulse voltage shall be
applied according to the procedure given in IEC 60230 with standard
switching impulse withstand voltage levels according to Table 8.1. The
transition joint shall withstand without failure 10 positive and 10 negative
voltage impulses.
8.8.4.8 Examination
Examination of the transition joint, whenever possible, by dismantling, with normal
or corrected vision without magnification, shall reveal no signs of deterioration
which could affect the system in service operation (e.g. electrical degradation,
corrosion, harmful shrinkage or leakage, in particular across any seal separating
the extruded and oil filled cables).
The tests specified in this clause are intended to demonstrate the satisfactory long
term performance of transition joints.
The prequalification test may be omitted:
The minimum length of free cable between accessories shall be 5 m. One sample of
each transition joint type shall be tested.
The accessory shall be assembled on the cables in the manner specified by the
manufacturer’s instructions, with the grade and quantity of materials supplied,
including lubricants and insulating fluids if any. There should be provision for
measuring internal pressure of insulating fluid in the lapped cable compartment
during the test.
In units that are intended to operate with internal oil pressure, whether such
pressure is from the cable system or a separate source, the maximum pressure during
the test must not exceed the minimum design operating pressure +25%. If the
accessory includes a gas filled compartment then the gas pressure must be set so
that at 20 C the pressure is no greater than the minimal functional pressure for
insulation specified for the accessory +0,02 MPa.
If the prequalification of the transition joint is to qualify the joint for use both in
flexible and in rigid installations, the joint shall be installed in a rigid configuration.
Otherwise the joint shall be installed in a flexible configuration.
If the joint is installed for test in a rigid configuration, the manufacturer of the
joint shall consider the aspects of the design which might affect operation in a
flexible installation and subject to agreement between manufacturer and customer
the prequalification shall apply to both rigid and flexible installations.
384 M. Marelli
Neither the cables nor the accessories shall be subjected to any form of condi-
tioning not specified in the manufacturer’s instructions which might modify the
electrical, thermal or mechanical performance.
Note: If suitable oil filled cable of the required insulation thickness is not
available then it is allowed to use a cable with a greater insulation thickness
and to reduce the insulation thickness in the region where the joint is to be
installed to the required level.
Note: If the conductor temperature exceeds the upper limit the test is still valid.
8 Test Procedures for HV Transition Joints for Rated Voltages 30 kV up to. . . 385
The heating shall be applied for at least 8 h. The conductor temperatures shall be
maintained within the stated temperature limits for at least 2 h of each heating period.
This shall be followed by at least 16 h of natural cooling. The conductor current
during the last 2 h of each heating period shall be recorded.
The cycle of heating and cooling shall be carried out 180 times.
A voltage of 1.7Uo (see Table 8.1) shall be applied to the assembly during the
whole of the test period.
Interruption of the test is allowed provided 180 complete heating cycles in total
under voltage are completed.
8.9.3.5 Examination
Examination of the transition joint, whenever possible, by dismantling, with normal
or corrected vision without magnification, shall reveal no signs of deterioration
which could affect the system in service operation (e.g. electrical degradation,
corrosion, harmful shrinkage or leakage, in particular across any seal separating
the extruded and oil filled cables).
Tests on newly installed transition joints are carried out when the installation of the
cable and its accessories has been completed.
386 M. Marelli
If required the new cable section with extruded insulation may be tested
separately according to its relevant standard before the transition joint is
installed.
The test voltages recommended for general use are given in Table 8.2, however
test regimes should be evaluated on an individual basis to take into account the
condition of an existing cable system.
A d.c. oversheath test according to clause 8.10.1 and an a.c. insulation test
according to clause 8.10.2 are recommended.
Note: Where it is required to test the oversheath of the two cable sections
separately it is recommended to install a sheath sectionalised transition joint.
The a.c. test voltage to be applied shall be subject to agreement between the
purchaser and contractor. The waveform shall be substantially sinusoidal and the
frequency shall normally be between 20 Hz and 300 Hz. However if the capacitance
of the cable is such that this cannot be achieved, then subject to agreement between
purchaser and contractor, the minimum frequency may be reduced to 10 Hz. A
voltage according to Table 8.2 shall be applied for 1 h.
Note: For installations, which have been in use, lower voltages and/or
shorter durations may be used. Values should be determined, taking into
account the age, environment, history of breakdowns and the purpose of
carrying out the tests.
The main body of this document specifically addresses transition joints connecting
low pressure oil filled cables and extruded cables. The extruded cable types are those
covered by IEC 60840 and IEC 62067.
However three other main types of paper cable exist and are covered by IEC
60141 parts 2, 3 and 4. Specific differences which should be taken into account
when testing transition joints for use on these types of cables are given in this
Appendix.
Routine Test: – A hydraulic test as specified in the main body of this report should
be carried out. In addition a gas leak test is required for the casing on the paper cable
side of the joint at maximum operating pressure for 24 h. There shall be no leakage.
AC Test Voltages for Heating Cycle Voltage Tests: – Test voltages with heating
cycles are not specified in IEC 60141. The test voltages given in the main body of
this report may be used. However the manufacturer should consider the values to be
applied in relation to the known performance of the particular cable and adjust the
AC test voltages if appropriate.
Lightning Impulse Test and AC Voltage Test After Impulse Voltage Test: –
As specified in IEC 60141-2 the lightning impulse test voltage is calculated
according to the formula:
388 M. Marelli
Note: These test voltages are lower than those specified in the main body of
this document.
After installation test: the test may be carried out at Uo for 24 h. If a one hour
AC test is proposed then the condition of the cable should be taken into account in
determining the voltage. Nevertheless the test voltage should not exceed the value
specified in Table 8.2 of the main document.
Routine Test: – A hydraulic test as specified in the main body of this report should
be carried out. In addition the following tests to IEC 60141-3 are required where
applicable:
• A gas leak test is required for the casing on the paper cable side of the joint, if it is
exposed to gas pressure in service, at maximum operating pressure for 24 h. There
shall be no leakage.
AC Test Voltages For Heating Cycle Voltage Tests: – Test voltages with
heating cycles are not specified in IEC 60141. The test voltages given in the main
body of this report may be used. However the manufacturer should consider the
values to be applied in relation to the known performance of the particular cable and
adjust the AC test voltages if appropriate.
Lightning Impulse Test And AC Voltage Test After Impulse Voltage Test: –
As specified in IEC 60141-3 the lightning impulse test voltage is calculated
according to the formula:
Note: These test voltages are lower than those specified in the main body of
this document.
After installation test: the test may be carried out at Uo for 24 h. If a one hour
AC test is proposed then the condition of the cable should be taken into account in
determining the voltage. Nevertheless the test voltage should not exceed the value
specified in Table 8.2 of the main document.
Table 8.4 Test Voltages, case of external gas-pressure (gas compression) cables
1 2 3 8 9
Rated Highest Value of Uo for Impulse voltage AC Voltage test after
voltage voltage for determination of test of 8.8.4.5 impulse voltage test of
equipment test voltages and 8.9.4.4 8.8.4.5 and 8.9.4.4
U Um Uo 6Uo + 40 1,73Uo +10
kV kV kV kV kV
30–33 36 18 148 41
45–47 52 26 196 55
60–69 72,5 36 256 72
110– 123 64 424 121
115
132– 145 76 496 141
138
150– 170 87 562 161
161
220 to 245 127 802 230
230
275 to 300 160 1000 287
287
Lightning Impulse Test And AC Voltage Test After Impulse Voltage Test: –
As specified in IEC 60141-4 the lightning impulse test voltage is defined by the
manufacturer of the cable. In practice the lightning impulse voltages given in
Table 8.2 of this report are those normally used. The value of test voltage given in
Table 8.2 for the AC voltage test after impulse voltage test is also recommended to
be used.
These values are recommended subject to agreement and consideration of the
condition of the cable used for the test.
After installation test: the test procedure as given in the main body of this
document is recommended.
Transition joints might be either of innovative design, in which case the full scale
development and type tests need to be performed or the joints might be constructed
of well known and type tested components, in which case development and type
tests are not necessary.
This Appendix is a general description of constructional principles of some
common types of transition joint (Cigré TB 89), with drawings and principal design
8 Test Procedures for HV Transition Joints for Rated Voltages 30 kV up to. . . 391
features and is meant to give a general understanding and guidance to those studying
this subject for the first time (See ▶ Chapter 1 of this book).
In the last section of this Appendix a methodology is described which may be
employed to assess the need for testing a particular new design.
Plumb
Insulator
Gas or insulating liquid
Connector Corona shields
Conductor stalk
Fig. 8.1 Single phase back-to-back transition joint with (2) insulators
392 M. Marelli
In the case of oil immersed terminations the chamber required may be very large,
see EN 50299.
In special cases, the busbar connection can be designed so that the two cables may
be disconnected allowing independent high voltage commissioning tests on the two
cables.
Figure 8.2 shows example of the GIS or oil immersed type termination with rigid,
epoxy or porcelain, insulator on the paper-insulated cable side. The insulator anchors
cable conductors and centres the corona shield within the joint shell filled with
insulating fluid (SF6 gas, mixture of SF6 and nitrogen or insulating oil). The insulator
of the GIS/transformer termination is the barrier between insulating liquid of the
paper-insulated cable and the insulating oil of the joint shell.
The extruded cable end is terminated by a stress cone, which is directly immersed
in the insulating fluid of the joint. It is necessary to seal the strands and sheath of the
extruded cable conductor to prevent loss of insulating fluid.
The arrangement of the joint with the rigid insulator at the extruded cable side can
be utilized too. In this case the joint shell is filled with insulating liquid of the paper
cable and the stress cone of the paper cable is directly immersed into this liquid.
Features
The terminations with and without rigid insulator are identical to terminations
used in either SF6 switchgear or transformer applications.
Current carrying connection between two terminations may be specific to transi-
tion joint.
Corona shield (individual or collective) may be specific to transition joint.
An oil reservoir might be required to control thermal expansion/compression of
the insulating fluid.
Plumb
Insulator
Gas or insulating liquid
Fig. 8.2 Single phase back-to-back transition joint with one insulator
8 Test Procedures for HV Transition Joints for Rated Voltages 30 kV up to. . . 393
The composite type transition joint shown in Fig. 8.3 features central barrier, usually
made of cast thermoset resin, which closely resembles the stop joint barrier
employed to segregate pressure between single core liquid-filled cables. The barrier
is cylindrical with an embedded metallic HV electrode, which is sealed to the
conductor connection to form a seal between the two sides of the joint.
The stress control on the paper cable is made of hand applied oil-impregnated
paper tapes or a combination of hand applied paper tapes and thermoset resin stress
cone. In the case of single core cables there is a channel at the connector to permit
insulating liquid from the cable conductor duct to be fed into the joint shell on the
paper cable side. For three core cables the oil feed comes directly from the core
separation position near the end of the cable sheath.
The extruded cable side of the transition joint is similar to a dry-type GIS
termination, the stress cone and springs normally being identical to those used in
GIS terminations. The elastomeric stress cone is sandwiched between the cable
insulation and central barrier and the interface pressures are maintained by the
springs.
Features
A common thermoset resin barrier with an embedded corona shield may be
specific for use in the transition joint.
The stress cone for the extruded cable may be identical to that used in dry-type
terminations.
The paper cable side may be identical to a stop joint in which case testing of the
stop joint will be applicable.
In the case of the extruded cable side, testing of similar dry type accessories may
be considered in conjunction with electrical stress calculations.
Plumb Plumb
Oil or gas Compression device
Joint shell
Semiconducting Elastomeric
Insulated flange elastomer moulded stress
Insulated elastomer cone
The current carrying connection between two cables may be specific to the
transition joint.
The same electrical design applies to single or three core versions of this joint.
A central barrier plate with a single bushing or multiple bushings separates lapped
cable joint side from the side with extruded cable. The barrier and bushings that are
usually made of premoulded thermoset resin are designed to withstand operating and
test pressures required for the lapped cable.
The bushing is connected to the extruded cable in the form of extruded cable joint
that can be of various designs, such as taped insulation, premoulded elastomeric
body, heat shrink sleeve, etc. The joint on the paper cable side is usually insulated
with either impregnated plain or crepe paper tapes.
The joint shell on the paper cable side is filled with the insulating liquid of the
paper cable.
Features
Thermoset resin bushing may be similar to one used in stop joints.
On the paper cable side the design is usually identical to a stop joint and thus
previous testing of a stop joint may be applicable.
Interface of insulation with the bushing on the extruded side is specific to
transition joint, however standard premoulded components or taping methods may
be used.
The current carrying connection between the bushing and paper cable is usually the
same as in the stop joint. Likewise, current carrying connection between bushing and
extruded cable may be the same as the connection in extruded cable joint. In these
cases testing of these items will already have been carried out for the standard joints.
Electrical testing of a single core can be considered valid for three core designs,
only thermomechanical and pressure characteristics of the casings need to be
considered when moving from single to three core versions (Fig. 8.4).
Plumb Plumb
Barrier plate
Oil or gas Spacer Joint shell Insulated flange
In assessing the need for type and/or prequalification tests it is first necessary to
consider the proposed design and to evaluate which parts of the accessory are similar
to established accessories or parts of established accessories (for example the oil
filled side of a transition joint might resemble an established stop joint). Then, based
on available knowledge or lack of knowledge of performance of the particular design
feature, the confidence in performance in certain test conditions should be evaluated.
This can be done by considering the range of service and related test conditions
which have to be met. The following table gives an example for this for a fictitious
design. The need for test can then be judged based on the number of entries on the
“Type Test Required” column.
Type tests of transition joints are covered by paragraph 8.8 (Table 8.5).
Table 8.6 gives a summary and references for type testing of transition joints.
Prequalification tests of transition joints are covered by paragraph 8.9.
Table 8.7 gives a summary and references for prequalification testing of these
transition joints.
Part of the terms of reference of WG B1-24 was to review the range of transition
joints currently available. To this end the WG has carried out a survey amongst its
members to investigate the types of transition joint used, their availability and
number in service in the members’ countries.
The results of this survey are presented in the following table (Table 8.8):
396 M. Marelli
Table 8.5 Example of evaluation of need for performing certain type tests of novel transition joint
Condition (examples – Confidence Type Test Reason for confidence-level rank &
others might be chosen in Level Required? remarks (typical comment shown as
practice) High Low Yes No an example)
PD initiation X X
Breakdown at AC X X
withstand voltage
Breakdown at DC X X Thermoset resin barrier is new
withstand voltage
Breakdown at impulse X X
withstand, at ambient
Breakdown at impulse X X
withstand, hot
Ionization initiation in X X Electrical stress in paper insulation
paper insulation is influenced by the stress cone
design. Test is not required if PD
level is acceptable.
Load Voltage X X Thermoset resin barrier is new
cycling breakdown in
oil (or gas) in
shell
Voltage X X
breakdown in
termination
Thermal X X
runaway of
centre
connector
Mechanical or thermal X X Manufacturer to evaluate necessity
failure during short-time of performing these tests as
current test development tests based on past
experience.
Breakdown at AC X X
withstand voltage after
short-time current test
Mechanical or thermal X X Metallic shield restoration has been
failure of ground individually tested
connections during short-
time current test
Voltage breakdown of the X X Jacket restoration and shield-break
shield break during load have been individually tested
cycling in water
Pressure and leak test X X Material and dimensions of the shell
and the sealing system are critical for
pressure and leak test. No test is
required if previously tested on
similar design
8 Test Procedures for HV Transition Joints for Rated Voltages 30 kV up to. . . 397
References
Cigré Electra no. 176, February 1998 Diagnostic Methods for HV Paper Cables and Accessories
Cigré Paper B1-301 Qualification of transition joint between oil – filled paper insulated cable and
XLPE insulated cable for the 150 kV Belgian network (Liemans, D., Mella, J., Gille, A.,
Szczepanski, C., Mampaey, B.) (2008)
Cigré Paper B1-303 HV-EHV transition joints: a solution to optimize the cable route (Courset, L.,
Hondaa, P., Argaut, P., Bénard, L., Mirebeau, P.) (2008)
Cigré TB 279 Maintenance for HV Cables and Accessories
Cigré TB 303 Revision of Qualification Procedures for HV and EHV AC Extruded Underground
Cable Systems (Chapter 4 of this book)
Cigré TB 89 Accessories for HV Extruded Cables (Chapter 1 of this book)
IEE Conference Publication No. 382, Page 267 The HV transition joints (Gahungu, F., Francois, D.,
Darcy, A., Becker, J., Brouet, J., Couturier, J., Mella, J.) (1993)
IEEE 404–2006 Extruded and Laminated Dielectric Shielded Cable Joints Rated 2500 V to 500000 V
IEEE 48–1996 Standard Test Procedures and Requirements for Alternating-Current Cable Termi-
nations 2.5 kV Through 765 kV
JICABLE Paper A.5.3 A range of transition joints for 33 kV to 132 kV polymeric cables (Attwood,
J., Gregory, B., Svoma, R.) (1991)
JICABLE Paper C.5.1.14 Compact transition joints for up 154 kV Power cable (Niinobe, H.,
Yokoyama, S., Toraki, Y., Kaneko, S.) (2007)
JICABLE Paper C.5.1.15 Upgrading quality of 275 kV Y-branch pre-fabricated transition joints
(Nakanishi, T.) (2007)
Contents
9.1 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
9.2 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
9.3 Thermal Ratings of Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
9.3.1 Basic Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
9.3.2 Conclusions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
9.4 Thermo-mechanical Ratings of Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
9.4.1 Basic Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
9.4.2 Conclusions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
9.5 Systems Design Aspects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
9.5.1 Thermal Ratings of Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
9.5.2 Thermo-mechanical Ratings of Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
9.6 Conclusions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
Annexes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
Annex 1. Thermal Calculations in HV and EHV Cables and Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
Example 1: Dynamic Temperature Calculations in a 132 kV Cable and Joint . . . . . . . . . . . . 408
Example 2: Thermal Behavior of a 400 kV Joint during IEC Loading Cycles in Air . . . . 410
Annex 2. Overview of International Standards on Thermal Aspects of Accessories
(as a Result of a Questionnaire under the Members of the Task Force) . . . . . . . . . . . . . . . . . . . . . . . 412
Annex 3. Guide to Aid Development Engineers for Testing the Thermal Properties
of Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
H. Geene (*)
Prysmian Group, Product Management HV Accessories, The Hague Area, Netherlands
e-mail: henk.geene@prysmiangroup.com
R. Schroth
Berlin, Germany
e-mail: reinhard.schroth@gmx.de
9.1 Summary
The abstract of the work was published in Electra No 212 February 2004.
9.2 Introduction
International standards as IEC specifications 60840 Ed.3 and 62067 Ed.1 have
defined the thermal ratings of extruded HV/EHV cables by their maximum cable
conductor temperatures for different insulations. The thermal ratings of accessories
are not explicitly mentioned as they were generally considered to have equal or
better levels than those of the cable.
Questions have been raised, whether and how the thermal and thermo-mechanical
ratings of accessories, i.e. terminations and joints, should be defined and how these
should be taken into account in the design of cable systems.
In 2001 a Task Force TF 21-10 was established with the following scope:
• Terminations installed in normal conditions are not considered as a hot spot for
the cable due to more effective heat transfer to the environment (e.g. air circula-
tion for outdoor terminations, axial conductor heat transfer in GIS and trans-
former terminations).
• In steady state test conditions (i.e. when a single cable is installed in air in a test
loop) joints will develop higher conductor temperatures than the remote cable,
due to their larger dimensions (Annex 1).
• Longer thermal time constants for joints may result in lower conductor temper-
ature in the first part of a heating period than for the cable, but higher temperatures
at the end of the heating period, followed by delayed cooling after disconnecting
the current (Annex 1).
• Depending on the time constants and duration of the cooling period, joints may
not cool down completely to the ambient temperature, resulting in a gradual
increase of conductor temperatures in subsequent cycles (Annex 1).
• Additional thermal insulation may extend the thermal time constant for the cable.
• Most existing standards require current heating for cable and accessories
(Annex 2).
9.3.2 Conclusions
9.4.2 Conclusions
9.6 Conclusions
Thermal ratings of accessories need not be specified separately from cables, as they
are considered identical due to the presence of cable inside the accessory.
The thermal performance of terminations in normal operation is not to be
considered critical; therefore they do not have to reach the rated temperature for
the cable during test.
The successful completion of IEC thermal tests at the complete cable
system can be considered as simultaneous verification of the adequate thermal
design of both, cables and accessories, provided that comparable or higher
conductor temperatures as rated for the cable are achieved inside joints. These
test conditions will be achieved by applying cable conductor current heating
only.
For the heating of cables and accessories during type test, the following clause is
recommended to IEC:
For IEC 62067 Ed.1 clause 12.4.7 becomes:
The cable shall have a U-bend with a diameter as specified in 12.4.4.
The assembly shall be heated by conductor current until the cable conductor
reaches a steady temperature 5 C to 10 C above the maximum conductor temper-
ature in normal operation. No additional external heating or heating by sheath
current shall be allowed. If for practical reasons the test temperature cannot be
reached, additional thermal insulation can be applied, which then must be described
in the test report.
408 H. Geene and R. Schroth
The heating shall be applied for at least 8 h. The conductor temperature shall be
maintained within the stated temperature limits for at least 2 h of each heating
period. This shall be followed by at least 16 h of natural cooling to a conductor
temperature within 15 C of ambient temperature, with a maximum of 45 C. The
conductor current during the last 2 h of each heating period shall be recorded.
The cycle of heating and cooling shall be carried out 20 times.
In the case of IEC60840/Ed3/CDV clause 12.3.6:
The same wording is recommended as given above except that “12.4.4” is
changed to “12.3.3” and “within 15 C of ambient” is replaced by “within 10 C
of ambient” in accordance with the existing wording.
For the Impulse voltage test and “hot” partial discharge test, the same method of
heating shall be applied.
External (thermo-) mechanical forces in normal installation condition may be
reproduced in the prequalification test for EHV systems. However, external
(thermo-) mechanical (and other mechanical) forces, in special installation condi-
tions, cannot be reproduced comprehensively in standardized tests and should there-
fore be considered by systems design engineering.
Completely new generation of accessories (e.g. dry outdoor terminations) might
need further considerations, regarding thermal and thermomechanical aspects.
Annexes
Joints and cables have different thermal properties. The basic differences can be
expressed in:
• Thermal resistances
• Thermal time constants
9 Thermal Ratings of HV Cable Accessories 409
2m
Φa Φa
Φr Φr
Tj
Tc
Tc
To verify the differences in the joint and cable temperature during one heating
cycle, dynamical calculations were made for an 800mm2 132 kV XLPE cable.
First, the heating current is calculated to obtain a stable cable conductor temper-
ature of 95 C. Based on the heating current, the temperature was calculated inside
the joint and cable for a period of 10 h after switching on the current. The results are
given in Fig. 9.3 at a conductor heating current of 1800A.
110
100
90
80
Temperature (°C)
70
60
50
40
30
20
10
0
0 1 2 3 4 5 6 7 8 9 10
Time (hours)
Joint Cable
Fig. 9.3 Typical heating curve of a 132 kV 800 mm2 Cu cable and joint
410 H. Geene and R. Schroth
Conclusion
In stationary conditions, the joint reached a higher temperature than the cable, as a
result of higher thermal resistance of the joint. In the first 6 hours of the heating
cycle, the temperature in the joint is lower than in the cable due to the longer thermal
time constant of the joint.
Introduction
In order to evaluate the temperature difference between a 400 kV cable and the
relevant premoulded joint during the heating cycle voltage test, specified in IEC
60840 Ed. 3 and 62067 Ed.1, thermal calculations have been carried out using the
finite element method.
The test loop assumed for the calculation is installed in air and includes 20 m of
cable and a 400 kV premoulded joint complete with its anticorrosion protection. The
length of cable is such that the presence of the joint does not affect the asymptotic
temperature of the cable.
Due to the use of the FEM method, the joint is subdivided in finite elements where
both radial and longitudinal heat transmission is taken into account.
During the heating cycle test the cable conductor is heated by conductor current in
order to reach in 6 hours a conductor temperature of 95 C (far from the joint),
followed by 2 hours where the current is reduced in order to maintain the cable
conductor temperature between 95 C and 100 C, then the current is switched off
for 16 hours still maintaining the voltage on. This cycle under constant voltage of
2 Uo is repeated for 20 times. The calculation has been made for 400 kV XLPE
cables with a 1600 mm2 and a 2500 mm2 copper conductor. Both conductor losses
and dielectric losses have been considered in the calculation.
During the loading cycles a constant current of about 3450 A is circulated in the
conductor, so that a temperature of 95 C is reached in the cable conductor after
6 hours, starting from a uniform ambient temperature of 20 C. Then the current is
reduced in order to maintain the temperature in the cable conductor between 95 C
and 100 C for 2 hours. Subsequently the conductor current is switched off for
16 hours.
The results of the calculations of the cable and joint daily cycles are shown in
Fig. 9.4.
It can be observed that initially the joint ferrule temperature is slightly lower
than 95 C, then it increases and reaches a stable value of about 101 C after four
cycles.
9 Thermal Ratings of HV Cable Accessories 411
110
100
90
80
Temperature (°C)
70
60
50
40
30
20
10
0
0 10 20 30 40 50 60 70 80 90 100
Time (hours)
Joint Cable
Fig. 9.4 Loading cycles (8 hours on, 16 hours off) on a 400 kV 2500 mm2 Cu cable and joint
110
100
90
80
Temperature (°C)
70
60
50
40
30
20
10
0
0 10 20 30 40 50 60 70 80 90 100
Time (hours)
Joint Cable
Fig. 9.5 Loading cycles (8 hours on, 16 hours off) on a 400 kV 2500 mm2 Cu cable and joint
The initial conductor current in order to bring the cable conductor temperature to
95 C after 6 hours (including dielectric losses) is of about 2500 A. The results of the
joint and cable load cycle calculation are shown in Fig. 9.5.
412 H. Geene and R. Schroth
It can be observed that the temperature of the joint has the same behavior as in
Fig. 9.4, i.e. the periodic asymptotic temperature in the joint is reached after 4 cycles,
but its value is a little smaller (99 C instead of 101 C).
Conclusions
During IEC loading cycles, with only conductor current heating, the joint ferrule
temperature of a 400 kV joint follows the cable conductor temperature with a certain
delay due to the higher thermal time constant of the joint compared to the cable.
However, after about 4 cycles also the joint reaches stable periodic conditions
with a maximum temperature generally slightly higher than that of the cable
conductor.
These conclusions depend on the design of the joint. Joints longer than the one
considered in these calculations or with thicker insulation would present a higher
time constant, so that stable cycle conditions for the joint would be reached after
more than 4 cycles, but certainly within the 20 IEC cycles.
The higher periodic temperature in the joint is also due to the fact that, during the
type test, the joint is provided with the thick outer protection foreseen for the
underground installation (as in the case of these calculations), while for actual
installations in air the casing is normally unprotected.
Introduction
The aim of the guide is to give the development engineer some recommendations on
how to measure the thermal characteristics of a prefabricated joint in transient and
steady state conditions.
Test Installation
The test loop has to contain at least 15 m of cable and one joint. The distance
between the joint and cable ends has to be at least 5 m. No direct contact of the cable
or joint with the lab floor is allowed. It is important that cable and joint should be
subjected to the same thermal ambient conditions. No additional thermal insulation
should be applied.
Thermocouples (or other temperature sensors) should be installed in the follow-
ing positions:
• At the cable, at least 5 m from the joint and 5 m from the cable end,
– On the conductor
– On the metallic sheath
– On plastic outer sheath
416 H. Geene and R. Schroth
Thermal Test
The heating current shall be applied for at least 24 h until the cable conductor, remote
from the accessories, reaches a steady temperature of at least 5 C above the
maximum conductor temperature in normal operation for the cable. During the
entire heating period, the temperatures shall be recorded. No other means than
current heating shall be used.
Test Results
From the recorded heating curves the following characteristics can be calculated:
• The thermal resistance between conductor and outer covering of the joint
(deduced from the ratio between the steady state temperatures)
• The thermal resistance between the conductor and outer covering of the cable
(deduced from the ratio between the steady state temperatures)
• Thermal time constant of the cable
• Thermal time constant of the joint.
Introduction
The aim of the guide is to give the design engineer some recommendations regarding
important thermal and thermo-mechanical characteristics to check on accessories.
When possible or appropriate, the guide indicates the way to control or measure
the described characteristics.
References
This guide has been established taking into account the recommendations and
guidelines included in the following documents:
Cigré WG 21-09: Electra No. 140, February 1992
Considerations of ageing factors in extruded insulation cables
Cigré WG 21-17: TB 194, October 2001 Construction, laying and installation
techniques for extruded and self contained fluid filled cable
systems
9 Thermal Ratings of HV Cable Accessories 417
Rigid Systems
• Tunnel
• Above ground
• Tower/shaft
• Jointing chamber.
• Bridge
• Unfilled ducts.
The cable system including the accessories has to sustain any of the thermal or
thermo-mechanical constraints, which could happen under:
• Normal operation
• Transient operation: Short-circuit (phase to phase or phase to earth)
• Overload
• Earthquake.
Table 9.1 summarises main properties to take into account by the design engineer
to avoid any failure linked to a bad design regarding thermal or thermo-mechanical
properties.
418
Table 9.1 Characteristics to control or tests to perform for assessing the reliability of accessories on cable systems
Constraints Classification
Thermo – Test to perform/ characteristics
Constraints Mechanical Thermal mechanical to control IEC tests
Steady-state Mechanical forces linked to X Calculations of the thrust (see
operation snaking Longitudinal dilatation WG 21-17) or specific tests
of the cable – axial thrust made by the cable
(conductor thermo-mechanical manufacturer
thrust) and retraction
Cable components retraction X Short-term and long term test Test report has to be clear
(insulation, metallic screen, including accessories with about the way of laying
outer sheath) thermal cycles and a (in particular for the
representative configuration of prequalification test)
laying and clamping.
Radial thermal expansion of the X Design of the clamp
cable components
Maximum temperature X To be known and taken into
(surroundings of cable or account for the design
accessories)
Vibrations X X Support design, flexible link
from power apparatus and
terminations
Overload Same constraints as above for Same as previously described
steady-state operation but for steady state operation.
higher level of constraints Adjustment of level of
constraint and test duration
H. Geene and R. Schroth
9
Contents
10.1 Background . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425
10.1.1 Terms of Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425
10.1.2 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 426
10.1.3 Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 426
10.2 Cable Conductors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 427
10.2.1 Basic Cable Conductor Types and Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 427
10.2.2 Materials for Cable Conductors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428
10.2.3 Fillers (Compounds, Yarns, Cloth, Powder, . . .) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 431
10.2.4 Construction of Cable Conductors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 431
10.3 Connectors for HV/EHV Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 434
10.3.1 Basic Theory of Current Carrying Cable-Connections . . . . . . . . . . . . . . . . . . . . . . 435
10.3.2 Connector Construction and Types for HV and EHV Extruded Cables . . . . . 440
10.3.3 Diagnostics for Cable Connector Condition Assessment . . . . . . . . . . . . . . . . . . . . 455
10.4 Cable Connectors in Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 456
10.4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 456
10.4.2 Mechanical Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 457
10.4.3 Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 458
10.4.4 Cable Connectors in Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 459
10.4.5 Cable Connectors in Outdoor Terminations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 460
10.4.6 Cable Connectors in Equipment Type Terminations . . . . . . . . . . . . . . . . . . . . . . . . . 461
10.4.7 Connections to the Cable Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 462
10.5 Installation of Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 466
10.5.1 Installation Instruction Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 466
10.5.2 Cable Conductor Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 466
10.5.3 Mechanical Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 467
10.5.4 Crimp Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 467
10.5.5 Exothermic Welding Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 468
10.5.6 MIG or TIG Welding Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 468
M. Uzelac (*)
G&W Electric Co, R&D, HV Cable Accessories, Bolingbrook, USA
e-mail: muzelac@gwelec.com
Executive Summary
The current IEC 61238-1-3 [1] standard applies to connectors for medium voltage
(MV) cables up to 30 kV (Um ¼ 36 kV). There is no IEC standard for connectors for
cables for high voltage (HV) and extra high voltage (EHV) networks. The IEC standards
for testing HV/EHV cable systems/accessories (IEC 60840 and IEC 62067 correspond-
ingly) do not specify separate tests for qualifying only connectors. The task of CIGRE
WG B1.46 was to propose test regimes for connectors for cables above 30 kV, with
focus on larger conductor sizes typically used in HV/EHV cable systems.
The type tests specified in IEC 61238-1-3 consider connectors to be commodity items.
Such connectors may be, and in some cases, are used and installed in MV cable
accessories without consent from the cable accessory manufacturer. Inappropriate use
and improper installation of MV connectors have been the cause of numerous failures in
MV networks, especially in systems with high and intermittent loads such as wind farms.
In HV/EHV applications where the system approach is dominant, connectors are
considered to be an integral part of the cable system. The design, development
testing, and in many cases installation of such connectors are under strict control of
the cable system/accessory manufacturer who takes full responsibility for the per-
formance of each component in a particular project, including connectors. This is
one of the reasons why there have been a very small number of failures that can be
attributed to the malfunction of the connectors in HV/EHV networks, compared to
MV. Although for HV/EHV systems the connectors are not challenged often to their
rated values, there is a trend to utilize cable systems closer to their maximum rating.
10 Test Regimes for HV and EHV Cable Connectors 423
Section 10.3 gives a short introduction into the connection theory. It also describes
design of the most commonly used connectors in HV/EHV cable networks. Com-
pression (crimp) connectors are still the most commonly used but mechanical con-
nectors are gaining popularity due to simple field installation. Other connector types
like MIG (Metal Inert Gas) welded and TIG (Tungsten Inert Gas) welded, exother-
mically welded, clamp connectors, and others are all used in special applications.
Section 10.4 talks about cable connectors in accessories where the connectors
may be exposed to significant thermal and mechanical stresses. Expansion and
contraction of cable conductors during normal and abnormal (e.g., short circuit)
operation may generate significant thrust and tensile forces on cable connectors.
Encapsulation of connectors with components of cable accessories changes the
thermal environment from that when connector is tested on a bare conductor. Finally,
connections to the cable connectors in HV/EHV terminations and transition joints
are exposed to the same thermo-mechanical stress. These connections have not been
specifically addressed in any of the standards.
Section 10.5 considers the installation of connectors. Many failures of connectors in
the MV cable systems are contributed to either improper installation or improper use of
the connectors. Use of proper tools and strict following of instructions for connector
installation is essential for proper connector operation as outlined in ▶ Chaps. 5, “Cable
Accessory Workmanship on Extruded High Voltage Cables” and ▶ 6, “Guidelines for
Maintaining the Integrity of Extruded Cable Accessories” of this book. This section
provides more in-depth information on installation of various connector types.
Section 10.6 discusses field experience. The working group launched a CIGRE
sponsored survey on experience with cable connectors in HV/EHV systems. In
addition, representatives from major utilities were invited to present their experience
in the WG meetings. The survey was answered by 34 utilities from 12 countries and
presentations at the working group meetings were done by three major utilities from
USA, France, and Germany. Field experience is very good. No failures were
reported on connectors in HV/EHV terminations. The few failures reported on
through connectors (joint connectors) were attributed to installation error.
Section 10.7 describes existing test methods for cable connectors. The MV
connectors are tested per IEC61239-1-3, while the HV/EHV connectors are tested
per proprietary test procedures set forth by cable system/accessory manufacturers
and, in some cases, by user’s requirements.
Section 10.8 contains proposals for development tests of HV/EHV connectors. All
manufacturers of HV/EHV cable systems perform certain tests on connectors at their
own discretion before doing Type and PQ (when required) tests on accessories/systems.
Most follow existing IEC and ANSI Standards for MV connectors but with some
deviations from the standard, especially when it comes to connectors for large size
conductors. The WG has made an effort to “standardize” these development tests and
define test sequences and range of approval combining experience of cable system/
accessory manufactures, manufacturers of connectors for MVand HVapplications, and
experience of the laboratories in connector testing as well as the input from academia.
Section 10.9 lists conclusions of the work. Statements to acknowledge current
practice in development testing of connectors are included. The WG proposes a
10 Test Regimes for HV and EHV Cable Connectors 425
10.1 Background
Thus, when WG16 of IEC TC20 commenced work on revision of the current
IEC61238-1-3 standard a part 4 was reserved for HV cable connectors and is
planned for the future. Technical evaluation by experts in the area was necessary
and TC20 agreed to pass the work to CIGRE. Study Committee B1 of CIGRE set up
WG B1.46 to review this subject and issue report with the terms of reference and
scope given below.
• Review: Existing conductor types and sizes; The range and types of cable
conductor connectors; The types of connection systems used in joints and termi-
nations; Existing national and international standards and the extent to which they
cover the testing of connectors; Any work been done by CIGRE, CIRED,
JICABLE, and other; Extent of service experience so far for different connector
types (prepare survey and invite users to the WG meetings to share their experi-
ence); Extent of experience in type testing MV cable connectors; Extend of
experience in testing HV?EHV cable connectors (PQ tests, type tests failure
mode tests. . .); Customer’s needs.
• Analyses: Operation on high loaded systems where conductors are approaching
or temporarily exceeding maximum conductor operating temperature. Academia
input on physical properties of connector material vs. temperature and mechanical
stress; Thermo-mechanical performance of connectors under cycling loads;
426 M. Uzelac
10.1.2 Scope
The conductor connectors for HV and EHV applications are to be considered. The
WG will make recommendation to include or not connectors for MV applications.
The connectors for extruded cables are of prime interest. The connectors for
submarine cables are not in the scope of the WG.
The WG should consider the tests that reflect mutual impact between connectors,
cable conductors, and accessories.
10.1.3 Terminology
The following terminology is used in this TB, following that used in IEC 61238-1-3
which is also generally in line with IEC 60050, International Electrotechnical
Vocabulary (IEV) – Chap. 461: Electric Cables.
Current experience and practices are outlined in this section. It includes review of
cable conductor and cable connector state of the art designs, existing national and
IEC standards, users experience with connectors both in medium voltage and high
voltage application, the extent of testing connectors by manufacturers, users, and
independent laboratories and so on.
In general conductors in high voltage XLPE cables are made of solid or stranded
copper, aluminum, or aluminum alloy for fixed installations. In terms of the con-
ductor cross-section the electrically effective value, rather than the geometric cross
section, is used. It is represented by the measured resistance of the conductor.
General design parameters of conductors are:
For high voltage cables conductors usually consist of stranded single wires or in
some cases of just a solid conductor. General design parameters of wires are:
In terms of the used conductor material wires or profiles are applied. The material for
wires and profiles of conductors is specified in IEC 60228 and it can be made from:
• Plain copper
• Metal-coated annealed copper
• Aluminum
• Aluminum alloy
In order to block the radial conductivity sometimes insulated wires are used with
copper. Aluminum is very ignoble and the surface reacts at room temperature with
air and water immediately to an aluminum oxide layer.
Since the very beginning of production of cables, copper has been known for its
unique and useful properties. The chemical element copper is in the periodic table,
together with gold and silver in group 11 and the fourth period between the elements
nickel and zinc [11]. Its good conductivity and ductility make copper well proven
material for high voltage cable conductors. Copper is a malleable metal, stretchable
and under cold conditions a deformable material with an excellent conductivity.
Copper with a level of purity (99.95%) is used, which enables the production of fine
wires down to a diameter of 10 microns.
Aluminum, in contrast to copper, has a lower density, but conductors made from
aluminum need a larger cross section than their counterparts of copper because of
10 Test Regimes for HV and EHV Cable Connectors 429
their lower conductivity. Aluminum creeps at high temperatures and high pressures
(cold flow) due to changes its shape in the micron range and in combination with
moisture or nobler metals is aluminum electrochemically negative and therefore
highly susceptible to corrosion.
In general, the surface of aluminum is oxidized. Aluminum oxide is difficult to
remove and has high electrical resistance.
However, the surface of a conductor with oxidized of enameled layer may be
treated in a special way as requested in the work instruction manual for the
connector.
Table 10.1 shows typical properties of copper and aluminum.
According to the mass density, the weight of an equivalent conductor cross-
section of copper to aluminum is:
– 1 kg Cu ~ 0.3 kg Al
– 1 Sm2/kg Cu ~ 2 Sm2/kg Al
In general aluminum is lighter and lower in cost, but to achieve the same
conductivity, a larger conductor cross-section must be used. But considering the
better conductivity/weight relationship and lower costs for raw material of alumi-
num, the relationship between copper and aluminum is approximately 6:1 at the
same transmission capacity.
Therefore, the replacement of copper by aluminum, which has a lower price, is
becoming a developing trend in the cable industry.
However, the significant greenhouse gas emission during aluminum production
may restrict this development, because aluminum has more carbon (CO2) emission
in contrast with copper.
Another and just as important aspect is that increasing the cross section of
conductors for cables can significantly increase electrical energy efficiency. Incorpo-
rating a higher cross section can save a huge amount of greenhouse gas emissions
(CO2) due to lower losses in the cable. At the same time, the energy savings achieved
will, in the vast majority of cases, lead to lower costs over the life cycle of the system.
In this matter, IEC 60287 sets out a method for the selection of a cable size taking
into account the initial investments and the future costs of energy losses during the
anticipated operational life of the cable. Matters such as maintenance, energy losses
in forced cooling systems, and time of day energy costs have not been included in
this standard. All conductor sizes have an economic current range for given instal-
lation conditions [12].
In terms of life time assessment, it has been shown that in general the difference
between copper and aluminum cables over their entire lifetime is not as significant as
generally thought. The cost for raw copper material is about 3.5–4 times higher than
aluminum but looking at lifetime costs, and within the uncertainties of LCCA over
the long cable lifetime, both solutions can be considered equivalent [13].
In general, there are different types of wires in use, for example, round solid or
round enameled solid as shown in Fig. 10.1. Enameled wires are applied only with
copper conductors. In high voltage extruded cables, typically round and solid wires
are used.
Due to the manufacturing process in which the wires inside of a conductor are
compacted, an individual deformation of single wires is a typical result after
production. Especially the outer surface of the outer layer receives a strong
d d d D d
Basecoat D-d=increase
1mm
Cu Cu Cu Al
bare oxidized enameled bare
(thickness 1 µm) (D-d)/2 = approx. 10 µm
deformation. For smaller cross sections of conductors, the outer surface has to be
more compacted and smoothened as shown in Fig. 10.2.
Conductors are either round or sectoral in shape. They are realized with solid metal,
stranded wires. Up to 1000 mm2 the minimum number of wires in the conductor is
specified. For larger cross sections, the minimum number of wires for these sizes is
not specified. These sizes are usually constructed as a “Milliken” conductor with
4, 5, or 6 equal segments, which is designed to reduce the skin effect, and thus
improving the value of the ac resistance of the conductor.
432 M. Uzelac
For smaller cross-sections, both stranded and solid conductors can be used. In a
few cases, solid aluminum conductors are used up to 1600 mm2. For larger conduc-
tors, the increased bending force limits the use of solid conductors.
Round stranded
Round, solid Round, stranded
compacted
Fig. 10.6 Mechanical connector for HV and EHV joints for extruded cables with the same
conductor size but different voltage level
The typical values for the cable insulation wall thickness are shown in the
Table 10.2.
The cable connector transfers electrical current from cable conductor to substation
equipment or to another cable length or section. It is imperative that the contact
resistance between connector and cable conductor remains stable during the lifetime
of a cable accessory. An increase of contact resistance beyond an acceptable limit
causes an increase of connector temperature which may result in failure of the
accessory (e.g., by thermal runaway).
In operation, cable connectors are subjected to thermal and mechanical stresses
which depend on many factors, for example, nominal and intermittent circuit load,
short circuit current value and duration, the size, material and construction of the
cable conductor, voltage level, type of accessories used in a particular project, level
of thrust and tensile forces, cable route, just to mention few. The manufacturer of an
HV cable system/accessory must take into account all these factors when making a
decision on which type of cable connectors and which installation method of the
connectors are the most appropriate to use in accessories for a specific project. Some
connector designs for HV/EHV cables are described in this section.
Many cable accessory manufacturers make their own connectors and in some
cases connector installation tools. The connectors are specifically designed to meet
their requirements and constraints of design of an HV/EHV accessory and cable.
Some cable accessory manufacturers purchase connectors from connector manufac-
turers, but then again to meet strict requirements of the designs of a particular cable
accessory and cable. Mixing and matching of cable accessories and connectors,
which sometimes is the case in MV applications, is not possible in HV/EHV
applications.
In the absence of the industry standards for testing connectors for HV cables, the
manufacturers of cable the systems/accessories perform tests on connector/
10 Test Regimes for HV and EHV Cable Connectors 435
conductor combinations at their own discretion as development tests. These tests are
combination of applicable requirements from industry standards for MV connectors
and manufacturer’s own experience. Once they are satisfied with the results of
development tests, the connectors are installed in accessories which in turn are tested
to the requirements of type and prequalification (where required) tests of IEC 60840
(for HV) and IEC 62067 (for EHV) Standards. The requirements for the type tests of
the cable system/accessory include 20 load cycles at maximum operating tempera-
ture of the cable plus 5–10 K. For the prequalification, the number of cycles is 180 at
maximum operating temperature plus 0–5 K.
This section explains a very basic concept of the contact surfaces and theory in
calculation of contact resistance. Refer to Sect. 10.10, Bibliography/References, for
comprehensive references on the subject.
F =0 F >0
Impurity layer
conductor 1 conductor 1
A-spots A-spots
Current-flow through A-spots
conductor 2 conductor 2
a) No external force applied to conductors. Only b) External force applied. The A-spots are
few micro contacts (A-spots) due to surface deformed and impurity layers are broken at higher
roughness force
Key:
As
As apparent contact area
A t1 A t3 At load bearing contact area
Ai insulating contact area
A i1 A m1 A q A i2 A i4 A m2 A i5 Aq quasi conducting contact area
Ai3 = A t2 Am conducting contact area
and As >> At > Am
n…number of A-spots
Area of homogeneous R M2
current-flown material
Conductor 2 RM2
mechanically loaded which is again larger than the area which is electrically
conducting. Within the A-spots there are conducting areas, where the metal of the
conductors is in true contact, quasi conducting areas where some surface impurity
layer is still present, giving limited conductivity, and insulating areas which are in
mechanical contact but provide no significant conduction.
• Sphere and ellipsoid model [14]: this is a development of the A-spot model. Holm
considered that the A-spots cause a “restriction” of current flow in the vicinity of
the contact, see the red lines in Fig. 10.9, representing the current flow in a single
A-spot contact between two cylinders. An increase in resistance compared to that
for a solid rod is considered to be caused by the increase in current density close to
the A-spots.
[21]. The model divides the connection in infinitesimal elements of the length dx,
each consisting of the material resistances R1 and R2 per unit length of the jointed
conductors and a resistivity Rq. This resistivity is assumed to be equally distributed
along the connection.
The Kirchhoff’s laws are applied to the circuit and a differential equation is
formed for the voltage ux. An expression for the joint resistance Rj is derived from
the solution of the differential equation [21]:
R þ R cosh ðαsÞ
R1 ð R1 R2 Þ αs
Rj ¼ R sþ tanh þ 1 2
ð10:1Þ
R1 þ R2 2 α 2 α sinh ðαsÞ
with
rffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
R1 þ R 2
α¼ ð10:2Þ
Rq
with
R1 R2
a¼ þ
R2 R1
pffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
c ¼ s K F ð R1 þ R2 Þ
If the resistivity Rq fulfills the condition in Eq. (10.4), Eq. (10.3) may be solved
for resistivity Rq analytically:
Rq s2 ðR1 þ R2 Þ ð10:4Þ
h i2
c 0
Rq ¼ k ð10:5Þ
a
In case the condition in Eq. (10.4) is not fulfilled, Eq. (10.3) may only be solved
numerically. In both cases, a solution for the characteristic value Rq of a connection
may be calculated. For this purpose, the material resistances of conductor and sleeve
and the geometry of the compression connection must be known. The resistivity Rq
provides the opportunity to rate the electrical performance of a connection indepen-
dently from the material resistances. Thus, the resistivity Rq is related to the contact
resistance of a connection directly. Of course, due to the constraints of the electrical
model it may only be applied for those types of connections that meet the following
conditions. The electrical model implies the assumption that the distribution of the
a-spots in the connection is almost homogenous in axial and radial direction. Of
course, the resistivity Rq integrates the influence of all a-spots in a connection
regardless of their actual size and location or whether there is more than one actual
contact surface. Thus, it cannot be separated, whether a rise in the resistivity Rq stems
from the a-spots between conductor and sleeve or from those a-spots between the
single strands. Nevertheless, the value of Rq is a suitable criterion to analyze and
compare the electrical behavior of different designs of compression connectors.
However, the derived ratio k’ still contains a part of the material resistances and is
therefore no autonomous criterion to rate the electrical performance of different
connections. Further conclusions can be found in [21].
Unlike connectors for medium voltage which are a commodity product, the connectors
for high voltage applications are carefully selected for a particular application in the
cable system. There are many designs of cable connectors for high voltage applications.
Some of those are described in this section. Compression type connectors are used most
commonly for HV cable accessories, but lately mechanical (shear-bolt) types are
gaining ground due to the ease of installation which does not require any special tools.
compress and will not crack while being crimped. The connector designer has to take
into consideration the increase of material hardness during crimping operation.
The length of the ferrule and its inner and outer diameters depend on many factors
including conductor material, size, and crimping method.
Typically, the inner ferrule diameter is selected to be a tight fit to the bare
conductor diameter. The cross-sectional area of the connector does not necessarily
need to match effective area of the conductor. In general, the cross-section of
connectors for copper conductors is somewhat smaller than the effective area of
the conductors while aluminum connectors have significantly larger area than the
associated conductors. In the case of copper connectors, a smaller area is possible
due to a higher heat dissipation from the connector surface. In the case of aluminum
connectors, a larger area is required for mechanical reasons.
The length of the ferrule is very critical. It establishes the length of engagement
between the cable conductor and the connector. Some of the variables that influence
selection of the length of the ferrule include the crimping method, the size of the
crimping dies (if used), the number of crimps, the type of connector material, and the
conductor size, material, and construction. The longer the ferrule the better connec-
tion between the conductor and connector may be achieved. On the other hand, due
to constraints involving cable accessories, the goal of a connector manufacturer is to
make the ferrule as short as possible.
Fig. 10.12 Four-ram, deep-indent press and crimp connector for 2000 mm2 Cu cable
Fig. 10.13 200 ton press with hex-dies and crimp connector on 2500 mm2 Cu cable
varies from few tons to few hundred tons. Figure 10.13 shows a 200 ton crimping
tool used for the connector for a 2500 mm2 copper conductor.
The pressure of the die on the connector depends on the force, the width of the
crimping surface of the die, and shape of the die (hex, circular, oval. . .). A good
crimp is achieved when die is fully closed. In that case the crimped connector
under the die forms to the shape of the die. The die design usually allows for flow
of the metal.
Some connector manufacturers characterize crimp efficiency of specific die set by
the crimp ratio, which is the ratio between the area of closed die set and sum of
10 Test Regimes for HV and EHV Cable Connectors 443
effective cross section area of the cable conductor and connector ferule. The
following formula defines the crimp ratio.
Adie
CR ¼ 100
ACond þ Aferule
The procedure for connector installation should be provided for each project. The
procedure should specify starting point of the crimp, the number and sequence of
crimps, the distance between crimps, rotation of the crimping head, and the necessity
for full closure of the dies. The procedure should also include preparation of the
conductor for crimping, for example, cleaning the conductor and necessity for
removing fillers and/or cleaning individual strands in case of strand filled or enam-
eled conductors.
oxide layer on the connector body is removed by dipping in a caustic bath. Tin is
very ductile. During installation of the conductor, the tin is pushed aside while the
peaks of the threads are cutting into the conductor surface. The lubricant remains in
the “valleys” of the threads or grooves of the body preventing further oxidation of
the just created metal contact areas between connector body and conductor.
Tin-plating of the threated holes for the shear-bolts in the connector body controls
the coefficient of friction during fastening of the shear bolts.
It may be required that for HV and EHV joints the outer diameter of the body of
the connector matches insulation diameter (see Fig. 10.6). Hence, the wall thickness
of shear-bolt connector bodies for HV and EHV joints is typically much bigger
comparing to MV-applications (Fig. 10.14). The thicker the connector wall the
longer is the length of a threaded hole for the shear bolt, and higher force from
shear bolt to conductor may be achieved. This increases design margin for the yield
strength and decreases possibility of relaxation of compression force in service.
It also has to be kept in mind, when designing shear bolt connectors, that the
bigger the conductors are, the higher radial forces must be applied to break oxide
layers of stranded aluminum conductors.
A given mechanical connector design may be adopted to a specific slip-on joint on
specific cables by modifying body of the connector and keeping the design and number
of shear bolts constant for a specified conductor. Features of such connector are:
• Outer diameter of the connector body closely matches the outer diameter of
prepared cable insulation to minimize the slip-on step.
By leaving almost no “air” between connector and the rubber body of the joint,
the heat transfer from connection through the connector and the joint is maxi-
mized and
By increasing the OD of connector body (to match cable insulation OD), the
electrical resistance of the connection is lowered.
• The inner diameter of the connector is tight fit to actual conductor in the project to
minimize the gap between cable conductor and connector body.
The design of the face of the shear bolt that presses on the cable conductor also
varies; some designs avoid rotation of the face against the conductor to prevent
strand damage, whereas others have direct contact from flat, curved, or conical ends.
Mechanical connectors with aluminum bodies can be used on both copper and
aluminum conductors although conclusions as to their long-term suitability for the
latter are not yet generally available [26].
The above features can be seen in Fig. 10.14, which is provided courtesy of
European Manufacturers.
Mechanical connectors are widely used for LV and MV accessories, sizes suitable
for conductors from 25 mm2 up to 630 or 1000 mm2 being widely available.
Development of designs suitable for HV conductors up to 2500 mm2 is also in
progress. To achieve satisfactory connection of such large conductors can require a
large number of shear bolts in a relatively long connector body. An example of a
2500 mm2 mechanical connector is shown in Fig. 10.15. The picture depicts
connector secured to cable conductors but the bolts need yet to be sheared off during
final installation.
conductors above approximately 1250 kcmil (~630 mm2) while for smaller alumi-
num conductors a crimp connection is utilized.
Welded connections fuse two cable conductors (in case of cable joints) or cable
conductor and connector (in case of cable terminations) by application of molten
metal. Either the Metal Inert Gas (MIG) or Tungsten Inert Gas (TIG) welding
process is adopted in these cases. The MIG welding process, which generates less
heat during the welding operation, is commonly used in the USA for large aluminum
cable conductors.
Welded connections are also used for copper conductors with enameled strands. If
crimp connectors were used on these conductors, the enamel coating would need to
be removed from every strand, which is a quite elaborate and time-consuming
process.
As significant heat is generated during welding, care should be taken that cable
insulation is not overheated. It is necessary to dissipate excess heat to keep temper-
ature of the adjacent conductor and surrounding cable insulation below a specified
value. Once the cable conductor reaches the maximum allowed temperature, the
welding operation has to be interrupted to let conductor cool down. This is why
installation of welded connections is more time consuming than for other connection
types. Only trained, highly skilled operators using appropriate welding and cooling
equipment can perform this task.
Efficient cooling speeds up the process. Use of heat-sink clamps in combination
with forced air or gas flow is the most common method. In some cases, water is used
as coolant for extruded cables. In case of oil filled cables, the cooling system is more
elaborate since it has to incorporate provision of vacuum application in order to
remove the oil from the strands in the weld area.
The strands of the cable conductor have to be thoroughly cleaned to remove any
insulating tapes or cable conductor filler material before welding. If these are not
removed, the weld is contaminated and becomes porous which results in reduced
conductivity and low mechanical strength of connection.
As shown, the procedure for welding power cable conductors is elaborate. That is
one of the reasons why commercial installations of underground cable with large
aluminum conductors only began after methods for field-welding the conductors
were developed and proven.
The conductors to be joined are cut in a wedge shape, and then buttered with weld
metal, and the two “V” grooves are filled until the conductor diameter is reached. As
a result, this connection is flush with the conductor, which is necessary when the
joint must have a minimum diameter, such as in laminated paper cable joints.
Fig. 10.17 Steps in installation of MIG weld connector for HV cable termination
Fig. 10.18 Aluminum and copper exothermically welded connector for HV cable terminations
Fig. 10.19 Aluminum and copper exothermically welded connections for HV cable joints
development tests. Notice that there are very few porosity holes inside the connector
as well as at the outside holes. Each connector manufacturer has their own criteria in
size and population of the porosity holes and depressions.
The equipment for making exothermically welded connection consists of crucible
made from graphite and unique ceramic fiber smoke filter system as shown in
Fig. 10.20. The filter prevents sparks and reduces generation of dust and other
emissions to acceptable level, even if used in unventilated manholes and cable tunnels.
The installation equipment is portable with no external source of power required.
Like welding, brazing and soldering are important methods of thermally joining
metals. Both welding and brazing/soldering lead to the formation of a metallic joint;
however, the chemical composition of these joints differs. Whereas a welded joint
has the same chemical composition as that of the two identical parent metals being
joined, the use of a filler alloy in a brazing or soldering procedure means that the
brazed or soldered joint has a different chemical composition to that of the parent
materials. Brazing and soldering do not involve any melting of the parent material,
that is, of the surfaces to be joined. Instead, the work pieces are joined by introducing
an additional molten metal, the “filler metal,” possibly in combination with a flux
and/or in a protective gas atmosphere. Some of the advantages of brazing or
soldering compared to welding are:
• As less heat is applied in the joining process, brazed or soldered parts tend to
exhibit greater dimensional accuracy and less distortion.
• Multiple brazed/soldered joints can be created on a single work piece in a single
operation.
• Intricate assemblies can be brazed/soldered without damage.
• Brazed/soldered joints exhibit good thermal and electrical conductivity.
• As brazing/soldering directs less heat into the joint than welding, there is less
residual stress and distortion in the component.
and the braze/solder metal have different chemical potentials; there is a risk of
chemical corrosion due to the presence of flux residues; extensive preparatory and
after-treatment procedures are often required, such as degreasing, etching, removal
of flux residues.
The related joining techniques of brazing and soldering are distinguished in the
DIN ISO 857-2 standard by the liquid temperature of the filler metal used. In
soldering, the liquid temperature of the filler metal is below 450 C; in brazing it
is above 450 C.
Brazing is used if the joint will be subjected to high mechanical and thermal
stresses. When brazing copper, the filler metals of choice are brass brazing alloys,
copper-phosphorus, and silver brazing alloys. Silver brazing filler metals have lower
brazing temperatures, which reduces the risk of forming coarse grains and enables
faster brazing speeds. Copper brazing procedure is shown in Fig. 10.21.
In order to achieve a high-quality brazed joint between cable conductors, the
mating surfaces need to be carefully prepared. Surface preparation can involve
chemical, mechanical, or thermal cleaning procedures or a combination thereof.
The parts to be brazed must be clean and free from any residues that might inhibit
wetting, such as oxides, oil, grease, dirt, rust, paint, cutting fluids. In case of stranded
conductor, inner wires as well as outer wires of near mating surface of the conductor
should be cleaned carefully. The connecting mold can be mounted to position each
end of conductor properly. In order to avoid overheating of cable insulation, heat-
sink or cooling blocks of water or forced air or cooling gas are usually set up near the
insulation. The choice of an appropriate brazing process and suitable flux and filler
materials is critically important to produce conductor joint with sufficient mechan-
ical properties. Conductors are brazed with a single brazing seam across the entire
diameter or layer by layer or segment by segment or wire by wire.
The quality of a brazing process depends on the skill and experience of the
operator. If the parent material and filler alloy are properly matched, and if the
joint is properly designed and made, a brazed joint can provide as a reliable join as
that achievable by welding. Brazing faults and defects such as flux burning,
de-wetting, discontinuities, cracks, porosity, incomplete fusion, or penetration and
nonmetallic inclusions must be avoided. Sometimes, in order to check brazing
excess of heat and to maintain temperature of the conductor and surrounding cable
insulation below specified value.
Creuset welding produces connection with high performances as it is a perfect
molecular bond, the conductor is not broken, and there are no contact surfaces.
The integrity of the effective cross section of the conductor is unaltered. The final
result is shown in Fig. 10.25.
Only trained and qualified jointers using appropriate welding and cooling equip-
ment can perform this kind of welding (see ▶ Chaps. 5, “Cable Accessory Work-
manship on Extruded High Voltage Cables” and ▶ 6, “Guidelines for Maintaining
the Integrity of Extruded Cable Accessories”) of this book.
Fig. 10.25 Mold removed and finished “Creuset” weld after final cleaning
Particular attention has to be paid to the endurance of the ground connection at the
accessories, currents in the screen may be important, and the ability of the screen
connection must not to overheat during cycling should be checked.
The TB 446 (Advanced Design of Metal Laminated Coverings: Recommenda-
tions for Tests, Guide to Use, Operational Feedback) by WG B1.25 [35] describes
the three successful designs that are today covering the market:
• Lead sheath
• Lead sheath with copper wires
• Aluminum corrugated sheath
• Aluminum smooth sheath
• Aluminum laminated sheath
• Copper wires + aluminum laminated
• Copper wires + Cu laminated
• Aluminum wires + aluminum laminated
Chemical functions:
In the case of a single phase short circuit, the current can flow through the metal
screen, the metal screen/grounding connection, the ground lead of the joint or the
termination.
Existing short circuit tests as per TB 446 [35] have been designed to test metal
screen/grounding connection in a simple way, electric parameters of this test have
been chosen to be such that the test capabilities are available in many laboratories at
an acceptable cost.
Test
Five short circuits shall be applied successively to the assembly:
• Before the short circuit test, the cable conductor shall be heated and stabilized for
at least 2 h at a temperature 90–95 C.
• The short circuits are separated by an interval of time long enough to cool down
the cable screen within 5 K of its initial temperature.
Rating
Result
Examination of the samples should reveal no cracks or separation of the metal foil
of laminated protective coverings or damage to other parts of the cable.
There shall be no sign of harmful deterioration of the cable/joint screen connec-
tion, neither at the cross-bonding leads nor at the grounding connections.
The temperature of the connection of the molded rubber joint may be controlled
be fiber optic cable which may be laid over the joint body or over the housing in
which the joint is installed. The CIGRE TB 247 on Optimization of Power Trans-
mission Capability of Underground Cable Systems Using Thermal Monitoring
shows current practice of laying FO cable over the joint in different countries [33].
CIGRE TB 756 “Thermal Monitoring of Cable Circuits and Grid Operators use of
Dynamic Rating Systems [36] by CIGRE WG B1.45” provides an update and a
comprehensive bibliography.
The X-ray method is mostly used in MV applications. This method shows proper
positioning of the cable connector inside the joint. Improper positioning of the
connector may cause dielectric failure. This method is also used to periodically
check for signs of cable distortion resulting from thermo-mechanical movement of
cables and joints in the HV pipe-type cable systems, resulting in thermo-mechanical
bending (TMB) of the cables, which eventually may cause electrical failure.
10.4.1 General
Accessories are an essential part of HV cable system. They need to operate under the
same electrical conditions as the cable.
In relation to the connector system of the accessories, we can distinguish between
current load and mechanical load.
The current load is enforced by the operation current of the cable and can be
divided in normal load, emergency load (in some countries), and the load under short
circuit conditions, that is, short circuit currents.
The mechanical load or forces in the connector system can be divided in internal
and external forces. The internal forces, also called thermo-mechanical forces, are
generated by the thermal expansion of the cable due to operating and short circuit
currents. The external forces are generated by the environment of the cable system
and are, for example, the consequence of gravity, clamping, soil movements,
vibrations, etc.
Forces generated by gravity or thermo-mechanical movements of the system are
the so-called static forces. These forces act continuously under the influence of
gravity or have a cyclic behavior as a consequence of the load cycles, which usually
appear in a daily sequence. The forces usually start as pushing forces, so called thrust
forces, caused by the thermal expansion of the conductors, but will eventually also
generate pulling forces during no load or low load of the system.
Under the influence of the high thrust forces (in the order of tons) the conductor
starts to deform, distributed over the entire cable, making it effectively shorter. Once
the load decreases the thrust forces will go down and eventually generating pulling
forces. For this reason, the connector system has to be able to withstand both pushing
and pulling forces.
10 Test Regimes for HV and EHV Cable Connectors 457
The main cause for the dynamic load of the system is short circuit forces passing
through the system. Due to the magnetic field, generated by the short circuit current,
forces are generated perpendicular on the cable. These forces, the so-called Lorentz
forces, can generate pushing and pulling forces and are usually of short duration (less
than 1 s).
Apart from the magnetic forces there is also the effect of the thermal expansion of
the conductor under the short circuit conditions. In case of HV systems, with usually
large conductor sizes, the temperature increase is low and the impact of the thermo-
mechanical expansion negligible.
Short circuits can also have a very local impact on the connector system,
thermally and magnetically.
High contact resistance will cause high local dissipation and increasing temper-
atures. Because of this the mechanical properties of the conductor material can
change (annealing) lowering the contact pressure and increasing the contact
resistance.
The currents in the parallel conductor wires will cause a strong magnetic field and
related magnetic forces pushing the wires more closely. Also, this effect may
temporary lower the contact pressure with the connector, increasing the contact
resistance.
Detailed overview of the thermo-mechanical forces involved with large conduc-
tor XLPE cable system (1000 mm2 and above) is provided in CIGRE TB
669 “Mechanical Forces in Large Conductor Cross-Section XLPE Cables” [32].
Such forces can generate high axial thrust and tension and/or significant cycling
movements in the installed cable system. The designer of connectors for these cables
in HV and EHV applications has to take these forces into account and to incorporate
into development tests.
The connectors for HV cables are exposed to significant mechanical forces during
assembly process of cable accessories due to movement of the cable and accessory
into their final position [32]. More importantly, connectors are exposed to thermo-
mechanical forces in service generated by thermal expansion and contraction of the
cable due to variations of the load current or exposure to the short circuit current
[32]. In practice, the forces caused during the installation process are not problem-
atical and are not usually limiting for an HV connector. However, the loads imposed
on the conductor due to changes in conductor temperature can be very significant.
After initial installation, the cable conductor is normally relaxed with little axial
mechanical force present. However, as the temperature increases the conductor
expands and, if the cable is rigidly installed [27], then axial thermal expansion is
prevented and instead a compressive force develops in the conductor (which is
evidenced as a thrust force from the conductor at the cable ends). If a rigidly installed
cable is heated rapidly to its full operating temperature on the first load cycle, then
relatively high forces can be developed. However, if expansion is fully prevented
458 M. Uzelac
then the result is that relaxation of the maximum thrust occurs towards the maximum
conductor temperature, reducing the compressive force produced. However, a con-
sequence of this relaxation is that a tensile force develops in the conductor when it
cools down to the initial installation temperature (or below). Typically, after a
number of cycles the compressive and tensile forces developed in a conductor
cycling over its full temperature range will be similar, and with values of approxi-
mately 50% of the maximum force that might be achievable in a single rapid cycle.
As far as the connector is concerned the conductor tensile force is the most critical
as it will tend to pull the conductor out of the connector. In the case of the conductor
compressive force then this is normally equal and opposite to the force from the next
cable length on the other side of a joint or in the case of a termination has to be
resisted by the connection of the connector to the body of the termination itself.
Thus, in terms of testing the performance of connectors only the tensile (pullout)
force from the conductor has to be considered.
In assessing the behavior under tension of a conductor to connector connection,
the tensile load that can be resisted with minimum movement has to be assessed.
10.4.3 Environment
10.4.4.1 General
Joints are subjected to current load and mechanical forces.
The main consequence of the current load is the heating of the cable and
connector system, leading to elevated temperatures inside the joint. In continuous
operating conditions, temperatures exceeding the maximum operating temperature
of the extruded cable need to be avoided [30]. In this respect the conductivity of the
connector system and the thermal properties of the joint have to be considered.
460 M. Uzelac
The connector system needs to withstand the mechanical forces that do exist in cable
systems, such as pushing (thrust), lateral and pulling forces. See Reference [32]. These
forces should not lead to instabilities in the performance of the connector system.
The Annex 1 of referenced document [30] shows thermal calculation for HV and
EHV extruded cable joint. It is shown that in stationary conditions, the cable conduc-
tor in the joint reaches a higher temperature than in the cable, because of higher
thermal resistance of the joint. In the first 6 h of the heating cycle, the temperature of
the cable conductor in the joint is lower than in the cable conductor outside the joint,
as shown in Fig. 10.26 and Fig. ▶ 9.3 in ▶ Chap. 9, “Thermal Ratings of HV Cable
Accessories” of this book, due to the longer thermal time constant of the joint.
In most of the termination designs, the connector is located in the top of the
termination. The connectors in terminations are usually large, compared to the
10 Test Regimes for HV and EHV Cable Connectors 461
110
100
90
80
Temperature (˚C)
70
60
50
40
30
Joint
20
cable
10
0
0 1 2 3 4 5 6 7 8 9 10
Time (hours)
Fig. 10.26 Typical heating curve of 138 kV extruded cable and molded rubber joint
connectors in joints, and therefore usually not considered critical. Beside this, the
termination connectors are exposed to environmental conditions, which usually
represents effective cooling. Exposed section of connector has to be designed to
operate under different environmental conditions.
Important for termination connectors is its thermal stability and the resistance
against thermo- mechanical forces. The conductor below and inside the termination
will generate thrust forces during load, which might change to pulling forces in no
load conditions. Depending on the conductor arrangement inside the terminations,
the thrust force can result in cable bending causing cantilever loads.
The connector systems have to be able to handle all these forces.
For the connection with the conductor, similar conditions apply as for the joints
and outdoor terminations.
Plug-in contacts are based on a male/female connector system, connected through
a multicontact system, achieving continuous contact pressure.
In the equipment terminations, there are the locked and unlocked designs of the
connector system. In the locked design, the plug-in connector is fixed in the
termination, transferring the forces to the termination insulator.
In the unlocked design, the cable is fixed below the termination by means of
clamping. The clamping can be integrated in the termination design or installed
externally.
10.4.7.1 General
Cable connectors are used for connecting two or more cable conductors to each other
inside the joint or connecting cable conductor to the terminal of the overhead line or
terminal of the equipment such as GIS, transformer. The construction, type, material,
and installation methods of connecting cable conductors to the cable connectors are
well explained other part of this report, so in this section, it will be described to
connect cable connectors to the terminal of overhead line or the equipment.
Fig. 10.27 Fluid-filled cable connection assembly for GIS – typical arrangement ([7], Fig. 2)
Fig. 10.28 Dry-type cable connection assembly for GIS – typical arrangement ([7], Fig. 4)
and depend largely on the switchgear layout, termination installation, cable design, and
the methods of mechanical support. The design of any support structure shall take into
account these forces and movements. It is particularly important that the support for the
switchgear shall not be affixed to the insulator collar and/or clamping flange.
The top conductor design of cable termination can be divided in open and closed
system whether embedded top metal part of insulator is open or closed. Figure 10.30
shows typical open and closed top connector systems.
In case of open top connector system, conductor connector is generally connected
to the embedded top metal part of insulator by screw connection. In order to prevent
gas (or oil) penetration from GIS (or transformer) to cable termination, additional
sealing systems are required between conductor connector and embedded top metal
part of the insulator. Because cable conductor, conductor connector, and embedded
metal part are all connected directly, the thermo-mechanical force due to thermal
expansion and extraction of the cable may affect to the insulator. To minimize this
affection, suitable clamping system is required inside the cable termination or near
the termination. During installation, cable with conductor connector inserted to the
10 Test Regimes for HV and EHV Cable Connectors 465
Cable connector
Cable conductor
Insulator
Fig. 10.30 Typical open and closed top connector system of cable termination
insulator together first and then cable termination is assembled to the GIS or
transformer generally. So, equipment (GIS or transformer) metal enclosure cannot
be factory tested with the insulator. During the final assembly, both installers
(equipment and cable termination) are needed and vacuuming and gas or oil filling
must be performed after final assembly.
In case of closed top connector system, conductor connector with cable is
plugged-in to the embedded top metal part by multicontact, spring, or tulip contact
system. The current-carrying surfaces of conductor connector, multicontact, and
embedded top metal parts are generally silver-coated. The dimensions of outer
diameter of multicontact and the inner diameter of the embedded top metal part
are important in order to maintain suitable contact pressure. Because embedded top
metal part is closed and normally leak test is performed as a routine test, additional
sealing system is not required and more reliable structure in a viewpoint of gas or oil
leakage compared with the open top connector system. There are two types of closed
top connector system. One is locked plug-in type and the other is unlocked plug-in
type. The plug of locked plug-in type cannot be removed without disassembling
insulator from the equipment enclosure, whereas the plug of unlocked plug-in type
can be removed without disassembling insulator from the equipment enclosure.
The thermo-mechanical force of cable may affect directly to the insulator or partly
be compensated according to the design of locked plug-in type; however, clamping
system inside the termination or near the termination is needed to minimize this
affection. Unlocked plug-in type can partly or fully be compensated according to
466 M. Uzelac
the design; however, clamping is essential because plug can easily be removed without
clamping during operation. In case of closed top connector system, insulator can be
preinstalled in the equipment enclosure and the cable with plug inserted later on site.
In this case, equipment metal enclosure can be factory tested including the insulator
including voltage test. During the final assembly, both installers (equipment and cable
termination) are not needed at the same time.
More information will be found in ▶ Chap. 11, “Standard Design of a Common,
Dry Type Plug-in Interface for GIS and Power Cables up to 145 kV” of the book.
Proper cable conductor preparation and connector installation are crucial for a long
and successful field performance of cable systems. Many failures of medium voltage
accessories have been caused by thermal runaway because of poor connector
installation or/and poor conductor preparation. Most common mistakes are insuffi-
cient engagement of conductor into the connector ferrule, insufficient tightening of
the bolts in mechanical connectors, use of inappropriate crimping die for a press-type
connector, fail to remove water blocking material from filled conductors, when
required, or fail to remove insulating coatings from individual strands, when present.
Mandatory trainings in installation of HV/EHV cable accessories, including prepa-
ration of conductors and installation of connectors, increase awareness of importance of
proper installation and provides opportunity to check the skills of the splicers. Hence,
there are very few field failures of HV/EHV cable accessories due to connection failure.
The manuals for installation of cable accessories (joints and terminations) either
describe steps in installation of connectors or refer to separate manual for connector
installation. Selection of installation tools and strict minding of steps described in
instructions is of essence.
The CIGRE TB 476 Cable Accessory Workmanship on Extruded High Voltage Cables
[31] which is the content of ▶ Chap. 5, “Cable Accessory Workmanship on Extruded
High Voltage Cables” of this book describes in detail technical risks and required skills for
preparation of conductors and installation of different types of connectors.
Only competent and trained personnel familiar with cables, accessories, and safe
operating practices should install accessories, both for testing and field assembly.
Cleanliness during the whole installation is of great importance.
strand filling materials (powders, yarns, cloth. . .) if present, removal of coating from
individual strands when strand insulating conductors are used and cleaning exposed
conductor. The cable insulation must be protected from damage and metallic parti-
cles during all these steps.
Figure 10.31a shows example of preparation of segmental, strand filled cable
conductor. Individual strands from each segment must be flared out, cleaned from
the filler, and then put back together to form the segments of the same shape as in
original conductor. Considerable skill and training is required to perform this
operation. If not done properly, the strands may be damaged or conductor shape
and outer diameter changed such that connector would not fit.
This connector type uses bolts to apply pressure to the underlying conductor. It can
be used on both copper and aluminum conductors. Mechanical connectors do not
require special tools for installation and the skill level is relatively easy to achieve in
proper training, positioning of properly prepared conductor(s) into connector and
tightening the bolts is spelled out in instructions. Most connector designs are of the
shear-bolt type where the bolt is tightened until they shear. Other designs require
tightening of the bolts to specified value.
The tightening sequence must be followed as specified in instructions. Factory
applied lubricants (if present) are not to be removed.
The sharp points need to be removed and, if required, the holes filled after all the
bolts are tightened or sheared.
The most common connectors in HV applications are still of the crimp type.
Depending on the cable size and manufacturer, many crimping tool types are used.
They may be either with or without crimping dies.
468 M. Uzelac
The die-less crimping tools feature one, two, or four rams (indenters). Rams put
deep indents in the ferrule and deform the ferrule and underlying conductor. The
die-less crimping tools are adjustable to take larger span of connector/cable conduc-
tor sizes.
The crimping tool with dies features the crimping head that accommodates dies
for different connector sizes. The dies are usually of circular or hexagonal shape but
other shapes, for example, ellipse, are also used. The width of the die differs
substantially between manufacturers.
Material of connector ferrule matches material of conductor: copper ferrules are
used on copper conductors and aluminum ferrules on aluminum conductors. Since
the cross-sectional area of aluminum ferrule is bigger than cross-sectional area of
conductor, the crimping dies for copper and aluminum connectors are different. The
aluminum ferrules tend to be longer than the copper ones, accommodating larger
number of crimps.
All the variables mentioned above are taken into account by cable accessory
manufacturer when the connector is designed and the crimping tool, crimping dies,
sequence, and number of crimps are specified. It is important that the cable accessory
manufacturer is consulted if different crimping tool or set of dies are intended to
be used.
The installer must be qualified and experienced for this kind of installation and
follow the instructions for the welding equipment.
This technique involves using arc welding in an inert gas with a feed wire of
copper or aluminum. The wire must be appropriate to the welding machine. The
conductor ends are cut diagonally to form a V shape when placed in the welding jig.
10 Test Regimes for HV and EHV Cable Connectors 469
10.6 Experience
10.6.1.1 USA
Two major utilities from the USA shared their experiences. One of the utilities
addressed cable connectors in HV applications (69–345 kV) and the second one in
MV applications (up to 46 kV).
While there were only a few connector failures in 60 years history of HV
laminated cable connectors, there were no reported failures for connectors in over
20 years’ experience with HV XLPE cable systems.
Experience for MV cable connectors is not so good. The number of failures, and
in particular connector failures, in joints increased with introduction of wind farms.
Analysis of the failures indicated the cause generally to be the incorrect selection of
connectors.
10.6.1.2 Germany
The following is a short summary of the presentation by Christian Walter at the third
CIGRE B1.46 meeting in Winterbach, Germany, on 26 Nov 2014.
Mr. Christian Walter leads the technical team “HV cable systems” of “E.ON
Centre of competence grid and distributed energy” in the legal entity “Bayernwerk
AG” located in Bayreuth, Germany. As a global player, E.ON sources cable systems
worldwide.
Up to now their experience shows no connector failures. The load management
on cable systems is conservative due to the n-1 criterion and is reaching up to 50% of
the nominal rated load. For the implementation of new cable systems, measures have
been taken to improve the quality management systems to be able to run cable
systems at their calculated limits, adapted and verified for each single project,
especially when connecting wind farms and renewables.
Systems for distribution cables up to 110 kV are specified in a technical specifi-
cation following in most parts test conditions for the next higher voltage level
132 kV according to Cenelec HD 632.
470 M. Uzelac
For future operation, the ampacity calculation according to IEC 60287 is verified
by DTS measurements taking into account the soil conditions while increasing loads.
Even joints will be equipped with optical fibers to determine the connector temper-
atures. In particular there will be an evaluation of the behavior of new cable systems
due to rapidly changing grid loads from nearly 0% up to 100% daily (in solar plants)
or weekly (in wind farms). There will also be a lifecycle evaluation process with
periodic PD and tan Delta measurements being made.
Cable-system delivery for a project is only accepted by a single contractor
representing the cable manufacturer, the accessory manufacturer, and the installation
company. During the qualification process, two type tests according to HD 632 have
to have been completed: One for a small aluminum conductor, for example,
630 mm2, and one for the biggest aluminum conductor, for example, 2500 mm2.
The cable conductor has to be according to IEC 60228 with the following design-
restrictions: conductors to be compacted stranded circular (class 2). Solid conductors
made are not used. Conductors above 1200 mm2 shall be segmented (Milliken
conductor). Milliken designs shall have at least five segments. In future only cables
with aluminum conductors will be purchased. Due to increasing ampacity require-
ments, cross sections larger than 2500 mm2 may be needed in future projects.
Longitudinal water tightness of stranded conductors is required. Materials used
for that purpose shall not be toxic. A semi-conductive bonding tape shall be used to
prevent the inner semi-conductive layer penetrating the gaps between the conductor
wires.
To reduce installation failures, only mechanical connectors equipped with shear
bolts shall be used on stranded conductors. Due to a lack of test experience, no
compression connectors are in use. Welding of connections will no longer be
accepted due to an incomplete quality management system and for safety reasons
on site.
Because connector type tests for high voltage cable applications are not yet
specified, available type tests similar to IEC 61238-1-3 are requested with a mini-
mum of 1000 heat cycles showing temperature stability with a min. 2500 A for
2500 mm2 aluminum. Currently just a few type tests can be shown on connectors for
big cross-sections. Short circuit withstand ability should be tested with a min. 40 kA/
1 s (3 phase). A mechanical tensile test with a min. 100 kN for 2500 mm2 will be
required. Aluminum should show no slippage and no elongation. As long as no
standardized types and designs for conductors and connectors are available a
qualification of each combination will be necessary.
To get at least limited comparability, a common type test specification for
connectors will be appreciated.
10.6.1.3 France
As the transmission engineering and expertise center for the EDF Group, the CIST
(Power System and Transmission Engineering Centre) shared its experience in
HV/EHV cable systems. It is the focus for all the specialist disciplines involved in
power transmission (power systems and transmission grids).
10 Test Regimes for HV and EHV Cable Connectors 471
A survey was sent to utilities in order to assess their cable system and the type of
problems encountered due to connector failures.
The following tables summarize the data collected.
Table 10.6 shows the number of utilities with the range of cable length per voltage
range at the present time, and the additional number of utilities that will fall in that
range. On the bottom of the table, we have the total length of cable per voltage range
for the surveyed utilities. In voltages above 220 kV, we will see an increase of over
35% of the installed base within the next 5 years.
Table 10.7 shows the number of utilities that use a range of conductor sizes at the
present time, and the additional number of utilities that will use these sizes in the next
5 years. Large sizes up to 1600 mm2 and above are used at all voltage levels. The
trend is to use larger size conductors in higher voltage systems.
Table 10.8 shows the number of utilities that use copper and aluminum conduc-
tors at the present time and the additional number of utilities that will use them in the
next 5 years. Copper is still mostly used for heavy loads, but aluminum is used as
well.
Table 10.9 shows the number of utilities that use the different types of outdoor
terminations of different voltage class. Oil filled type terminations are still used,
especially at higher voltages. Dry types are becoming more popular at up to 161 kV.
Table 10.10 shows the number of utilities that use different types of termination
vs. voltage class. Dry type terminations are mostly used nowadays, at other than the
highest voltage range.
Table 10.11 shows the number of utilities that use the different joint types
vs. voltage class. An outer housing is widely used, especially at higher voltages.
Table 10.12 shows the number of utilities that experienced connector failures on
accessories vs. Voltage class.
Table 10.13 shows the number of utilities that experienced connector failures
attributed to different causes vs. voltage class. Failures were reported on termina-
tions, but more so in joints (at all voltage levels). Generally, the failures were due to
installation errors, but also from overheating.
Conclusions
• A good number of responses from the utilities (34 surveys from 12 countries)
were received.
472
Table 10.6 Number of surveyed utilities that own cable systems and planned in the next 5 years. Total installed length (at surveyed utilities only)
Nominal cable system voltage (kV)
45–70 110–161 220–287 315–500 500+
Range (km) Now Future Now Future Now Future Now Future Now Future
1–10 1 3 4 7 4 2 4 3 1
11–25 1 1 1 2 2 2 2 1
26–50 1 1 2 3 2 2 1
51–100 5 5 1 1 1 1 1
101–250 1 1 2 2 4 1 1
251–500 3 3 7 1 3 1 1
501–999 1 1 6
1000+ 3 3 1
Total cable system length in service (km). Surveyed utilities only
12108 9456 1840 777 101
M. Uzelac
10
630–1000 12 4 23 8 7 2 1 1 1
1001–1600 9 2 18 10 12 6 3 3
>1600 8 2 13 7 12 8 6 8 1 1
473
474
Table 10.8 Conductor material currently used and planned for future
Nominal cable system voltage (kV)
45–70 110–161 220–287 315–500 500+
Range (mm2) Now Future Now Future Now Future Now Future Now Future
Copper 7 8 25 17 16 10 11 7 1
Aluminum 3 1 3 6 2 1 2 1 1
M. Uzelac
10 Test Regimes for HV and EHV Cable Connectors 475
The principles for connecting connector to cable conductor are basically the same in
HV, EHV, and MV systems. Since type tests are standardized only for MV connec-
tors, it is important to understand the issues encountered in the world of MV
connectors in order to specify test requirements for HV/EHV connectors.
Some differences between MV connections and HV connectors are:
There are three test criteria for evaluation of MV connectors per this standard:
stability of temperature, stability of connection resistance, and mechanical strength.
The statistical method of assessing test results described in this standard is mainly
based on a compromise between the Italian Standard CEI 20-28 and the British
Standard BS 4579: Part 3.
The connection resistance and temperature stability are checked by performing
1000 heat cycles on the test loop consisting of six connectors and the corresponding
reference conductor, which is identical to that used in the connectors. The influence
of short circuit current on resistance and temperature stability is also checked. This
is done by interrupting temperature cycling after 200 cycles and applying a short
circuit current of certain intensity and duration.
The connectors are installed on bare cable conductors. The test loop shall be
installed in a location where the air is calm. The ambient temperature of the test
location shall be between 15 C and 30 C. The heat is generated by circulating ac
current in the test loop. The preferred method of measuring temperatures is using
thermocouples.
The temperature of the reference conductor, which is the control parameter of the
test, is determined in the first cycle of the test. The current is adjusted to bring
reference conductor to 120 C at equilibrium (the moment when the reference
conductor and the connectors do not vary in temperature by more than 2 K for
15 min). If at that time the connector with the third highest temperature (median
connector) is below 100 C, the current is further increased until the temperature of
median connector reaches 100 C at equilibrium, subject to the reference conductor
temperature not exceeding 140 C. Subsequent cycles are controlled by this refer-
ence conductor temperature.
During the cooling period, the reference conductor has to be cooled down to
35 C or below.
The criterion for temperature stability is that temperature of any of six connec-
tors does not exceed temperature of reference conductor at any time during the test.
478 M. Uzelac
The criterion for connection resistance is much more involved. Here, a statistical
method of evaluating the trend of electrical resistances was adopted. It requires
calculation of the connector resistance factor (k) for each connector each time the
resistance is measured. The measurement is done before cycling, immediately before
and after the short circuit test at cycle 200, after the 250th cycle and then after every
75 cycles (total 14 times from start to finish of heat cycling). A total 64 k values
(6 connectors 14 resistance measurements) are then used in the statistical analysis
to determine if the connector passed or failed the test.
Statistical parameters for k, to which the connectors are evaluated, are set in the
standard. The selection of assessment criteria and values was made after evaluating
test results and experience from different laboratories and countries. In short,
assessment criteria require that:
• Six specimens shall be similar in resistance at the beginning of the test. This is
assessed by calculating initial scatter δ between the six values of k before heat
cycling and shall not exceed the value 0.3.
• The resistance should not change extensively during test. This is assessed by
calculating:
– The mean scatter β between the six values of k averaged over the last
11 measurements which verifies that the connectors behave in the same way
and that they belong to the same “family.” The mean scatter β shall not exceed
the value 0.3.
– The change in resistance factor D, which shows the change of the resistance
factor k for each connector over the last 11 measurements. Statistical methods
are used to assess the probability that the change of resistance will not exceed
the specified value. The change in resistance factor D shall not exceed 0.15.
Note: These 11 readings start at the 250th cycle point, and then every 75 cycles
up to 1000 cycles.
• The resistances shall not change excessively as a result of the short-circuit test.
This is assessed by calculating the resistance factor ratio L, which shows the
relationship between the resistance at any stage of the measurements and the
initial resistance. The resistance factor ratio L shall not exceed 2.0.
Range of Approval
In general, tests made on one type of connector/conductor combination apply to that
arrangement only. However, to limit the number of tests, using the same conductor
material, the following is permitted:
uses the same design criteria. Approval of the complete termination can be
achieved if the termination connection does not influence the barrel performance,
proven through design parameters, drawings or through thermal verification test.
• If conformity to this document is achieved by successfully testing a connector on
a conductor with water blocking, approval is achieved for the same conductor
without any water blocking but not for the same conductor with different types of
water blocking.
Some recent studies show an increase in the failure rate of MV joints in several
countries. It seems to be related to the increase of the load and new cycle types
(especially in the case of renewable generation, e.g., wind farms) and failures appear
in unusual conditions. The main contributor to those failures was identified as
thermo-mechanical force, which can induce an increase of the resistance of the
contacts, a bending of the conductors and a loss of water tightness, and pure thermal
effect.
The above aspects, except for the thermal effect, are not addressed in current
standards for MV connector and accessory testing. For example, in testing MV joint
or joint connector, the cables are not required to be fixed; therefore, no mechanical
forces are applied to the connector and the joint. The influence of the size of the
connector on the thermal behavior of the accessory is also not considered.
Axial force generated by temperature change of conductor may be calculated
[32]. Calculated values are very high. The values of axial forces measured in
laboratories are much lower from calculated but still significant. For example, a
theoretical force of more than 60 kN is calculated when temperature of a 630 mm2
aluminum conductor is increased for 60 C, while in the lab the force was measured
16 kN on fixed cable. Another interesting observation from these tests is that type of
cable conductor (stranded or solid) does not seem to influence the force.
• Test of the cable system (with the connector and cable as used by the company)
with additional cycles at a higher temperature (Belgium). The requirement is
50 cycles at 110 C and 2.5 U0 with a thermal analysis during the last cycle.
• Real condition test (France) – Robustness test.
temperatures of the cable conductor, cable connector, and the joint are measured at
each temperature level at locations shown in Fig. 10.32.
The requirements were set to:
• Temperature TC1 of the joint connector not to exceed temperature TC5 of cable
conductor at the point which is at least 1500 mm from the joint body.
• Temperatures TC2 and TC3 of cable core in the joint 10 mm away from either
side of connector not to exceed temperature TC5.
The value of this test is to find out which joint/connector/conductor systems are
suitable for the application. In some instances the system with a” large connector”
failed the test while the same system with the same joint body with a smaller
connector passed.
The temperature of the outer surface of the joint TC4 and the hot spot temperature
were recorded for engineering information.
To evaluate the behavior of the conductor connections, a dedicated test setup was
built to allow for the application of higher forces and evaluation of the conductor
slippage.
The test specimen consists of two identical connectors
pffiffiffiffi installed in the same way
on the conductor with a small distance (e.g., A with A ¼ cross section of the
conductor) between the edges of the connectors (Fig. 10.35).
This assembly is mounted to the test fixture by appropriate connection parts
installed on the barrel of the connectors. Several connector types – including
hexagonal and deep indent crimped contacts and screw type connectors – installed
on solid and stranded Al conductors of 240 mm2 and 630 mm2 were tested.
484 M. Uzelac
The joint, with 5 m of cable connected to each side, is mounted in a fixture that
blocks lateral and longitudinal forces of the cables.
Cable cleats are installed every 30 cm for a length of 4 m on both sides of the
joint. On each side of the joint 1 m cable section is not blocked such that lateral
movement is possible in order to get a maximum stress on the water seals. The test
setup is shown in Fig. 10.39 and the expected behavior is described in Fig. 10.40.
There is a water filled plastic pipe installed around the cable joint with a diameter of
at least three times the diameter of the joint. The pipe is water sealed at both ends,
between the PVC pipe and the cable. Oversized silicon rubber (for flexibility under
mechanical stress) will be utilized as the seals. These seals exist and are commonly used
in current water penetration tests. Water will be entered using either an elevated water
vessel (for pressure build-up) or directly to a water pressure vessel in order to exert a
water pressure according to the desired standard or customer required pressure level.
The length of the pipe is 2 m plus the length of the joint so that the water seals
inside the pipe are located close to the cable cleats. This minimizes movement of the
cable inside the artificial seals which in its turn minimizes the chance of leakage at
486 M. Uzelac
that location. Furthermore, this minimizes the effect of the plastic pipe on the cable
movement.
After the test setup has been fully built up at, the following testing procedure applies:
1. After the cable has been installed, the PVC pipe will be filled with water at the
required pressure. As soon as the pipe is filled a first sheath test is performed.
2. The assembly is left to soak for 24 h.
3. A second sheath test is performed at 10 kV DC, for 5 min.
4. The cable is subjected to 10 heating cycles as prescribed by IEC 61442, clause
9 [6]. No test voltage shall be applied. The water temperature will not be
controlled or measured.
5. A third sheath test is performed at 10 kV DC, for 5 min.
Separate tests on connectors are not required in existing IEC Standards for HV/EHV
cable systems and accessories (62067 and 60840). However, details of connectors
used in accessories must be provided, together with information concerning type test
approval where applicable as per the following extract from IEC 62067 (or 60840):
• assembly technique,
• tooling, dies and necessary setting,
10 Test Regimes for HV and EHV Cable Connectors 487
In practice, specific type testing of connectors per IEC61238-1-3 Standard has not
been carried out, except in cases of a specific customer request.
In the absence of IEC test requirements for HV/EHV connectors, manufacturers
of HV/EHV cable systems and accessories have been performing tests at their
discretion to evaluate performance of new connector designs. Different manufac-
turers have different test protocols but in essence those are combination of modified
requirements from IEC 61238-1-3 (MV connectors) or other national Standards, for
example, US Standard ANSI C119.4, Italian Standard CEI 20-28, and British
Standard BS 4579: Part 3 (now withdrawn); the network requirements, user’s
specifications, and manufacturers’ experience.
After being “qualified” in development tests, those connectors were further
checked in type and PQ tests of HV and EHV cable systems and accessories.
These tests were performed per IEC 60840 and IEC 62067 Standards.
Fig. 10.41 Preparation of the setup for temperature cycling in connector development test
“c): the cable and the accessories have the same or similar constructions as that of the tested
cable system(s)”.
“NOTE 3 cables and accessories of similar construction are those of the same type and
manufacturing process of insulation and semi-conducting screens. Repetition of the electri-
cal type tests is not necessary on account of the differences in the conductor or connector
type or material or of the protective layers applied over the screened cores or over the main
insulation part of the accessory, unless these are likely to have a significant effect on the
results of the test. In some instances, it may be appropriate to repeat one or more of the type
tests (e.g. bending test, heating cycle test and/or compatibility test)”.
• IEC 60840 (edition 4, 2011): a PQ test was added, together with the EQ test, for
cables with high conductor screen or insulation screen stress.
• IEC 62067 (edition 2, 2011): the EQ test was added.
Tables 2.4 (for EHV cable systems) and 3.4 (for HV cable systems) in TB
303 [27], which are the guides to the selection of tests due to modifications of
cable system component in a prequalified HV cable system, do not give any
recommendation for tests in the case of change of connector or connector/conductor
combination and the current versions of IEC Standards (edition 4 of IEC 60840 and
edition 2 of IEC 62067) do not specify any test to be performed in the case of such a
modification.
490 M. Uzelac
10.8.1 General
The WG has considered the test methods described in the current Standard for MV
connectors (IEC 61238-1-3) and existing practice in testing and evaluation of
HV/EHV connectors performed by cable system/accessory manufacturers. The
general view is that test methods and test sequence from IEC 61238-1-3 should
not be applied for evaluation of cable connectors for HV and EHV cable systems.
During the maintenance cycle for the revision of IEC 61238-1-3 (MV cable
connectors), it was decided to limit the scope of the standard to a maximum
conductor size of 1200 mm2 mainly because verified test experience for larger size
conductor/connector combinations is not available for the time being. Generally
larger conductor sizes are in use in HV and EHV cable systems, currently up to
3500 mm2 with a tendency towards even larger sizes. The large cable sizes
(>1200 mm2), variety of conductor designs, and variety of designs of connectors
for HV/EHV cable accessories may lead to unrealistic test results and unnecessary
expense when test requirements from IEC 61238-1-3 are fully followed.
It is acknowledged by the WG that current practice adopted by manufacturers of
HV/EHV cable systems/accessories in testing and evaluation of connectors
10 Test Regimes for HV and EHV Cable Connectors 491
Table 10.15 Updated and abbreviated excerpt of Table 5.4.2 on functional analysis when joint
component is changed (CIGRE TB 303/Chap. 4)
Function or Test to check the
property Specification/threat functionality Comments
Metallic connection and its eventual covering
Electrical Transports nominal Heat cycles on Not required per IEC
continuity/ current without connections. Use IEC 60840 ed4 or 62067 ed2
electrical overheating 61238-1-3 when The IEC 61238-1-3
resistivity appropriate (¼ not presently applies only to
welded): Suggested as connectors for cables
Development test 30 kV and below but
could be useful for HV
connections
Supports short circuit Short circuit test Short circuit test is not
current and temperature following the network required per IEC 60840
needs: (Such test is part ed4 or 62067 ed2
of IEC 61238-1-3). The short circuit
Suggested as temperature shall not be
Development test at 250 C as required per
IEC 61238-1-3 but
derived from short
circuit currents selected
from IEC 61443
Mechanical Supports longitudinal Heat cycles of cable Are 20 cycles enough to
properties tension and thrust forces loop with joint installed: see the effects of
from cable conductor in Test requirements are longitudinal forces?
service. Prevents specified in Type and See tensile strength of
twisting of conductor PQ tests of IEC 60840 welded connectors
during heat cycles and 62067
Thermal Dissipates correctly the Heat cycles of If a reliable program to
function heat generated in the connections per system calculate the
connection and avoids type tests in IEC 60840 temperature profile in a
overheating in the center and IEC 62067, but joint is available, it may
of the joint without voltage + replace the test on cable
Measurement of system
temperature of
connector versus
conductor +
examination. Suggested
as Development test
Interface Compatibility of the Long- term test Test is also possible on
with joint possible used additives (suggested as materials: semi-con
semi-con with the semi-con of the development test or plates in air oven
joint (grease, mastic, PQ + examination) exposed to the additives
water sealant)
Possible additives (grease, mastic, water sealant. . .)
Electrical No negative influence Heat cycles on
function on the conductivity of connections (see above)
the contact
Thermal Supports the Heat cycles of
properties temperature of the connections: see above.
(continued)
492 M. Uzelac
Table 10.16 Updated and abbreviated excerpt of Table 5.4.2 on functional analysis when termi-
nation component is changed (CIGRE TB 303/Chap. 4)
Function or Test to check the
property Specification/threat functionality Comments
Metallic connection of conductor to network
Electrical Transports nominal Heat cycles on Not required per IEC
continuity/ current without connections. Use IEC 60840 ed4 or 62067
electrical overheating 61238-1-3 when ed2
resistivity appropriate (¼ not
welded): Suggested as
Development test
Supports short circuit Short circuit test Short circuit test is not
current and temperature following the network required per IEC
needs 60840 ed4 or 62067
ed2
Short circuit test values
could be selected from
the data of IEC 60859
(now 62271-209).
Mechanical Supports compression/ Heat cycles per System aspect
properties extension efforts during requirements specified in Long term PQ tests
cycling of cable Type and PQ tests of IEC missing in IEC 60840
conductor 60840 and 62067 ed3 (included in ed4)
Supports the thermal Short circuit test No such test in HV
short circuit efforts following the needs of IEC specifications (for
the network would be cable systems and
useful as a development accessories)
test
Chemical Resistance to corrosion Humidity and pollution
properties test as a development
test
Interface Connection fits with Matter for engineering
with terminal lugs of network of network
network interface (sliding
contacts, bimetallic
interfaces. . .)
10 Test Regimes for HV and EHV Cable Connectors 493
connector manufacturers, are new and not yet tried on a large scale, they are
presented for evaluation purposes at this stage.
tests can also be used for evaluation of other connections to cable connectors in cable
accessories, for example, aerial lugs, sliding connections in equipment type termi-
nations, and so on.
See Sects. 10.8.4, 10.8.5, and 10.8.6 for proposed test loop, development test
sequence, and test methods.
stranded conductor with the same or less number of strands and the same material
and class (e.g., within the same class according to IEC 60228, which is different for
stranded, fine stranded and flexible) or for conductors to be rounded and where all
nonconductive material(s) on and between strands are removed during installation of
the connector.
10.8.4 Test Loop for Heat Cycling and Temperature Stability Tests
for Development Tests with Conductor Sizes Above
1200 mm2
For each series of tests, at least four connectors shall be fitted in accordance with the
manufacturer’s instructions, on a bare conductor or on a conductor that has had the
insulation removed before assembly, to form a test loop together with the corresponding
reference conductor. The installation instructions and the tools recommended by the
connector manufacturer must be used for the preparation of the test assembly.
An example of the test loop is shown in Fig. 10.43. The figure indicates the
minimum length of exposed conductor on either side of the test object and the
minimum lateral distance between test objects and between conductors.
In this example, individual legs of the test loop with connectors may be easily
disassembled for transport to short circuit and mechanical test labs and reassembled
quickly when needed.
Connectors of the type to be tested are applied onto bare conductors of the appro-
priate size, material, and type for the connector/conductor combination under test.
Disconnecting terminals may be additional test objects (e.g., terminal lug). All conduc-
tors of the same cross-sectional area in the test loop shall be taken from the same length.
The test setup is applicable to all types of connector in combination with any
conductor design and material, not restricted to mechanical and compression
connectors.
The development tests for connectors to be used on conductors above 1200 mm2
should be performed in the proposed test sequence acting on the same samples to
10.8.5.1 Prestress
Preferably applied separately to each of the four legs of the test loop shown in Fig. 10.43.
Each leg consists of: disconnecting terminal lug–conductor–test connector–conductor–
disconnecting terminal lug.
After passing tests, a and b above the test samples should be assembled for heat
cycling as shown in Fig. 10.43. The test arrangement should be placed in one
horizontal plane in a test area where the air is calm, minimizing variations in
convection acting on the different specimens. Ambient temperature should be
maintained below 35 C during cooling. The test loop may be of any shape, if it is
arranged in such a way that there is no adverse effect from the floor, walls, and
ceiling.
The temperature regime of the cycle should be such to ensure that targeted
connector temperatures are held stable within the target temperature range as
shown in Fig. 10.44.
At the end of the heating period, forced air cooling may be used. The reference
conductor must cool to within 10 K of ambient temperature before the next heating
cycle commences.
140 C) will be used as control parameter for duration of the test. This temperature
should be maintained within 5 K for 200 h.
Temperature readings for each connector and the reference conductor should be
taken 8 h after reaching equilibrium and then at least every 24 h.
Verification: Every recorded maximum temperature of each connector in each
measurement campaign should not exceed that of the reference conductor measured
at the same time by more than 5 K. Additionally the arithmetic mean value calculated
from all (four) connector temperatures in all (eight) measurement campaigns should
not exceed the highest temperature value of the reference conductor out of this record.
The test is considered as successfully passed if the verification criteria are met.
The data and the evaluation should be included in the test report.
Subsequent cycles: The reference conductor temperature is the only control param-
eter, to reproduce the temperature regime for all subsequent cycles. In this way, the
fluctuation of the ambient temperature will not affect the temperature profile of the
reference conductor within the specified tolerances. The heating regime of the reference
conductor containing the characteristics of temperatures in time is shown in Fig. 10.43
and should be reproduced in subsequent cycles, while the median connector will not be
controlled anymore and may differ by more than 3 K compared to the initial situation.
Instead of cooling down below 35 C as done in the first cycle, it is recommended to
cool down at least to 10 K above ambient temperature before starting a new cycle.
Temperature measurements should be taken by using the method described in Sect.
10.8.6.3. The first measurement campaign should be collected after the 10th cycle, the
next campaigns then every 10 cycles. One measurement campaign consists in record-
ing temperatures on each connector and the reference conductor taken every minute
during the last 15 min. of the heating period t1. The maximum measured connector
temperature in every measurement campaign should be recorded together with the
reference conductor temperature measured at the same time. A set of 20 measurement
campaigns with four pairs of connector/conductor combinations temperature values
will then be available for the assessment of temperature stability.
Heat-cycle temperature stability verification: Every recorded maximum temper-
ature of each connector in each measurement campaign should not exceed that of the
reference conductor measured at the same time by more than 5 K. Additionally the
arithmetic mean value calculated from all (four) maximum connector temperatures
in all (20) measurement campaigns should be below the highest temperature value of
the reference conductor out of this record.
The test is considered as successfully passed if the verification criteria are met.
The data and the evaluation should be included in the test report.
10.9 Conclusions
WG B1.46 has taken into account current practice in testing cable connectors for
HV/EHV cables that included: development testing on connectors currently performed
by cable system/accessory manufacturers at their own discretion; system/accessory type
504 M. Uzelac
and PQ tests per IEC 60840 and 62067 Standards; existing positive experience with
HV/EHV cable connectors in service; existing requirements and experience in testing
MV connectors per IEC 61238-1-3 for MV connectors; and work of the CIGRE WG
B1.06 on Revision of Qualification Procedures for HV/EHV AC Cable Systems. The
WG came to the following conclusions:
• A separate type test for mechanical or compression connectors per IEC 61238-1-3
is not required and not mandatory in HV/EHV applications for cable systems and
accessories complying with IEC 60840 or IEC 62067.
• A separate development tests for HV/EHV connector/conductor combinations
followed by type/PQ tests on cable system/accessory is recommended.
• The connectors for HV/EHV cables that have been included in type and PQ tests
(where applicable) and have been used historically should continue to be used
without further separate component testing being required.
• Additional testing is also not required for connector/conductor combinations that have
not been used in service yet but successfully passed proposed development test for
connectors and type and PQ tests (where applicable) for cable systems/accessories.
• If separate connector development or type tests have been made according to
other specifications these tests are not required to be repeated according to this
recommendation.
• Recommendations have been made for development tests and the range of
approval for new connector/conductor combinations in accordance with pro-
posals made in Annex 5.4 of TB 303, taking into account the existing IEC
standard for MV connectors and experience from manufacturers and users.
• The WG proposes a sequence of development tests for HV/EHV connector/
conductor combinations based on current practice in development testing of
HV/EHV connector and type testing of MV connectors.
• To avoid the need to test every size and type of connector, details are given of the
range of approval that is valid for different test scenarios (e.g., large and small
sizes tested to also cover intermediate sizes).
• Involved parties are invited to collect and share experience with the here proposed
development tests of new connector/conductor combinations to verify practical
use of proposed procedure and assessment before a further standardization of type
testing of HV and EHV cable connectors is considered.
10.10 References
3. IEC 62067 Power cables with extruded insulation and their accessories for rated
voltages above 150 kV (Um ¼ 170 kV) up to 500 kV (Um ¼ 550 kV) – Test
methods and requirements
4. IEC 60050 (461) International Electrotechnical Vocabulary (IEV) –
Chap. 461: Electric cables
5. IEC 60228 Conductors of insulated cables
6. IEC 61442 Test methods for accessories for power cables with rated voltages
from 6 kV (Um ¼ 7.2 kV) up to 36 kV (Um ¼ 42 kV)
7. IEC 62271-209, 2007: High-voltage switchgear and controlgear – Part
209: Cable connections for gas-insulated switchgear for rated voltages above
52 kV – Fluid filled and extruded insulation cables – Fluid filled and dry-type
cable-terminations
8. EN 50299-1, 2014: Oil-immersed cable connection assemblies for transformers
and reactors having highest voltage for equipment Um from 72.5 kV to 550 kV.
Fluid-filled cable terminations
9. EN 50299-2, 2014: Oil-immersed cable connection assemblies for transformers
and reactors having highest voltage for equipment Um from 72.5 kV to 550 kV.
Dry-type cable terminations
10. IEC TR 62125 Environmental statement specific to TC 20. Electric cables
11. IUPAC Periodic Table of the Elements 22/11/16. https://iupac.org/what-we-do/
periodic-table-of-elements
12. IEC 60287-3-2 Ed.2: Electric cables – calculation of the current rating – part
3-2: sections on operating conditions – economic optimization of power cable
size
13. BOONE Wim, KACKER Arnav, BAL Remco “Copper or aluminium cable
conductors, broadly compared in a life-cycle perspective” JiCable Conference
2015
14. Holm R.: Electric Contacts-Theory and Applications. Springer-Verlag 2000.
ISBN 3-540-03875-2.
15. Vinaricky, E.: Elektrische Kontakte, Werkstoffe und Anwendungen. 2. Auflage:
Springer-Verlag 2002. ISBN 3-540-42431-8.
16. Böhme, H.: Mittelspannungstechnik-Schaltanlagen berechnen und entwerfen.
2. stark bearbeitete Auflage Berlin: Verlag Technik 2005. ISBN 3-341-01495-0.
17. Hildmann, C. Schlegel, S.; Lücke, N.; Großmann, S.: Vergleich genormter
elektrischer Alterungsprüfungen für Verbindungen der Elektroenergietechnik
mit Erkenntnissen aktueller wissenschaftlicher Untersuchungen. Connectors
Symposium, Lemgo, 2015
18. Braunovic, M.: Aluminium connections: legacies of the past. Tagungsbd. 40th
IEEE Holm Conference on Electrical Contacts. 17.10-19.10.1994, Chicago,
S. 1–31.
19. Naybour, R. D.; Farrell, T.: Degradation mechanisms of mechanical connectors
on aluminium conductors. Proceedings of the Institution of Electrical Engineers,
1973, vol. 120, no. 2, S. 273–280.
20. Braunovic, M.: Effect of Current Cycling on Contact Resistance, Force, and
Temperature of Bolted Aluminium-to-Aluminium Connectors of High
506 M. Uzelac
Terms of Reference
Scope
To review
To analyze
To propose thermal and mechanical test regimes for connectors for HV and EHV
cables with special attention be given to connectors for large size cables.
• Type, routine, and sample tests including mechanical, cycling, and resistance
stability tests
• Consider practicality of the short circuit test for large-size conductors and test
loop arrangement
• WG should be free to consider mechanical tests (e.g., tensile, thrust forces. . .) in
order to evaluate mechanical strength of connection and physical properties of
connector itself
• WG should be free to consider separate or integral test sequences combining
mechanical, cycling, short-circuit, and resistance stability (assessment) acting on
the same samples
• Extent of connector type test experience so far (for different connector types)
• Evaluate necessity of performing type tests on connectors that already success-
fully passed qualification tests per IEC 60840
• WG should consider range of type test approval
The WG should consider the tests that reflect mutual impact between connectors,
cable conductors and accessories.
The conductor connectors for HV and EHV applications are to be considered. The
WG will make recommendation to include or not connectors for MV applications.
Deliverables
Technical Brochure with summary in Electra and Tutorial
Clauses IEC 60840 up to 245 kV IEEE Std 404-1993 for IEEE Std 48-1990 for terminations
Type tests on cable systems, cables, accessories joints 138 kV 138 kV
Test values
(applicable to Cable
Test accessories) systems Cables Accessories Joints Terminations
Bending test 5 pC at 1.5Uo 12.4.3 12.4.3 – 5 pC at 1.5Uo 7.6.1 5 pC at 1.5Uo 8.4.1.1
Partial discharge test at 12.4.4 12.4.4 12.4.4 (120 kV) (120 kV)
ambient temperature
AC withstand voltage 3Uo (240 kV), 7.7.1
15 min
AC voltage 1 min dry 310 kV, 1 min 8.4.1.2/
withstand 8.4.1.4
AC voltage 10 s wet 275 kV, 10 sec 8.4.1.3
withstand
DC voltage 15 min dry 315 kV, 15 min 7.7.2 315 kV, 15 min 8.4.1.5
withstand
Test Regimes for HV and EHV Cable Connectors
Heating cycle voltage test 20 cycles at 12.4.6 12.4.6 12.4.6 30 cycles at 7.9.2 30 cycles at 8.4.2 item c
Tcmin ¼ 95 C, Tcmin ¼ 105 C, Tcmin ¼ 105 C,
2Uo 2Uo 2Uo
Partial discharge test at high 5 pC at 1.5Uo, at 12.4.4 – 12.4.4 5 pC at 1.5Uo 7.6.1 5 pC at 1.5Uo 8.4.1.1
temperature Tcmin ¼ 95 C (120 kV) (120 kV)
Partial discharge test at 5 pC at 1.5Uo 12.4.4 12.4.4 12.4.4 5 pC at 1.5Uo 7.6.1 5 pC at 1.5Uo 8.4.1.1
ambient temperature (after (120 kV) (120 kV)
final cycle or after lightning
impulse voltage test in item
i)
Lightning impulse voltage 650 kV, 10+/ 12.4.7 12.4.7 12.4.7 650 kV, 10+/10, 7.7.3 650 kV, 10+/10, 8.4.1.6
test followed by power 10, at at at
frequency voltage test Tcmin ¼ 95 C Tcmin ¼ 105 C Tcmin ¼ 105 C
509
(continued)
510
Heating cycle voltage test 20 cycles at 12.4.6 30 cycles at 7.9.2 30 cycles at 8.4.2 item c
Tcmin ¼ 95 C, Tcmin ¼ 105 C, Tcmin ¼ 105 C,
2Uo 2Uo 2Uo
Partial discharge test at high temperature 5 pC at 1.5Uo, at 12.4.4 5 pC at 1.5Uo 7.6.1 5 pC at 1.5Uo 8.4.1.1
Tcmin ¼ 95 C (120 kV) (120 kV)
Partial discharge test at ambient temperature 5 pC at 1.5Uo 12.4.4 5 pC at 1.5Uo 7.6.1 5 pC at 1.5Uo 8.4.1.1
(after final cycle or after lightning impulse (200 kV) (200 kV)
voltage test in item i)
Lightning impulse voltage test followed by power 1050 kV, 10+/10, 12.4.7.2 1050 kV, 10+/ 7.7.3 1050 kV, 10+/ 8.4.1.6
frequency voltage test at Tcmin ¼ 95 C 10, at 10, at
Tcmin ¼ 105 C Tcmin ¼ 105 C
5 pC at 1.5Uo 7.6.1 5 pC at 1.5Uo 8.4.1.1
(200 kV) (200 kV)
(continued)
511
512
The following table gives a brief explanation of the background behind some
recommendations for covering other applications by a successfully performed
development test.
Pierre Mirebeau
Contents
11.1 Background . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 532
11.2 Terms of Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 532
11.3 Definitions and Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 533
11.3.1 Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 533
11.3.2 Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 535
11.4 Criteria for Interface Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 536
11.4.1 Number of Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 536
11.4.2 Technical Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 537
11.4.3 Impact of Short Circuit Time Going to 40 kA 3 s . . . . . . . . . . . . . . . . . . . . . . . . . . . 537
11.4.4 Interface Designs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 538
11.5 Cable Library Dimensions State of the Art . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 538
11.5.1 Voltage Class 72.5 kV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 538
11.5.2 Voltage Class 123 kV and 145 kV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 538
11.6 Inner and Outer Cone Evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 539
11.6.1 General Evaluation of Inner and Outer Cone Technologies . . . . . . . . . . . . . . . . . 539
11.6.2 Evaluation of Inner and Outer Cone Technologies per Voltage Class . . . . . . . 541
11.6.3 Evaluation of Conductor Locking Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 543
11.6.4 Conclusion on Interface Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 543
11.7 72.5 kV Insulator Design and Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 543
11.7.1 Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 544
11.7.2 Type Tests and Routine Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 547
11.7.3 Examples of Implementation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 547
P. Mirebeau (*)
Villebon sur Yvette, France
e-mail: Pierre.mirebeau@sfr.fr
Executive Summary
In many countries, the market trends are towards a commoditization of the high
voltage cables lower or equal to 145 kV. IEC TC 17, in charge of the maintenance of
IEC 62271-209 for “Cable connections for gas-insulated metal-enclosed switchgear
for rated voltages above 52 kV” asked CIGRE to evaluate technically the feasibility
of a common interface. A first joint Working Group B1–B3 was set up in 2010 and
concluded that it is feasible to have a common interface for voltages up to 145 kV
and a rated current 1000 A. See TB 605.
A second Working Group was set up in 2015 to propose standardized dimensions
of the interface(s). The work of this Working Group B1–B3.49 is presented in
CIGRE TB 784 and in this chapter of the book.
After evaluation of the requirements such as:
• GIS cable enclosure dimensions
• Cables and accessories portfolio
• Feedback from the maintenance team of IEC 62271-209
• Test requirements from the IEC 60840
• Market trends
In some countries, there are other maximum voltage levels Um such as 82.5 kV
(Belgium), 84 kV (Japan), 100 kV (France), 126 kV (China). The common interfaces
design can be used for these voltage levels; however, the test voltages need to be
defined by national standards or specification. It is recommended to use the common
design with Um values where test voltages are higher than the national level test
voltages.
There is only one design applicable for one voltage level. This is a
consequence of the common interface concept. The Working Group is aware that
other designs are existing as inner cone for 72.5 kV and outer cone for 123 kV and
145 kV.
The designs are based on the manufacturers’ field and qualification experience,
electrical field calculations, known material properties.
• For 72.5 kV, the design is based on the on-going standard EN 50673. It has been
validated by existing qualifications and installations.
• For 123 and 145 kV, the proposed design is new, with larger design margins in
reference to existing designs. No prototype has been made nor tests performed
during the Working Group progress.
The proposed designs of the inner and outer cone are described in Figs. ▶ 5.1 and
▶ 6.1, paragraphs 5.1 and 5.3. In addition to the drawings in written form, a .dxf file is
included in the downloadable document, which can be used with any standard drawing
software.
For the range of products as defined by the terms of reference, the GIS manufac-
turer will get the possibility to order the cable termination interface and complete the
GIS manufacturing up to and including the cable termination insulator, independent
from the supplier of the cable and cable termination.
With the common interface, the responsibilities will change as compared to the
division of supply that is specified in IEC 62271-209. The scope of supply of the GIS
manufacturer includes the insulator. In this new context, a risk assessment has been
performed. It is available in Sect. 11.10.
The proposed designs allow more compact cable termination envelopes which
may be developed by GIS manufacturers.
The qualification process, based on IEC 60840 requirements, has been studied.
Three different cases were identified:
• Initial qualification
• Cross qualification in case of available initial qualification for both insulator and
cable/stress cone assembly
• Cross qualification without initial qualification of either insulator or cable/stress
cone assembly
The qualification process is available in Sect. 11.12.
If these proposed interfaces are accepted by the market, they can be used for
standardization.
532 P. Mirebeau
11.1 Background
Taking into account the market trend in some countries towards a commoditization
of the High Voltage cables lower or equal to 145 kV, and as per a request of IEC TC
17 who is in charge of the maintenance of IEC 62271-209, the working group B1–
B3.33 (TB 605) had concluded that there is room in these voltage levels for a
standard design in parallel with the present designs.
The common interface does not replace the cable termination standard IEC
62271-209; it consists basically in an alternate choice of a design which is given
to the GIS manufacturer.
1. Current is 1000 A. Short circuit is 40 kA 1 s. Cross sections are 1000 mm2
Cu or 1600 mm2 Al.
2. Technology has to be defined (inner or outer cone), with a detailed evaluation of
technical advantages/disadvantages of the two technologies.
3. The number of sizes has to be defined; the short circuit current can be altered for
the smallest sizes. Dimensions of insulator components have to be defined
(current connection, electric design and properties, mechanical design and prop-
erties). The type and dimension of the main current connection have to be
defined.
4. Consideration to be given to the consequence of a termination failure, the
upgrading of the cable link for higher current loads, and installation constraints,
with a special focus on the basement dimensions.
5. The design has to meet the requirements of IEC 62271-209 and IEC 60840 and
there is a need to define the initial and cross qualification processes.
6. The stress cone design and material, the lubricant, and the design of the com-
pression device should be left to the discretion of the accessory manufacturer
within the limits of the standardized insulator properties.
Note: The common interface proposed in this chapter is situated between the
insulator assembly and the cable stress cone assembly as defined in Sect. 11.3.1.
11 Standard Design of a Common, Dry Type Plug-in Interface for GIS and Power. . . 533
The definitions and terms of the different components of the dry type GIS cable
terminations as described in IEC 62271-209 and CIGRE TB 605 (Chap. 7) are
shown in Tables 11.1 and 11.2.
11.3.1 Definitions
Table 11.1 Identification of the different parts of GIS termination, inner cone type design
Insulator assembly
Insulator
Cable connection enclosure
Flange (if needed)
. Sectionalising insulation
Stress cone
Cable/stress cone
assembly
Cable gland
Cable
.
534 P. Mirebeau
Table 11.2 Identification of the different parts of GIS termination, outer cone type design
Connection interface
Insulator assembly
Insulator
Sectionalising insulation
Plug-in connector of insulator
Stress cone
Cable/stress cone
assembly
Cable gland
Cable
11.3.2 Units
11.3.2.1 Pressure
All pressure values in this document are given in bar as relative pressure.
U0 ¼ the rated r.m.s. power-frequency voltage between each conductor and screen
or sheath for which cables and accessories are designed.
U ¼ the rated r.m.s. power-frequency voltage between any two conductors for which
cables and accessories are designed.
Um ¼ the maximum r.m.s. power-frequency voltage between any two conductors for
which cables and accessories are designed. It is the highest voltage that can be
sustained under normal operating conditions at any time and at any point in a
system. It excludes temporary voltage variations due to fault conditions and the
sudden disconnection of large loads.
Unless specified differently all voltages mentioned in this brochure are consider-
ing Um values.
IEC 62271-209 includes definition of rated voltages and insulation levels taking
into account both standards IEC 60840 and IEC 62271-203.
This chapter details the different requirements that were set by the Terms of
Reference regarding the interface selection.
• Number of interfaces
• Compliance to standards
• Technical considerations
• Interface design
Hence there is a total of three voltage levels: 72.5, 123, and 145 kV.
In some countries, there are other maximum voltage levels such as 82.5 kV
(Belgium), 84 kV (Japan), 100 kV (France), 126 kV (China). The common interfaces
design can be used for these voltage levels; the test voltages need to be defined by
national standards or specification. It is recommended to use the common design
with Um values where test voltages are higher than the national level test voltages.
To anticipate the future needs, the following properties of the GIS termination were
selected as relevant factors for the interface selection.
• Feasibility of capacitive couplers for power conductor voltage and partial dis-
charges measurements
• Current access for DC routine test resistance measurement of GIS (100 A and
voltage drop), without the cable – stress cone assembly
• Minimum parts of the further installed cable – stress cone assembly
• Clear responsibility of supply
• Feasibility to be used as an interface to a test bushing for GIS after installation test
• Feasibility to be used as an interface to a test bushing for cable after installation
test
• Feasibility to be used as an interface to Lightning Arrester, or to a Voltage
Transformer at the same time as cable connection
• Cable oversheath testing to be simple
• Qualification to be simple
• Measurement of cable screen voltage
• Possibility of dimension decrease of the cable termination enclosure of the GIS
• Conductor lockable/unlockable
• Anticipate future developments to larger cross section and current
• Safety
In IEC 62271-1, paragraph 4.7 the standard time is 1 s. But lower and higher values
up to 3 s. are allowed (recommended values are 0.5 s, 2 s, and 3 s).
Most TSO (Transmission System Operators) use the 1 s. short circuit time; UK
TSO is the only utility that specifies the Icc 40 kA 3 s.
An enquiry had been made to UK TSO: it seems that UK TSO has taken a worst-
case position when determining the short circuit current levels and clearance times.
At 132 kV, 40 kA is a practical value and will not be considered for change; however,
the clearance time appears to be something that can be looked at further. The feeling
is that this may be able to be reduced to 1 s.
Following discussion of the matter it was agreed in the WG that for the standard
design of insulator (for 145 kV), we should consider 40 kA/1 s and not 40 kA/3 s.
538 P. Mirebeau
To allow for a fair and unbiased selection of the common interface, the design will be
selected
The cable catalogue was constructed taking into account all cable models that were
collected by the group members. It applies only to extruded cables, XLPE and EPR.
The purpose is not to build a comprehensive catalogue; it is intended to give the
diameter range that the interface must accommodate.
The cable characteristics that are dimensioning the GIS interface are mentioned in
Table 11.3.
The cable characteristics that are dimensioning the GIS interface are mentioned in
Table 11.4.
11 Standard Design of a Common, Dry Type Plug-in Interface for GIS and Power. . . 539
The grey cells are given for information as they are not in the TOR. Some cable models are coming
from a single source
The choice of the interface technology (inner or outer cone) has been performed
Inner cone and outer cone technologies have been evaluated as a function of the
selection criteria (refer to Sect. 11.2). This did not bring any obvious advantage to
one technology. Details of the comparison can be found in Appendix General
Evaluation of Inner and Outer Cone Technologies; first lines are reported in
Tables 11.5 and 11.6.
540 P. Mirebeau
The grey cells are given for information as they are not in the TOR. Some cable models are coming
from a single source.
11 Standard Design of a Common, Dry Type Plug-in Interface for GIS and Power. . . 541
50673 standard “Plug-in type bushings for 72.5 kV with 630 A and 1250 A for
electrical equipment” is in its finalization stage at the time of publishing this
brochure.
A tendency to move from inner to outer cone was recognized and implemented in
some projects of offshore windfarms at that voltage level.
The outer cone design would allow a more compact GIS equipment compared to
the dimensions specified in IEC 62271-209.
11 Standard Design of a Common, Dry Type Plug-in Interface for GIS and Power. . . 543
Due to large thermomechanical forces (refer to TB 669), the discussion has led to
give the possibility to lock the conductor connection inside the common interface.
This feature is already implemented by some manufacturers.
For the 72.5 kV voltage level, the outer cone is chosen. It is according to the F cone
as per EN 50181 that is currently being standardized at the 72.5 kV level in EN
50673.
For the 123 kV and 145 kV voltage levels, the inner cone is chosen. It is a new
insulator where dimensions have to be specified, see Sect. 11.8.
The conductor connection design must allow to lock the conductor.
The interface is specified in EN 50673 “Plug-in type bushings for 72.5 kV with
630 A and 1 250 A for electrical equipment,” which is derived from EN 50180 and
EN 50181. The selected interface type is “F5.”
544 P. Mirebeau
11.7.1 Design
I ØD
Interface type A mm
F5 1250 32
Examples are shown to illustrate the benefit of this interface (Figs. 11.3 and 11.4).
These examples show principles of assembly. They do not fulfill all the specifi-
cations of this brochure.
Each accessories manufacturer will develop his own termination.
548 P. Mirebeau
Fig. 11.3 Examples of implementation of the common 72.5 kV GIS interface: (a) in straight
arrangement in accordance with IEC 62271-209; (b) in elbow arrangement
11.8.1 Design
The recommended design is the inside of the inner cone, the outer shape of the
epoxy is drawn for information, and recommendations are given here under.
The selected interface is shown in Fig. 11.1. The dashed lines give an example of
possible outer shape design. A principle DXF file of the insulator is included as a
downloadable document in the online version of this chapter.
The angle of the conical dielectric part has been chosen to have one single
insulator for the complete cable range. If a sharper angle was chosen, the epoxy/
stress cone interface pressure would have been higher, but the acceptance of
different cable diameters lowered. If a wider angle was chosen, there would
have been a higher electrical field inside the enclosure and the increase of
epoxy/stress cone interface tangential stress would have restricted the design of
stress cones.
550 P. Mirebeau
The metal part has been designed so that all cable termination manufacturers can
implement the conductor connection inside the dedicated space. It includes (there is
room for) an interface to a sliding connection, a lock-in area, a second interface to a
sliding connection. Each manufacturer can use the allocated interface(s) (Fig. 11.5).
The length and shape of the electrode over the conductor connector has been
specified for field control purpose. Its cross section is enough to carry the full
specified nominal current of 1000 A and short circuit current of 40 kA 1 s.
Details about the selection of different parameters (dimensions, angles. . .) can be
found in appendix Information on the Selection of 145 kV Interface Selection.
Excerpt from the CIGRE TB 605 (Chap. 7) that is quoted here as it is fully applicable
to the common interface insulators.
M12 n.12
Silver plating
55 min 204±0,2 150±1,0
thickness 10 μm min
50 max
Rt ≤ 6,3 μm
8,4
R7 150±1,0
10 36±0,2 Ra 0,4 μm
4,85
65 17 5 35
in
°m
,0
R5
Ra 0,8 μm
76
104
1,0°
(14°0')
Ra 0,8 μm
0,00
+0,50
+0,2
+0,05
+0,05
298±0,3
320±0,5
Ø80±0,30
Ø82±0,5
Ø62±0,5
Ø255 0,00
Ø60-0,00
Ø85-0,00
Ø185-0,0
Ø100±1,0
Ø136±0,2
Ø245±0,5
Ø278±0,5
Ø280±0,5
Ø190-1,00
(250 max)
MIN Ø224
MAX Ø198
Ø 350 max
Ø300 (min)
Ø100 (min)
Ø110 (max)
Ra 0,8 μm
354±1,0
204±0,2
Ra 0,4 μm
>9
0°
A-A
,5
2±0
Ø8 +0,05
,5
Ø8 5-0,00
±0
62 ,05
Ø +0
,00
0-0
Ø6
123/145 kV COMMON INTERFACE
20
Cigré WG B1-B3.49 27
Status: 04.02.2019
VIEW A-A
Standard Design of a Common, Dry Type Plug-in Interface for GIS and Power. . .
All insulators are pretested, tested in modules or complete in factory, and on site after
installation.
This requires adjusting the compartment pressures several times during the different
phases of the GIS delivery.
• The design pressure is 7.5 bars relative (reference to IEC 62271-209).
• During transportation, the pressure is decreased to 0.5 bar.
• During works, the pressure in adjacent compartments is decreased to 0.5 bar.
• The customer or an authorized third party can perform the pressure decrease and refill.
There may be legal regulation regarding authorized persons.
• Supervision performed by experienced people or GIS manufacturer is recommended.
• SF6 maintenance equipment is available at the customer premises.
• Decrease of pressure is specified in the operating/maintenance manual.
The limit of supply of GIS and cable termination manufacturer is specified in IEC
62271-209 for both inner and outer cone designs of cable interface to GIS. The
epoxy insulator assembly is in the scope of termination manufacturer per this
standard. A full design of epoxy insulator assembly is not provided. Only interface
dimensions between the GIS housing and termination are specified.
The task of CIGRE WG is to propose design of the common insulator assembly
for plug-in terminations to enable interchangeability between the insulator assembly
and cable stress cone assembly. Once standardized, the common insulator assembly
will not be in the scope of termination manufacturer supply and will become
responsibility of the GIS manufacturer, even if the insulator assembly is
manufactured by a third party.
This section discusses possible failure mechanisms of both designs of cable/GIS
interface (outer cone for 72.5 kV and inner cone for 145 kV). It provides estimate of
the risk that failure occurs in particular failing mechanism, lists possible root causes for
each failing mechanism, and provides assessment of difficulty to allocate responsibil-
ity for failure to either GIS or cable termination manufacturer for each root cause.
Five failing mechanisms are discussed (see Table 11.12):
The level of the risk of failure for each failing mechanism is estimated and
categorized. Levels of risk of failure are:
– Low. It is very unlikely that the failure will occur due to this failing mechanism.
– Moderate. It is unlikely for failure to occur.
– High. Failure may occur.
– Easy to allocate when there is no doubt what caused the failure (white symbol is
used ).
– Somewhat questionable when there is high level of certainty in what caused the
failure (black and white symbol is used ).
– Very difficult to allocate when there is high level of uncertainty what caused the
failure (black symbol is used ).
556
Assesment of
responsibility
allocation
Comment on responsibility
Root cause of failure Responsible Mitigation
allocation
Inner Outer
Cone Cone
Assesment of
responsibility
allocation
Comment on responsibility
Root cause of failure Responsible Mitigation
allocation
Inner Outer
Cone Cone
(continued)
557
Table 11.12 (continued)
558
Assesment of
responsibility
allocation
Comment on responsibility
Root cause of failure Responsible Mitigation
allocation
Inner Outer
Cone Cone
Failing mechanism#2: Dielectric breakdown of interface between the epoxy insulator and the stress cone
Risk: LOW - Installation is done by trained and skilled jointers
Springs are used only in the inner
Insufficient stress cone/insulator cone design. Certified, skilled fitters.
It may be possible to prove that Accessory installation Installation manual and
interface pressure due to improper N.A. the failure was caused by
setting of spring tension insufficient spring tension and to check-sheet are clear
exclude insulator
Easy to check quality of spring
Insufficient stress cone/insulator material. Accessory supplier if the Incoming inspection check
It may be possible to prove that springs of inferior quality (material properties) and
interface pressures due to N.A. the failure was caused by the certification received
reduction of spring tension in service insufficient spring tension and to are used from spring manufacturer
exclude insulator
Accessory supplier if the
Insufficient stress cone/insulator wrong stress cone size is In-house quality
interface pressures due to There may be sufficient evidence provided. procedure.
to pin-point failure to improper Accessory installation if the skilled fitters.
incorrect stress cone dimension or N.A. stress cone size or cable insulation outer diameter of prepared Certified,
smaller then specified cable insulation diameter and exclude insulator Installation manual and
cable is not checked at the check-sheet are clear
outer diameter site
Applies only to the outer cone Accessory supplier if the In-house quality
Insufficient stress cone/insulator wrong size stress cone is
interface pressures due to design. provided. procedure.
N.A. There may be sufficient evidence Accessory installation if Certified, skilled fitters.
improper stress cone stretch, e.g. to pin-point failure to insufficient manual and
incorrect stress cone dimension stretch of the stress cone dimensions are not checked Installation
check-sheet are clear
at the site
Insufficient stress cone/insulator In-house quality check of
interface pressures due to wrong Easy to check GIS (insulator) the certification received
insulator dimensions from spring manufacturer
P. Mirebeau
11
Assesment of
responsibility
allocation
Comment on responsibility
Root cause of failure Responsible Mitigation
allocation
Inner Outer
Cone Cone
(continued)
559
Table 11.12 (continued)
560
Assesment of
responsibility
allocation
Comment on responsibility
Root cause of failure Responsible Mitigation
allocation
Inner Outer
Cone Cone
Failing mechanism#3: Dielectric breakdown of interface between the cable and the stress cone
Risk: LOW - Installation is done by trained and skilled jointers
Springs are used only in the inner
Insufficient cable/stress cone cone design. Certified, skilled fitters.
interface pressure due to improper It may be possible to prove that Accessory installation Installation manual and
N.A. the failure was caused by
setting of spring tension insufficient spring tension and to check-sheet are clear
exclude insulator
Easy to check quality of spring
Insufficient cable/stress cone material. Accessory supplier if the In-house quality check of
interface pressures due to It may be possible to prove that springs of inferior quality the certification received
N.A. the failure was caused by
reduction of spring tension in service insufficient spring tension and to are used from spring manufacturer
exclude insulator
Inner-cone: There may be
Insufficient cable/stress cone sufficient evidence to pin-point Accessory supplier if the In-house quality
interface pressures due to failure to improper stress cone wrong stress cone size is procedure.
incorrect stress cone size or smaller size or cable insulation diameter provided. skilled fitters.
then specified cable insulation and exclude insulator Accessory installation if the Certified,
Installation manual and
outer diameter Outer-cone: It would be possible OD of prepared cable is not check-sheet are clear
to exclude insulator since the checked at the site
failure is on cable section
Easy to allocate responsibility. Accessory supplier if the In-house quality
Chemical analysis may be wrong lubricant is provided. procedure.
Certified, skilled fitters.
Wrong lubricant used performed to check composition of Installation crew if other
lubricant lubricant is used Installation manual and
check-sheet are clear
P. Mirebeau
11
Assesment of
responsibility
allocation
Comment on responsibility
Root cause of failure Responsible Mitigation
allocation
Inner Outer
Cone Cone
Inner-cone: There may be
sufficient evidence to exclude Certified, skilled fitters.
Lubricant not applied per insulator Installation (almost Installation manual and
instructions Outer-cone: It would be possible impossible to prove) check-sheet are clear
to exclude insulator since the
failure is on cable section
Evidence of contamination failure
will be destroyed by the
breakdown Certified, skilled fitters;
Contamination of the stress cone Inner-cone: There may be Installation (almost Installation manual and
insulator interface during sufficient evidence to exclude impossible to prove) check-sheet are clear.
installation. insulator
Outer-cone: It would be possible
to exclude insulator since the
failure is on cable section
Inner Cone: It may be possible
Poor workmanship in cable to prove that insulator did not Certified, skilled fitters.
preparation cause failure Installation crew Installation manual and
Outer Cone: It is obvious that check-sheet are clear
insulator did not cause failure
Improper engagement of the Geometrical distortion is easy to Cable system engineering Check point in the
cable in the insulator verify or installation installation instructions
Initial alignment by
Misalignment of cable and Geometrical distortion should be Cable system engineering certified skilled fitters and
insulator easy to demonstrate or installation proper cable laying.
Check point in the
Standard Design of a Common, Dry Type Plug-in Interface for GIS and Power. . .
installation instructions
561
(continued)
Table 11.12 (continued)
562
Assesment of
responsibility
allocation
Comment on responsibility
Root cause of failure Responsible Mitigation
allocation
Inner Outer
Cone Cone
Movement of cable may cause
failure. Certified, skilled
Cable not properly clamped Evidence of cable not being Cable system engineering installation crew.
supported per requirements or/and installation crew Installation manual and
specified by the termination check-sheet are clear
manufacturer is evident
Assesment of
responsibility
allocation
Comment on responsibility
Root cause of failure Responsible Mitigation
allocation
Inner Outer
Cone Cone
Failing mechanism #5: Thermal runaway
Risk: LOW - Installation is done by trained and skilled jointers
Cable connector not properly Certified, skilled
installed (e.g. insufficient crimp Evidence of improper connector Installation crew installation crew.
or not tightened bolts) installation may exist Installation manual and
check-sheet are clear
Evidence of improper connector Certified, skilled
Connection interface failed installation or improper connection Installation crew installation crew.
surface preparation may exist Installation manual and
check-sheet are clear
Standard Design of a Common, Dry Type Plug-in Interface for GIS and Power. . .
563
564 P. Mirebeau
The table 11.12 is based on assumption that epoxy insulator is provided and
installed into GIS housing by the GIS manufacturer.
Risk assessment of failure is based on following assumptions:
The routine tests of the stress cone have been performed per IEC 60840 and
additional routine test procedure of the manufacturer (responsibility of cable acces-
sory manufacturer).
It is to be noted that after-installation tests including Partial Discharge
(PD) measurements can show up defects before the operation phase. PD monitoring
during operation may allow to pinpoint some defect types before breakdown.
This section describes the technical parameters, tests, and/or the field experience that
give the supporting arguments that proposed insulator designs will work and provide
a lifetime in agreement with the cable systems design.
The proposed insulator design concept is based on a long and positive experience at
the medium voltage level up to 52 kV.
It has been already submitted to tests and actual installations at the 72.5 kV level.
It is being standardized.
Fig. 11.7 Example of 72.5 kV installed links using the common insulator during tests (three
different GIS)
11.11.1.6 Conclusion
The credibility shows that there is a limited field experience for the selected
interface; however, it has been type tested for a set of heating current and cross
sections that give confidence to this design. It is to be noted that the stress in the
insulator is independent from the stress and dimension of the cable.
The common insulator is new, but proposed by the experts of the WG, based on
proven design parameters, with long and positive field experience. These designs
have been type tested and are in service for over 30 years.
Fig. 11.8 Example of electrical field calculation on 72.5 kV outer cone termination
The hereunder electric fields are calculated for a reference impulse voltage of
650 kV (or U0 ¼ 76 kV).
Along the surface of conductive electrode, inside epoxy-resin insulator the calcula-
tion shows acceptable values up to: Emax. ¼23.5 kV/mm (2.75 kV/mm).
568 P. Mirebeau
Fig. 11.9 Example of electrical field calculation on 145 kV inner cone termination
Along the surface of conductive deflector inside rubber insulation part, the calcula-
tion shows acceptable values up to: Emax. ¼38.5 kV/mm (4.50 kV/mm).
The tangential field plot along interface between rubber and epoxy-resin insulator
starting from HV side has a maximum at 9 kV/mm (1.05 kV/mm).
Along the insulator interface surface to gas starting from HV side, the calculation
shows acceptable values up to: Emax. ¼13.7 kV/mm (1.60 kV/mm).
11 Standard Design of a Common, Dry Type Plug-in Interface for GIS and Power. . . 569
2.5e+007
4e+007
2e+007
3.5e+007
1.5e+007 3e+007 2
2.5e+007
1e+007
1
2e+007
5e+006
1.5e+007
0
1e+007
9e+006
8e+006
7e+006
6e+006 1e+007 4
5e+006
4e+006 3 5e+006
3e+006
2e+006
1e+006
0
0
Fig. 11.10 Stresses as per Fig. 11.9 (example as illustration): (1) along the surface of conductive
electrode; (2) along the surface of conductive deflector inside rubber insulation part; (3) along
interface between rubber and epoxy-resin insulator; (4) along the insulator interface surface
11.11.2.2 Connection
The principle design and material of the current carrying path have been used in the
field for more than 30 years for dry and for fluid filled GIS cable terminations.
11.11.2.3 Conclusion
The dielectric design of the 123–145 kV interface is safe and achievable. There is
design margin available when compared to the various manufacturers’ designs. A
more compact insulator could be specified or the application range extended after
there will be a market harmonization and field experience of the proposed current
connection solutions.
The cases of cable and accessory qualification are specified in IEC 60840. The
related extensions of qualification are recommended in CIGRE TB 303 (▶ Chap. 4,
“Qualification Procedures for HV and EHV AC Extruded Underground Cable
Systems” of the book).
IEC 60840 requires to qualify each cable together with its accessories and the
validity of type test result is limited to the tested design provided from a single
source of supply. Up to now it is not foreseen in high voltage applications to “mix
and match” components. According to this Technical Brochure, preinstalled
570 P. Mirebeau
Legend:
cable/stress cable/stress
insulator assembly cone assembly insulator assembly cone assembly
never qualified never qualified qualified qualified
Cross qualification without Type test according to IEC 60840 with the following amendment:
initial qualification of 20 heating cycles with 2 hours between 95°C and 100°C , leaving the
either insulator assembly heating and cooling time free.
or cable/stress cone Prequalification test according to IEC 60840 when applicable.
assembly Tests of sectionalising insulation according to IEC 60840.
insulators assemblies from different manufacturers should work together with cable/
stress cone assemblies coming from different suppliers. Rules are necessary to deal
with combinations of materials which might have been qualified separately before.
The table 11.16 focuses on the qualification and cross qualification of insulator
assembly and cable/stress cone assembly as defined in Sect. 11.3.1 representing the
complete termination. Three different cases were identified and evaluated (see detail
of experts views in Appendix E).
Table 11.16 applies to insulators that already comply with the requirements of
previous sections, regarding geometrical, dielectric, and mechanical parameters.
11 Standard Design of a Common, Dry Type Plug-in Interface for GIS and Power. . . 571
11.13 Conclusion
• Um ¼ 72.5 kV
• Um ¼ 123 kV and 145 kV
• Current 1000 A
These designs meet the requirement of IEC 62271-209 and IEC 60840.
• For 72.5 kV, the outer cone design is based on the on-going standard EN 50673.
• For the 145 kV, the proposed inner cone design is new, with larger design margins
in reference to existing designs.
Table 11.17 is a collection of the evaluation made by each expert. These evaluations
were taking into consideration the 2 solutions (inner or outer cones) and the 2 voltage
class ranges (72.5–100 kV and 123–145 kV).
Each expert evaluation is identified by a single color.
Table 11.18 and 11.19 following tests lists are determined considering different types
of characteristics to control. These lists are for information.
These characteristics are grouped according to the following classification table.
Some of these tests were excluded as they were considered not relevant.
572
Inner Outer
Cone Cone
Model Model
Dimensions/size of insulator Larger above the base plate, smaller 0 0 Can be shorter above the base plate, 0 0
above but longer below the base plate
P. Mirebeau
11
Inner Outer
Cone Cone
Model Model
Dimensions/size of insulator Insulator is larger than outer cone - - Insulator is smaller than inner cone 0 0
model due to insert inner cone inside model due to almost same diameter
insulator with outer cone if there is no necessary
to set up metal covering
Mismatch risk insulator Outer diameter of stress-cone is more - Can accommodate a larger range of +
assembly/cable - stress depending on the cable diameter and cable diameters per size without
cone assembly influences the installation difficulty and influence on the position
position of the connection
Need for a large number of sizes
Standard Design of a Common, Dry Type Plug-in Interface for GIS and Power. . .
(continued)
Table 11.17 (continued)
574
Inner Outer
Cone Cone
Model Model
Inner Outer
Cone Cone
Model Model
Mismatch risk 0 0 0 0
cable dimensions
Mismatch risk Depended on maker’s design, but 0 0 Depended on maker’s design, but 0 0
insulator/stress cone applicable range is limited due to more applicable range is comparably wider
assembly risky change of interface pressure in due to generate interface pressure by
case rubber deformation by different rubber deformation
diameter between rubber and cable
Mismatch risk Depended on maker’s design 0 0 Depended on maker’s design 0 0
cable dimensions
Easier installation No difference to install insulator 0 0
displacement
575
(continued)
Table 11.17 (continued)
576
Inner Outer
Cone Cone
Model Model
Ease of installation concentric positioning during plug-in + + concentric positioning during plug-in - -
process can be controlled process cannot be controlled during
entire process
Plugging to insulator + + 0 0
Ease of installation Much time to set up spring device, Must 0 0 Easy handling cable without overlap to + +
insert cable and inner cone and be cable insulator
off-set process
Consequence of failure Failure in interface insulator-stress-cone - Does not affect GIS side +
-> risk of bursting of insulator
Failure in interface cable-stress-cone → - Does not affect GIS side +
risk of bursting of insulator
Failure of cable under stress-cone → - Does not affect GIS side +
less risk of bursting of insulator
P. Mirebeau
11
Inner Outer
Cone Cone
Model Model
Consequence of failure Failure in interface will affect the barrier - - Failure in cable/mould part outside GIS + +
In the stress cone and between GIS and cable
interface stress cone/epoxy
Consequence of failure Failure in cable part can affect the GIS - - Cable in cable will not affect the GIS ++ ++
In the cable related part
In the epoxy
577
(continued)
Table 11.17 (continued)
578
Inner Outer
Cone Cone
Model Model
Consequence of failure 0 0 0 0
In the epoxy
Consequence of failure 0 0 0 0
In the stress cone and
interface stress cone/epoxy
Consequence of failure 0 0 0 0
In the cable related part
Consequence of failure in 0 0 0 0
the epoxy
Consequence of failure in 0 0 Potential pressure release in case of + +
the stress cone and failure (no vessel damage)
interface stress cone/epoxy
P. Mirebeau
11
Inner Outer
Cone Cone
Model Model
Consequence of failure in Higher electric field in epoxy but much 0 0 Lower electric field in epoxy but less 0 0
the epoxy experience experience
Must open GIS enclosure Must open GIS enclosure
Consequence of failure in Higher interface field but much 0 0 Higher field in rubber electrode 0 0
the stress cone and experience embedded in cone
interface stress cone/epoxy
Consequence of failure in Much damage of epoxy insulator with 0 0 Estimated less damage of epoxy 0 0
the cable related part high inner pressure by breakdown but insulator but less mechanical experience
much experience for cable transient reaction during short
circuit phenomenon etc.
Separation of In case of failure most likely all - - Interface epoxy/rubber stress cone and + +
responsibilities/liabilities in components (epoxy/stress cone/cable) interface rubber/cable responsibility of
case of failure will be affected termination/cable supplier
case of failure
579
(continued)
Table 11.17 (continued)
580
Inner Outer
Cone Cone
Model Model
Separation of 0 0 0 0
responsibilities/liabilities in
case of failure
Separation of Simple interface between gas and 0 0 Simple interface between gas and 0 0
responsibilities/liabilities in insulator, longer interface of epoxy insulator, shorter interface of epoxy
case of failure insulator insulator
Inner Outer
Cone Cone
Model Model
Quality assurance Components can be factory tested 0 0 Components can be factory tested 0 0
Components
Quality assurance Testing of epoxy and rubber stress cone - - Interface epoxy/rubber mould can be + +
Installation separately pre-assembled and pretested
Components
581
(continued)
Table 11.17 (continued)
582
Inner Outer
Cone Cone
Model Model
Quality assurance ++ ++ + +
Components
Quality assurance + + + +
Installation
Quality assurance 0 0 0 0
Components
Quality assurance 0 0 Better visibility of insulator surface (can + +
Installation be easier cleaned)
Quality assurance Complete establishment for quality + + Not establish electrical routine test - -
Components assurance in factory Must need additional equipment
Inner Outer
Cone Cone
Model Model
Experience/commonly used ++ ++ - -
Experience/commonly used ++ ++ 0 --
Experience/commonly used + +
Experience/commonly used
(continued)
Table 11.17 (continued)
584
Inner Outer
Cone Cone
Model Model
Economic considerations 0 0 0 -
Economic considerations 0 0 0 0
Economic considerations
Inner Outer
Cone Cone
Model Model
Testing of insulator in GIS Testing possible with adapter or closing 0 0 Testing with test adapter 0 0
plate and SF6
cover)
585
(continued)
Table 11.17 (continued)
586
Inner Outer
Cone Cone
Model Model
Substation basement Inner cone needs more space during - Outer cone needs more space under GIS +
dimensions, plug-in (pull installation casing after installation
back) space needed
Substation basement Shorter endbell, but longer plug 0 - Longer end bell, mould exceeding the + +
dimensions, plug-in (pull base-plate, but shorter plug requiring
back) space needed less space to pull back
Inner Outer
Cone Cone
Model Model
Sheath break application Many experience, reliable design ++ ++ Developing aspect (positioning, 0 0
insulating, evaluation, qualification) due
to few experience
Metal covering Many experience, reliable design ++ ++ No metal covering for MV class But need 0 0
(Protection) metal covering to protect water
penetration??
Standard Design of a Common, Dry Type Plug-in Interface for GIS and Power. . .
587
588 P. Mirebeau
Routine Tests
Type Tests
Sample Tests
Prequalification Tests
Development Tests
Cable conductor
Fig. 11.12 Example of connection application: contact above lock-in system area
11 Standard Design of a Common, Dry Type Plug-in Interface for GIS and Power. . . 595
Cable conductor
Fig. 11.13 Example of connection application: contact below lock-in system area
596 P. Mirebeau
cable/stress cable/stress
insulator assembly cone assembly insulator assembly cone assembly
never qualified never qualified qualified qualified
or
Type Test according to IEC Sample Test according to IEC Type Test according to IEC
60840 (with 20 heating 60840 / § 11.2 i.e. 60840 (with 20 heating
cycles) + Prequalification a) partial discharge test cycles) + Prequalification
Test in case of high stress b) voltage test + impulse Test in case of high stress,
test at ambient temperature i.e. follow TB 303
Stick with existing standards. Sample Test according to IEC Type Test according to IEC
Type Test according to IEC 60840 / § 11.2 i.e. 60840 (with 20 heating
60840 (with 20 heating a) partial discharge test cycles) + Prequalification
cycles) + Prequalification b) voltage test + impulse Test in case of high stress,
Test in case of high stress test at ambient temperature i.e. follow TB 303
Type Test according to HD Voltage and impulse tests Type Test according to HD
629.1 (with 120 heating 629.1 (with 120 heating
cycles) but test values taken + 10 heating cycles in case cycles) but test values taken
from IEC 60840. Cycles: 5 h of smaller cross section from IEC 60840. Cycles: 5 h
heating + 3 h cooling with a heating + 3 h cooling with a
maximum cross section of maximum cross section of
Expert's
630 mm² AL or 500 mm² Cu 630 mm² AL or 500 mm² Cu
views
Type Test according to IEC Type Test according to IEC Type Test according to IEC
60840 (with 20 heating 60840 (with 20 heating 60840 (with 20 heating
cycles) on maximum cycles) on any conductor size cycles) on any conductor
conductor size. - i.e. follow TB 303 size. i.e. follow 303.
Stick with existing standards. Sample Test according to IEC Type Test according to IEC
Type Test according to IEC 60840 / § 11.2 i.e. 60840 (with 20 heating
60840 (with 20 heating a) partial discharge test cycles) + Prequalification
cycles) + Prequalification b) voltage test + impulse Test in case of high stress,
Test in case of high stress test i.e. follow TB 303
Type Test according to IEC Sample Test according to IEC Type Test according to IEC
60840 (with 20 heating 60840 / § 11.2 i.e. 60840 (with 20 heating
cycles) + Prequalification a) partial discharge test cycles) + Prequalification
Test in case of high stress. b) voltage test + impulse Test in case of high stress,
With no range extension test at ambient temperature i.e. follow TB 303. With no
limitation on the cable range extension limitation on
stresses. the cable stresses.
(continued)
11 Standard Design of a Common, Dry Type Plug-in Interface for GIS and Power. . . 597
or
Type Test according to HD Voltage and impulse tests Type Test HD 629.1 (120LC)
629.1 (with 120 heating but test values from 60840
cycles) but test values taken + 10 heat cycles in case of with 5 h Heat 3h Cooling with
from IEC 60840. Cycles: 5 h smaller cross section maximum cross section
heating + 3 h cooling with a 630mm² AL or 500mm² CU
maximum cross section of
630 mm² AL or 500 mm² Cu
Conclusion Type test with voltage level Sample Test according to Type test with voltage level
of IEC 60840. IEC 60840 / § 11.2 i.e. of IEC 60840.
20 heating cycles with 2 a) partial discharge test 20 cycles with 2 hours
hours between 95°C and b) voltage test between 95°C and 100°C
100°C and leave the and leave heating and
heating and cooling time Lightning impulse test: at cooling times free +
free + prequalification test ambient temperature prequalification test in cas
in cas of high stress. of high stress.
Tests of sectionalising Tests of sectionalising
Tests of sectionalising insulation according to IEC insulation according to IEC
insulation according to IEC 60840 60840.
60840
Cross qualification is in
The range of approval of accordance with TB 303,
IEC 60840 remains with no range extension
applicable limitation on cable stresses
as recently introduced in
IEC 60840.
References
EN 50180:2010 – Bushings above 1 kV up to 52 kV from 250 A to 3,15 kA for liquid filled
transformers
EN 50181:2010 – Plug-in type bushings above 1 kV up to 52 kV from 250 A to 2,5 kA for
equipment other than liquid filled transformers
EN 50673:2019 – Plug-in type bushings for 72.5 kV with 630 A and 1 250 A for -electrical
equipment
HD 629.1 S3:2019 – Test requirements for accessories for use on power cables of rated voltage from
3,6/6(7,2) kV up to 20,8/36(42) kV. Accessories for cables with extruded insulation
IEC 60068-2-14. Edition 6 – environmental testing – part 2–14: tests – test N: change of
temperature
IEC 60085. Edition 4 – Electrical insulation – thermal evaluation and designation
IEC 60137. Edition 7 – Insulated bushings for alternating voltages above 1000 V
IEC 60183. Edition 3 – Guidance for the selection of high-voltage A.C. cable systems
598 P. Mirebeau
IEC 60840. Edition 5 – Power cables with extruded insulation and their accessories for rated
voltages above 30 kV (Um ¼ 36 kV) up to 150 kV (Um ¼ 170 kV) – test methods and
requirements
IEC 62271-1. Edition 2 – High-voltage switchgear and controlgear – part 1: common specifications
for alternating current switchgear and controlgear
IEC 62271-203. Edition 2 – High-voltage switchgear and controlgear – part 203: Gas-insulated
metal-enclosed switchgear for rated voltages above 52 kV
IEC 62271-209. Edition 2 – Cable connections for gas-insulated metal-enclosed switchgear for
rated voltages above 52 kV – fluid-filled and extruded insulation cables – fluid-filled and
dry-type cable terminations
TB 303: Revision of qualification procedures for HV and EHV AC extruded underground cable
systems, WG B1.06 (2006)
TB 605: Feasibility of a common, dry type plug-in interface for GIS and power cables above 52 KV,
WG B1/B3.33 (2015)
TB 669: Mechanical forces in large cross section cables systems, WG B1.34, WG B1.44 – Work
under induced voltages and induced currents, to come (2016)
TB 758: Test regimes for HV and EHV cable connectors, WG B1.46 (2019)