Ref. No.

: VNM-1605-STP-001
Rev. No. :0
Page No. : 1 of 14

Bid No.: :
User / Customer :
Project Title :
Tenderer : LS-VINA Cable & System
Document Title :

Site Test Procedure Manual

for
150kV Cable and Accessories

0 May 25, 2016 For reference only B.D.Tan V.H.Duong T.M.Trung

Rev. No. Date Descriptions Prepared By Reviewed By Approved By
 Doc. No. : VNM-1605-STP-001
Rev. No. : 0

Table of Contents

 Cable Jacket Insulation Resistance Test ----------------------------------------------------------- 3

 Conductor Continuity and Phasing Tests ---------------------------------------------------------- 4

 Cable Insulation Test by Megohmmeter ----------------------------------------------------------- 5

 High Voltage AC & PD Test -------------------------------------------------------------------------- 6

 Grounding Resistance Measurement at Link Box ------------------------------------------------ 8

 Cable Impedance Measurement -------------------------------------------------------------------- 9

 DC Resistance Test ------------------------------------------------------------------------------------ 11

 Cross Bonding Verification Test --------------------------------------------------------------------- 12

 SVL Insulation Test ----------------------------------------------------------------------------------- 13

 Link Box Contact Resistance Test ------------------------------------------------------------------- 14

 Capacitance Measurement --------------------------------------------------------------------------- 15

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Cable Jacket Insulation Resistance Test

 Test Purpose : Cable jacket insulation resistance test and DC 10kV test shall be performed to confirm the
soundness and integrity of the cable outer jacket.
 Standard : Customer standards.
 Test Equipment : DC Voltage Tester (Hipotronics 8175PL or Hi-Leakester or Equivalent), Megger
 Procedure

Cable jacket insulation resistance test and DC 10kV test shall be carried out for each minor section after cable pulling. At
that time the cable metallic sheath should be open. After completion of the reinstatement of the whole route, both cable
jacket insulation resistance test and DC 10kV test for 1 minute shall be performed for each minor section in the link box
including coaxial cable. Detailed procedures are given below.

1. Make a defense in order to prevent personnel from being injured.

2. Set up the tester and wiring as shown in Fig. 1. For the grounding, earthing wire is connected to ground wire of the
joint bay.
3. After completion of cable laying for the each minor section, jacket insulation resistance and DC 10kV test shall be
measured between cable metallic sheath and earth electrode with the adjacent cable conductors and the shield
grounded. Maximum allowable leakage current (IL) shall be derived from the following equations.
ρ D 1
R  ln   106 --------------------------------------------------------------------------------------------------- (1)
2π d L

R : Calculated Insulation Resistance ------------------------------------------------------------------------ [MΩ]

ρ : Volume Resistivity of the Cable Jacket Insulation at 20℃ ------------------ 1014 for XLPE or PE [Ω-m]

D : Outer Diameter of the Cable Jacket -------------------------------------------------------------------- [mm]

d : Inner Diameter of the Cable Jacket -------------------------------------------------------------------- [mm]

L : Length of the Cable Phase under Test ---------------------------------------------------------------- [m]

E
IL  ------------------------------------------------------------------------------------------------------------------------ (2)
R

IL : Leakage Current (excluding Terminal Leakage) ------------------------------------------------------ [mA]

E : DC Test Voltage -------------------------------------------------------------------------------------------- [kV]

4. After completion of the reinstatement of the whole route, prior to applying DC 10kV voltage between the cable
metallic sheath and the earth electrode, cable jacket insulation resistance shall be measured by 5kV DC
Megohmmeter for each minor section in the link box including coaxial cable.
5. Upon completion of test, applied voltage shall be discharged by using the earthing wire.

Jacket
MEGGER Metallic Sheath
Insulation
Conductor

Fig. 1 Cable Jacket Insulation Resistance Test Diagram

 Requirement : Measured leakage current shall be lower than calculated value, and no breakdown shall be
occurred.

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Conductor Continuity and Phasing Tests

 Test Purpose : To ensure the continuity and phasing of the cable conductor from terminal to terminal, the
cable conductor shall be tested using a minimum of DC 1kV per Fig. 2 and Fig. 3.
 Standard : SEC-COA Specification
 Test Equipment : DC Voltage Tester (PGK80 or Equivalent) or Megger (BM21 or Equivalent)
 Procedure

1. Conductor continuity and phasing test will be performed after completion of all joints/terminations installation.
2. Conductor continuity tests will be carried out by using main conductor as shown in Fig. 2. (Cable jacket insulation
resistance test will be substituted for the metallic shield continuity tests.)
3. Phasing tests will be carried out by using main conductor as shown in Fig. 3, where the phase undergoing the test is
grounded while the other two phases of cable are opened.
4. Phase checking shall be performed after all joints and terminations are installed completely.

R R1

Y Y1

B B1

MEGGER

Fig. 2 Cable Conductor Continuity Test

R R1

Y Y1

MEGGER
B B1

Fig. 3 Cable Phasing Test

 Requirement : There are not any discontinuities of the cable conductor.

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Cable Insulation Resistance Test by Megohmmeter

 Test Purpose : To ensure the soundness of the cable insulation, prior to performing the high voltage tests on
the cable and after high voltage test, cable insulation resistance by Megohmmeter shall be
measured by applying DC 5kV for 1 minute between cable conductor and the metallic sheath
which is grounded with the adjacent cable conductors and sheaths as shown in Fig. 4.
 Standard : Customer Specification, IEC Standard
 Test Equipment : Megger (BM21 or NIEAF Megohmmeter or Equivalent)
 Procedure

1. This test shall be performed after completion of all joints/terminations installation with all cable conductors and
metallic sheaths of the test end grounded except cable conductor under test as shown in Fig. 4.
2. All cable conductors and sheaths at the remote end shall be free.
3. Minimum cable insulation resistance shall be determined by the Equation (1) except D and d; D is outer diameter of
the cable insulation and d is inner diameter of the cable insulation.

Jacket
MEGGER Metallic Sheath
Insulation
Conductor
Fig. 4 Cable Insulation Resistance Test

 Requirement : Measured cable insulation resistance should be higher than calculated value and put on record.

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High Voltage AC Test

 Test Purpose : This test will be carried out to ensure that installed cables have no defects.
 Standard : IEC 60840 Section 15.2, 15.2 AC voltage test of the insulation
 Test Equipment : HV Resonant Test Set
 Procedure

1. The following points should be checked before starting AC High Voltage Test according to site conditions.
a. Is the space enough to set test equipments and test bushing?
b. Is it possible to inject voltage directly to test bushing or terminations? If difficult, special insulation cable or
insulation support should be ready for injection.
c. Are Switchgear parts disconnected from this test object (power cable system) ?
d. Are Switchgear chambers fully vacuumed and Gas-refilled suitably by OEM (Original Equipment Manufacturer)?
e. Is it possible to get suitable power source for test equipments?
f. Is earth point for testing suitable?
g. Is the capacity of test equipment enough to carry out this AC Testing considering cable parameter, cable length,
and test voltage as bellow calculations?
1
f  [Hz ] I  2fLc CV  10 6 [A]
2 Le C  Lc ,

f : Resonant Frequency -------------------------------------------------------------------------------------- [Hz]

Le : Inductance for AC equipment ----------------------------------------------- 16.2H for LS AC Tester [H]
C : Capacitance for Power Cable ---------------------------------------------------------------------------- [μF/km]
Lc : Cable Length ----------------------------------------------------------------------------------------------- [km]
V : Injected Test Voltage-------------------------------------------------------------------------------------- [kV]
I : Charging Current ------------------------------------------------------------------------------------------ [A]
Note

- Quantity of AC Tester should be decided based on charging current which is not less than 80A per equipment
in case of LS AC equipment.

- When using other AC Test equipment, capacity of test equipment should be reviewed.

2. After review above points, jumper all SVL of the cable system under test & restore the case after test.
3. Before and after high voltage test, measure and register cable insulation resistance.
4. Test Voltage and Time: using grid voltage Uo for 24h or test voltage specified in table 4 - IEC 60840 page 65 for 1h
5. All cable conductors and shields not during the test shall be grounded.
6. Test voltage shall be applied through frequency tuned series resonant test set between the conductor and the
metallic sheath of each individual XLPE cable. The Fig. 5. is one of the test Loop for XLPE Cable System.

 Requirement : No breakdown of the insulation shall be occurred, and the test results shall put on record.

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Grounding Resistance Measurement at Link Box

 Test Purpose : To confirm that grounding resistance at grounding locations complies with the requirement,
grounding resistance shall be measured as shown in Fig. 6.
 Standard : Customer Specification
 Test Equipment : Grounding Resistance Tester
 Procedure

1. This test should be carried out before the complete backfill of the joint bay to confirm the adequacy of the
measured value with respective specified value (Normally max.10Ω).
2. The measurement instrument will be a digital earth resistance meter type DET 5/4D with current calibration
certificate. The test connection used will be three points configuration whereby the ground electrode under test is
one point and the other two points are temporary electrodes driven into the ground at predetermined separations
and so that all three points form a reasonably straight line per Fig. 6.
3. The ground grid/electrode to be tested shall be isolated by opening all links or connections to eliminate parallel
paths to ground.
4. The two long test leads of the instrument will be run out to their full extent to an open un-surfaced area. The leads
are 25m & 50m long so that the required locations of the temporary test electrode are easily determined. At the end
of each lead a test electrode (steel pin) is driven into the ground. The test leads are connected to their respective
temporary electrode by crocodile clip.
5. The instrument is positioned near the electrode under test. The leads from the temporary electrodes are connected
appropriate terminals (indicated by a diagram marked on the instrument). A short test lead is connected between
the ground electrode under test and the remaining terminal of the instrument. This lead must be kept short because
its resistance will be included in the measured values.
6. The test button on the instrument is pressed and released to start the measurement. The instrument indicators will
be checked to ensure that the test circuit is satisfactory and the instrument battery voltage adequate.
7. After a few seconds the measured resistance will be shown on the digital display. The value will be recorded. If the
value exceeds the specified maximum resistance the test will be repeated with the temporary test electrodes
installed in a different direction from the instrument.

Link Box

Resistance Tester P2 C2

Ground Rod

Fig. 6 Grounding Resistance Test

 Requirement : Measured grounding resistance shall not exceed the requirement specified in customer
specification.

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Cable Impedance Measurement

 Test Purpose : To measure the Positive Sequence and Zero Sequence Impedance of completed cable circuits in
order to provide information for protection relay settings.
 Standard : Customer Specification
 Test Equipment : Electric Power Analyzer
 Procedure
[Positive/Negative Sequence Impedance]

1. All cable shields, link-box connections, ground wires and bonding cables for the circuit to be tested and any parallel
circuits shall be configured in the normal service state.
2. Connect the three phases of cable at the one end of the cable circuit by using the conducting wire, and the other
end is connected to the testing circuit as shown in Fig. 7.
The readings are applicable for individual phases.

3. Close the power supply switch. Set up the electricity in the circuit. Adjust the testing current to the appropriate value
by using the transformer.
4. Take the readings of V, I and cosФ (Power Factor) of individual phases, thereafter calculate the test result as per
following formula;
V 1
Z1  1  ----------------------------------------------------------------------------------------------------------------- (3)
I1 L

R1 = Z1 x cosФ1 --------------------------------------------------------------------------------------------------------------- (4)

2 2
X1  Z1  R1 ------------------------------------------------------------------------------------------------------------ (5)

Z1 : Calculated Positive/Negative Sequence Impedance of Each Phase-------------------------------- [Ω/km]

V1 : Measured Voltage------------------------------------------------------------------------------------------ [V]

I1 : Measured Current ----------------------------------------------------------------------------------------- [A]

R1 : Calculated Sequence Resistance ------------------------------------------------------------------------ [Ω/km]

X1 : Calculated Sequence Reactance------------------------------------------------------------------------- [Ω/km]

cosФ1 : Measured Power Factor -----------------------------------------------------------------------------------

L : Cable Route Length --------------------------------------------------------------------------------------- [km]

R R1

R
G Y
B Y Y1
3Ф 220V Short
GND
R At Far End
Y
B B B1
Power Supply
Terminal

R Y B R Y B
Electric Power Analyzer
(3 Phases 3 Line)

Fig. 7 Positive/Negative Sequence Impedance

5. Measure and record the environmental temperature and relative humidity.

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[Zero Sequence Impedance]

1. Connect the three phases of cable at both ends of the cable circuit, and far end to the earth. The other end is
connected to the testing circuit as Fig. 8 below.
2. Close the power switch and set up the electricity in the circuit. Adjust the testing current to the appropriate value by
transformer.
3. After reading the value of V, I and cosФ (Power Factor), thereafter calculate the test result as per following formula;
3V 1
Z0  0  ---------------------------------------------------------------------------------------------------------------- (6)
I0 L

R0  Z0  cos φ0 ------------------------------------------------------------------------------------------------------------ (7)

2 2
X0  Z0  R 0 ------------------------------------------------------------------------------------------------------------ (8)

Z0 : Calculated Zero Sequence Impedance ----------------------------------------------------------------- [Ω/km]

V0 : Measured Voltage------------------------------------------------------------------------------------------ [V]

I0 : Measured Current ----------------------------------------------------------------------------------------- [A]

R0 : Calculated Sequence Resistance ------------------------------------------------------------------------ [Ω/km]

X0 : Calculated Sequence Reactance------------------------------------------------------------------------- [Ω/km]

cosФ0 : Measured Power Factor -----------------------------------------------------------------------------------

L : Cable Route Length --------------------------------------------------------------------------------------- [km]

R R1

R Common &
G Y Earthing
B at Far End
Y Y1
3Ф 220V
GND
R
Y
B
B B1
Power Supply
Terminal

R Y B R Y B
Electric Power Analyzer
(1 Phase 2 Line)

Fig. 8 Zero Sequence Impedance

 Requirement : Measured sequence impedance shall put on record.

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DC Resistance Test
 Test Purpose : To verify that measured conductor resistance meet the requirement.
 Standard : IEC Standard 62067 and 60228
 Test Equipment : Portable Double Bridge (Micro-Ohmmeter or Thomson Bridge or Equivalent)
 Procedure

[Conductor Resistance Test]

1. Connect the three cables together with copper bare conductor or equivalent wires (along with terminal, if any) at the
far end as diagram given below (Fig. 9)
2. Measure the independent loop (e.g. between R & Y, R & B and Y & B), and the results will be as RtRY, RtYB and RtBR
respectively.
3. The ambient temperature around over-sheath of the tested cable will be taken as the conductor temperature.
Record the ambient temperature and relative humidity.
4. Corrected resistance value at 20℃ and 1 km is calculated from the following formula as per IEC standard 60228;

R tR 
R tRY  R tBR  R tYB  RBC  --------------------------------------------------------------------------------------- (9)
2

R tR 1 ---------------------------------------------------------------------------------------------
R R 20 
1  αt  20  L
(10)

RtR : Measured DC Resistance of R Phase Conductor at Ambient Temperature ----------------------- [Ω]

RR20 : DC Resistance at 20℃ ------------------------------------------------------------------------------------ [Ω/km]

RBC : DC Resistance of Jumper Wire -------------------------------------------------------------------------- [Ω]

α : Temperature Coefficient ------------------------------------------------------------- Copper 0.00393

t : Ambient Temperature ------------------------------------------------------------------------------------- [℃]

L : Cable As-Built Route Length ----------------------------------------------------------------------------- [km]

R R1

Y Y1

C1
P1
B B1
P2
C2
E

Fig. 9 Cable Conductor DC Resistance Test

 Requirement : Measured conductor and shield DC resistances shall be equal or lower than the scheduled
figures and shall be recorded.

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Cross Bonding Verification Test

 Test Purpose : To verify whether the cross-bonding connections have been made correctly so that circulating
current in the cable shields are effectively suppressed.
 Standard : Electra 75
 Test Equipment : Generator, DC Regulated Power Supply, Kyoritsu 2007A Clamp Meter, Digital Voltmeter or
Equivalent
 Procedure

Note: All the cable shields, link box connections, ground wires and bonding cables for the circuit under test are

configured in the normal service state.

1. Refer to Fig. 10 below at the remote end, all conductors for the circuit under test are bonded together under test by

a minimum of 38mm2 copper jumper cable.

2. Connect the output leads of generator to the three conductors of the circuit so that the generator output current will

circulate through the circuit.

3. Start the generator, and adjust the speed to give an output power frequency. Then, adjust the excitation to produce

an output current of approximately 100 Amperes, which is maintained constant during the test.

4. Measure and record the current at every link of the grounding/cross bonding link boxes and the voltage between the

links and ground at cross bonding link boxes only.

5. Switch off the power sauce and select at random one cross bonding link box and reverse its links or use a temporary

clip lead (links removed) to achieve the link reverse. Then measure the sheath current and voltage.

6. Start the power sauce and regulate to obtain the conductor 100A as per item 3. Measure and record the sheath

current and voltage at the randomly selected link box.

V V

Power Source
A
& Auto Transformer

Fig. 10 Cross Bonding Verification Test

 Requirement : When the injected current is referenced to the current rating of the cable, the rated sheath
current shall have the same rate. The measured voltage between sheath and earth when
referenced to current rating of the cable shall not exceed 200 volts.

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SVL Insulation Test

 Test Purpose : To verify insulation integrity of the SVL.
 Standard : Electra 75
 Test Instrument : Megger (BM11D, Hipotronics 815PL 15kV DC Test Set, or Equivalent)
 Procedure

A. At the cross bonding link boxes:

1. With three terminals of SVL connected to earth and the other three terminals are free.

2. Measure the earth and each free terminal of the SVL and record using the megger after adjusting to 1kV DC for one

minute.

3. Discharge the induced charge at all the free terminals after each measurement.

4. Inject D.C voltage using 10kV tester until reaching leakage current of 1mA and record the injected voltage then.

5. Discharge the induced charge at all the free terminals after each measurement.

6. Return back the connection after above test.

B. At the GIS termination:

1. Repeat as in item A and three free links are disconnected from the clamping ring (GIS) at the termination.

(Megger, 10kV Tester)

(SVL)

(Earth bar of the link box)

Fig. 11 SVL Insulation Test

 Requirement : The measured insulation resistance of SVL shall not be less than value specified in the
specification, and the measured voltage should be the same as SVL characteristics supplied.

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Link Box Contact Resistance Test

 Test Purpose : To verify that the link contact resistance shall be satisfied.
 Standard : Electra 75
 Test Instrument : Digital Micro Ohmmeter or Equivalent
 Procedure

Note: This test shall be done on every link contact point of all the Link Boxes. All link boxes shall be inspected to ensure
that all links are correctly connected. If any links are disturbed and reconnected, the link contact resistance test
shall be satisfactorily complied with on those links.
1. Keep the cable sheath system like service case.

2. Apply micro-ohmmeter as shown in fig. 12 below, measure and record.

E I1 P1 P2 I2

Fig. 12 Link Box Contact Resistance Test

 Requirement : Link box contact resistance measured shall not exceed 20 micro-ohms.

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Capacitance Measurement

 Test Purpose : The purpose of this test is to compare the measured capacitance with the capacitance
calculated value. Capacitance is measured for the calculation of energized cable charging
currents as required for protection relay setting.
 Standard : Customer standard
 Test Instrument : Fluke 177 or NIEAF TeraOhm 5kV or Equivalent
 Procedure

1. The connection of the cable under test is as shown on below diagram. The Test Instrument line terminal will be

connected to the phase conductor and the outer terminal to be connected to the metallic sheath of the same phase.

Test Instrument

Fig. 13 Cable Capacitance Measurement

2. Refer the test result to the unit length using the formula as follows:

C  Cx --------------------------------------------------------------------------------------------------------- μF/km (10)

L

Where: Cx is the measured value of one phase of the cable circuit in μF.

C is the referenced capacitance of one phase of the cable circuit per kilometer in μF/km.

L is the route length in km.

 Requirement : Measured cable capacitance shall not exceed the specified value (μF/km).

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