Extruded Cable Reliability- life estimation and life extension

N. Srinivas, Fellow IEEE, O. Morel, Member IEEE, W. Chatterton, Member IEEE, and B.S. Bernstein, life Fellow IEEE.
Abstract--The reliability of distribution class cable systems installed in utilities can be significantly improved by employing cost effective strategies offered by innovative technologies. This will provide a better engineering tool to prioritize the capital expenditure. The on line condition assessment technology offers a non invasive, non destructive approach, which will assist the user to establish a predictive maintenance program in a proactive manner. The technique is particularly applicable for identifying the type of defects that cause aging and loss of life in system components. The rejuvenation technology extends the operating life of aged extruded cables commonly used in distribution systems. It is based on a well proven silicone fluid injection process, which is successfully employed in distribution systems all over the world. This paper describes the aging mechanism of the distribution class power cable system with extruded insulation, principles used in the technologies mentioned above and the results obtained in the field.

adequate to cause failure, but only to weaken the insulation (and raise the dielectric constant which means that a water-treed cable remains an insulation, but not necessarily a very good one.).Hence the dielectric strength of an XLPEinsulated cable will decrease as a result of water tree presence. Failure later results when a water tree is converted to an electrical tree. Water trees are converted to electrical trees by additional stress being placed on the weakened localized region. This can be the result of increased operating stress or a surge (lightning, thumping) .While a water tree consists of locally oxidized regions, the electrical tree consists of continuous charred regions. When these charred regions fully penetrate the full insulation wall, the discharge channel then is composed of air and the cable can no longer function. An operating cable is continuously emitting signals during operation, many of which are difficult to detect. The changes described above lead to changes in the exact nature of those signals, with identification becoming easier as degradation proceeds. Thus special equipment is required to detect signals from defects such as water trees, reported to be in the femtocoulomb range (3). When a cable exhibits partial discharge (a phenomena that is active in converting a water tree to an electrical tree, or when extending the length of an electrical tree prior to actual failure), signals are easier to detect. It is also possible to detect signals prior to partial discharge from energized and operating cables; some information on this technology is described below. Of all the diagnostic methods available today; condition assessment diagnostic testing is very promising, as it provides early identification of weak components of the cable system. It can locate the degraded components of the system and determine the extent of the degradation. This is essential to maintain system reliability. Cost savings can be realized by prioritizing the replacement of weak sections of a circuit.

I. Background The issue of reliability of extruded installed cables and mechanisms of degradation of cables employing hydrocarbon-based polymer insulated cables has been reviewed often (1). As a result of the exposure of potential problems generated by the common DC HiPot test or exposure to surges, when applied to aged extruded XLPEand EPR-insulated cables(2), the development in recent years of in-situ testing methods for cable systems to address user concerns has been dramatic. The well known mechanism of degradation of extruded cables is water treeing. These defects result from water that migrates to high stress localized sites within the insulation wall. These are due to manufacturing defects or imperfections that result on aging. Migration of ions has led to bow-tie trees (ions being present from processing of the carbon black in the shields) .Water trees consist of oxidized regions of the insulation encompassed by less degraded regions, but the degradation that occurs is not

The objective of diagnostic testing is to identify defects that result in a system failure (4) and predict the time required for these defects to fail the cable system (5). The test should be economically justified and should not cause additional degradation to the system under test. Diagnostic test methods that detect partial discharges (PD), which are active during the time of testing, can only detect defects or imperfections that produce partial discharge greater than the sensitivity of the test method. Cable accessories such as splices and terminations are most likely to fail because of PD that causes degradation. In order to ensure reliable operation of the cable system, an integral method that provides detection, location and condition assessment of both pre and post partial discharge (PD) and water content is needed. Some PD testing techniques are carried out by switching off the system and then disconnecting the cable to be examined. This also requires that shut down be coordinated with interlinked parts of the system and this may not always be convenient or economical. In contrast to this, the CableWISE on-line condition assessment technique is capable of detecting and locating PD and other aging defects in cable systems. It is apparent that methods that apply an overvoltage lead to a number of issues that influence interpretation of the signals. (a) Measurement of discharge magnitude, which while of interest, does not distinguish between defect types that are leading to the discharge, (b) lack of information provided on the exact defect location within the cable wall; it is well known that a specific diameter void (for example) would be more harmful the closer it is to the strand shield (c) potential activation of dormant sites that may not cause problems for many years is possible. Finally, (d) applying an overvoltage renders it difficult to see low level signals present at operating voltage; a reduced number of partial discharge pulses is located (Locating such pulses and interpreting their significance is different from activating them). It should also be noted that all these procedures are performed off line. CableWISE technology represents an online predictive technology that addresses these issues. Signals are always being emitted by energized lines. For field measurements, partial discharge

(apparent discharge) magnitude is not as important as is the partial discharge pattern. From the pattern, it is possible to ascertain the cause of the discharge, and then place a degree of relevance relative to future concerns, on what is being measured. Signal patterns are related to the discharge source (void, electrical tree, surface tracking, contaminant, etc). Since this is an on-line test, the test can be performed while the total system remains in operation. This paper describes the CableWISE methodology, provides examples, describes expectations for cable system users, and also expands the approach that the user can employ by joining the concept of silicone fluid injection after the on line diagnostic test has been performed. II. CableWISE On-Line Predictive Testing This on-line test involves the use of sensors that are placed at discrete locations along the cable system length. The sensors detect signals that are always present during cable system operation, from analysis of the signals, the condition of the cable system between sensors is determined. The sensors are moved to different locations as testing is continued; this allows branched system to be appropriately evaluated, and avoids potential confusion regarding signal source. This on-line predictive test is performed while the system is in operation, hence eliminating any concerns about potentially harmful effects of overvoltages. Signals are emanated from defects within the cable insulation wall or at the insulationsemiconducting shield interface. This activity leads to high frequency pulses that travel along the cable conductor and ground shield. The pulse patterns are related to the type of defects causing the signals. The CableWISE technology collects information in both the time and frequency domains (6). The CableWISE online technology assesses the condition of each section of cable and each component in a cable system. Also, CableWISE can assess the condition of transformers, switchgear and motors that are connected to the cable system.

Figure 1 is a summary of degradation sites that are possible as a cable system ages. CableWISE can detect, locate, and assess the effects of these sites. Most of the sites can progress to electrical trees and eventual failure, if no action is taken to mitigate the condition.

Several significant advantages of this on-line diagnostic tool are noted here: The test is passive as the test procedure itself cannot induce a minor defect to become a major one Signal analysis and pattern recognition data allows for determination of the type of defect causing the signal (the defects causing loss of life facilitate identification of the extent of degradation) Signal analysis locates the source of the defect within the equipment Since this on-line test measures signals that are always present at operating voltage, the technique detects signals resulting from both post partial discharge and pre-discharge events. Total signal data collection facilitates estimation of future performance and ranking of the degree of estimated loss of life. The on line test measures the condition of the cable system at operating temperature; this is significant as the cable system undergoes changes in physico-chemical properties as the temperature is elevated (leading to different signal emanation). The test cannot lead to trapped space charge, which is theoretically possible when an overvoltage is employed. The on line method allows the estimation of future performance of all equipment located between sensors, including joints and terminations.

Contamination

Water tree sites

Interfacial discharge Partial discharge

Tracking

Floating metal Partial discharge

Protrusion

Cavities

Partial discharge

Partial discharge

Partial discharge

Electrical trees

FAILURE

Figure 1

Figure 2 shows the pre discharge signals (Water treeing) in a 20 year old XLPE cable.

Figure2: Figure 3 shows partial discharge signals (electrical treeing in a 25 year old XLPE cable) From the data analyzed, the condition of the cable system between each set of sensors is determined, and the cable system length is placed into one of five categories. III. Severity assessment for extruded cables Level 1: The system is not degraded. action needs to be taken. No

Figure 3

Level 2: There is a small amount of agingrelated signals in joints and terminations. This amount of signal is normal and thus, no action needs to be taken. However, in extruded cables, retesting is recommended

within the next two years. Alternatively, Cable sections can be proactively rejuvenated. Level 3: The system has a low probability of failure within the next two years. Rejuvenate the cable sections within one year. Level 4: The system has a medium probability of failure within the next two years. Further discussion is recommended before replacement or rejuvenation. Level 5: The system has a high probability of failure within the next two years. Consider immediate replacement. IV. Case Histories Case History A: The principles discussed above as applied to a major Western Utility are noted here, and serve as an example of how to apply the predictive technology(7). An initial trial was performed, in this case a 5 day study at a location with a known circuit construction. This was a radial 15kV XLPE feeder system along with several higher voltage circuits. Five circuits exiting at a substation, and over 30,000 feet of cable and accessories were involved. The cables included direct buried XLPE cable from the early 1970s as well as jacketed XLPE cable installed in conduit in the late 1980s. After testing, in one case Cable/wise concluded that a Level 5 section existed on one feeder. A decision was made to replace this cable section, but before actual replacement was performed (a few weeks after testing) this section failed in service. This failure overrode any consideration to leave the level 5 section in service indefinitely to determine if it would indeed fail at a future time; it did. Overall, test results allowed this utility to evaluate the potential of utilizing this predictive condition assessment method as part of the overall cable replacement program. This utility monitors and maintains records on their system; the dedicated action to assess the predictive technology provided cost savings and avoided customer complaints. Following the guidelines of the test organization has assisted the utility to meet their cable replacement needs. Removing located weakened sections via a planned program and avoiding intentional application of external stresses after predictions have been made has paid dividends.

Case History B: This case demonstrates the need to re-think how users apply predictive testing as compared to the more traditional methods of seeking to remove the weak link at the time of testing. A broad study was performed at a utility site in a congested area of a major IOU. Predictions were made, but after several years, it was observed that predictions did not agree with the levels (1 to 5) projected years earlier. Thus, 4-5 year after the testing was performed; the original data kept by both the tester and the user was reexamined and compared (8). Significant anomalies were noted relative to (a) comparative record keeping and (b) post treatment of the tested cable feeders. The differences in record keeping related to (in)accurate recording of cable sections actually tested, missing in the recording of what actually was ranked (cable or accessory), and differences in noting of the rankings recorded by both organizations. In addition, it was learned that the Utility performed DC Hi Pot testing on the cable feeders regardless of their ranking, hence skewing and confounding the predictions. When this was accounted for during the re-analysis, the correlation between the original rankings and failure predictions within the first two years after testing was projected to be 80 % correct. This experience confirmed that when applying predictive technology, the user requires either (a)a modified approach relative to normal procedures, or (b) follow the approach of Utility (A) described above. CableWISE recommends removing the isolated sections tested with high ranking within two years via a planed program. It has further been concluded that several best practices approaches are required after predictive testing. * Employ good record keeping practices: assure that in house records and those of the test organization are in agreement. * Avoid DC HiPot testing; this practice can lead to trapped space charge and release at a later time, influencing predictive conclusions. * Avoid uncontrolled thumping for fault location; this is a common present day recommendation, and should be applied in general. * Avoid VLF testing. Very low frequency

testing, ease intended as a substitute for DC, but is also applied at an over-voltage. [It is also potentially misleading as it is reported to be effective for weeding out cables with a few but large defects, but not effective for cables that possess many small defects.] In addition, no exact procedure to be employed for applying VLF as a DC substitute has yet been established. Clearly this should also be avoided where predictive technology is applied. These approaches can assure that errors of the past are not repeated (9). V. Predictive Technology and Extending Cable Life Having established that condition assessment when properly applied can provide meaningful information for utilities seeking to assure reliability of their distribution system, the next step in this process is to combine information on the state of the cable system with technology designed to extend the life of the extruded cable system. CableCURE fluid is injected directly into the interstitial region of the electrical cable. This is accomplished by employing special elbows attached to the cable that are then connected to the transformer. The fluid is pumped into the conductor through the elbows injection port while the cable is energized. The injection of the fluid does not otherwise interrupt the service to the customer. From the interstices the fluid diffuses into the polymer insulation of the cable seeking out the Polar Regions that contain water. CableCURE is made up of 100% water reactive cable treatment fluids removing water on a molecular level from the void as well as water diffusing through the cable in transit. CableCURE oligomerizes in contact with the water closing the water tree void thus, preventing further growth of the water tree. As it reacts with the water in the void it undergoes oligomerization (molecular weight increase). This monomeric starting material slowly polymerize in the water tree regions. This process causes the monomeric starting material to slowly polymerize in the water tree regions. This fills the voids as the water is removed and slows down the diffusion of the material. Since the molecules of the resulting oligomer are 47 times larger than water molecules, they lock into place and retard the growth of future water trees. The oligomers contain latent water reactivity such that any future water ingress is also blocked. The entire process dries out the

electrical cable restoring the dielectric strength, thus increasing the service life of the cable. The diffusion occurs at a rate which is fast compared to the aging process and the diffusion of water. The fluids saturation level in the cable insulation is sufficiently high compared to water (100 to 1) that the statistical probability of complete water reaction is guaranteed. The benefits of the CableCURE cable rejuvenation system are that 1) the useful life of the underground cable is extended 2) the electrical breakdown strength is increased in the cable which stabilizes the system, 3) the system reliability is quickly improved leading to fewer, if any, outages due to dielectric breakdown The ultimate objective is to significantly extend the economically useful lifespan of an underground power distribution cable, deferring by decades the cost of cable replacement. Over 70 million feet of the worst performing cable in the world have been treated with CableCURE/XL in the past 20 years. Over 99% of those cables remain in failure-free service today. More than 500 utilities world wide have utilized CableCURE to improve system reliability. VI. Summary: Reliability of an electrical distribution system can be significantly improved by adopting non destructive technologies. Condition of the aging cable system can be assessed using an on line non invasive and non destructive Cable WISE methodology. Proper Engineering judgment can be made which sections need to be replaced and which sections can be rejuvenated. . The remaining life of the aging sections can be significantly extended using the well proven Silicone injection technology (cableCURE). Applying these two technologies as part of a maintenance program will considerably enhance the reliability of the electrical distribution system in a Utility.

VII. References 1)See for example, Proceedings Jicable 2007, Papers C.7.1.1 to 7.1.13 (pages 714-768 for state of the art studies on Water Treeing and Reliability, Versailles, France (June, 2007) 2)N.N. Srinivas and B.S, Bernstein Effect of DC Testing on XLPE Insulated Cables

Proceedings Jicable 95, Versailles France,(June 1995),pages 139-144; EPRI Reports TR-101245 V 1 and V2. Effect of DC Testing on Extruded Crosslinked Polyethylene Insulated Cables Phase 1 (January 1993) and Phase 2 (October 1995); EPRI Report TR-108405 V1. Aging study of Distribution Cables at Ambient Temperatures with Surges (August, 1997) 3) D.L. Dorris, M.O.Pace, T.V.Blalock and I Alexeff IEEE Trans Dielectrics and Electrical Insulation 3(4) 515-522(1996): D.L.Dorris, M.O.Pace, T.V.Blalock and I Alexeff, IEEE Trans Dielectrics and Electrical Insulation 3 (4) 523-528 (1996) 4) C. Dang and S. Pelissou Some Technical Considerations on Very Low Frequency Cable Diagnostic Conference Proceedings of 2003 IEEE Transmission and Distribution conference, Dallas Texas, IEEE Catalog No. 03CH37495C 5 ) N. Ahmed and N. Srinivas Partial Discharge Measurements in Distribution Class Extruded Cables IEEE T&D conference , New Orleans (1999) 6) N. Ahmed and N. Srinivas On-Line Partial Discharge Diagnostic System in Power Cable Systems IEEE T&D Conference (2001) 7) N. Srinivas, T. Nishioka, K. Sanford and B. Bernstein Non-Destructive Condition Assessment of Energized Cable Systems paper presented at 2005/2006 Transmission and Distribution Conference, Dallas Texas (2006 8) Cable/Wise Internal Technical Report (2006) 9) B.S. Bernstein Cable Testing: Can We Do Better IEEE Elec. Insulation Magazine, Vol. 10, No. 4 (July/August 1994) 10) W. Stagi and W. Chatterton Cable Rejuvenation-Past Present and Future Proceedings Jicable 2007, paper C7.2.14, Versailles, France (2007), pages 858-861 VIII. Biographies
Nagu Srinivas is an Electrical Engineer with 40 years of experience in the field of cables, high voltage and power equipment evaluation. At present he is the Vice President of Cable Assessment at UTILX Corporation. Previously he was the .Managing Director at DTE Energy Technologies, in charge of cable wise business. Earlier, he was Supervising Engineer of Electrical & Instrumentation group in

Engineering support organization at Detroit Edison, Prior to 1982, he was with Phelps Dodge Cable & Wire Company as Chief Engineer in R & D department. He has the patent on line detection of partial discharge in electrical power systems. He was the project manager for several EPRI sponsored projects on treeing, life estimate of polyethylene cables and effect of dc testing on cable life. He has been awarded with Innovators with technology by EPRI (Electric Power Research Institute) twice (in1991 and 1996). He has been elevated to a Fellow of IEEE (Institute of Electrical and Electronic Engineers) , based on his work on extruded cables. He is the chairman of IEEE- ICC # C subcommittee on cable systems. He was a member of IEEEDEIS Ad-com for 2 consecutive terms. He has published several papers at U.S. and international conferences. He has chaired and moderated several conferences and seminars on cable aging and equipment evaluation. Oscar Morel: received his M.S. and Ph.D. from the Pennsylvania State University. Dr. Morel was Manager of Cable Operations for CableWISE, DTE Energy Technologies and is recently became Senior Engineer Cable Assessment at UtilX Corp. His industrial experience includes failure analysis, condition assessment and life expectancy of underground transmission cables. Dr. Morels other interests include chemical and physical testing of dielectric materials utilized in high voltage applications studies which have led to novel techniques for handling and testing of insulating fluids in high voltage equipment. He has published many papers and participated in many EPRI sponsored projects. He is a member of the IEEE. Wayne Chatterton: holds 4 U.S. & numerous international patents on cable restoration and related technologies. He obtained a B.S. in Chemistry from University of Toronto, an M.S. from University of Toronto in Organosilicone Chemistry, and a Ph.D. from University of Toronto in Organic Chemistry (silicone). Wayne is a 9-year member of the Institute of Electrical and Electronics Engineers (IEEE) and the Dielectric and Electrical Insulation Society (DEIS), and is a member of numerous industry associations including the American Chemical Society and the American Society for Testing and Materials (ASTM). Most recently, Chattertons career includes 16 years at Dow Corning, a global leader in silicon-based technology, where he was an Organosilicone Chemist with Dow Corning, and a lead contributor on the joint Dow Corning/UtilX cable restoration team. Bruce S. Bernstein is a consultant in the area of electrical insulation materials. Prior to establishing his LLC in 2001, he was associated with the Electric Power Research Institute for 24 years. His most recent EPRI responsibility was as Underground Distribution Infrastructure Target Leader. He managed projects for underground distribution, underground transmission, overhead lines, and the substation program, as well as for the Office of Exploratory Research. He consults in areas related to distribution and transmission cables, reliability issues, diagnostics, life estimation of electrical equipment, and areas relating to polymer technology. He attended City University of New York, Iowa State University (MS) Polytechnic Institute of New York, and is a Life Fellow of IEEE.