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RECOMMENDATIONS FOR TESTING OF LONG AC
SUBMARINE CABLES WITH EXTRUDED INSULATION FOR
SYSTEM VOLTAGE ABOVE > 30 (36) TO 500 (550) KV
Convener: Anders Gustafsson
Secretary: Johan Karlstrand
TUTORIAL B1.27 TB 490
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Copyright
DISCLAIMER
Ownership of a CIGRE publication, whether in paper form or on electronic support only infers right of use
for personal purposes. Are prohibited, except if explicitly agreed by CIGRE, total or partial reproduction of
the publication for use other than personal and transfer to a third party; hence circulation on any intranet
or other company network is forbidden.
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Why new test recommendations?
Power ratings of submarine cable links increase, which need
higher rated voltages. Electra 189, covered a voltage range of
> 36 - 170 kV
The rationale and background behind the tests needed to be
clarified
The longitudinal water tightness test needed a revision
Tests of rigid repair joints should be taken into account
The Technical Brochure aims to provide stakeholders with an
improved understanding and quality assurance of testing long
AC submarine extruded cable systems
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Examination of relevant IEC standards / CIGRE recommendations and
documentation
The work should adopt a system approach. Particular attention should
be paid to repair joints as part of the submarine cable system and the
WG should consider tests with external water pressure, heat cycling
and mechanical handling (during installation of a repair joint)
The work should propose development and prequalification tests for
the EHV submarine cable system and requalification in case of minor or
major changes and define the range of prequalification and type approval
for EHV submarine cable systems
The work should propose tests for long submarine cable lengths - both
in the factory and after installation and explain clearly the basis for the
recommended tests and the range of application
The work should include a review of the currently available technologies
for submarine cable and joint design and consider possible implications
for testing
A Technical Brochure should be prepared for publication
The work should also include an update of the existing recommendations
in Electra 189 for U > 36-170 kV. (added in 2010)
Terms of Reference
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Working Group B1.27: Deliverables
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Anders Gustafsson SE Convener
Johan Karlstrand SE Secretary
Anders Jensen DE
Christian Remy FR
Geir Clasen NO
Gianni Miramonti IT
Harry Orton CA
Juan Prieto ES
Robert Donaghy EI
Ronald Gruntjes NL
Sren Krger Olsen DK
Takenori Nakajima JP
Work started in Feb 2008 and was finished in Sep 2011
Member list of WG B1.27
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Recommendations for AC submarine cables - History
Recommendations for mechanical tests on submarine cables
o Electra 68 1980 Electra 171 1997 WG B1.43 (2011)
Recommendations for tests of long
lengths of extruded cables
o Electra 189 2000 (170 kV - extruded)
Standards for land cables and systems
o IEC 60840, IEC 62067, TB 303
TB490 follows a System Approach for the whole voltage range
> 36 - 550 kV
TB490 - WG B1.27
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Submarine cable testing Overview
SYSTEM TEST Pre-Qualification Test
Type Test
Routine Tests Sample Tests
Water Penetration Test
Mechanical Tests SYSTEM TEST
COMPONENT TESTS
After Installation Test SYSTEM TEST
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High voltage submarine cable system
Termination
Prefabricated Joint Factory Joint (Flexible)
Repair Joint
ON-SHORE OFF-SHORE
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Table of Contents
Executive Summary
1. Introduction
2. Definitions
3. Current technologies for submarine cable designs
4. Current technologies for submarine joint designs
5. General aspects on submarine cable testing
6. Routine Test
7. Sample Test
8. Type Test on Cable System
9. Prequalification Test
10. Extension of Qualification Test
11. After Installation Test
12. References
13. Appendices
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1. Introduction: Selected projects 170 kV
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1. Introduction: Reference Projects > 170 kV
> 200 km for U 245 kV installed in the next few years
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2. Definitions: What is a long length?
A long length is considered to be:
o a delivery length which includes
factory joints
or
o a delivery length for which the
carrying out of high voltage tests
and partial discharge tests strictly in
accordance with IEC is impractical
or
o a delivery length which cannot be
accommodated on an individual
transportable drum
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2. Definitions: Internal/External design of joint
Internal design of joint - The joints electrical function based on
the design principles
o to transfer the current
o to control and withstand the electrical stresses
o to screen the joint electrically
o to protect the insulation system from moisture ingress.
External design of joint - The joints mechanical function based
on the design principles
o to withstand the impact from the surroundings
o to withstand (in some designs) the mechanical bending
o to withstand the mechanical tension and torsion during laying
and operation.
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3. Current Technologies for Submarine Cable Designs
Single-core designs
Three-core designs
Cable components
o Conductor (water tight)
o Insulation system
o Metal screen/sheath
o Armour
o Outer protection
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3. Submarine Cable Design: Water Tightness
Dry versus Wet design:
o Dry no water/moisture is in direct contact with the XLPE core
o Wet water/moisture is in direct contact with the XLPE core
Dry designs are mostly used for HV/EHV submarine cables; i.e. a
metallic moisture barrier is mostly used
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3. Submarine Cable Design: Water Tightness
Water tightness in both radial and longitudinal directions is
crucial for HV/EHV cables
Water tightness of a conductor is the ability to limit longitudinal
water penetration at the maximum depth of the cable
Water tightness may be improved by proper selection of
conductor design and water blocking technologies
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3. Submarine Cable Design: Conductor
Conductor designs can be solid, key-stone shaped, stranded-
compacted or stranded - Milliken
Conductor design contributes to the water penetration rate or the
level of water blocking ability
o Water swelling (powders), swellable yarns or tapes, blocking
compounds
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3. Submarine Cable Design: Conductor
Solid Conductor Water tightness inherent in design
Compacted, profiled and segmental conductors powders
and/or tapes are swelling when in contact with either fresh or
saline water
o The swelling ability is worse for saline water
Compacted, profiled and segmental conductors different
types of water blocking filling compounds may also be used to
fill up the interstices between the strands
o The compatibility with inner semi-conducting screen should be
checked
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3. Submarine Cable Design: Insulation System
Extruded HVAC submarine cables consist
predominantly of cross-linked polyethylene
(XLPE)
o The cross-linking of polyethylene (LDPE) forms a
three-dimensional network which implies higher
temperature and higher mechanical strength
o The insulation system consists of an inner
conductor screen, insulation and an outer
insulation screen
EPR insulation may also be used for U < 150 kV
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3. Submarine Cable Design: Insulation System
The quality of XLPE materials
and manufacturing processes
has continuously improved
While the electrical stress level
on the XLPE insulation has
continuously increased, the
failure rate and unavailability of
XLPE cable systems has
decreased
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3. Submarine Cable Design: Metal Sheath
An extruded lead alloy sheath covered by an extruded
anticorrosion polymeric sheath or a semiconducting tape are
the most common radial water barriers used today
The polymeric anticorrosion oversheath is either insulating or
semi-conducting
o To avoid dielectric breakdown of the insulating oversheath, a
semi-conducting oversheath is often used
For wet designs, an ordinary copper wire or tape screen are
commonly used
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3. Submarine Cable Design: Armour
The armour is applied:
o to provide enough tensile strength during installation
o to protect the cable from external impact
o to make the cable torsional-free during installation
Copper, steel or stainless steel wires are used as armour
materials
o In single-core submarine cables the steel armour creates a large
iron loss from the magnetic fieldcopper or stainless steel are
used
o In three-core cables, the resulting magnetic field will be
significantly lower steel wires are normally used
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4. Current Technologies Flexible Joint
Flexible joints are fully flexible; i.e. designed with the same
limitations on bending radius and tensile strength as the cable
Flexible joints have the same electrical and thermal performance
as the cable
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4. Current Technologies Flexible Joint
The flexible joint is needed due to the following reasons:
o limitation in continuous extrusion lengths, due to filter cleaning, scorch
formation etc.
o limitation of storage capacity (e.g. process platforms) of the individual
lengths
o limitation of degassing equipment and processes
o limitation in the laying-up baskets volumes (for three-core cables)
o power limitation of the AC testing equipment
o damage to the cable core during handling
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4. Current Technologies- Repair Joint
Repair joints can be divided
into the following types:
o A1: Fully flexible
o A2: Flexible with some
mechanical restrictions
o B: Rigid joint
R
T
R
T
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4. Current Technologies - Repair Joint
A repair joint is made on the complete armoured cable and
usually onboard on a repair vessel or barge. Suitable
equipment and sufficient space have to be planned for.
Repair joints are necessary to have in stock for most long
submarine cable systems
Rigid joint (Type B)
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5. General Aspects on Submarine Cable Testing
Routine tests (Chapter 6)
o Test on manufactured length
o Test on factory installed joints
o Factory acceptance test
Sample tests (Chapter 7)
o Sample tests on cable
o Sample tests on joint
Type tests (Chapter 8)
o Mechanical tests on complete cable
o Electrical tests on complete cable
o Non-electrical tests on cable components and on complete cable
Prequalification test (Chapter 9)
Extension of qualification test (Chapter 10)
After installation tests (Chapter 11)
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5. General Aspects: Conditions
Follow IEC
o Ambient temperature: 5-35 C
o 10-500 Hz for routine testing
Additional design data needed to document tests according
to IEC :
Design of armour/tension/laying depth
Method of water blocking technologies
Maximum conductor temperature
Ability to be coiled and relevant test parameters
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5. General Aspects: Development Tests
Recommendations and standards are generally not sufficient
to take all design and installations conditions into account
Examples of issues that may need to be considered are:
Vibration and strumming of cable in water currents; free spans
Ability to withstand deep water pressures and deformation
Design of hang-offs
Efficiency of water blocking tapes/compounds after years of
operation
Handling of optical fibre unit/cable integrated in cable
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6. Routine Test: Introduction
General
o Routine tests are made to demonstrate the integrity of the
manufactured cable and to verify that the product meets the
design and manufacturing specifications within specified
tolerances
Routine tests are mainly performed on the following parts for
submarine cable systems:
o Manufactured lengths
o Factory joints
o Complete delivery length
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6. Routine Test: Frequency Range
Today IEC 62067 and ICEA S-108-720 stipulates 20 300 Hz for After
Installation Test
o but new edition of IEC 60060/3 stipulates 10 500 Hz for onsite testing
AC resonant equipment (ACRF) has been used below 20 Hz
Longer lengths (high C) and EHV (high U) need some degree of freedom
regarding frequency range WG B1.27: longer time duration at lower
voltages for factory acceptance and after installation tests compared to
IEC 62067 may be agreed
VLF-testing is not considered mature for HV and EHV
WG B1.27 recommends 10-500 Hz for routine, factory acceptance and
tests after installation
The lower frequency limit of 10 Hz is important for testing of long
lengths
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Source: Gockenbach/Hauschild-2000
6. Routine Test: 10 Hz as lower frequency limit
IEC 62067 prescribes 20 Hz as lower frequency limit for AC resonant
tests. IEC 60060/3 prescribes 10 Hz. The new lower frequency limit in
TB490 is set to 10 Hz giving insignificant change in breakdown strength
but a 4 times higher load capacity!
10 Hz 20 Hz
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6. Routine Test: Long Lengths
Testing of long cables is on the agendaWG B1.38
o AC and DC cables face the same challenges
o New equipment and new testing methodologies are under
development
o Research is ongoing
Group No : WG B1. 38 Name of Convener : J ohn Densley
TITLE of the Working Group :

After laying tests on AC and DC cable systems with new technologies

Needs of Target Groups:
Background: Extruded (XLPE) insulation is rapidly becoming the insulation of choice in both new and
replacement transmission class cable circuits. While the cable and accessories are tested in the factory, the
k hi i ll h i l b d f h i ll i h b l d db f h
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6. Routine Test: Summary in Annex A (Example)
Manufactured Lengths
Test
References
>36-170 kV >170 kV

Partial discharge (PD) test [TB 6.3.1] IEC60840 9.2 IEC62067 9.2
High voltage test [TB 6.3.2] IEC60840 9.3 IEC62067 9.2
Factory Joints
Test
References
>36-170 kV >170 kV

See TB 6.4
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TB 6.4 TB 6.4
Repair Joints
Test
References
>36-170 kV >170 kV

See TB 6.6 TB 6.6 TB 6.6
Terminations
Test
References
>36-170 kV >170 kV

See TB 6.7 IEC60840 9.1 IEC62067 9.1
Complete Delivery Length (FAT)
Test
References
>36-170 kV >170 kV

High voltage test [TB 6.5.1] TB 6.5.1 TB 6.5.1
Partial discharge (PD) test [TB 6.5.2] TB 6.5.2 TB 6.5.2

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7. Sample Tests
Sample tests - In Electra 189 described as Special tests
When routine tests are not possible
Frequency of tests according to IEC except:
o If PD-test is not possible on long length (as defined by the
WG), impulse and PD-tests shall be performed on samples
taken out from start/stop of each extrusion run
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7. Sample Tests New tests
Volume resistivity of conductor screen, insulation screen and
semi-conductive polymeric sheath
Examination of completed cable
o A sample of completed cable (length: more than one pitch of
wire armour) shall be subjected to a visual inspection
o The number of wires shall be counted in each armour layer and
validated according to the design
o The pitch length(s) of the armour layer(s) shall be measured and
validated relative to the declared value by a tolerance of 10%.
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8. Type Test: Overview
The type test shall demonstrate the satisfactory performance
of the submarine cable system design
Main components:
o Check on insulation thickness of cable
o Mechanical tests on complete cable system
o Water penetration tests
o Electrical test on complete cable system
o Non-electrical tests on cable components and on complete cable
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8. Type Test: Range of Type Approval
The range of type approval for land AC cable systems is
described in IEC 60840 and IEC 62067. Those and the
additional conditions below must be met:
o less severe mechanical stress
o method of water tightness is unchanged
o the design of conductor connection for joints is unchanged
o electrical stress at the conductor screen in the flexible joint
does not exceed 10 %
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8. Type Test: Mechanical Tests
Refers to CIGRE recommendation Electra No. 171 (1997)
WG B1.43 will update and add features in a new TB (ready 2014)
Group No : WG B1.43 Name of Convener : Marc Jeroense
TITLE of the Working Group: Recommendations for mechanical testing of submarine cables
Background:
Update of mechanical tests for submarine cables is needed since submarine cable installations are growing for
higher powers and new applications (wind farmconnections, dynamic power cables and deeper sea installations
etc).
The existing recommendation is from1997 (Electra 171) needs to be updated.
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8. Type Test: Mechanical Test of Repair Joints
Tensile Bending Test
Electra 171 2.2
Tensile Test
Electra 171 2.3
Handling / laying
Simulation Test
Flexible Joint Mandatory.
Same R and T as for
cable. No limitations for
application
For information only
(on the same or other
cable / joint assembly)
Not necessary
Flexible Joint
with some
mechanical
restrictions
Mandatory with R ,T as
appropriate for the
intended application,
i.e. different from cable.
E.g. repair in reduced
water depth only.
For information only
(on the same or other
cable / joint assembly)
Not necessary
Rigid Joint Bending test only with
radius R without load, if
applicable.
Mandatory.
Straight tensile test at T
on the same joint
assembly subjected to
bend test at radius R
without load
Advisable.
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8. Type Test: Water Penetration Tests
For long submarine cables the water penetration tests are
divided into three tests:
o Conductor water penetration test LWPa
o Metal sheath water penetration test LWPb
o Radial water penetration test of joints RWP
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8. Type Test: Background of LWP Test
Mechanical and thermal preconditioning
o simulate actual installation conditions
Water propagation distance is not fixed
o B1.27 recommendation < 30 m
LWPa - conductor
o Water ingress in the conductor during a cable fault at the
deepest part
LWPb - metal sheath
o Water ingress under the metal sheath (reference is made to lead)
at the near shore area where the water pressure does not
increase the ability to stop water penetration ( 30 m water head)
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LWPa on Conductor
+ 33%
d1
Mechanical test
o Tensile bending test (Electra 171)
o 3 x 24 h heating cycles
Expose conductor to water
o Put into pressure vessel (at a pressure corresponding to the
maximum laying depth) for 10 days (5-35C water temp) no
heat cycling !
o Cut at distance d1
Water detected?
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LWPb on Metal Sheath
d2
Mechanical test:
o Tensile bending test (Electra 171)
Expose outer semiconducting layer to water
o Put into pressure vessel (5-35C water temp) for 10 days heat
cycling
o Cut at distance d2
Water detected?
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8. RWP Test on Joint
Mechanical test
o Mechanical test according to Electra 171
o 10 x 24 h heating cycles
Put into pressure vessel (at a pressure corresponding to the
maximum laying depth) for 2 x 24 h (5-35C water temp)
o Only pressurized part needs to be tested
Water detected?
Shape irregularities?
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9. Prequalification (PQ) Test: Background
The PQ-test for land cable systems described in IEC were
introduced to demonstrate that the manufacturer is able to
design, produce and install cables at the required voltage
level
A special focus was put on the cable and accessory
insulation characteristics, the cable core/accessory
interfaces and the thermo-mechanical behaviour over time
Which are the specific issues needed for verification of a
submarine cable system?
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9. PQ-Test: Land versus Submarine Cable Systems
For an AC extruded submarine cable system there are
mainly four parameters that are most often different
compared to an AC extruded land cable system:
1. a flexible (factory) joint is needed
2. the cable is armoured
3. the repair joints have a mechanical housing
4. the cable conductor is not of segmented design
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9. PQ-Test: Land vs. Submarine cable systems
When is then a PQ-test required?
1. Flexible joint: PQ-test needed for either a land or submarine cable
system
2. Armour: External design Electra 171, performed prior to the electrical
type test
3. Repair joint: External design Electra 171+ RWP, performed prior (or
after) to the electrical type test
4. Conductor design: May be qualified in a PQ-test for a land cable system
a. An exception could be a special water blocking compound not earlier tested for a land
segmented design
Thus, a land cable system PQ-test may prequalify a submarine cable
system, if all relevant conditions are met
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9. PQ-Test: Range of Approval
Refer to IEC 60840 and 62067
If a land (or submarine) cable system already is prequalified,
another submarine cable system is qualified if the following
conditions and the conditions given in IEC 60840 and 62067
are met:
o electrical stress at insulation screen of a repair joint is equal or
lower
o if a flexible joint already is PQ-tested on a larger conductor and
the proposed flexible joint on the smaller conductor has more than
10% higher electrical stress, the flexible joint shall be subjected to
a type test with a stress larger than that already prequalified
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PQ-Test: Example for Range of Approval of Joints
Factory Joints - inner stress is decisive - but large conductor
cross-sections may be more challenging to manufacture.
Therefore;
o +10% higher inner stress is allowed (for smaller conductor cross-
sections than tested for)
o Larger conductor cross-sections than tested for are not allowed
Pre-molded Joints outer stress is decisive
o 0% higher outer stress is allowed
o Larger conductor cross-sections than tested for are not allowed
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9. PQ-Test: Example for Range of Approval of Joints
Inner Stress for Factory Joints
(< 10%)
Cross-section Area
Electrical Stress
Outer Stress for Premolded Joints
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10. Extension of Qualification EQ-Test
Refer to TB303, IEC 60840 and 62067
The EQ-test is mainly related to changes in accessories
which already have undergone a PQ-test (TB303)
The arguments for not introducing an EQ-test specifically for
submarine cable systems are the same as for the PQ-test
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11. After Installation Test
Test on new installations are made when the installation has
been completed
If the complete installed length is too long a reduced test
voltage with a longer duration may be agreed. Alternatively, a
voltage of U
o
may be applied for 24 hours
Time Domain Reflectometry (TDR) give a fingerprint of the
cable system to be used if needed during the cable life
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Submarine cable testing Overview
SYSTEM TEST Pre-Qualification Test
Type Test
Routine Tests Sample Tests
Water Penetration Test
Mechanical Tests SYSTEM TEST
COMPONENT TESTS
After Installation Test SYSTEM TEST
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