Cable Termination 291209 PDF

FAILURE OF CABLE
TERMINATION
A COMMON CAUSE VOLTAGE DIP
IN SINGAPORE
By
LEE WAI MENG
J.M. PANG & SEAH (PTE) LTD
J.M.PANG & SEAH (PTE) LTD

CONTENTS
• FUNDAMENTAL OF CABLE TERMINATION
• SITE TESTING OF CABLE TERMINATION
• PARTIAL DISCHARGE MEASUREMENT IN

CABLE TERMINATION
• CASE HISTORY OF PREMATURE FAILURE

OF CABLE TERMINATION
JMPS J.M.PANG & SEAH (PTE) LTD CONTENTS

FUNDAMENTAL OF
CABLE TERMINATION
JMPS J.M.PANG & SEAH (PTE) LTD FUNDAMENTAL OF CABLE TERMINATION

Armour PVC Copper Semi XLPE copper
PVC outer sheath Screen conducting
screen
CONSTRUCTION OF CABLE
JMPS J.M.PANG & SEAH (PTE) LTD FUNDAMENTAL OF CABLE TERMINATION - 1

Copper
pp Screen
Cable Insulation
C bl C
Cable Conductor
d t (E (Energized)
i d)
Electric Field
Flux Lines
Uniform distribution of electric field Non uniform distribution of electric field

for screened cable for un-screened cable

LINES OF ELECTRICAL STRESS WITHOUT STRESS CONTROL
30%
80%
40%
50%
90%
60%
70%
20%
Copper Screen
10%
Copper
XLPE
Semi-conducting Screen
LINES OF ELECTRICAL STRESS WITH STRESS CONTROL
20%
30%
40%
60%
10%
50%
70%
80%
Copper Screen
90%
Copper
XLPE
Semi-conducting Screen Stress Control
S C
Tube

30%
50%
70%
10%
90%
Insulator 90% Line
Conductor
Electric field in the

shape of a funnel
Copper Screen
30%
50%
70%
10%
connected to earth
90%
LINES OF ELECTRIC FIELD
JMPS J.M.PANG & SEAH (PTE) LTD FUNDAMENTAL OF CABLE TERMINATION – 4

deep cut
Armour PVC Copper Semi XLPE copper

PVC outer sheath Screen conducting
screen
Deep Cut At XLPE

Guideline for Stress Control Tube
Length of Stress Control Tube (mm)
Operating Voltage (kV) Single Core Cable Multi-Core Cable
22 190 250
11 130 190
6.6 100 130

SECTION 3: DESIGN & CONSTRUCTION (22kV & 6.6kV TERMINATION KITS)
Design 3.1 The heat shrink, cold shrink or slip over type of Semi-Conductive 3.4 Semi-conductive stress control mastic
t
termination
i ti kits
kit and
d accessoriesi offered
ff d shall
h ll b
be d
designed
i d M ti
Mastic shall
h ll be
b provided
id d ffor th
the iinsulation
l ti semi-
i
for both 185mm² and 300mm² cables described in conducting screen cutback.
Clause 1.1, Section 1 of this specification.
Termination 3.2 To suit the various cable termination heights found in Anti-Track 3.5 The insulation shall be a heat-shrinkable
Height the Company
Company’s s different switchgear and transformer cable Insulation flexible polymeric tubing, easily distinguished
boxes/compartments, the supplier shall provide insulation Sleeve/Tubing by colour from non anti-track material and
sleeves of 800mm and 700mm standard length for the 22kV shall not be coloured black, possessing anti-
and 6.6kV termination kits respectively. track and erosion resistant properties for use
as an external covering of the insulation cable
It shall be possible to cross the cable cores with the
cores.
termination kit installed and for the kit to function normallyy in
this manner. Three-Legged 3.6 Three legged semi-rigid mould glove
Mould Glove shall be provided.
Stress Control 3.3 For heat shrink type of termination, the stress control Earth Braids 3.7 Three lengths of 1000mm tinned copper
g
Tubing tubing
g shall be a flexible p
polymeric
y tubing,
g, p
permanentlyy braids shall be pprovided with each termination
colour black, possessing properties to provide electrical kit for earthing of the metallic tape screen of
stress control over the insulated cable cores. Stress control the cable. The minimum cross-sectional area
tubing incorporating paste like stress-relief compound of each braid shall be 25mm². A copper lug
coated on the inner wall of the tubing will not be accepted. shall be crimped at one end of each braid.
The length of stress control tubing shall not be less than The lug shall be suitable for a bolt size of
250mm and 130mm for 22kV and 6 6.6kV
6kV respectively
respectively. The 12mm
12mm.
stress control tubing shall have the words “Stress Control”
in white printed on it to distinguish it from black coloured LV
heat-shrink tubing.

Breakdown Strength of Insulation
Type of Insulation kV/mn
Oil - paper 40
XLPE 70
Air 3

Method of Air Void Elimination
The following methods can be used to eliminate the air voids

t
tapped
d beneath
b th the
th stress
t control
t l tube
t b att the
th interface
i t f
between the semi conducting screen and the insulation :
• By using mastic tape (new method)
• By using paint (old method)

Types of Cable Termination
• Heat Shrink Type
• Cold Shrink Type
• Slip Over Type

Heat Shrink Type Termination
Vendor:Tyco

Prepare the cable to the required length and
remove the oversheath. The armouring should
be removed according to the dimensions given
or according to the types of glands being used.
used
Remove both the innersheath 75 mm above
armouring or according to the gland type, and
the metal tape shield according to the
dimensions. Then remove the conductive core
screen to 20 mm above the metal tape shield.
The core insulation should be kept clean and
smooth any irregularities should be smoothed
smooth,
out using non-conductive abrasive paper.
Earthing - Fasten the earth braid to the copper
tape screen with one turn of the constant force
spring Fold back the earth braid and wrap the
remaining constant force spring over the earth
braid. Wrap Red HV-adhesive tape SMVA (50%
overlap) for a distance of 90 mm around the
cable jacket and lay the earth tails on top of the
Red HV-adhesive tape SMVA.

Remove any binders from the end of screen and
remove the release paper from the Stress
control mastic SMCM. Place the point of the
tape at the conductive screen cutback, then
stretching the tape to ½ its original width, tightly
wrap 3 - 4 layers to fill the conductive screen
step and create a smooth transition. The tape
should overlap the screen and insulation by 10
mm on either side.
Slide the Stress control tubing SMCT over

each core with a 50mm overlap onto the
screen. Shrink down the tubing using a torch
working from the bottom upwards.

Slide the Breakout SMBH over the cores and
remove any release paper which may be in the
breakout. Pull the breakout out well down into
the crutch and shrink the breakout into place
starting at the centre. First shrink down towards
to the skirt (1), then finally upwards toward the
end of the fingers (2).
(2)
With the cores in the correct position, fit the

connectors
t or lugs.
l Th using
Then i a slight
li ht tension,
t i
wrap the Red H.V. adhesive tape SMVA (50%
overlap) on the lug barrel. Build up the barrel
diameter
d a ete aand
d ooverlap
e ap tthe
e co
core
e insulation
su at o by 20 0
mm.

Wrap one layer of the Red Adhesive SMVA over
each of the breakout turrets.
Slide the Non-tracking g SMVT onto each
g tubing
core. Start shrinking in an upward direction.
The core tubes can thus be trimmed off on the
cable lugs or connectors.
Up to indoor terminations are now complete.

Position the Sheds SMVS according to the
specified dimensions and shrink into position.
Hold the edge of the Shed with a pair of pliers and
brush with flame. Only the collar will shrink.
Outdoor and indoor terminations are now

complete.

Cold Shrink Type Termination
Vendor: 3M

P
Preparation
i for
f Cable
C bl Termination
T i i
Prepare cable using dimension shown in below figure, be sure to allow for depth of terminal lug
Wrap 2 highly stretched half-lapped layers of semi-conducting tape① over the tape shield and
semi-con extending ½″ (13mm) on to cable insulation. Start and end tapping ¾″(19mm) onto tape
shield. Provide a smooth, even leading edge over cable insulation as shown②. Select one of two
Mastic seal strips, provided in kit and remove white liners. Using light tension , wrap a band of
mastic around the cable jacket ½″(13mm) from cut edge③. Cut off excess

Position pre-formed Ground Braids④ along opposite sides of cable jacket and secure in place
with binding wire on vinyl tape as shown in below. Ground Braid Legs⑤ over cable tape shield
should be position ¼″ from jacket cut edge. Lay each Ground Braid Legs⑤ around the cable
shield and trim its length to prevent overlap as needed⑥.
needed⑥
Secure Ground Braid Legs to cable

shield using supplied Constant-Force
spring⑦. Start the spring on one braid
folded section⑧ and wrap p Ground Braid
Legs and spring together in a common
direction. Capture both Ground Braid
Legs while wrapping and cinch the
spring after wrapping the final winding

Select second Mastic Seal Strip from kit and remove white liners. Using light tension, wrap a
band of mastic over the Ground Braids covering the Solder-Blocks and the previously
i t ll d Mastic
installed M ti Seal St i ⑨ Apply
S l Strip⑨. A l one highly-stretched,
hi hl t t h d half-lapped
h lf l d layer
l vinyl
i l tape
t over
Constant Force Spring⑩ and Mastic Seal Strip ⑨. Start tapping ¼″ (½″ Max) over applied
13 Tape⑪, extend over Mastic Seal Strip and finish by covering binding wire or vinyl tape
band⑫ applied in step 1

Position Jacket Seal PST Assembly① over cable jacket with loose core tab② Direct
away from prepared cable end.
Install Jacket Seal PST by pulling loose core pull tab while unwinding counter-
clockwise②. Silicone rubber tube (not the core) should be align with ridge formed by
previously applied 13 tape③.
tape③

Cover the edge of the 13 Tape with a liberal coating of Silicone Grease④.
Slide 8-Skirt Termination Body on to the cable and remove core. Pull while unwinding
counter-clockwise
counter clockwise,⑤ ⑤ starting with the loose end.
end Make sure the termination body
(not the core) is aligned as shown⑥ below.

Position Silicone 4-Skirt Insulator over cable end and install by pulling loose core end
while unwinding counter-clockwise. Align 4-Skirt Insulator (not the core) to overlap
previously installed 8-Skirt
8 Skirt Termination by ¾
¾″(19mm)
(19mm) as shown⑦ below
Install terminal lug per manufacturer’s direction. Wrap 4 half-lapped layers of Silicone
Rubber Tape over the lug and onto the insulator for 1″(25mm)①. If lug is not used,
solder block conductor and wrap 4 half-lapped layers of 70 Tape from the solder block
to 1″(25mm) on to the insulator using “Tapping Hint”

Slip Over Type Termination
Vendor: ABB

Single Core Cable with Copper Tape Screen
• Remove the oversheath,

oversheath according
to dimension A+X below
• Cut of excess length of the core
Size mm2 A
Cu<70 205
Others 185

Remove the copper tape until dimension B+X mm from the edge of the
oversheath
Size mm2 B
Cu<70 175
Others 155
St i back
Strip b k the
th insulation
i l ti and
d XLPE-insulation
XLPE i l ti according
di tot dimensions
di i C+X
Size mm2 C
Cu<70 135
Others 115

• Cut the earth braid in three pieces 0.5m each
• Fasten the earth braid to the copper
pp tape
p screen with one turn of the
constant force spring
• Fold back the earth braid and wrap the remaining constant force spring
over the earth braid

• Apply one layer of filling tape (FT) on the
edge
d off the
h over sheath
h h
• Put the earth braid over and wind remaining
FT tape over all
• Apply two layer of Electrical tape (ET) with

50% over lap
p
• Start 10mm below the FT tape, continue
over the edge of the copper tape screen
and
d 10mm
10 up on the
h insulation
i l i screen off
the cable and back again

• Confirm 30mm
• Make a tape mark 75 mm from the end of the insulation screen
• Apply one of FT tape at the center of the taping
• Wind one layer of ET tape

• Start on the insulation and wind
towards the end of the conductor

• Apply grease over the insulation and spread it by means of the
brush included.
• Use half the g
grease content in tube
• Apply remaining grease on the black

layer inside the bottom end of the
termination.
• Spread the grease by squeezing the
termination

• Push and twist the termination over the cable and the FT tape down
to the tape marking

• Fold
F ld down
d th end
the d off the
th termination
t i ti andd remove the
th tape
t
• Crimp the cable lug on the cable
• M
Make
k a seall by
b wrapping
i a few
f t
turns off the
th FT tape
t over the
th
cable lug
• Fold
F ld back
b k the
h end
d off the
h termination
i i

S
SITE TESTING
S G OF
O
CABLES TERMINATION
JMPS J.M.PANG & SEAH (PTE) LTD SITE TESTING OF CABLE TERMINATION
Site High Voltage Testing of Cables
• DC or AC 50 hertz or AC VLF test. It is a

pass/fail
/f il test.
t t
• Quantitative
Q test includes measurement
of dissipation factor or tangent delta
JMPS J.M.PANG & SEAH (PTE) LTD SITE TESTING OF CABLE TERMINATION - 1
DC Hi-pot Test On Cables
Micro
Ampere
p
It = I1+I2+I3
I1 - leakage current across the cable insulator
I2 - depends on the capacitance of the cable
I3 - polarization current
I2
It
I1
I3
time/minutes
5 10 15
Advantages of DC test
• The test set is small and portable.
Disadvantages of DC test
• DC breakdown voltage very much higher than
equivalent
q AC breakdown voltage
g for same fault.
• DC voltage distribution very different from AC voltage

in the insulation.
AC at 50 Hz versus AC at 0.1 Hz
The voltage stress distribution for

frequencies as low as 0.1 hertz is not
significantly
g y different from that at 50 hertz.
Series resonant test set
R
L
Vout C
AC
Mains
VE C - capacitance of the test object
L - variable inductance
regulator
l t excitation
it ti
transformer
Block Diagram of AC 50Hz Test Set

Series Resonant Testing
• The excitation transformer supplies the power to the high voltage
circuit consisting of the variable inductance and the test object.
p
• Operation starts by
y first adjusting
j g the variable inductance to match
the capacitance of the test object. This tunes the system to
resonance and is normally done at low voltage.
• The test voltage can be increased to the required value by the

voltage regulator and testing proceeds as in a conventional test
transformer system.
y
• Able to provide very high test voltage to a test object having very
high capacitance from a low voltage,
voltage low kVA source.
source
Equation
VE
Voutt =
(ωRC ) 2 + (1 − ω 2 LC ) 2
at resonance, ω 2 LC = 1
VE
then Vout =
ωRC
Vout ωL
= = Q, where Q is the quality factor of the circuit
VE R
JMPS J.M.PANG & SEAH (PTE) LTD SITE TESTING OF CABLE TERMIN8TION - 7
IEEE P400
P400.2-2004
2 2004 for
f AC VLF
Site Testing of Cables
• guideline
g for field testing
g of shielded p
power cable
systems using very low frequency.
• Sine wave, 0.1 hertz
• 15 minutes at 2 to 3 times phase to neutral voltage
• pass/fail
/f il test
t t
Variable HV Polarity
y
Voltage Transformer Switch
50 Hz
HV
230 V
VLF
Sinusoidal
Rate of Rise
Rate-of-Rise Rectifier and
Discharge Network
Functional Schematic of the VLF System
Dissipation
Di i ti Factor
F t
- Equivalent Circuit for Cable Insulation
I
IR IC IR
V
tan δ =
R C IC
⎛ 1 ⎞
=V
R ⎜⎝ VωC ⎟⎠
IC I
1
=
RωC
δ
IR
Dissipation
Di i ti Factor
F t or
Tangent Delta Measurement
• It is the measure of the quality of the insulation.
• It is measured in the normal AC operating mode

of the cable.
• It is a more sensitive indicator of abnormal cable

insulation.
insulation
CRE CBE
CRB
Red
phase
Blue
phase
CRE , CYE , CBE - capacitance between
conductor to earth
earth.
CRY, CYB , CRB – capacitance between

CRY CYB conductors.
Yellow
phase
CYE
Dissipation Factor Equivalent Circuit of the Electrical

Insulation of Multi Core Cables
Dissipation Factor in %
85°C
25°C
Voltage / kV
Dissipation Factor -Temperature Behavior
Dissipation Factor in %
5 10 15 20 25 30 Time
Applied Voltage/kV
Dissipation Factor -Voltage Behavior
Dissipation Factor Typical Values
Insulation Tangent delta (%)

LDPE ((low density
yppolyethylene)
y y ) 0.1
HDPE (high density polyethylene) 0.1
XLPE (cross linked polyethylene) 0.1
Oil-paper 0.3
EPR (ethylene propylene rubber) 0.5
Neoprene 30
3.0
PARTIAL DISCHARGE
MEASUREMENT IN
CABLE TERMINATION
JMPS J.M.PANG & SEAH (PTE) LTD PARTIAL DISCHARGE MEASUREMENT IN CABLE TERMINATION
Partial Discharge - Equivalent circuit
Cable insulation
Cavity
CV
CP
CS
where CP - capacitance of cable

CV - capacitance
p of cavity
y
CS - capacitance of the insulation in series with the cavity
JMPS J.M.PANG & SEAH (PTE) LTD PARTIAL DISCHARGE MEASUREMENT IN CABLE TERMINATION - 1
Partial Discharge in Cables
• D
Due to
t cavity
it in
i the
th insulation
i l ti d
due t improper
to i extrusion
t i
process or impurity of the insulation material.
• If a voltage is applied across an insulation containing a cavity,

then the cavity will start to discharge when the voltage exceeds
the breakdown voltage,g Vb.
• Vb is a function of pd where,
p = gas pressure
d = gas gap separation
Partial Discharge in Cables
Vb
pd
Cavity
y that does not discharge
g at the operating
p g voltage
g of the cable are
quite harmless.
But cavity that discharges at operating voltage cannot be tolerated, since
the ensuing g degradation
g of the insulation due to p
partial discharge
g will
lead to breakdown of the insulation.
Partial Discharge
On Line Type Off Line Type
Partial Discharge – Off Line Measurement
step-up
step up cable under test
transformer Blocking inductor
coupling
capacitor
Standard
capacitor,CS
Pico-Coulomb
PD measurement Pulse
set Generator
Calibration circuit
Partial discharge
sensors
HFCT type
TEV type
(High frequency Capacitor coupler
(Transient earth Ultrasonic type Embedded RTD
current type
voltage)
transformers)
Partial Discharge – Types of Sensors
Partial Discharge – What Is TEV?
• TEV stands for Transient Earth Voltage.
• Transient - a temporary phenomenon.

phenomenon
• Earth Voltage - refers to voltage of exposed

conductive parts which are
connected to earth.
• TEV - temporary
t increase
i iin earth
th voltage
lt
which disappear after a very short time.
Partial Discharge – Transient Earth Voltage
• Amplitude varies from mill volts to volts
• nanoseconds rise time
• electromagnetic wave of 3 to 60 MHz
• TEV amplitude - a function of discharge

amplitude and attenuation of
propagation path.
• Capacitive couplers placed at external metal

surface of electrical equipment using a magnet
• Pulse width - a few tens of nanoseconds

1
• Bandwidth =
10 nanoseconds
= 100 MHz
JOINT
HIGH VOLTAGE CONDUCTOR

Discharge
Probes
DETECTOR
EM WAVE

P ti l Di
Partial Discharge-TEV
h TEV Sensor
S from
f EA Technology
T h l off UK
Partial Discharge
Discharge- TEV Sensor from IPEC of UK
Partial Discharge-
Discharge- Good TEV readings for 24kV rated Toshiba AIS, VCB
Front Reading (DB)
PANEL
Jan-03 Mar-03 Apr-03 May-03 Jun-03 Jul-03 Aug-03 Sep-03 Oct-03 Nov-03 Dec-03
1 3 3 2 3 2 1 1 1 1 1 1
2 3 3 2 0 2 1 1 1 1 1 1
3 3 2 2 0 1 1 1 1 1 1 1
4 3 3 2 3 2 2 1 1 1 1 1
5 3 3 3 0 2 1 2 1 1 1 1
6 3 4 2 0 2 1 1 1 1 1 1
7 3 0 1 3 2 1 1 1 1 1 1
8 3 0 1 2 1 1 1 1 1 1 1
9 3 2 2 2 1 1 1 1 1 1 1
10 3 2 2 2 1 1 1 1 1 1 1
11 4 2 1 0 2 1 1 1 1 1 1
12 4 2 1 0 2 1 1 1 1 1 1
13 3 3 2 1 2 1 2 1 1 1 1
14 3 4 2 1 2 1 0 1 1 1 1
15 4 2 1 2 2 1 0 1 1 1 1
16 4 0 0 2 2 1 1 1 1 1 1
17 4 0 0 1 1 1 1 1 1 1 1
18 4 0 0 0 1 1 1 1 1 1 1
19 4 3 0 0 2 1 1 1 1 1 1
20 4 3 3 1 2 1 1 1 1 1 1
BACKGROUND 2 2 3 2 2 1 2 1 4 1 1
Back Reading (DB)

PANEL
Jan-03 Mar-03 Apr-03 May-03 Jun-03 Jul-03 Aug-03 Sep-03 Oct-03 Nov-03 Dec-03
1 3 3 4 3 2 1 1 2 1 0 2
2 3 4 4 3 2 1 2 2 1 0 2
3 3 2 5 3 2 2 2 2 1 2 1
4 4 3 3 0 3 1 2 3 1 1 1
5 4 3 3 0 3 1 2 3 1 0 2
6 5 4 2 1 2 1 1 2 1 0 1
7 5 1 1 3 1 1 1 2 1 2 2
8 6 1 1 0 1 1 2 2 1 3 1
9 6 0 1 0 2 1 2 2 1 0 1
10 7 0 1 1 2 1 1 2 1 0 1
11 3 0 0 0 2 1 1 1 1 0 2
12 3 0 0 0 2 1 1 2 1 1 1
13 3 0 1 0 2 1 2 2 1 1 1
14 3 3 3 3 2 2 2 2 1 2 2
15 4 4 2 3 2 1 3 2 1 2 2
16 3 4 2 2 2 1 2 2 1 0 2
17 3 3 3 2 2 1 2 1 1 1 1
18 3 3 4 1 1 1 2 1 1 1 1
19 3 4 4 1 1 1 2 2 1 2 1
20 3 3 3 0 1 1 2 2 1 2 2
Side Reading (DB)

PANEL
Jan 03
Jan-03 Mar 03
Mar-03 Apr 03
Apr-03 May 03
May-03 Jun 03
Jun-03 Jul-03
Jul 03 Aug-03
Aug 03 Sep 03
Sep-03 Oct 03
Oct-03 Nov 03
Nov-03 Dec 03
Dec-03
1 2 3 2 0 2 2 1 1 2 2 1
10 4 3 2 0 2 1 2 1 2 2 1
11 3 4 2 1 2 1 2 2 1 1 1
20 4 4 3 2 2 1 1 2 1 1 1
JMPS J.M.PANG & SEAH (PTE) LTD PARTIAL DISCHARGE MEASUREMENT IN CABLE TERMINATION -13
Partial Discharge – What is HFCT?
• HFCT = high frequency current transformer
• Does not respond to 50Hz current
• Frequency range of 300kHz to 20MHz
• Soft ferrite range
• Split core construction
Partial Discharge
g - Split
p core HFCT sensor ((300kHz to 20MHz))
1.0
0.8
0.6
04
0.4
0.2
0
0MHz 10MHz 100MHz
Partial Discharge Frequency Spectrum
0 1.3 6.7 104 180 222 222 224 218 200
Partial Discharge-
Discharge Frequency response of HFCT
Partial Discharge – Transfer Impedance
Ratio of the output voltage to a constant input current,

as a function of frequency.
Output Voltage
Transfer Impedance =
Input Current
50
45
mA)
40
ance (mV/m
35
30
Transfer impeda
25
20
15
10
0
0.010 0.100 1.000 10.00 100.0
Frequency (MHz)
Partial Discharge – Transfer Impedance Curve
What is Ultrasound?
• Sound waves beyond the hearing range of

the human ear
• Audio range of human ear (20Hz to 5000Hz)
• Sound waves in the 20kHz to 120kHz range

range.
Ultrasound- Airborne ultrasonic sensor with output in the ultrasonic
frequency range (40kHz ± 1kHz)
Ultrasound-Contact ultrasonic sensor with output in the ultrasonic
f
frequency range (100kHz
(100kH ± 20kHz)
20kH )
Ultrasound-Contact ultrasonic sensor with output in the audio
f
frequency range (20Hz
(20H tto 5000H
5000Hz))
Ultrasound-Airborne ultrasonic sensors with output in the audio
f
frequency range (20Hz
(20H tto 5000H
5000Hz))
Ultrasound – Frequency Range
1) Frequency range of human ear (20Hz - 5000Hz)
2) The sound of arcing, tracking, corona. (around 40Hz)
3) The sound of internal partial discharge. (20kHz - 30kHz)
Ult
Ultrasound
d – Block
Bl k Di
Diagram for
f Ultrasonic
Ult i MMeasurementt
ULTRASONIC DETECTOR
OSCILLATOR 20 Hz TO 5000 Hz
EAR PHONE
20 kHz TO AMPILFIER
100 kHz PIEZO-ELECTRIC
SENSOR SOUND RECORDER
MIXER
A/D MINI DISC D/A
EAR PHONE
SOUND CARD FFT SOFTWARE
FREQUENCY DOMAIN TIME DOMAIN

DISPLAY DISPLAY
COMPUTER
JMPS J.M.PANG & SEAH (PTE) LTD FAILURE OF CABLE TERMINATION
Common Mistakes
• Deep
D cutt att insulation
i l ti & semi-conducting
i d ti iinterface.
t f
• Absence of air-void elimination material.
• Incorrect length of stress control tube.
• Insufficient air clearance.
• Incorrect p
positioning
g of components.
p
JMPS J.M.PANG & SEAH (PTE) LTD FAILURE OF CABLE TERMINATION - 1

Case History 1
1.1 Petrochemical plant at Jurong Island.
1.2 Fault
• Failure of 22KV cable termination at the cable box of
consumer 2MVA, 22KV/400volts transformer.
1.3 Consequence
• Voltage dip at Jurong Island.
1.4 Root Cause

• Deep cut at XLPE near the semi-conducting screen.
• No air-void
air void elimination at the semi
semi-conducting
conducting screen and
XLPE interface.
• Foreign material used.

Case History 2
2.2 Fault
• Failure of 22KV cable termination at the power receiving
switchgear of consumer.
2.3 Consequence
• Voltage dip at Jurong Island.
2.4 Root Cause

• Length of stress control tube not sufficient.
• Overlapping of stress control tube
tube.
• No air-void elimination at the semi-conducting screen and
XLPE interface.
• Foreign material used.
Case History 3
3.1 Refinery at Jurong Island.
3.2 Observation
• Client ordered 22KV cable termination direct from supplier.
• 11kV cable termination was delivered but stress control tube
was only 150mm in length.
• Discovered at the last minute when 66/22kV transformer
was de-energised for work.
3.3 Root Cause

• Authorized distributor had no knowledge of required length
of stress control tube.

Case History 4
4.2 Observation
• 4000 micro-ampere reading at DC hi-pot test of cable.
• Semi conducting screen was not stripped off
Semi-conducting off.
4.3 Root Cause

• Jointer was not licensed and was asked by superior to
read instructions and proceed with work.

Case History 5
5.2 Observation
• Copper bar tied across the red, yellow and blue phase of
single core,11KV cables at the stress control tube.
5.3 Root Cause

• Electrical contractor had no knowledge of cable
termination.

Case History 6
6.2 Observation
• 11kV cable termination was used at all their 22kV
cable termination.
Stress Control Tube Power Grid
at Site/mm Requirement/mm
150 260
6.3 Root Cause

• Licensed jjointer had no knowledge
g of required
q
length of stress control tube.

Case History 7
7.1 Chemical plant at Jurong Island.
7.2 Observation
• Anti tracking tube was used as stress cone.
• Effectively no stress cone.
7.3 Root Cause

• Jointer had no knowledge of cable termination.

Length of Stress Control Tube Visible From The Outside

Mastic Tape Missing At Interface Of Punture Through The XLPE Insulation
XLPE And Semi Conducting Screen

Mastic Tape Missing And Air Will Be Failure At Interface Of XLPE And Semi
Trapped Under The Stress Control Tube Conducting Screen

Incorrect Position Of Stress Control Tube Stress Control Tube Located Near
Metal Opening

Red phase
Severe Burn Marks At The Interface Of The XLPE And Semi Conducting Screen

Insufficient Air Clearance Of Stress Control Tube To Ground
And Between Stress Control Tube

Severe Overheating At Interface Of Severe Overheating Of XLPE
XLPE And Semi Conducting Screen Underneath The Stress Control Tube
JMPS J.M.PANG & SEAH (PTE) LTD FAILURE OF CABLE TERMINATION -15
Visible Overheating At The Inside Of The No Mastic Tape At The Interface Of
Stress Control Tube XLPE And Semi Conducting Screen

No Mastic Tape At Interface Of XLPE Overheating At The Inside Of The
And Semi Conductor Stress Control Tube

Insufficient Air Clearance Between Stress Control Tubes

STRESS RELIEF MASTIC
STRESS CONTROL APPLIED AT WRONG PLACE
TUBE
ANTI TRACKING TUBE

STRESS RELIEF WHITE POWDER COPPER METALLIC
MASTIC SHOULD BE LIKE OXIDES SCREEN
APPLIED HERE
DISCOLOURATION STRIPPING OF
AT XLPE DISCOLOURATION SEMICONDUCTIVE SCREEN
& PITTED SURFACE NOT UNIFORM

SEMICONDUCTIVE SCREEN WAS STRIPPED
BACK 15MM, XLPE NOT DAMAGED

CONDUCTOR STRANDS CUT AROUND CIRCUMFERENCE

JMPS J.M.PANG & SEAH (PTE) LTD SUCESSFUL CASES USING VARIOUS PD EQUIPMENTS
Case history 1 using on-line continuous mode TEV method
LO CAT ION MOD E
EA Te chno log y P DM03 Ve rsi on 6
Ac ces s fi le 1.l oc
St art tim e 16/ 09/2 004 09 :56: 00

Fi nis h ti me 17/ 09/2 004 13 :41: 00
[- --- ---- --- LE VEL --- --- ---- --- --] [--- - N UMB ER O F P ULS ES - --- --- ---- --- --- ---- ]
Ch M ax N os of Av Sh ort Nos of % M ax As soc % S eve rity
Le vel P uls es Le vel Te rm Puls es Pu lses P uls es Le vel Tim e L ong Max
pe r c ycle Se ver ity p er cycl e T erm Sho rt
1 31 0 .00 5 6 0 56 43 1 0.0 06 25 47 0 0
2 49 0 .01 2 19 3 151 81 3 0.0 45 46 59 0 9
3 25 0 .67 1 23 12 1185 21 23 0.6 71 25 100 0 12
4 40 0 .04 3 30 4 1946 40 37 0.0 70 28 100 1 4
5 28 0 .02 9 26 1 1027 33 20 0.0 30 25 100 0 1
6 0 0 .00 0 0 0 8 0 0.0 00 0 2 0 0
7 0 0 .00 0 0 0 48 0 0.0 00 0 10 0 0
8 13 0 .00 0 0 0 40 0 0.0 00 13 8 0 0
9 16 0 .00 1 0 0 65 0 0.0 01 0 7 0 0
10 19 0 .73 2 11 7 2545 29 48 0.7 32 19 81 0 7
11 16 0 .00 3 0 0 3 50 0 0.0 05 0 25 0 0
12 19 0 .00 3 0 0 7 77 0 0.0 04 0 61 0 0
T ota l nu mbe r o f pu lse s = 5 2672 6
T ota l nu mbe r o f se ts of data = 33 4
1 2 c hann els co nnec ted , 1 4400 cy cle s pe r 5 m inut es
Partial Discharge Equipment used : PDM03 from EA Technology of UK Mode of

measurement : On-line, Continuous mode TEV method
1) Date of measurement : 16th September 2004
2) Total hours measurement : On-line, 28hrs continuous mode
3) Date of off-line inspection : 18th September 2004
4) Type of equipment : 22kV AIS-VCB
5) Analysis
Anal sis :
Pd detected at channel 3, 4, 5 from the % pulse column. Off-line inspection
revealed bad discharge at the insulating sprouts at the switchgear.
JMPS J.M.PANG & SEAH (PTE) LTD SUCESSFUL CASES USING VARIOUS PD EQUIPMENTS - 1
Case history 2 using on-line continuous mode TEV method
LOCATION MODE
EA Technology PDM03 Version 6
Start time 2005-07-29 16:28:00

Finish time 2005-01-08 15:48:00
[----------- LEVEL ---------------][---- NUMBER OF PULSES ---------------------]

Ch Max Nos of Av Short Nos of % Max Assoc % Severity
Level Pulses Level Term Pulses Pulses Pulses Level Time Long Max
per cycle Severity per cycle Term Short
1 28 0.022 1 1 3161 3 0.022 28 22 0 1
2 0 0.000 0 0 7 0 0.000 0 1 0 0
3 22 0.001 0 0 380 0 0.004 0 8 0 0
4 19 0.002 0 0 176 0 0.002 19 4 0 0
5 19 0.000 0 0 81 0 0.001 0 3 0 0
6 16 0.112 5 1 55156 60 0.112 16 63 0 1
7 19 0.006 0 0 541 1 0.008 0 3 0 0
8 19 0.001 0 0 334 0 0.003 0 3 0 0
9 0 0.000 0 0 13 0 0.000 0 1 0 0
10 19 0.011 0 0 793 1 0.016 0 5 0 0
11 34 0.071 4 4 32688 35 0.094 25 45 0 4
12 0 0.000 0 0 15 0 0.000 0 2 0 0
Total number of pulses = 92515
Total number of sets of data = 857
12 channels connected, 14400 cycles per 5 minutes
Partial Discharge Equipment used : PDM03 from EA Technology of UK Mode of

measurement : On-line, Continuous mode TEV method
1)) Dateate o
of measurement
easu e e t : 29
9th Ju
July
y 2005
005
3) Date of off-line inspection : 19th August 2005
4) Type of equipment : 12kV AIS-VCB
5) Analysis :
Pd detected at channel 6. Off-line inspection revealed bad discharges at the cable
termination compartment at the switchgear.
Case history 3 using on
on-line
line snapshot Ultrasonic method
Partial
a t a Discharge
sc a ge Equipment
qu p e t use : U
UE 9000 Mode
ode o
of measurement
easu e e t : ssnapshot
aps ot
1) Date of measurement : 15th November 2003
2) Type of equipment : 22kV connection of 8MVA, 22/6.6kV Dry type Transformer
3) Analysis :
Loud and audible discharge was heard at the 22kV side of the dry type transformer.
Ultrasonic scan showed large 50Hz spike and located the source of the discharge at a defective insulating support.
Case history 4 using on-line continuous mode Ultrasonic method
Panel Start Time Stop Time Average Voltage Max Volt / Min Volt
22kV Panel 18th March 19th March 2.93V 5.96V / 0.12V

2005 2005
15:45pm 14:00pm
Partial Discharge Equipment used : DS 386 from UE Systems of USA

Mode of measurement : On-line, Continuous mode, Airborne method
1) Date of measurement : 18th March 2005
3) Date of failure : 6th July 2005
4) Type of equipment : 22kV AIS-GCB
Analysis :
Average noise = 2.93volts
ΔV1 = Vmax – Vmin = 5.84volts
ΔV2 = Vmax – Vaverage = 3.03volts
Both exceeds the 2.5volts guideline.
Case history 5 using on-line Snapshot HFCT method
Measurement done at Red phase
2 ‘camel humps’
p
Measurement done at Blue phase
Partial Discharge Equipment used : OSM

OSM--ST1 from IPEC, UK
Mode of measurement : Snapshot
1) Date of measurement: 23rd Mar 2007

2) Type of equipment: 230kV cable termination at transformer
3) Analysis:
• Measurement done at 230kV cable termination for 5 minutes
on line voltage.
• 2 ‘camel humps’ detected at Red phase whereas none was
evident at Blue phase.
Case history 6 using RTD embedded in the windings of the motor
Tag: 9K-9601A
Equipment: 3Ø synchronous motor
Rating: 4200kW/6.3kV
Brand: Toshiba
S/no: Toshiba 9624021
Manufacture: 1996
Partial Discharge Equipment used : OSM-ST1 from IPEC, UK

Mode of measurement : Snapshot
1) Date of measurement: 30th July 2008

2) Measurements done using OSM-ST1 set from IPEC of UK.
3) The measurement was recorded with duration of 5 minutes
snapshot recording with RTD sensors embedded in the motor.
4) Measurement taken at the local control panel which is 3 meters
away from the motors.
5) Measurement done with red + white pair of the RTD embedded
in the motor.
6) Analysis
• There is evidence of Pd discharge pattern above the
background noise at phase U for all four dates of
measurements.
• Glass tapes were found exposed on a few locations just
outside the slot area due to peeling of corona tape.
Case history 6 using RTD embedded in the windings of the motor (con’t)
Phase 7th May 2008 11th June 2008 10th July 2008 30th July 2008
Pd activity of Pd activity of Pd activity of Pd activity of
Ch1 – Phase U
1004mV 1004mV 1600mV 1000mV
Ch2 – Phase V No Pd activity Pd activity of 490mV Pd activity of 100mV No Pd activity
Ch3 – Phase W No Pd activity No Pd activity No Pd activity No Pd activity
Case history 6 using RTD embedded in the windings of the motor (con
(con’t)
t)
Glass tapes were found exposed on a few locations just outside the slot area due to peeling of corona tape
tape.

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FAILURE OF CABLE

J.M.PANG & SEAH (PTE) LTD

• FUNDAMENTAL OF CABLE TERMINATION

• SITE TESTING OF CABLE TERMINATION

• PARTIAL DISCHARGE MEASUREMENT IN

• CASE HISTORY OF PREMATURE FAILURE

JMPS J.M.PANG & SEAH (PTE) LTD CONTENTS

JMPS J.M.PANG & SEAH (PTE) LTD FUNDAMENTAL OF CABLE TERMINATION

JMPS J.M.PANG & SEAH (PTE) LTD FUNDAMENTAL OF CABLE TERMINATION - 1

Uniform distribution of electric field Non uniform distribution of electric field

JMPS J.M.PANG & SEAH (PTE) LTD FUNDAMENTAL OF CABLE TERMINATION - 2

LINES OF ELECTRICAL STRESS WITH STRESS CONTROL

JMPS J.M.PANG & SEAH (PTE) LTD FUNDAMENTAL OF CABLE TERMINATION - 3

Electric field in the

LINES OF ELECTRIC FIELD

JMPS J.M.PANG & SEAH (PTE) LTD FUNDAMENTAL OF CABLE TERMINATION – 4

Armour PVC Copper Semi XLPE copper

Deep Cut At XLPE

JMPS J.M.PANG & SEAH (PTE) LTD FUNDAMENTAL OF CABLE TERMINATION - 5

Length of Stress Control Tube (mm)

Operating Voltage (kV) Single Core Cable Multi-Core Cable

6.6 100 130

JMPS J.M.PANG & SEAH (PTE) LTD FUNDAMENTAL OF CABLE TERMINATION - 6

JMPS J.M.PANG & SEAH (PTE) LTD FUNDAMENTAL OF CABLE TERMINATION - 7

Type of Insulation kV/mn

JMPS J.M.PANG & SEAH (PTE) LTD FUNDAMENTAL OF CABLE TERMINATION - 8

The following methods can be used to eliminate the air voids

• By using mastic tape (new method)

• By using paint (old method)

JMPS J.M.PANG & SEAH (PTE) LTD FUNDAMENTAL OF CABLE TERMINATION - 9

• Heat Shrink Type

• Cold Shrink Type

• Slip Over Type

JMPS J.M.PANG & SEAH (PTE) LTD FUNDAMENTAL OF CABLE TERMINATION - 10

JMPS J.M.PANG & SEAH (PTE) LTD FUNDAMENTAL OF CABLE TERMINATION - 11

JMPS J.M.PANG & SEAH (PTE) LTD FUNDAMENTAL OF CABLE TERMINATION - 12

Slide the Stress control tubing SMCT over

JMPS J.M.PANG & SEAH (PTE) LTD FUNDAMENTAL OF CABLE TERMINATION - 13

With the cores in the correct position, fit the

JMPS J.M.PANG & SEAH (PTE) LTD FUNDAMENTAL OF CABLE TERMINATION - 14

Up to indoor terminations are now complete.

JMPS J.M.PANG & SEAH (PTE) LTD FUNDAMENTAL OF CABLE TERMINATION - 15

Outdoor and indoor terminations are now

JMPS J.M.PANG & SEAH (PTE) LTD FUNDAMENTAL OF CABLE TERMINATION - 16

JMPS J.M.PANG & SEAH (PTE) LTD FUNDAMENTAL OF CABLE TERMINATION - 17

JMPS J.M.PANG & SEAH (PTE) LTD FUNDAMENTAL OF CABLE TERMINATION - 18

Secure Ground Braid Legs to cable

JMPS J.M.PANG & SEAH (PTE) LTD FUNDAMENTAL OF CABLE TERMINATION - 19

JMPS J.M.PANG & SEAH (PTE) LTD FUNDAMENTAL OF CABLE TERMINATION - 20

JMPS J.M.PANG & SEAH (PTE) LTD FUNDAMENTAL OF CABLE TERMINATION - 21

JMPS J.M.PANG & SEAH (PTE) LTD FUNDAMENTAL OF CABLE TERMINATION - 22

JMPS J.M.PANG & SEAH (PTE) LTD FUNDAMENTAL OF CABLE TERMINATION - 23

JMPS J.M.PANG & SEAH (PTE) LTD FUNDAMENTAL OF CABLE TERMINATION - 24

• Remove the oversheath,

JMPS J.M.PANG & SEAH (PTE) LTD FUNDAMENTAL OF CABLE TERMINATION - 25

JMPS J.M.PANG & SEAH (PTE) LTD FUNDAMENTAL OF CABLE TERMINATION - 26

JMPS J.M.PANG & SEAH (PTE) LTD FUNDAMENTAL OF CABLE TERMINATION - 27

• Apply two layer of Electrical tape (ET) with

JMPS J.M.PANG & SEAH (PTE) LTD FUNDAMENTAL OF CABLE TERMINATION - 28

• Wind one layer of ET tape

JMPS J.M.PANG & SEAH (PTE) LTD FUNDAMENTAL OF CABLE TERMINATION - 29

• Apply remaining grease on the black

JMPS J.M.PANG & SEAH (PTE) LTD FUNDAMENTAL OF CABLE TERMINATION - 30