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Direct Current Field Tests

DIRECT CURRENT FIELD TESTS

LOW VOLTAGE NON-SHIELDED CABLES: "HI-POT" Test


LOW VOLTAGE NON-SHIELDED CABLES: "MEGGER" Test
IEEE 400: IEEE Guide for Making High-Direct-Current-Voltage Tests
AEIC CS-5-94: Cross-Linked Polyethylene Insulated Shielded Power Cables
AEIC CS-6-??: Ethylene Propylene Rubber Insulated Shielded Power Cables
Time-Leakage Test: Direct Current Time-Leakage Test

INTRODUCTION
SAFETY
Before conducting tests on a cable system, verify that the cable system is properly de-energized.
If the system has been previously energized, follow the prescribed rules for switching necessary
to de-energize, lockout, tag, and ground the cable system. The personnel conducting the testing
must be qualified to operate the test equipment and be familiar with the cable system and its
components.

PREPARATION FOR TESTING


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Disconnect cables from non-cable system equipment and apparatus. This will reduce the
possibility of erroneous test results. In the case of HVDC (High-Voltage-Direct-Current) testing,
it will prevent damage to equipment and apparatus. Adequate physical clearances between the
cable ends, and other equipment, other energized conductors, and to electrical ground must be
checked. During the testing, be sure that unauthorized access to the cable system is maintained.
Verify that proper procedures are taken to clear all tap(s) or lateral(s) in the circuit. Remove
grounds from the cable phase to be tested. Phases not under test should remain grounded at all
ends.

CONDUCTING TEST
Conduct test according to prescribed procedures and instructions. Record test results and retain
for future reference.

LOW VOLTAGE NON-SHIELDED CABLES


"HI-POT": High Voltage Potential DC Test
High potential tests are "go no-go" tests. The cable is required to withstand the specified voltage
for the specified time duration. These tests will normally reveal gross imperfections due to
improper field handling. Recommended test voltages are given in tables for dc and ac.
Alternating current new installation test voltages are 80% of the factory test voltage. Direct
current voltages are two times the ac new installation test voltage. Test duration should not
exceed five minutes.

Recommended DC Dielectric Test Voltages For New Installations


Size

XHHW/RHH/RHW

USE

THHN/THWN

14

4800

---

3200

12

4800

4800

3200

4800

4800

3200

4800

5600

3200

1 - 4/0

6400

6400

4000

250 - 500

8000

8000

4800

550 - 1000

9600

9600

5600

1100 - 2000

11200

11200

6400

10
8-

Recommended AC Dielectric Test Voltages For New Installations


Size

XHHW/RHH/RHW

USE

THHN/THWN

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14

2400

---

1600

12

2400

2400

1600

10

2400

2400

1600

8-2

2800

2800

1600

1-4/0

3200

3200

2000

250-500

4000

4000

2400

550-1000

4800

4800

2800

1100-2000

5600

5600

3200

"MEGGER": Insulation Resistance Test


Low voltage, non-shielded cables can be tested using a battery powered ohmmeter or a device
called a "megger". Hand held ohmmeters generally have outputs from several volts to 24 volts.
They are excellent for detecting direct "shorts" such as bolted faults and low resistant
measurements in the kilohm range. A "megger" measures resistance in the megohm range using
higher voltages than an ohmmeter. Manual or motor-driven meggers are available for a range of
fixed dc voltages. Typical fixed dc voltages are 500, 1000, 2500 and 5000 volts.
2 to 50 Megohm Rule
Applied dc potential may be 500 or 1000 volts dc with the insulation resistance reading taken
at one minute. A megohm meter reading of less than 50 megohms may be used for deciding
when to investigate the cable installation, readings less than two megohms will most likely
indicate damaged insulation. Readings of 2 to 50 megohms are usually associated with long
circuit lengths, moisture, or contamination. In most cases a 2 to 50 megohm reading does not
indicate the insulation quality, therefore 2 to 50 megohms should not be specified as a pass/fail
value. Insulation resistance readings should be made and interpreted by experienced testing
specialists to determine the condition of the cable's insulation.
Note that it is difficult to obtain accurate insulation resistance measurements in the field. Factory
tests are done in a controlled environment with the cable submerged in water to provide an
electrical ground. Using factory test values are not recommended.

MEDIUM VOLTAGE SHIELDED CABLES


IEEE 400
"IEEE Guide for Making High-Direct-Current-Voltage Tests on Power Cable Systems in
the Field"
With any HVDC testing it is highly recommended that IEEE Standard 400 be understood
and that there is concurrence of the manufacturers of the cables, terminals, and splices
prior to the performance of any proposed testing. Table 1 is taken from IEEE Std. 400:
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IEEE Standard 400 tests are "go no-go" tests. The system is required to withstand the
specified voltage for the specified time duration. These tests will normally reveal gross
imperfections due to improper field handling such as excessive bending or air gaps
between the insulation and shield interfaces.

Table 1
Field Test Voltages for Shielded Power Cable Systems
5 kV to 35 kV

System
Voltage
(kV rms)
phase-phase

System BIL
(kV)
(crest)
(cond-gnd)

Acceptance Test
Voltage*
(kV dc)
(cond-gnd)

Maintenance Test
Voltage**
(kV dc)

75

28

23

95

36

29

15

110

56

46

25

150

75

61

28

170

85

68

35

200

100

75

* Acceptance test voltage duration is normally 15 minutes.


** Maintenance test voltage duration is normally not less than five minutes or more than 15
minutes.

AEIC CS-5-94
"Specifications for Cross-Linked Polyethylene Insulated Shielded Power Cables Rated 5
Through 46 kV"
Tests During and After Installation
During Installation. At any time during installation, a dc proof test may be made at a
voltage not exceeding the dc test voltage specified for During Installation, applied for five
consecutive minutes.
After installation. After the cable has been completely installed and placed in service, a
dc proof test may be made at any time within the first five years at a voltage not
exceeding the dc test voltage specified for the First five Years, applied for five consecutive
minutes. After that time, dc testing is not recommended.
DC test voltages are applied to discover gross problems such as improperly
installed accessories or mechanical damage. DC testing is not expected to reveal
deterioration due to aging in service. There is some evidence that dc testing of aged crosslinked polyethylene cables can lead to early cable failures.

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Table 2
DC FIELD TEST VOLTAGES
Cross-Linked Polyethylene Insulated Shielded Power Cables
DC Test Voltages (kV)
Rated Voltage During First
Phase to Phase (kV)
Insulation Thickness During Installation (5 min) First 5 Years (5 min)
5
90
28
9
5 or 8
115
36
11
15
175
56
18
15
220
64
20
25
260
80
25
25
320
96
30
28
280
84
26
35
345
100
31
35
420
124
39

AEIC CS-6-?? ---DO NOT SPECIFY COMPLIANCE--"Specifications for Ethylene Propylene Rubber Insulated Shielded Power Cables Rated
5 Through 69 kV"
This information has not been adopted and is pending review by AEIC!

Tests During and After Installation


During Installation. At any time during installation, a dc proof test may be made at a
voltage not exceeding the dc test voltage specified for During Installation, applied for five
consecutive minutes.
After installation. After the cable has been completely installed and placed in service, a
dc proof test may be made at any time within the first five years at a voltage not
exceeding the dc test voltage specified for the First five Years, applied for five consecutive
minutes.
DC test voltages are applied to discover gross problems such as improperly
installed accessories or mechanical damage. DC testing is not expected to reveal
deterioration due to aging in service.
This information has not been adopted and is pending review by AEIC!

Table 3
DC FIELD TEST VOLTAGES
Ethylene Propylene Rubber Insulated Shielded Power Cables
DC Test Voltages (kV)
Rated Voltage Phase to
Phase (kV)
Insulation Thickness During Installation (5 min) First 5 Years (5 min)
5
90
28
22
5 or 8
115
36
29
15
175
56
45
15
220
64
51
25
260
80
64
25
320
96
77
28
280
84
67
35
345
100
80
35
420
124
99
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This information has not been adopted and is pending review by AEIC!

Time-Leakage Test
For more sophisticated evaluations, it is important to recognize the components of dc "leakage"
current. The output current of the test set into the cable is not the true leakage current. The
output current is the sum of three currents; geometric capacitance, absorption, and true leakage
current. The absolute value of output current is not of primary importance. This value is virtually
impossible to predict and is dependent upon the previously mentioned factors which can affect
the resultant output current from a few microamperes to hundreds of microamperes.
Time-Leakage Test, Components of DC Test Output Current (Diagram not available)
It is the shape of the total current curve (it) with respect to time that indicates the condition of
the dielectric. A drop-off of current with respect to time is an indication of sound insulation. A
rising current is an indication of questionable condition or impending failure. A flat curve is
generally due to test conditions.
The output current variation with respect to time of voltage application is generally considered
more indicative than the absolute value. The characteristic shapes of the time-leakage current
curve and probable causes are outlined below.
1. A rising leakage curve at a steady voltage may be indicative of faulty insulation.
However, other leakage paths (over porcelain surfaces and through insulating fluids) can
contribute to such a result.
2. A falling leakage curve is indicative of good insulation characteristics, especially if at
similar levels for all phases.
3. A flat leakage curve at low value is generally indicative of acceptable insulation.
Flatness may be influenced by circuit length, cable geometry, and possible presence of
moisture or contaminants over terminal surfaces.
4. A flat leakage curve at high value may indicate any of the following conditions:
a. presence of moisture
b. contaminants over terminal surfaces or other creepage surfaces
c. surface leakage greater than volume leakage
d. moist laminated insulation
e. condition of insulating fluids
f. air ionization losses (corona) from projections
5. Dissimilar leakage curvesare indicative of nonuniformity of circuit insulation. The
characteristic curve of each phase should be analyzed to determine the cause of dissimilarity. Air
ionization losses from projections may affect one phase more than the others, dependent upon
corona shielding (such as at terminals), temperature and humidity transients, air movement, and
the like.
Generally speaking, the increase of current with test voltage is approximately linear for sound
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insulation. Care should be exercised to prevent terminal corona and minimize terminal surface
leakage as these can mask test results.

Southwire Company, One Southwire Drive, Carrollton, Georgia 30119, USA


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