AFTER LAYING TESTS OF 400 kV XLPE CABLE SYSTEMS FOR BEWAG BERLIN
R. Plath; U. Herrmann K. Polster
Institut „Prüffeld für elektrische Bewag-Berliner
Hochleistungstechnik“ Berlin Kraft-und Licht AG
Abstract. The after laying tests carried out on a
400 kV XLPE cable double-system (length 6.3 km)
used AC test voltage combined with partial
discharges (PD) measurement on joints and sealing
ends for the first time. The approx. 30 MVA test
power was delivered by the two-stage mobile
resonant test system of variable frequency which
was specifically designed for this duty. The
requirements to be met by the test system as well as
the test arrangement and its connection technology
are explained. For the PD measurements,
directional couplers were integrated into each joint.
The data measured on all joints were
simultaneously recorded and centrally evaluated.
The voltage tests carried out up to 400 kV and the
high-sensitive PD measurements done on the joints
with a PD detection level of 2 pC confirm that such
test and measuring systems allow to achieve
informative commissioning and diagnostic tests on
extra high-voltage cables also under difficult on-site
conditions
1. 400-kV cable installation
To enhance the long-term secure and economical
power supply of Berlin, Bewag is building a 400 kV
diagonal interconnection through Berlin's load
centres.
For the section between the substations of Mitte and
Friedrichshain, Bewag decided to use 400 kV XLPE
insulated cables for the first time /1/. They were
assembled in the continuous cable tunnel running at a
depth of approx. 25 m beneath the surface. The cable
suppliers were to successfully pass a one-year long-
time test and a type test.
To assure the reliable and safe service life of the
cable installation as a whole, quality assurance
measures were an additional part of the project. They
included tests during the manufacturing process and
routine tests conducted on every essential component
of the cable installation. Quality assurance was
completed by commissioning tests carried out after
assembling. It was checked whether there were any
defects produced during on-site assembling.
Therefore, the XLPE-insulated cable installation was
subjected to AC testing after assembling and at the
same time high-sensitive partial discharge (PD)
measurements were done on all accessories
simultaneously.
Due to the very high capacitive load, on-site AC
C:\Webpages\HVTech\CIGRE SC 21, St. Petersburg 1999 400 kV XLPE Bewag.doc
J. Spiegelberg; P. Coors
HIGHVOLT Prüftechnik
Dresden GmbH
testing of the 6.3 km long cable link was only possible
by using the world-wide most powerful mobile
resonant test system. At the maximum test voltage level
of 400 kV RMS (√3 U0), the available test power
reached approx. 32 MVA at 25 Hz.
2. Frequency-tuned resonant test systems
2.1 Principle of voltage generation
For commissioning HV testing of extruded HV cables
AC voltage of variable frequency (25 ... 300 Hz)
became the preferred test voltage within few years
/2/,/3/, because of the realistic simulation of the
operational stress and the advantages of its generation
by frequency-tuned test systems, which are among
others:
- the minimal specific weight (approx. 1kg/kVA) in
comparison with resonant circuit with adjustable
inductance (approx. 5kg/kVA) as well as test
transformers with compensation (more than
10kg/kVA),
- the lower feeding power (at least factor two in
comparison with resonant circuits with adjustable
inductance),
- the three-phase power supply, and
- the simple mechanic construction especially the
resonant reactor has no movable parts.
The frequency-tuned resonant test system works as a
series resonant circuit. The resonant point is reached by
tuning the frequency converter to the natural frequency
of the series oscillation circuit (resonant reactor and
capacitive load). The frequency range of 30 ... 300 Hz
(1 :10) is generally accepted which means a
permissible load range between minimum and
maximum test object capacitance of 1 : 100. The load
range can be increased up to 1 : 144 if the minimal
frequency of 25 Hz is permitted. In comparison with
them the resonant systems with adjustable inductance
have only an operating range of 1 : 20. Furthermore an
important characteristic is the frequency-dependent
quality factor which can be described as the
comparison of the capacitive test power PP to the active
power PL. The power loss is mainly caused by the
losses of the reactor and the exciter transformer. By
using a suitable construction of the resonant reactor a Q
factor greater than 100 can be achieved at least. In this
case the feeding power is lower than one percent of the
test power.
2.2 Rating of the test systems

The technical data and the mechanic design of the

resonant reactor affect the parameters and
characteristics of the test systems. The test conditions
of the 400 kV cable installation of BEWAG have
been determined the nominal parameter of the test
systems which are as follows:
Vtest = 1.73 U0 = 400 kV
C = 0.190 µF/km 6.3 km ≈ 2.2 µF
fmin = 25 Hz
I = 80 A, 8 h ON/16 h OFF
P = 32 MVA (!)
Additionally the test system should also suitable for Fig. 1: Load-frequency and voltage characteristics
testing of cables in a rated voltage range of 110 kV to
220 kV as well as for 400 kV gas insulated tors (ONAN). According to the BEWAG test
transmission lines (GIL) at 80% of the routine test conditions which request a test duration of 8 hours it is
level Vtest = 0.8*630 kV = 504 kV. Furthermore the necessary to cool the radiators with a ventilator
weight of the transportation unit including trailer and (ONAF).
truck shall be taken into consideration because a A minimum quality factor (design quality factor) of
weight of not more than 40 tons avoids a special more than 100 at a frequency f = 25 Hz needs a feeding
permission for the road traffic. These conditions power of only 200 kVA for a test power of 20 MVA.
require to separate the resonant reactor into two units. This is equal to the rated power of the frequency
Consequently, the frequency converter and the converter. Therefore the two frequency converters
exciter transformer are separated too. As a result, work in a master-slave operation if the two resonant
there are two independent test systems which can reactors are connected in a series or parallel circuit.
operate separately or be connected in parallel (higher Additionally the two exciter transformers are circuited
test power) or in series (higher test voltage) as well. on the primary side in parallel (Fig. 2) and on the
Hence, the second resonant reactor is installed on a secondary side in series.
insulating construction which is rated for 254 kV (see
also Fig. 5). Thereby, the covered test cases are
shown in Table 1 and Fig.1.

rated test capa- cable test test

volt. voltage citance length current power
kV kV µF km A MVA
110 160 (2.5Uo) 2.5 12.5 64 10.3
132 190 2.5 12.5 75 14.3
a) 150 220 2.1 10.5 80 17.6

220 254 (2.0Uo) 1.6 8.0 80 20.3

110 160 (2.5Uo) 5.0 25 128 20.5
132 190 5.0 25 150 28.5
b) 150 220 4.2 21 160 32.2

220 254 (2.0Uo) 3.2 16 160 40.6

c) 400 400 (1.73Uo) 1.25 6.5 78.5 31.4 Fig. 2: Test circuit with 2 reactors in series
504 (0.8Up) 0.8 11.5* 80 40.3
* 70 nF/km 2.3 Acceptance test of the resonant test system

Table 1: Test system 2 x 80 A / 254 kV
Maximum parameters of cable testing
a) single test system
b) two test systems in parallel
c) two test systems in series
The oil insulated resonant reactor is especially
designed for outdoor conditions with a steel tank and
an oil-to-air bushing of composite insulation (fibre-
glass tube with silicon rubber sheds). Its nearly load
independent inductance of 16 H is realised by an iron
core with multiple gaps which enable a linear
magnetization. The high quality factor is caused by a
special design of this core and of the winding to
guarantee minimum losses. During the 1 hour test
operation the dissipation heat can usually drawed off
by self-cooling from the surfaces of vessel and radia-
Before the resonant test system was used for the on-site
tests, it had been carefully tested at its rated voltage
254 kV (1 hour including PD measurement) at voltages
up to 120% of this value, at test object punctures and so
on. These tests were repeated for the series and parallel
connection of two test systems.
By means of switchable load capacitors and therefore
different resonant frequencies the semiautomatic
operation up to the test voltage was proven. The
voltage measuring system was calibrated for the
operating frequency range from 25 Hz to 300 Hz. The
harmonic content of the test voltage meets the
requirements of the international standard IEC 60060-1
and is always less than 5 percent. The measured quality
factor confirms the calculated frequency response (Fig.
3) and exceeds its design value (Q = 100) remarkably.
Therefore the requested test power of approximately
32 MVA can be generated by a feeding power of
approx. 200 kVA.
Fig. 3: Quality factor Q and test power P
characteristics (design value Q = 100)
measured values
3. Tests
3.1 Test arrangement
The AC voltage test and the PD measurement on the
400-kV cable installation was awarded to IPH, the
high-voltage and high-power test laboratory situated
at Berlin-Marzahn. The tests took place at the
substation (GIS) of Friedrichsfelde.
Due to its large dimensions the AC test system had to
be placed outside the cable installation and connected
by an additional test cable of 120 m length. One of its
ends was equipped with an SF6-sealing end for
connecting the test object. On the other side of the
test cable an SF6 sealing end was fitted in an SF6
tank, to which an outdoor sealing end was mounted.
The voltage connection to the AC test system was
realised by an aluminium tube (Fig. 4).
Fig. 4: Outdoor sealing end with test cable
One resonant reactor was used for the test up to 254
kV. It was mounted onto a trailer. Between resonant
reactor and test cable terminal a blocking impedance
was arranged to reduce interferences for the PD
measurement and to protect the resonant reactor
against fast transients in case of breakdown. The
blocking impedance was mounted to a capacitive
voltage divider on one side and to a support on the
other side. The voltage signal of the voltage divider is
used by the control and supply unit for voltage
regulation and simultaneously for voltage
measurement. The test voltage was furthermore
measured by the integrated capacitive pick-up at the
outgoing bushing of the resonant reactor. The safety for
the tested cables was improved by providing a second
independent switch-off device. To synchronise the PD
measurement system to the test voltage phase, the AC
signal was transmitted via an optical link to the control
room.
The resonant reactor was supplied by an excitation
transformer placed next to the resonant reactor on the
trailer.
The 400 kV tests need two AC test systems. A 254 kV
test system identical to that of IPH was therefore
provided by KEMA. One of the two resonant reactors
was mounted to an insulating construction and both AC
test systems were series-connected (Fig. 2 and 5).
Fig. 5: Arrangement for 400-kV test
The voltage connection was arranged from the resonant
reactor on high-voltage potential to the test cable via
the blocking impedance which, in this case, was
mounted on a capacitive 500 kV voltage divider and a
500 kV support.
3.2 AC voltage tests
Since the tests anyway included the observation of the
PD level, the test voltage was increased by steps of 50
kV/5 min until the final test voltage was reached.
In the first part of the tests, the individual phases of
each system were tested one after the other at the test
voltage of 254 kV requested by Bewag over a period of
15 min and after that at 230 kV over a 45-min period.
With the cable capacitance being approx. 0.190 µF/km,
the resulting resonant frequency of the test circuit was
approx. 37 Hz.
The second part of the commissioning test was a load
test for conditioning the cable installation with elevated
operating current (1685 - 1900 A). Over a 20-day pe-
riod a cyclic load was applied to simulate potential ser-
vice conditions that may occur in future service life.
Furthermore, the load test served to verify the effec-
tiveness of the cable installation's forced air cooling.
In the last part of the tests, the test voltages of 1,73·U0
= 400 kV during 15 minutes and of 350 kV during 45
minutes were applied one after the other to each of
the cable conductors. The result was a resonant
frequency of approx. 26 Hz for the test voltage. Fig. 6
shows the time characteristic of the 400-kV voltage
test, delivered by the computer control of the test
system.
Fig. 6: Time characteristic
3.3 PD measurement
PD measurement was carried out only on the
accessories, because all cables were already tested
during the routine test.
Each phase of both three-phase systems of the 6.3-km
cable installation included 8 joints and 2 GIS sealing
ends. On all of these accessories directional couplers
/4/ for the decoupling of PD impulses were
additionally fitted.
Bewag required simultaneous PD measurements on
all these accessories to detect any PD as early as
possible. This was to minimise the risk of
breakdown. During voltage testing no staff was
needed inside the tunnel because the distributed
measurement system was under remote control by
optical links.
Preliminary investigation showed that the noise level
in the tunnel was low as compared to typical on-site
conditions. The tunnel depth of 25 m and the large
length of cable between two joints attenuated high
frequency noise components very well. IPH designed
and applied a PD measurement system fulfilling
Bewag requirements including a PD detection level
of ≤ 2 pC on site. Furthermore, two directional
couplers left- and right-hand side of each joint
enabled on-site calibration and even high-precision
PD location.
Capacitive sensors instead of directional couplers
were used for the GIS sealing ends of one of the two
three-phase cable systems. These sensors did not
reach the same selectivity like the directional
couplers. Even at the far end, outer noise (e.g. PD
from rain) superimposed the PD measurement at the
GIS sealing end.
3.4 Test results
No breakdown occurred during all voltage tests. PD
measurements on 60 accessories (12 GIS sealing ends
and 48 joints) showed PD in only one single
case. Due to the low PD level (approx. 5 pC, single
pulses up to 7 pC) additional measurements were
carried out in order to be very sure before opening
the joint. After dismantling the joint, the PD causing
failure was found. The PD location executed before the
opening showed a displacement to the real failure
location of approx. 2 cm, confirming the high accuracy
of UHF measurement techniques. After repair, the joint
reassembling was done exactly in the same place,
because practically no damage on the cable insulation
occurred due to early fault recognition.
4. Conclusions
The experience from after laying tests of 400 kV XLEP
cables with frequency-tuned resonant test systems
confirms their simple erection on site, their easy
handling as well as their high reliability. Such test
systems for test voltages up to 500 kV and test power
up to 40 MVA are available.
The test results confirm also the high overall quality
level of the 400-kV-XLPE cable system. Nevertheless,
besides all routine tests on cables before laying and the
use of prefabricated and pretested accessories, a small
risk remains due to assembling work on accessories on
site. On-site AC testing combined with sensitive PD
measurements reduces this risk noticeably.
5. References
/1/ Henningsen, C. H., Polster, K., Müller, K. B.,
Schroth, R. G.:
New 400 kV XLEP long distance cable systems,
their first application for the power supply of
Berlin,
CIGRE Session (1998), paper 21-109
/2/ Schufft, W. et al.:
Powerful frequency-tuned resonant test systems
for after-laying tests of 110 kV XLPE cables.
9th ISH Graz 1995, paper 49.86
/3/ Hauschild, W., Schufft, W., Spiegelberg J.:
Alternating voltage on-site testing of XLPE
cables: The parameter selection of frequency-
tuned resonant test systems.
10th ISH Montreal (1997),Vol. 4, pp. 75-78
/4/ Pommerenke, D., Strehl, T., Kalkner, W.:
Directional coupler sensor for partial discharge
recognition in high voltage cable systems.
10. ISH Montreal 1997
Address of author:
Dr. Ing. R. Plath
Institut Prüffeld f. Hochleistungstechnik Berlin (IPH)
Landsberger Allee 376
12632 Berlin
C:\Webpages\HVTech\CIGRE SC 21, St. Petersburg 1999 400 kV XLPE Bewag.doc