ENGINEERING REPORT

Number PC 284

Title EXTENSION TO PRE-QUALIFICATION FOR

220KV XLPE CABLE AND ACCESSORIES -
OTAHUHU

Date 22nd July 2010

 Report No. PC284
Issue Date: 22/07/10
Page: 1 of 23

EXTENSION TO PRE-QUALIFICATION FOR 220KV XLPE

CABLE AND ACCESSORIES - OTAHUHU

SUMMARY
This report details extension to pre-qualification tests carried out on a single core 2500mm Cu 220kV XLPE
cable fitted with 2 x outdoor terminations.
The cable was manufactured by Prysmian Cables & Systems, France. The accessories were manufactured by
Prysmian Cables & Systems, Italy.
The tests were carried out in accordance Prysmian documents Test Procedure for 220kV XLPE Insulated
2500mm Cable Otahuhu 220kV Diversity Project Otahuhu Substation.
The tests were derived from CIGRE brochure 303, clause 2.3.3 Extension of Prequalification Test plus
additional tests required to make the type test part of this test cover all the tests required for a type test to IEC
62067: 2001-10 (including amendment 1:2006).
The test assembly is shown schematically in figure 1 at the end of this report (section 17).
The cable and accessories under test passed all the specified tests.
Tests were verified throughout by customer appointed representatives.
Cable
1. Type: Single core, Cu, XLPE, welded Al sheath, PE
2. Working voltage: U = 220kV ; (Uo = 127kV)
3. Sectional area of conductor: 2500mm2
4. Maximum dielectric stress at 220kV at;
conductor screen: 7.9MV/m
dielectric screen: 5.0MV/m
5. Specified insulation thickness (nominal): 20.5mm
6. Measured insulation thickness (ave): 20.71mm
7. Maximum conductor temperature: 90C
8. Cable Design No. HVSYS08/014 CD(1).1
Accessories
2 x Outdoor terminations type TES 1245/111, GA drawing no. 41.148.5.591
Note: The above accessories used a plumbed connection (anchorage) to connect to the welded aluminium
sheath.

CONCLUSION
The cable and accessories passed all the specified tests in the contract test procedure (given in the summary
above) without failure.

Prepared by: Approved by:

S C Williams J G Head
HV Laboratory Engineering Manager,
Manager HV Cables &
Accessories

Verified by:
L Trim
Cable Consulting
International Ltd

Prysmian Cables & Systems Ltd 2010

 EXTENSION TO PRE-QUALIFICATION Report No. PC284
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CONTENTS Page

1 DATES OF TESTS AND WITNESSES ........................................................................................ 3

2 BENDING TEST....................................................................................................................... 4
3 TEST VOLTAGE VALUES.......................................................................................................... 4
4 PARTIAL DISCHARGE TEST AT AMBIENT TEMPERATURE ..................................................... 5
5 PARTIAL DISCHARGE TEST AT HIGH TEMPERATURE............................................................ 5
6 THERMAL PRE-CONDITIONING TEST .................................................................................... 6
7 PARTIAL DISCHARGE TEST AT AMBIENT TEMPERATURE ..................................................... 6
8 PARTIAL DISCHARGE TEST AT HIGH TEMPERATURE............................................................ 7
9 TAN DELTA MEASUREMENT ................................................................................................... 7
10 HEATING CYCLE VOLTAGE TEST ............................................................................................ 8
11 PARTIAL DISCHARGE TEST AT AMBIENT TEMPERATURE ..................................................... 8
12 PARTIAL DISCHARGE TEST AT HIGH TEMPERATURE............................................................ 9
13 LIGHTNING IMPULSE VOLTAGE TEST FOLLOWED BY POWER FREQUENCY
VOLTAGE TEST................................................................................................................. 10
14 EXAMINATION OF CABLE AND ACCESSORIES..................................................................... 11
15 RESISTIVITY OF SEMI CONDUCTING SCREENS .................................................................. 12
16 CONCLUSION ....................................................................................................................... 12
17 APPENDED DOCUMENTS...................................................................................................... 13
 EXTENSION TO PRE-QUALIFICATION Report No. PC284
Issue Date:
FOR 220KV XLPE 22/07/10
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1 DATES OF TESTS AND WITNESSES

Witness
L. Trim Cable Consulting International Ltd (customer appointed) (LT)
B. Gregory Cable Consulting International Ltd (customer appointed) (BG)

The dates and witnesses for the electrical type tests are given in the following table:
IEC 62067 Test Date (s) carried Witness Result
clause no. out
12.4.4 Bending Test 10.02.10 LT Pass

12.4.1 Test voltage values 20.04.10 LT Pass

12.4.5 Partial discharge test at ambient 20.04.10 LT Pass

12.4.5 Partial discharge test at high 20.04.10 LT Pass

temperature
Thermal pre-conditioning test 21.04.10 to LT Pass
21.06.10
12.4.5 Partial discharge test at ambient 22.06.10 LT Pass

12.4.5 Partial discharge test at high 22.06.10 LT Pass

temperature
12.4.6 Tan Delta Measurement 22.06.10 LT Pass

12.4.7 Heating cycle voltage test 23.06.10 to LT Pass

13.07.10
12.4.5 Partial discharge test at ambient 19.07.10 BG Pass

12.4.5 Partial discharge test at high 19.07.10 BG Pass

temperature
12.4.9 Lightning impulse voltage test followed 20.07.10 to BG (impulse) & Pass
by power frequency voltage test 21.07.10 LT (voltage test)
12.4.10 Examination of cable and accessories 21.07.10 LT Pass

12.4.11 Resistivity of semi-conducing screens 21.07.10 LT Pass

 EXTENSION TO PRE-QUALIFICATION Report No. PC284
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2 BENDING TEST
Test Specification: IEC 62067, clause 12.4.4
Nominal diameter of conductor (d): 64.3mm
Nominal external diameter (D): 131.8mm

Bending test of 3 cycles around test cylinder of diameter no greater than;

25 (d + D) + 5% = 5148mm

Measured diameter of test cylinder: 4998mm

Length of cable tested: 35m

Test Result: Passed. No visible damage to cable following completion of the 3 cycles.
The partial discharge test following completion of the bend test is detailed in section 4 of this
report.
The 35m length of cable tested was subsequently used for all of the electrical tests detailed
within this report.

3 TEST VOLTAGE VALUES

Test Specification: IEC 62067, clause 12.4.1

Measured Average Thickness 20.71mm

Nominal Thickness 20.50mm
Variation (actual) 1.01%
Variation (requirement) 15%

Test Result: Passed, no adjustment of test voltages required.

 EXTENSION TO PRE-QUALIFICATION Report No. PC284
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4 PARTIAL DISCHARGE TEST AT AMBIENT TEMPERATURE

Test Specification: IEC 62067, clause 12.4.5
Following the bend test a suitable length of the cable was fitted with 2 x outdoor terminations
type TES 1245/111. The conductor connections of the outdoor terminations were connected
together to form a loop for conductor heating.
The test assembly is shown schematically in Figure 1 (see section 17 of this report).
The test voltage was raised to 222kV (1.75Uo) for 10 seconds and then reduced to 190kV
(1.5Uo) at which voltage partial discharge measurement was made according to the method
of IEC 60885-3.
The results are given below:
Ambient temperature: 12.4C Conductor temperature: 10.9C
Test Voltage *Test Sensitivity Test Result Requirement
190kV (1.5U0) 4.6pC No discharge 5pC
detected

In addition to the above requirement which conforms to IEC 62067, it was concluded that no
discharges were present above the background noise level, i.e. there were no discharges
detected above 2.3pC.
Test Result: Passed

5 PARTIAL DISCHARGE TEST AT HIGH TEMPERATURE

Test Specification: IEC 62067, clause 12.4.5
The test voltage was raised to 222kV (1.75Uo) for 10 seconds and then reduced to 190kV
(1.5Uo) at which voltage partial discharge measurement was made according to the method
of IEC 60885-3.
The results are given below:
Ambient temperature: 16.8C Conductor temperature: 96.5C
Test Voltage *Test Sensitivity Test Result Requirement
190kV (1.5U0) 4.6pC No discharge 5pC
detected

In addition to the above requirement which conforms to IEC 62067, it was concluded that no
discharges were present above the background noise level, i.e. there were no discharges
detected above 2.3pC.
Test Result: Passed

*Test sensitivity (as defined in IEC 60885-3) is twice the height of the background noise.
 EXTENSION TO PRE-QUALIFICATION Report No. PC284
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6 THERMAL PRE-CONDITIONING TEST

The test assembly shown schematically in Figure 1 was subjected to 60 heating cycles
consisting of 8 hours heating and 16 hours cooling.
The conductor temperature was maintained in the range 95C to 100C for a minimum of the
final 2 hours of each 8 hour heating period.
The test assembly was heated by conductor current with the use of a dummy or reference
cable on which the conductor temperature can be measured directly by thermocouple. The
conductor currents in the test assembly and the dummy cable were at all times the same to
within 1%.
No test voltage was applied during the thermal pre-conditioning test.

7 PARTIAL DISCHARGE TEST AT AMBIENT TEMPERATURE

Test Specification: IEC 62067, clause 12.4.5
Following the thermal pre-conditioning test the test assembly shown schematically in Figure 1
was subjected to a partial discharge test.
The test voltage was raised to 222kV (1.75Uo) for 10 seconds and then reduced to 190kV
(1.5Uo) at which voltage partial discharge measurement was made according to the method
of IEC 60885-3.
The results are given below:
Ambient temperature: 18.4C Conductor temperature: 17.5C
Test Voltage *Test Sensitivity Test Result Requirement
190kV (1.5U0) 2pC No discharge 5pC
detected

In addition to the above requirement which conforms to IEC 62067, it was concluded that no
discharges were present above the background noise level, i.e. there were no discharges
detected above 1pC.
Test Result: Passed

*Test sensitivity (as defined in IEC 60885-3) is twice the height of the background noise.
 EXTENSION TO PRE-QUALIFICATION Report No. PC284
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8 PARTIAL DISCHARGE TEST AT HIGH TEMPERATURE

Test Specification: IEC 62067, clause 12.4.5
The test voltage was raised to 222kV (1.75Uo) for 10 seconds and then reduced to 190kV
(1.5Uo) at which voltage partial discharge measurement was made according to the method
of IEC 60885-3.
The results are given below:
Ambient temperature: 24.5C Conductor temperature: 95.9C
Test Voltage *Test Sensitivity Test Result Requirement
190kV (1.5U0) 2pC No discharge 5pC
detected

In addition to the above requirement which conforms to IEC 62067, it was concluded that no
discharges were present above the background noise level, i.e. there were no discharges
detected above 1pC.
Test Result: Passed

*Test sensitivity (as defined in IEC 60885-3) is twice the height of the background noise.

9 TAN DELTA MEASUREMENT

Test Specification: IEC 62067, clause 12.4.6
The test assembly shown Figure 1 was heated to within the range 95C to 100C for the
measurement of loss tangent using a transformer ratio arm bridge.
The test results are given below:
Ambient temperature: 24.9C
Conductor temperature: 95.8C
Test Voltage Tan delta measured Requirement
127kV (U0) 1.94 x 10 -4
10 x 10-4

Test Result: Passed

 EXTENSION TO PRE-QUALIFICATION Report No. PC284
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10 HEATING CYCLE VOLTAGE TEST

Test Specification: IEC 62067, clause 12.4.7
Heating was by means of conductor current only.
The same test assembly was used as for the previous test and is shown schematically in
Figure 1 of this report.
The test assembly was subjected to 20 heating cycles consisting of 8h heating to a steady
conductor temperature between 95C and 100C for at least the last 2h of each period,
followed by 16h natural cooling. During the whole of the test period a voltage of 254kV was
applied to the assembly.
The conductor currents applied to the type test loop and reference loop were the same to
within 1% at all times. No breakdown occurred.
Test Result: Passed

11 PARTIAL DISCHARGE TEST AT AMBIENT TEMPERATURE

Test Specification: IEC 62067, clause 12.4.5
Following the heating cycle voltage test the test assembly shown schematically in Figure 1 was
subjected to a partial discharge test.
The test voltage was raised to 222kV (1.75Uo) for 10 seconds and then reduced to 190kV
(1.5Uo) at which voltage partial discharge measurement was made according to the method
of IEC 60885-3.
The results are given below:
Ambient temperature: 18.8C
Conductor temperature: 18.1C
Test Voltage *Test Sensitivity Test Result Requirement
190kV (1.5U0) 5pC No discharge 5pC
detected

In addition to the above requirement which conforms to IEC 62067, it was concluded that no
discharges were present above the background noise level, i.e. there were no discharges
detected above 2.5pC.
Test Result: Passed

*Test sensitivity (as defined in IEC 60885-3) is twice the height of the background noise.
 EXTENSION TO PRE-QUALIFICATION Report No. PC284
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12 PARTIAL DISCHARGE TEST AT HIGH TEMPERATURE

Test Specification: IEC 62067, clause 12.4.5
The test voltage was raised to 222kV (1.75Uo) for 10 seconds and then reduced to 190kV
(1.5Uo) at which voltage partial discharge measurement was made according to the method
of IEC 60885-3.
The results are given below:
Ambient temperature: 25.8C
Conductor temperature: 96.5C
Test Voltage *Test Sensitivity Test Result Requirement
190kV (1.5U0) 5pC No discharge 5pC
detected

In addition to the above requirement which conforms to IEC 62067, it was concluded that no
discharges were present above the background noise level, i.e. there were no discharges
detected above 2.5pC.
Test Result: Passed

*Test sensitivity (as defined in IEC 60885-3) is twice the height of the background noise.
 EXTENSION TO PRE-QUALIFICATION Report No. PC284
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13 LIGHTNING IMPULSE VOLTAGE TEST FOLLOWED BY POWER FREQUENCY

VOLTAGE TEST
Test Specification: IEC 62067, clause 12.4.9
The test was applied to the assembly shown in Figure 1.
Ambient Temperature;
at start of test: 25.2C
at end of test: 25.4C
Conductor Temperature;
at start of test: 97.6C
at end of test: 97.7C
Impulse withstand voltage applied (10+ve and 10-ve): 1050kVp
Wave shape in accordance with IEC 60230;
Front time (T1): 3.5s
Time to half value (T2): 55.1s
Oscillograms of the 1st and 10th positive and negative impulses can be found at the end of this
report.
Test Result: Test passed without breakdown or flashover.

Power Frequency Voltage Test

Following completion of the impulse voltage test and partial discharge test the assembly was
subjected to a power frequency voltage test at 2.0Uo for 15minutes.

Ambient Temperature: 19.8C

Conductor Temperature: 19.9C
Test Voltage: ` 254kV
Duration: 15mins

Test Result: No breakdown or flashover occurred. Test Passed.

 EXTENSION TO PRE-QUALIFICATION Report No. PC284
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14 EXAMINATION OF CABLE AND ACCESSORIES

Test Specification: IEC 62067, clause 12.4.10
TES 1245 outdoor termination
The oil was drained from the outdoor termination and the insulator removed. The stress cone
was removed from the cable end.
All items were inspected and revealed no signs of electrical degradation, moisture ingress,
leakage, corrosion or harmful shrinkage.
Examination of the cable externally and where exposed within the terminations showed no
signs of electrical degradation, moisture ingress, leakage, corrosion or harmful shrinkage.
Examination of oil samples taken from each of the terminations showed no signs of electrical
degradation.
A cable sample was removed from the area directly under the plumb, the core was cut and
prepared longitudinally and then examined. The prepared sample showed no signs of electrical
degradation, moisture ingress, leakage, corrosion or harmful shrinkage.
Test Result: Test passed
Cable
A sample of the cable (design HVSYS08/014 CD(1).1) was removed from the centre of the U
bend and 3 x 25mm wide samples were prepared with smooth surfaces then heated in an
oven until transparent.
The prepared samples revealed no signs of electrical degradation, no distortions and had
smooth / uniform conductor / outer screens.
Test Result: Test passed
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15 RESISTIVITY OF SEMI CONDUCTING SCREENS

Test Specification: IEC 62067, clause 12.4.11

Specification
Test Result /
Requirement / Comment
ohm.m
ohm.m
Resistivity of Insulation Meets specification
0.72 500 maximum
Screen of unaged cable requirements
Resistivity of Conductor Meets specification
4.97 1000 maximum
Screen of unaged cable requirements
Resistivity of Insulation Meets specification
0.98 500 maximum
Screen of aged cable. requirements
Resistivity of Conductor Meets specification
Screen of aged cable. 4.56 1000 maximum
requirements
.
Test Result: Test passed

16 CONCLUSION
The cable and accessories passed all the specified tests in the contract test procedure without
failure.
 EXTENSION TO PRE-QUALIFICATION Report No. PC284
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17 APPENDED DOCUMENTS

1. Calibrated Equipment Used During Test

2. Schematic Diagram of Type Test Assembly (Figure 1)
3. Heating of Cable for Tests at High Temperature
4. Impulse Oscillograms
5. Accessory Drawings
6. Cable Design Details
7. Photos of Examination
 EXTENSION TO PRE-QUALIFICATION Report No. PC284
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1. Calibrated Equipment Used During Test

Calibration
Calibration Due
Equipment Description Serial Number Certificate
Date
Number
U25264-001-01-01-
Eurotherm 4250M Chart Recorder 31st March 2011 PC/HVL/CAL/10/009
0894 J16(14)
CT HV867 + U25264-
Current transformer with
001-01-01-0894 30th April 2011 PC/HVL/CAL/10/012
Eurotherm 4250M chart recorder
J16(14)
CT AX90 + U25264-
Current transformer with
001-01-01-0894 30th April 2011 PC/HVL/CAL/10/012
Eurotherm 4250M chart recorder
J16(14)
Type K Mineral Insulated
070410 Next Use PC/HVL/CAL/10/011
Thermocouple Probes
Highvolt VLD1 kilovolt meter with 880858,
31st March 2011 PC/HVL/CAL/10/001
Biddle 350kV integral divider VLD1/MU16/X1, L1/2
Mtronix Partial Discharge
101 31st July 2010 1194
Simulator
Robinson Model 5 Partial
391 30th June 2011 1150
Discharge Detector
Tettex capacitance & tan delta
082-776-07 31st March 2011 1381
bridge TD470
Hartmann & Braun 800kV
5819230 31st July 2015 MTePX03430-K06
standard capacitor
Sangamo 0 to 200kV (indicated) 31st December
AL25325 0289662
meter 2010
Dr. Strauss TR-AS 100-12/2 Digital 897, 881375, 881376,
30th June 2012 MTePX03430-K01
Impulse Analysing System 127/50
Tinsley safety milliohm meter, 31st December
257141 0289663
type 5875S 2010
0277889, 458399,
Mitutoyo calibration discs 142361-2, 142361-3 31st March 2014
458400
Metrix digital multi meter 100213FAH 31st August 2010 0284990
Lem-Flex RR3030 AC current
F06290015612 31st March 2011 1131722
probe
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2. Schematic Diagram of Test Assembly
Figure 1
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3. Heating of Cable for Tests at High Temperature

The test loop was arranged with heating transformers to allow heating by AC circulating
current in the conductor, which formed the secondary winding of the transformers.
The correct temperature for the conductor was determined using a reference loop
(dummy cable), which was taken from the same cable length used for the type test and
had also been subjected to the bend test. The 6m long dummy cable was fitted with
thermocouples on the sheath and in the conductor at the centre of its length and was
sited in the test laboratory in the same ambient conditions as the main test loop. When
heating was required for the test loop the same conductor current was also applied to
the dummy cable at all times. It was then possible to determine the temperature of
the conductor of the main test loop (away from the immediate vicinity of the
accessories) by measuring the conductor temperature of the dummy cable directly. This
procedure was used for all the tests at high temperature including the thermal pre-
conditioning test and heating cycle voltage test.
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4. Impulse Oscillograms
1st Lightning Impulse 1050kVp +ve

10th Lightning Impulse 1050kVp +ve

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1st Lightning Impulse 1050kVp ve

10th Lightning Impulse 1050kVp ve

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5. Accessory Drawings
TES 1245/111 Outdoor Termination
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6. Cable Design Details
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7. Photos of Examination
TES 1245/111 outdoor termination
Insulator removed from termination

TES stress cone removal

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XLPE core and screen termination

Stress cone

END OF TEST REPORT