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622

Recommendations for Testing DC


Transition Joints for Power Transmission
at a Rated Voltage Up To 500KV

Working Group
B1.42

June 2015
RECOMMENDATIONS FOR TESTING DC
TRANSITION JOINTS FOR POWER
TRANSMISSION AT A RATED VOLTAGE UP TO
500KV
WG B1.42

Members
G. Evenset, Convenor (NO), B.Sonerud, Secretary (NO),
Marco Albertini (IT), Txús Correa (ES), Ivan Jovanovic (US) , Tae-Ho Lee (KR), Mohamed Mammeri (FR),
Hiroshi Niinobe (JP), Peter Sunnegårdh (SE), Roman Svoma (GB), Minh Nguyen Tuan (FR), Volker Werle
(DE)

Corresponding
Zheng-Zheng Chen (CH), Bruno Brijs (BE), Anders Jensen (DK), Pascal Streit (CH)

Copyright © 2015

“Ownership of a CIGRE publication, whether in paper form or on electronic support only infers right
of use for personal purposes. Unless explicitly agreed by CIGRE in writing, total or partial
reproduction of the publication and/or transfer to a third party is prohibited other than for personal
use by CIGRE Individual Members or for use within CIGRE Collective Member organisations.
Circulation on any intranet or other company network is forbidden for all persons. As an exception,
CIGRE Collective Members only are allowed to reproduce the publication.

Disclaimer notice

“CIGRE gives no warranty or assurance about the contents of this publication, nor does it accept
any responsibility, as to the accuracy or exhaustiveness of the information. All implied warranties
and conditions are excluded to the maximum extent permitted by law”.

ISBN : 978-2-85873-325-5
Recommendations for Testing DC Transition Joints for Power Transmission at a Rated Voltage up to 500kV

Recommendations for Testing DC Transition


Joints for Power Transmission at a Rated
Voltage up to 500kV
Table of Contents
EXECUTIVE SUMMARY ................................................................................................................. 3
1 Introduction................................................................................................................................. 3
1.1 Background .......................................................................................................................... 3
1.2 Scope.................................................................................................................................... 4
1.3 Condition assessment .......................................................................................................... 4
2 Definitions................................................................................................................................... 4
2.1 Definitions of tests ................................................................................................................ 4
2.2 Test Cables and Transition Joint Characteristics ................................................................. 5
2.3 Definitions of Test voltages .................................................................................................. 6
2.4 Thermal cable design parameters ........................................................................................ 8
2.5 Thermal conditions for tests ................................................................................................. 8
2.6 Conditions for test ................................................................................................................. 8
3 Development Tests .................................................................................................................. 10
3.1 Electrical Development Tests ............................................................................................. 10
3.2 Non-Electrical Development Tests ..................................................................................... 10
4 Routine Test ............................................................................................................................. 10
4.1 Extruded Cable Side of the Transition Joint ....................................................................... 10
4.2 Paper Cable Side of the Transition Joint ............................................................................ 11
4.3 Test on external housing .................................................................................................... 11
5 Sample Test ............................................................................................................................. 11
6 Type Test ................................................................................................................................. 11
6.1 General ............................................................................................................................... 11
6.2 Range of Type Test Approval ............................................................................................. 12
6.3 Type Test Arrangement ...................................................................................................... 12
6.4 Type Test Procedure .......................................................................................................... 13
7 Prequalification Test ................................................................................................................. 16
7.1 General and Range of Prequalification Test Approval ....................................................... 16
7.2 Summary of prequalification tests ...................................................................................... 16
7.3 Test arrangement ............................................................................................................... 17
7.4 Long duration voltage test .................................................................................................. 17
7.5 Superimposed impulse voltage test (optional) ................................................................... 18
7.6 Examination ........................................................................................................................ 19
7.7 Success criteria, re-testing and interruptions ..................................................................... 19
8 Electrical Test after Installation ................................................................................................ 19
References .................................................................................................................................. 20
Appendix A: Back-to-back Transition Joint with two insulators ................................................... 22
Appendix B: Temperature distribution in transition joints with dissimilar cable insulation .......... 23
Appendix C: Terms of Reference ................................................................................................ 26

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Recommendations for Testing DC Transition Joints for Power Transmission at a Rated Voltage up to 500kV

EXECUTIVE SUMMARY

HVDC cables with lapped insulation systems have been in operation since the 1950s and this technology is still
dominating for long cable circuits at the highest voltage levels. Most of the lapped cable systems are based on kraft
paper impregnated with a high viscous mass, but self contained fluid filled cables are also in operation in HVDC
systems. Polypropylene laminated paper impregnated with low viscous oil is also in service and mass impregnated
PPL insulation systems are developed.

Extruded insulation systems have been gradually introduced in the market the last two decades. Starting at a
voltage level of 80 kV in the late 90s this cable technology is today dominating for voltage levels up to 320 kV.
Further development of the technology for higher voltage levels is expected.

The number of HVDC circuits in operation has increased significantly for many years and it is expected that joints
between paper lapped cables and extruded cables will be required in the near future. Transition joints may be
required in new systems using different cable technologies along the route or for rerouting/replacement of parts of
existing cable systems.

This brochure gives recommendations on how transition joints between lapped insulation systems and extruded
insulation systems shall be qualified. The tests are as far as appliccable based on Cigre reccommendations in
TB496, TB415 and tests specified for lapped HVDC cables published in Electra No. 189. There is a large variation
in the maximum conductor temperature for the different insulation systems which needs to be taken into account
o
during system engineering and testing. Some of the insulation systems are limited to 50 C operating temperature
o
and others are designed to operate at 90 C. The axial heat transfer in the transition joint may therefore be high
and has to be considered. An example of such calculation is included in the brochure.

1 Introduction
1.1 Background
Mass Impregnated Paper Cables (MI) has been used predominantly in HVDC applications since the 1950s. Gas
filled (GF) as well as Self Contained Fluid Filled (SCFF) HVDC cables were also used, however the widespread
use of XLPE in AC transmission and distribution networks and further research and development in polymeric
insulation has resulted in the use of XLPE also for HVDC applications. In the 1990s, interest in Polypropylene
Laminate Paper (PPL) for use in SCFF cables resulted in the application of this technology not only for EHV AC,
but also in HVDC. Mass impregnated PPL has also been developed specifically for HVDC applications.

Gradually over the last decade the voltage of the HVDC XLPE projects has increased and it is probable that
interconnection between XLPE, MI and PPL MI will be necessary as the networks are reconfigured in the future, to
form diversions or as part of a repair. New projects may use combinations of technologies depending on markets,
voltage levels, manufacturing technologies and project risk profiles. The connection between the different cable
systems is likely to be a complex prospect as some of the specified cable operating temperatures are different at
this moment in time (50º-55ºC for MI, 70ºC-90ºC for XLPE and 85ºC-90ºC for PPL/MI and fluid-filled). The cable
systems may be type tested and qualified to operate for different HVDC converter technologies (VSC or LCC).

CIGRE set up WG B1.42 to review this subject and issue a brochure to include:

 A review of the existing recommendations and standards and the extent to which they cover the testing of
transition joints.
 Installation considerations and how the testing and specification impact project applications
 Definition of test regimes for transition joints for routine, sample, type, prequalification and after installation
tests.

The tests in this recommendation are mainly based on recommendations in TB 496 [1], TB 415 [2] and Electra No.
189 [3].

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Recommendations for Testing DC Transition Joints for Power Transmission at a Rated Voltage up to 500kV

1.2 Scope
The purpose of these new recommendations is to give general guidance for tests on DC transition joints for power
transmission. These recommendations are valid for transition joints between paper-insulated oil filled/mass
impregnated cables, including PPL, and extruded insulation cables with rated voltage up to 500 kV. Pipe type and
gas pressurized cables are not considered. Concentric cables with low voltage return insulation are considered, but
not bi-pole concentric cables. Transition joints for single core and multi core cables (i.e. cables with individual
metallic screen, but common armour) are covered. Both land and submarine transition joints are covered.

Different types of transition joints can be used to connect oil-filled/mass impregnated to extruded insulated HVDC
cables, for example a back-to-back transition joint [4] [5] (see Appendix A). Each manufacturer may have different
solutions. Y branched joints are not considered within these guidelines. Tests on joints between cables with similar
type of insulation are not considered in this document (covered by TB 496), even if they are used between cables
with different conductors or different screens [1].

Although the application of high voltage transition joints for interconnection of different cable systems is likely to
increase, the quantity of transition joints compared to the quantity of standard accessories required will be low.
There will also be a large variety of cable constructions which have to be connected using transition joints.

The number of type tests that can be performed may be limited due to the availability of suitable paper insulated
cables, thus guidance is given in 6.1 General.

Comments on the need for a prequalification test are also made.

1.3 Condition assessment


In some cases the existing paper cables on which a transition joint will be installed, have been in service for many
years and hence diagnostic tests may be advisable to assess the cable condition. A review of applicable
procedures is given in reference [6].

In the event that the cable is found to be in as-new condition then it would generally be considered unnecessary to
carry out any special diagnostic tests after installation of a transition joint.

Practices for maintenance of HV cable circuits are described in reference [7, 8, 9] and are not considered further in
this report.

2 Definitions
2.1 Definitions of tests
Where applicable, test definitions are in line with IEC 60840 [10] and IEC 62067 [11].

Development tests Tests made during the development of the cable system.

Prequalification test Test made before supplying on a general commercial basis a type of cable system covered
by this recommendation, in order to demonstrate satisfactory long term performance of the
complete cable system.

Note 1: The prequalification test need only be carried out once unless there is a substantial change in the
cable system with respect to material, manufacturing process, design or design electrical stress
levels.

Note 2: A substantial change is defined as that which might adversely affect the performance of the cable
system. The supplier should provide a detailed case, including test evidence, if modifications are
introduced, which are claimed not to constitute a substantial change.

Type tests Tests made before supplying on a general commercial basis a type of cable system
covered by this recommendation, in order to demonstrate satisfactory performance
characteristics to meet the intended application.

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Recommendations for Testing DC Transition Joints for Power Transmission at a Rated Voltage up to 500kV

Note: Once successfully completed, these tests need not be repeated, unless changes are made in the
cable or accessory with respect to materials, manufacturing process, design or design electrical
stress levels, which might adversely change the performance characteristics.

Routine tests Tests made by the manufacturer on each manufactured component (length of cable or
accessory) to check that the component meets the specified requirements.

Sample tests Tests made by the manufacturer on samples of complete cable or components taken from
a complete cable or accessory, at a specified frequency, so as to verify that the finished
product meets the specified requirements.

Tests after installation Tests made to demonstrate the integrity of the cable system as installed.

2.2 Test Cables and Transition Joint Characteristics


Where applicable, definitions are in line with IEC 60840 [10] and IEC 62067 [11].

Cable system A cable system consists of cables with installed accessories. Cable accessories are
typically joints and terminations. There may be other types of accessories associated with
a cable system (e.g. measuring devices or fixtures). These need only to be incorporated in
the test objects to the extent that they are deemed to have an impact on the operational
characteristics of the cable system.

Test object A test object is a cable length or an accessory to be subjected to testing.

Return cable A return cable is the low/medium voltage DC cable used for the return current in monopolar
operation of HVDC schemes. The return cable can either be connected over the full length
between the converters or only be connected for part of the length connecting a converter
to an electrode station.

Transmission cable A transmission cable refers to the high voltage cable of a monopolar or bipolar scheme.
The term is used in this document where appropriate to distinguish from the return cable.

Integrated return conductor

A high voltage transmission cable with a coaxial return conductor and low voltage return
conductor insulation.

Test loop A test loop is a combination of series connected test objects simultaneously under test
(Figure 1).

Test set-up A test set-up is a combination of clearly separate test loops. A number of test loops may be
simultaneously under test, possibly using same test equipment.

LCC A HVDC system using Line Commutated Converters. LCC is a converter that has the
feature of changing voltage polarity on the cable system when the direction of power flow is
reversed, IEC 60633 [12].

VSC A HVDC system using Voltage Source Converters. VSC is a converter that does not
change the voltage polarity of the cable system when the direction of power flow is
reversed, Cigré TB 289 [13].

Possible configuration of test objects in a test loop is shown in Figure 1. Special definitions are described hereafter.

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Recommendations for Testing DC Transition Joints for Power Transmission at a Rated Voltage up to 500kV

Example of test loop

0.5 m cable (extruded side)/1.0


m0.5 m cable
cable included
(lapped side)in the
included
test object Accessory
in the test test
Accessory objectobject test object
Termination Termination

Minimum 5/8 m
minimum 5 m cable
(extruded/lapped) cable test object Cable. Minimum 10 m.
test object
between
between Accessory
Accessory test test object
test objects Joint
objects Joint
Minimum 5/8 m (extruded/lapped)
minimum 5 m cable between
cable between Accessory test
Accessory test objects
objects

Figure 1: Possible configuration of test objects within a test loop

Transition joint A transition joint in the context of this recommendation is a joint between paper-insulated
fluid filled/mass impregnated cables, including PPL, and extruded insulation cables.

2.3 Definitions of Test voltages

U0 is the rated DC voltage between conductor and core screen for which the cable system is
designed.

UT is the DC voltage during the type test and routine test. For the scope of this
recommendation UT = 1.8 x U0.

UTP1 is the DC voltage during the prequalification test (load cycle test), type test (polarity
reversal test) and test after installation. For the scope of this recommendation U TP1 = 1.4 x
U0.

UTP2 is the DC voltage during the prequalification polarity reversal test. For the scope of this
recommendation UTP2 = 1.25 x U0.

UP1 is 1.15 x the maximum absolute peak value (Figure 2) of the lightning impulse voltage,
which the cable system can experience when the impulse has the opposite polarity to the
actual DC voltage.

UP2,S is 1.15 x the maximum absolute peak value (Figure 2) of the switching impulse voltage,
which the cable system can experience when the impulse has the same polarity as the
actual DC voltage.

UP2,O is 1.15 x the maximum absolute peak value (Figure 2) of the switching impulse voltage
which the cable system can experience when the impulse has the opposite polarity to the
actual DC voltage.

URC,AC is the maximum voltage a return cable can be subjected to due to temporary damped
alternating overvoltage. This voltage is typically induced by a commutation failure, and the
value should be supported by the supplier’s system calculations of the HVDC link. The

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Recommendations for Testing DC Transition Joints for Power Transmission at a Rated Voltage up to 500kV

nature of the overvoltage depends upon the configuration of the HVDC link and needs to
be calculated for each case

URC,DC is the max DC voltage in normal operation of the return cable.

Note 1: The ripple content of the DC test voltages shall not be greater than 3 percent.

Note 2: Calibration shall be according to IEC 60060-1 [14].

Note 3: The transition joint may experience different impulse levels than stated above depending
on the system design.

kV kV

U0 U P2,S U0
t
t - U P2,O

VSC, same polarity positive LCC or VSC, opposite polarity


switching impulse negative switching impulse

kV kV

t U P2,O
t
- U0 - U P2,S - U0

VSC, same polarity negative LCC or VSC, opposite polarity


switching impulse positive switching impulse

kV kV

U P1 U0
t
t
- U0
- U P1

LCC or VSC, positive lightning impulse LCC or VSC, negative lightning impulse

Figure 2: Schematic representations of the switching impulse and lightning impulse test
voltages. Due to the constraints within the DC system design U P2,S does not necessarily equal
U P2,O , i.e. the same polarity impulse is limited by surge arresters, but the opposite polarity
impulse may be limited by the converter.

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Recommendations for Testing DC Transition Joints for Power Transmission at a Rated Voltage up to 500kV

2.4 Thermal cable design parameters


Tcond,max is the maximum temperature at which the cable conductor is designed to operate. This
value is to be stated by the supplier.

Tmax is the maximum temperature difference over the cable insulation in steady state (not
including semiconducting screens) at which the cable is designed to operate. This value is
to be calculated and stated by the supplier, who shall also provide evidence of the
correlation between this design value and data measured during testing.

2.5 Thermal conditions for tests


The heating method used shall be conductor heating. The heating may be achieved by either DC or AC current,
possibly in combination with external thermal insulation or cooling/heating. The actual T and Tcond during testing
need to be demonstrated.

Load Cycles (LC) Load cycles consist of both a heating period and a cooling period.

“24 hours” load cycles (for prequalification and type tests) consist of at least 8 hours of
heating followed by at least 16 hours of natural cooling. During at least the last 2 hours of
the heating period, a conductor temperature  Tcond,max and a temperature drop across the
insulation  Tmax shall be maintained for the cable with the lowest T cond,max.

“48 hours” load cycles (for type test only) consist of at least 24 hours of heating followed by
at least 24 hours of natural cooling. During at least the last 18 hours of the heating period,
a conductor temperature  Tcond,max and a temperature drop across the insulation  Tmax
shall be maintained for the cable with the lowest T cond,max. 48 hour load cycles are only
required as part of the type test procedure to ensure that electrical stress inversion is well
advanced within the cycle.

High Load (HL) High Load consists of a continuous heating period. Within the first 8 hours of the heating
period conductor temperature  Tcond,max and temperature drop across the insulation 
Tmax, , both referring to the cable with the lowest T cond,max, shall be achieved and
maintained for the rest of the High Load test.

NOTE: If, for practical reasons, the specified temperatures can not be reached within the first 8 hours, a longer time
can be used. This additional time shall not be constituted as being part of the test period.

Zero Load (ZL) No heating is applied.

Impulse Test Referring to the cable with the lowest T cond,max the conductor temperature  Tcond,max and
temperature drop across the insulation  Tmax shall be reached minimum 10 hours before
voltage impulses (superimposed impulse, switching, lightning) are applied and shall be
maintained throughout the duration of the test

Ambient temperature

Unless otherwise specified in the details for the particular test, tests shall be carried out at
an ambient air temperature of (20 15C.

2.6 Conditions for test


Polarity reversal test The voltage and temperature conditions are defined in 2.3 Definitions of Test voltages
and 2.5 Thermal conditions for tests respectively. Starting with positive voltage, the
voltage polarity shall be reversed three times every “24 hours” load cycle (evenly
distributed) and one reversal shall coincide with the cessation of loading current in every
“24 hours” load cycle. The recommended time duration for a polarity reversal is within 2
minutes.

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Recommendations for Testing DC Transition Joints for Power Transmission at a Rated Voltage up to 500kV

NOTE: If, for practical reasons, polarity reversals cannot be achieved within 2 minutes, the duration for polarity
reversals shall be agreed between customer and supplier.

Superimposed impulse voltage test

Prior to the first impulse of each test, the test object shall be heated so that the
temperature conditions as defined in 2.5 Thermal conditions for tests are achieved for at
least 10 hours and the test object shall have been subjected to U 0 (of the relevant polarity)
for at least 10 hours. These conditions have been selected to reflect the electrical
dynamics present within extruded insulations used for HVDC. Superimposed impulse
voltage shall be applied according to the procedure given in Electra 189 [3].

Check on insulation Prior to the electrical tests, the insulation thickness shall be measured by the method
specified in IEC 60811-201 [15] on a representative piece of the length to be used for the
tests, to check that the thickness is not excessive compared with the nominal value t n
declared by the manufacturer.

If the average thickness of the insulation on either cable does not exceed the nominal
value by more than 5%, the test voltages shall be the values specified for the rated voltage
of the cable.

If the average thickness of the insulation on either cable exceeds the nominal value by
more than 5%, but not by more than 15%, the test voltage shall be adjusted by considering
the following coefficient  to maintain the same level of average electric field, e.g., a 10%
increase in average insulation thickness shall be accounted for by a 10% increase in the
test voltage:

t

tn

t = measured average insulation thickness

tn = declared nominal thickness

The cable lengths used for the electrical tests shall not have an average thickness
exceeding the nominal value by more than 15%.

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Recommendations for Testing DC Transition Joints for Power Transmission at a Rated Voltage up to 500kV

3 Development Tests
Development tests are carried out to prove the main electrical and non-electrical characteristics of the transition
joint.

Details of such development tests shall be at the discretion of the manufacturer, examples of possible tests are
given in the following clauses.

3.1 Electrical Development Tests


Electrical development tests can be adopted from the type test recommendations of this document, but may have
increased test voltage levels. The duration of withstand tests as well as the number of impulses during impulse
voltage test may be increased, too.

Examples for electrical development tests:

- An evaluation of the materials and processes employed. Such evaluations would normally include electrical
resistivity assessments, breakdown tests and space charge measurements.
- An analysis of the electric stress distribution within the cable system insulation for a range of typical
installation and loading conditions.
- An assessment of the long-term stability, possibly involving factory experiments to assess the ageing
effects of various parameters, e.g., electrical stress, temperature, environmental conditions etc.
- An assessment of the sensitivity of the electric stress distribution to the expected variations in cable
dimensions, material composition and process conditions (extrusion, post extrusion treatments and
finishing).

If new types of conductor connections are used as part of the transition joint design, the necessity for development
tests of such connections should also be considered.

Short circuit test on the sheath connection should be performed according to [16] [17]. The short circuit current and
duration used need to be based on system calculations. This test could be omitted if the design has been tested at
higher current and for longer duration.

3.2 Non-Electrical Development Tests


Non-electrical development tests are considered to demonstrate the sufficient tightness of the external transition
joint housing as well as the pressure maintaining barrier insulators between the different insulating fluids.

During operation, joint housings and barrier insulators are subjected to hydraulic/gas pressure. Barrier insulators
and related sealing systems may also be subjected to vacuum during the installation process. (Vacuum processing
is often used during assembly work on paper-insulated cable accessories).

Examples for non-electrical development tests:

- Pressure test

- Vacuum leak test

- Thermo-mechanical test

4 Routine Test
4.1 Extruded Cable Side of the Transition Joint
The experience of using DC voltage for routine testing of accessories for DC cables is limited and the efficiency of
DC testing for prefabricated accessories is arguable and has not been proven so far. It is the opinion of the WG
that the DC test could be in principle a necessary test; however, it may not be sufficient to prove the quality of the

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Recommendations for Testing DC Transition Joints for Power Transmission at a Rated Voltage up to 500kV

accessory, e.g. the presence of voids in the insulation after moulding. Testing with AC voltage could be considered
as a supplementary test, provided that the material and design allows it.

Epoxy resin components are to be tested with AC voltage with PD detection according to procedures in IEC
62067/60840 [10, 11] at voltage levels corresponding to the size of comparable AC components.

The DC test voltage applied to the main insulation of each individual premoulded accessory shall be as specified
under § 5.2 in TB 496 [1].The following additional tests may be carried out according to the quality assurance
procedures of the manufacturer:

- AC voltage test, if applicable


- PD measurement, if applicable

4.2 Paper Cable Side of the Transition Joint


The hydraulic tests specified in IEC 60141-1 shall be made on each accessory to which the relevant clauses apply
[18]. For very high internal pressure (>20 bar) the test margin should be agreed between customer and
manufacturer.

Epoxy resin components should be tested according to 4.1 Extruded Cable Side of the Transition Joint. If there
are premoulded components, these should be tested according to 4.1 Extruded Cable Side of the Transition
Joint. Testing of epoxy resin components may be performed in a separate test setup without the presence of MI
cable.

4.3 Test on external housing


It is recommended to perform leakage test/vacuum drop, gas leak and hydraulic pressure test as specified in
IEC 60141-1/60141-3 [18].

5 Sample Test
Due to the small numbers of transition joints which are expected to be supplied under single orders, sample tests
will not normally be appropriate.

Note: In special cases sample tests may be agreed between manufacturer and customer.

6 Type Test
6.1 General
The tests specified in this clause are intended to demonstrate the satisfactory performance of transition joints.

The type test may be omitted:

- As defined in the Range of Type Test Approval (see 6.2 Range of Type Test Approval) or

- If the transition joint is a combination of existing type tested accessories.

An example is a back-to-back transition joint.

Note 1: If suitable paper-insulated cable is unavailable, type testing will not be possible, thus approval of a
transition joint design is dependent on agreement between manufacturer and customer, subject to
consideration of any relevant test data.

Note 2: In the event that breakdown occurs in the paper-insulated cable or within the joint and the primary
cause is attributable to the quality of the paper-insulated cable then approval of a transition joint
design is dependent on agreement between manufacturer and customer, taking into account the
extent of tests passed and any other relevant test data.

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Recommendations for Testing DC Transition Joints for Power Transmission at a Rated Voltage up to 500kV

6.2 Range of Type Test Approval


When a type test has been successfully performed on a transition joint for connecting cables of specific conductor
cross-sections and of specific rated voltage and construction, the type approval shall be considered as valid for a
transition joint within the scope of these test recommendations with other conductor cross-sections, rated voltages
and with other cables provided that all the conditions of a) to h) are met:

a) The actual designs, materials, manufacturing processes and service conditions for the transition joint are in all
essential aspects equal.

b) All service voltages, U0, UP1, UP2,S and UP2,O (URC,AC and URC,DC in case of return cable), are less than or equal
to those of the tested transition joint.

c) The mechanical stresses for submarine transition joints to be applied during preconditioning are less than or
equal to those of the tested transition joint.

d) The temperature of the conductors on both sides shall be less than or equal to the tested transition joint cables.

e) The maximum temperature drop across the insulation layer ΔT max (excluding the semiconducting screens) on
both cables is less than or equal to that of the tested transition joint cables.

f) The actual conductor cross-section is not larger than that of the tested transition joint cables.

g) The calculated Laplace electrical stress (using nominal dimensions) at the conductor and insulation screen is
less than or equal to that of the transition joint cables.

h) A transition joint qualified according to this recommendation for LCC is also qualified for VSC provided the
switching impulse withstand tests at ±UP2,S voltage levels as specified in 6.4 Type Test Procedure - Switching
impulse withstand test for cable system to be qualified for VSC are carried out. A transition joint qualified
according to this recommendation for VSC is not qualified for LCC.

A type test certificate signed by the representative of a competent witnessing body, or a report by the manufacturer
giving the test results and signed by the appropriate qualified officer, or a type test certificate issued by an
independent test laboratory, shall be acceptable as evidence of type testing.

6.3 Type Test Arrangement


The transition joint shall comply with the tests specified in 6.4 Type Test Procedure. The minimum length of free
cable between accessories shall be 5 m.

By definition, a transition joint includes 0.5 m of cable on the extruded side and 1 m of cable on the lapped side, as
shown in Figure 1, measured from the point on the cables where no disassembling or dismantling for the purpose
of installation of the joint has taken place.

As a minimum one sample of each transition joint type shall be tested.

The accessory shall be assembled on the cables in the manner specified by the manufacturer's instructions, with
the grade and quantity of materials supplied, including lubricants and insulating fluids if any. There should be
provision for measuring internal pressure of insulating fluid/gas during the test.

In units that are intended to operate with internal oil pressure, whether such pressure is from the cable system or a
separate source, the maximum pressure during the test must not exceed the minimum design operating pressure
+25% (as specified in IEC 60141-3 [18]). If the accessory includes a gas filled compartment then the gas pressure
must be set so that at 20°C the pressure is no greater than the minimal functional pressure for insulation specified
for the accessory +0.02MPa [2, 19].

Neither the cables nor the accessories shall be subjected to any form of conditioning not specified in the
manufacturer's instructions, which might modify the electrical, thermal or mechanical performance.

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Recommendations for Testing DC Transition Joints for Power Transmission at a Rated Voltage up to 500kV

During electrical tests specified in 6.4 Type Test Procedure, it is advisable to test joints with their outer protection
fitted. If it can be shown that the outer protection does not influence the performance of the joint insulation, e.g.
there are no thermal or compatibility effects, the protection does not need to be fitted.

6.4 Type Test Procedure


Test Voltage Values

Test voltage factor for extruded and lapped HVDC cables in TB 496 and Electra 189 is different for the load cycle
and polarity reversal tests, even though the difference is small. Based on Electra 189, 1.8U0 and 1.4U0 respectively
are chosen for the load cycle and polarity reversal tests of transition joints in order not to overstress the lapped
insulation.

Note: If suitable paper lapped cable of the required insulation thickness is not available then it is allowed
to use a cable with a greater insulation thickness and to reduce the insulation thickness in the
region where the joint is to be installed to the required level. As an alternative it is also allowed to
adjust the test voltages in order to achieve the required electrical stress values.

Load cycle test

The load cycle test shall be performed on test objects that have been subjected to the appropriate mechanical
preconditioning. For testing of land joints, mechanical preconditioning of the cable is not mandatory. Submarine
transition joints need to be tested according to the recommendations in Electra 171, which will be replaced by work
done in WG B1.43 – Recommendations for mechanical tests on submarine cables.

The temperature conditions are defined in 2.5 Thermal conditions for tests.

The cable with the lowest Tcon,max should be at the maximum conductor temperature and temperature drop over
insulation (ΔTmax). The conductor temperature of the cable with the highest T con,max should be measured and used
as a design criteria for the joint installation conditions (Note that one cable system could be operating at much
higher temperature and the thermal influence of this may be difficult to replicate under test conditions see
Appendix B). This means that the cable on one side of the transition joint under test may not have been qualified in
this test to its maximum conductor temperature or ΔT max. It is recommended to perform the joint bay engineering
prior to performing the type test in order to define the relevant temperature conditions for the test.

The type test procedure is based on single core cables where the lay-out of the joint bay can be made to take into
account the thermal influence from the two cable types. For multi core cables the cable cores may have to be split
out before the transition joint in order to control the longitudinal temperature influence. For concentric cables with
low voltage return insulation, the return conductor may have to be split out before the transition joint.

Load cycle test for cable system to be qualified for LCC

The test objects shall be subjected to the following conditions (definitions of “24 hours” load cycles and “48 hours”
load cycles are described in 2.5 Thermal conditions for tests.

Eight “24 hours” load cycles at negative polarity at UT

Eight “24 hours” load cycles at positive polarity at UT

Eight “24 hours” load cycles with polarity reversal cycles at UTP1

Three “48 hours” load cycles at positive polarity at UT

A minimum rest period of 24 hours without voltage, but with heating, is recommended between blocks of different
polarities. This does not apply to the individual polarity reversals in the polarity reversal test.

Load cycle test for cable system to be qualified for VSC

The test objects shall be subjected to:

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Recommendations for Testing DC Transition Joints for Power Transmission at a Rated Voltage up to 500kV

Twelve “24 hours” load cycles at negative polarity at UT

Twelve “24 hours” load cycles at positive polarity at UT

Three “48 hours” load cycles at positive polarity at UT

A minimum rest period of 24 hours without voltage, but with heating, is recommended between blocks of different
polarities.

Superimposed impulse voltage test

The superimposed impulse voltage test is to be performed on test objects that have successfully passed the load
cycle test.

The test procedure is described in 2.6 Conditions for test – Superimposed voltage test.

Switching impulse withstand test for cable system to be qualified for LCC

the test object at U0, 10 consecutive impulses to -UP2,O

the test object at -U0, 10 consecutive impulses to UP2,O

Switching impulse withstand test for cable system to be qualified for VSC

the test object at U0, 10 consecutive impulses to UP2,S

the test object at U0, 10 consecutive impulses to -UP2,O

the test object at -U0, 10 consecutive impulses to -UP2,S

the test object at -U0, 10 consecutive impulses to UP2,O

Lightning impulse withstand test

If the intended installation of the cable system is such that it is not exposed to lightning strikes (direct or indirect),
these tests need not be done. For transition joints included in long cable systems, attenuation of lightning impulse
voltages from terminations to the joint location may be considered when lightning impulse test voltage for the joint
is determined [20].

the test object at U0, 10 consecutive impulses to -UP1

the test object at -U0, 10 consecutive impulses to UP1

Subsequent DC test

After the successful completion of the impulse testing, the test object shall be subjected for 2 hours to a negative
DC voltage of UT, no heating.

A rest period prior to this test is acceptable.

Test of outer protection for joints

Cable joints intended for burial on land shall be subjected to the outer protection test specified in § 12.4 in IEC
62067 [11].

Examination

Examination of the transition joint, whenever possible, by dismantling, with normal or corrected vision without
magnification, shall reveal no signs of deterioration which could affect the system in service operation (e.g.
electrical degradation, corrosion, harmful shrinkage or leakage, in particular across any seal separating the
extruded and oil filled cables).

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Recommendations for Testing DC Transition Joints for Power Transmission at a Rated Voltage up to 500kV

Success criteria, re-testing and interruptions

The criteria for a successful outcome to the type test are that all tests have been performed without breakdown of
that test object and that all other non-electrical requirements have been complied with.

After any interruption, for example an interruption caused by external factors, the test may be resumed. If the
interruption is longer than 30 minutes, the specific lost load cycle shall be repeated. If the interruption is longer than
24 hours, the actual test block (“24 hours” load cycles block at negative or positive polarity, “24 hours” load cycles
block with polarity reversals, “48 hours” load cycles block under positive polarity) shall be repeated.

In case of deviations in test parameters during load cycles or superimposed impulse voltage test, the load cycle or
the superimposed impulse in question shall be repeated.

In case of a breakdown of insulation, when testing several objects simultaneously, the faulty object may be
removed and the incident treated as an interruption. The faulty object is considered to have failed the test
requirements. Any fault within the extension (0.5m/1.0m for extruded and lapped side respectively) of a transition
joint is considered to be associated with that test object only.

Leak Test

The vacuum leak test is to be performed as per manufacturer’s instructions when applicable.

Pressure Test

Apply 2 times rated internal pressure for 1 hour. For very high internal pressure (>20 bar) the test margin should be
agreed between customer and manufacturer. Leakage shall be detected at the end of this period by visual
examination of the test specimen and by pressure drop. This test may be performed at the end of the type tests.

No leak or rupture shall occur.

Radial Water Penetration Test for joints

This test is only intended for submarine transition joints.

Preparation

The joint sample has to be taken from the joint subjected to mechanical tests, (see 8.6.1 and 8.6.2 in TB 490 [21])
and at least 10 heating cycles shall be applied. Each heating cycle consists of at least 8 hours of heating followed
by at least 16 hours of cooling. Current heating shall be used to give the declared maximum conductor temperature
for the cable with the lowest Tcon,max for that specific installation. The temperature shall be kept at the stated value
at least 2 hours in the end of each heating cycle.

The test is to be performed on the pressurised part of the joint and not necessary to the whole joint body for rigid
joints. The joint sample shall be suitably sealed at the cable ends by means of caps. The test sample shall be
placed inside a pressure vessel.

Test

The test object is submerged in pressurised water corresponding to the specified maximum laying depth. The test
continues for 48 hours with a water temperature of 5 – 35 °C.

When the test time has elapsed, the test object is removed from the water.

No water ingress should be present under the water blocking barrier of the joint.

No appreciable shape irregularity in the metal sheath.

Examination

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Recommendations for Testing DC Transition Joints for Power Transmission at a Rated Voltage up to 500kV

Examination of the transition joint, whenever possible, by dismantling, with normal or corrected vision without
magnification, shall reveal no signs of deterioration which could affect the system in service operation (e.g.
electrical degradation, corrosion, harmful shrinkage or leakage, in particular across any seal separating the
extruded and oil filled cables).

7 Prequalification Test
7.1 General and Range of Prequalification Test Approval
The prequalification test is intended to indicate the long-term performance of the transition joint and should
normally be completed after the development tests have been carried out. The prequalification test need only be
carried out once, unless there is a substantial change in the transition joint with respect to materials, manufacturing
processes, construction or design parameters. Substantial change is defined as that which might adversely affect
the performance of the transition joint. The supplier shall provide a detailed case including test evidence if
modifications are introduced, which are claimed not to constitute a substantial change.

NOTE: It is the opinion of the WG that the CIGRE TB 303 [22] can be regarded as a relevant document to assess
the need for further prequalification testing or not. However, the HVDC extruded cable system technology is at
present considered to be too immature to include the concept of “Extension of Qualification” in this document. As
no prequalification test is required for the paper lapped side of the joint, the requirements below are focused only
on the extruded side of the joint.

The prequalification test qualifies the manufacturer as a supplier of transition joints provided that the following
conditions are fulfilled:

a. The transition joint is a back-to-back joint (Appendix A) with prequalification tested extruded insulation
accessories.
b. The transition joint of the same design has been prequalified.
c. U0 is not more than 10% higher than that of the tested cable system.
d. The calculated Laplace electrical stress at U0 (using nominal dimensions) at the extruded cable insulation
screen is less than or equal to that of the tested system.
e. The maximum conductor temperature T cond,max is less than or equal to that of the tested extruded cable
system.
f. The maximum temperature drop across the insulation layer Tmax (excluding the semiconducting screens)
is less than or equal to that of the tested extruded cable system.
g. A cable system prequalified according to this recommendation for LCC is also prequalified for VSC. A
cable system prequalified according to this recommendation for VSC is not prequalified for LCC.

A prequalification test certificate signed by the representative of a competent witnessing body, of a report by the
manufacturer giving the test results and signed by the appropriate qualified officer, or a prequalification test
certificate issued by an independent test laboratory shall be acceptable as evidence of prequalification testing.

Note 1: If suitable paper-insulated cable is unavailable, prequalification testing will not be possible, thus
approval of a transition joint design is dependent on agreement between manufacturer and
customer, subject to consideration of any relevant test data.

Note 2: In the event that breakdown occurs in the paper-insulated cable or within the joint and the primary
cause is attributable to the quality of the paper-insulated cable then approval of a transition joint
design is dependent on agreement between manufacturer and customer, taking into account the
extent of tests passed and any other relevant test data.

7.2 Summary of prequalification tests


A minimum of 5 m of cable on each side of the joint with a dielectric design suitable for practical applications shall
be tested. Appropriate mechanical preconditioning may be considered before starting the prequalification test.

The normal sequence of tests shall be as follows:

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Recommendations for Testing DC Transition Joints for Power Transmission at a Rated Voltage up to 500kV

Long duration voltage test (see 7.4 Long duration voltage test)

Superimposed impulse voltage test (see 7.5 Superimposed impulse voltage test (optional))

Examination (see 7.6 Examination)

7.3 Test arrangement


Cable and accessories shall be assembled in the manner specified by the manufacturer's instructions, with the
grade and quantity of materials supplied, including lubricants if any.

Note: The main objective of the prequalification test is to satisfactorily demonstrate the insulation integrity
during long time periods under DC, given the long dielectric time constants as compared to AC. It is
however recognized that other aspects of a specific installation may be important, such as the
thermo-mechanical effects due to the installation conditions. A rigid joint design should only be
installed in rigid conditions to reproduce the net force effect resulting from different conductor cross
sections at each side of the joint.

Prior to the electrical prequalification test, the insulation thickness of both cables shall be checked as specified in
2.6 Conditions for test - Check on insulation.

The minimum length of free cable between accessories shall be 5 m. One sample of each transition joint type shall
be tested.

The accessory shall be assembled on the cables in the manner specified by the manufacturer's instructions, with
the grade and quantity of materials supplied, including lubricants and insulating fluids if any. There should be
provision for measuring internal pressure of insulating fluid in the lapped cable compartment during the test.

In units that are intended to operate with internal oil pressure, whether such pressure is from the cable system or a
separate source, the maximum pressure during the test must not exceed the minimum design operating pressure +
25%. If the accessory includes a gas filled compartment then the gas pressure must be set so that at 20°C the
pressure is no greater than the minimal functional pressure for insulation specified for the accessory +0,02 MPa.

Prequalification test done with a transition joint in rigid configuration qualifies the joint for use in rigid and flexible
installation.

Neither the cables nor the accessories shall be subjected to any form of conditioning not specified in the
manufacturer's instructions which might modify the electrical, thermal or mechanical performance.

7.4 Long duration voltage test


General: Minimum duration is 360 days.

Conductor temperature Tcon,max and temperature difference ΔTmax on the extruded side of the joint shall both be
controlled to a level corresponding to the maximum current carrying capacity of the system. The temperature
requirements of the lapped cable side might limit the current possible to apply in the test setup. If so, the conductor
temperature and temperature difference of the extruded side should correspond to expected service conditions of
the cable close to the transition joint (separation of the cables close to the transition joint will reduce the maximum
operating temperature – see Appendix B). If possible, it is recommended to perform the joint bay engineering prior
to performing the prequalification test in order to define the relevant temperature conditions for the test.

The sequence of tests for LCC and VSC are shown in the tables below.

Table 1: Line commutated converter, LCC

LC LC LC+P HL HL ZL LC LC LC+P S/IMP


R R

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Recommendations for Testing DC Transition Joints for Power Transmission at a Rated Voltage up to 500kV

Number of 30 30 20 40 40 120 30 30 20 Not applicable


cycles or days
cycles cycles cycles days days Days cycles cycles cycles
+ - + - - + - UP2,O = 1.2 x
U0
Test Voltage
UTP1 UTP1 UTP2 UTP1 UTP1 UTP1 UTP1 UTP1
UP1 = 2.1 xUTP2
U0*
LC=Load Cycle, HL=High Load, PR=Polarity Reversal, ZL=Zero Load, S/IMP=Superimposed Impulse Test.

* If required

Table 2: Voltage source converter, VSC

LC LC HL HL ZL LC LC S/IMP

Number of 40 40 40 40 120 40 40
Not applicable
cycles or
days cycles cycles days days days cycles cycles
+ - + - - + - UP2,O = 1.2 x
U0
Test Voltage
UTP1 UTP1 UTP1 UTP1 UTP1 UTP1 UTP1 UP1 = 2.1 x
U0*

LC=Load Cycle, HL=High Load, ZL=Zero Load, S/IMP=Superimposed Impulse Test.

* If required

Sections 2.5 Thermal conditions for tests and 2.6 Conditions for test provide guidance on test conditions.

Note: Ambient conditions may vary during the test and this is not considered to have any major influence.
In such cases, the conductor current shall be adjusted to maintain the conductor temperature and
temperature drop across the insulation within the specified limits.

The length and sequence of the thermal conditions were selected with regard to the particular electrical effects that
can occur in extruded insulations when operated under DC voltage.

A minimum rest period of 24 hours without voltage, but with heating, is recommended between blocks of different
polarities. This does not apply to the individual polarity reversals in the PR blocks of the LCC test scheme.

7.5 Superimposed impulse voltage test (optional)


It is the opinion of the WG that the prequalification test should not be evaluated on the basis of the impulse level.
The aim of the superimposed impulse test after the long duration test is only to check the integrity of the insulation
system. Evaluation of available specifications for different projects show that the values of UP2,O and UP1 vary
between the different projects. In this respect, and based on the recorded experience, the impulse voltage values
to be considered for the prequalification test have been defined as follows:

UP2,O = 1.2 x U0

UP1 = 2.1 x U0 (if required). The voltage may be limited by the LIWL of the lapped cable. If so, U P1 should
be adjusted accordingly.

Project specific requirements regarding impulse levels should be covered by the electrical type test (6 Type Test).

The temperature conditions are defined in 2.5 Thermal conditions for tests.

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Recommendations for Testing DC Transition Joints for Power Transmission at a Rated Voltage up to 500kV

The transition joint shall withstand without failure 10 positive and 10 negative superimposed switching impulses at
the voltage levels UP2,O.

If by agreement between supplier and customer a lightning impulse test is also to be performed, the transition joint
shall withstand without failure 10 positive and 10 negative superimposed lightning impulses at the voltage level UP1.

7.6 Examination
Examination of the transition joint, whenever possible, by dismantling, with normal or corrected vision without
magnification, shall reveal no signs of deterioration which could affect the system in service operation (e.g.
electrical degradation, corrosion, harmful shrinkage or leakage, in particular across any seal separating the
extruded and oil filled cables).

7.7 Success criteria, re-testing and interruptions


The criteria for a successful outcome of the prequalification test are that all tests shall have been performed without
breakdown of that test object and that the system examination is in accordance with 7.6 Examination.

If there is a breakdown in a test object the complete prequalification test shall be repeated for that particular test
object.

If a breakdown of a test object occurs, causing an interruption to the ongoing testing of connected test objects, the
test may be resumed after the failed test object is removed. The actual load cycle or impulse during which the
failure occurred shall be repeated for the remaining test objects. If breakdown occurs during a constant load period
the time elapsed without voltage applied shall be added to the remaining test period.

After any interruption, for example an interruption caused by external factors, the test may be resumed. If the
interruption is longer than 30 minutes, the specific lost load cycle shall be repeated. If the interruption occurs during
a constant load period and is longer than 30 minutes, the day the interruption occurred shall be repeated.

8 Electrical Test after Installation


Tests on newly installed transition joints are carried out when the installation of the cable and its accessories has
been completed.

If required, both sides of the transition joint may be tested separately according to the relevant standard before the
transition joint is installed.

The test voltages recommended for general use should be limited to the lowest test voltage for the two cable
system, 1.4U0 negative polarity for 15 minutes, however test regimes should be evaluated on an individual basis to
take into account the condition of an existing cable system.

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Recommendations for Testing DC Transition Joints for Power Transmission at a Rated Voltage up to 500kV

References

[1] CIGRE Technical Brochure 496, Recommendations for Testing DC extruded Cables Systems for Power
Transmission at Rated Voltage up to 500 kV, 2012.

[2] CIGRE Technical Brochure 415, Test Procedures for HV Transition Joints for Rated Voltages 30 kV up to 500
kV, 2010.

[3] CIGRE Electra 189, Recommendations for tests of power transmission dc cables for rated voltages up to 800
kV, 2000.

[4] CIGRE Technical Brochure 89, Accessories for HV extruded cable. Types of accessories and terminology,
1994.

[5] CIGRE Technical Brochure 177, Accessories for HV cables with extruded insulation, 2001.

[6] CIGRE Electra 176, Diagnostic Methods for HV Paper Cables and Accessories, 1998.

[7] Ongoing work, CIGRE WG B1.37, Guide for operation of fluid filled cable systems.

[8] CIGRE Technical Brochure 279, Maintenance for HV Cables and Accessories, 2005.

[9] CIGRE Technical Brochure 560, Guideline for Maintaining the Integrity of XLPE Cable Accessories, 2013.

[10] IEC 60840, Power cables with extruded insulation and their accessories for rated voltages above 30 kV
(Um=36kV) up to 150 kV (Um=170kV) - Test methods and requirements, 2004.

[11] IEC 62067, Power cables with extruded insulation and their accessories for rated voltages above 150 kV
(Um=170 kV) up yo 500 kV (Um=550 kV) - Test methods and requirements, 2011.

[12] IEC 60633, Terminology for high-voltage direct current (HVDC) transmission, 1988.

[13] CIGRE Technical Brochure 269, VSC Transmission, 2005.

[14] IEC 60060-1 Ed. 3, High-voltage test techniques. Part 1: General definitions and test requirements, 1989.

[15] IEC 60811-201, Electric and optical fibre cables - Test methods for non-metallic materials - Part 20: General
tests - Measurment of insulation thickness, 2012.

[16] CIGRE Technical Brochure 446, Advanced design of metal laminated coverings: Recommendation for tests,
guide to use, operational feedback, 2011.

[17] IEC 61901, Development tests recommended on cables with a longitudinally applied metal foil for rated
voltages above 30 kV (Um = 36 kV), 2005.

[18] IEC 60141, Tests on oil-filled and gas-pressure cables and their accessories, 1998.

[19] IEC 60859, Cable connections for gas-insulated metal-enclosed switchgear for rated voltages of 72,5 kV and
above - Fluid-filled and extruded insulation cables - Fluid-filled and dry type cable-terminations, 1999.

[20] CIGRE Technical Brochure 268, Transient voltages affecting long cables, 2005.

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Recommendations for Testing DC Transition Joints for Power Transmission at a Rated Voltage up to 500kV

[21] CIGRE Technical Brochure 490, Recommendations for Testing Long AC Submarine Cables with Extruded
Insulation for System Voltage above 30 (36) to 500 (550) kV, 2012.

[22] CIGRE Technical Brochure 303, Revision of Qualification Procedures for HV and EHV AC Extruded
Underground Cable Systems, 2006.

Page 21
Recommendations for Testing DC Transition Joints for Power Transmission at a Rated Voltage up to 500kV

Appendix A: Back-to-back Transition Joint with two insulators


The transition joint as shown in Figure A-1 comprises either:

a) Two GIS terminations in a common joint shell or

b) two oil immersed terminations in a common joint shell.

The terminations are in back-to-back arrangement and connected with a short length of bus bar. In the case of GIS
terminations the joint shell is filled by insulating gas (either with SF 6 gas or mixture of SF6 gas and nitrogen). In the
case of oil immersed terminations either cable oil, transformer oil or other insulating oil is used [4] [5].

Figure A-1: Back-to-back transition joint with (2) insulators

Features

Extruded and lapped cable terminations are identical to terminations used in either SF 6 switchgear or transformer
applications and therefore further approval testing should not be necessary.

Current carrying connection between two terminations may be specific to transition joint, in which case this may
need separate evaluation.

The electrical field design in the central region may be specific to the transition joint, however this may be assessed
by electric field calculations if adequate test data is available.

In the case of gas, a gas supply is required, and in case of oil the oil may be connected to the cable oil system or
alternatively a header tank of some type could be used. Both systems would normally require some sort of fluid
loss alarm.

In special cases, the bus bar connection can be designed so that the two cables may be disconnected allowing
independent high voltage commissioning tests on the two cables.

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Recommendations for Testing DC Transition Joints for Power Transmission at a Rated Voltage up to 500kV

Appendix B: Temperature distribution in transition joints with


dissimilar cable insulation
The transition joints may be used to connect cables with XLPE or paper insulation operating at significantly
different temperatures. To evaluate the likely distance over which the temperature may stabilize in a generic HVDC
joint configuration a simplified model was built in a 2D axisymmetric configuration.

It is well known that heat flows from the point of high temperature to a point of low temperature along a uniform
conducting bar with homogeneous material properties. Cable rating is fully covered in IEC60287 although joint bay
ratings are not and are further complicated by sections of higher thermal radial resistance at the joint positions
leading to localized increase in temperature.

The diagram below represents an HVDC transition joint bay with two identical cable poles.

A B C

Figure B-1 : HVDC Joint bay layout

This configuration can be further simplified by removing the mutual heating element due to the second cable which
can be reconstituted by temperature superposition. The distance between the cables has direct impact on the
operating temperature. The type approval test has to replicate the maximum temperature conditions, the cable on

If A is a cable system operating It therefore follows the spacing has to be The temperature at B
at a higher temperature than C adjusted so that by the time the cables are should already be the same
at B, the temperature is as for C plus a as at C
further temperature drop for the joint
insulation TR

Table B-1: Zones in Figure B-1

site has to match these conditions or the spacing has to be increased to confine the conditions to what is within the
specification. For example an XLPE cable system at position A may be able to operate at 90 ºC whereas an MI
cable system at B could have a maximum operating temperature of 50 ºC. It is uncertain how the longitudinal heat
flow would affect the temperature distribution and over what distance.

A series of models was run using Finite element software to evaluate the longitudinal heat flow based on volumetric
heat generated in the conductor and adjusted to match the maximum operating temperature of the cables.

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Recommendations for Testing DC Transition Joints for Power Transmission at a Rated Voltage up to 500kV

15ºC along this interface (axi-symmetric)

1m
Section 1 Section 2

CL

Figure B-2: Individual HVDC cable and joint FEA model

The other key parameters for the model are:

 Subsea Transition simulated at 1000mm depth and @1K.m/W


 Armour stripped off
 Epoxy Resin joint body
 Length of model 10m
 1000sqmm Cu to 1600sqmm Cu transition shown
 On approach cable temperatures at maximum (but would be lower due to increased spacing)
 Joint centre at 5m

The following scenarios were modelled:

Section 1 Section 2

(1000sqmm) (1600sqmm)

XLPE (70ºC) MI (50 ºC)

XLPE (90 ºC) MI (50 ºC)

PPL MI (85 ºC) XLPE (70ºC)

Table B-2: FEA section parameters

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Recommendations for Testing DC Transition Joints for Power Transmission at a Rated Voltage up to 500kV

The Figure B-3 shows the results of the model applied to a XLPE to MI transition. The XLPE cable outside of the
joint bay will be operating at almost maximum conductor temperature, this is at the point A of Figure B-1. The

Figure B-3 : Example figure XLPE (70 ºC) connected to MI (50 ºC)

temperature drops as the spacing between the two phases is increased but in this instance due to the longitudinal
2 2
flow from the smaller XLPE conductor (1000mm Cu) to a much bigger MI conductor (1600mm Cu). Small
increase in temperature is also expected in the middle of the joint due to the extra radial thermal resistance but in
this instance the size of the conductors negates this effect. The temperature on the MI side of the joint from the 5m
point onwards fall off to the 50 ºC as the heat flux is redistributed further up the MI cable.

In a full 3D rating, the phase separation would be increased to further reduce the temperature at the centre of the
joint to a maximum of 50 ºC. The FEA was able to demonstrate that within 5-9m the longitudinal flow stabilises the
temperature to within acceptable levels for mainstream conductor sized but specific 3D ratings will always be
necessary to confirm the exact site situation.

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Recommendations for Testing DC Transition Joints for Power Transmission at a Rated Voltage up to 500kV

Appendix C: Terms of Reference

WG* N° B1.42 Name of Convenor : Gunnar Evenset (NORWAY)


E-mail address: Gunnar.Evenset@Powercc.no
Technical Issues # (2): 3 Strategic Directions # (3): 1

The WG applies to distribution networks (4): No

Title of the Group: TESTING OF TRANSITION JOINTS BETWEEN HVDC CABLES WITH
LAPPED AND EXTRUDED INSULATION UP TO 500 KV

Scope, deliverables and proposed time schedule of the Group :


Background :
Although the extruded HVDC cable technology is developing very fast, lapped HVDC cables
will still be on the market for many years. There are projects that consider mass-
impregnated cables for the submarine part of the route and extruded cables for the land part
of the route. There is a need to define test specifications for how to qualify transition joints
between these two technologies.

Scope :
1. Review relevant test recommendations for testing of HVDC cables

2. Review relevant test recommendations for testing of transition joints for AC cables

3. Prepare a Technical Brochure on testing of transition joints between lapped and


extruded HVDC cables

4. Prepare report for Electra

5. Prepare a tutorial

Deliverables : Technical brochure with summary in Electra and tutorial


Time Schedule : start : August 2012 Final report : 2014

Comments from Chairmen of SCs concerned :

Approval by Technical Committee Chairman :


Date :

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