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1 Introduction
Cables for power distribution are mainly characterised by the material of the
conductor, voltage grade, type of insulation, type of sheathing, type of armouring
etc. Cables are designed to safely carry the current it is required to carry under
normal operating conditions as well as abnormal conditions. To carry a current
safely means (1) the temperature rise and voltage drop should be within the
prescribed limits and (2) the insulation of the cable should withstand the normal
operating voltage as well as higher voltages that may arise under abnormal
conditions. In some situations, the cable may encounter with severe mechanical
stress or highly contaminated environment in addition to the electrical stress.
Hence it is necessary to ensure by means of pre-test inspections and various field
tests that the cable is capable of withstanding the various types of stresses it may
come across during its service life.
6.2 Cable installation plan
Cables are usually laid according to a plan prepared for the purpose. However, after
completing the cable laying, it is necessary to prepare a revised plan incorporating
the changes made during execution of the work. This plan will help in locating faults
and in carrying out tests during the service life of the cable. The cable installation
plan should contain the following details.
(1) Location of cables and joints with reference to some fixed landmarks like
buildings, boundary stones etc.
(2) Type of cables, cross sectional area, rated voltage and details of cable core.
(3) Length of cables – between joints and ends.
(4) Year and month of laying.
(5) Date of making joints.
(6) Results of measurements and tests carried out on the cable.
(iv) Check the cable bends for minimum bending radius as per Table 6.1 and
clamping of the cable at both ends of the bend.
(xiii)Check whether the bottom most rack is used for the highest voltage cable and
upper racks for lower voltages. Check whether d.c and a.c control cables are
segregated.
(xiv)Check whether fire resistant Low Smoke Cables are used in hazardous areas.
(xv) Check whether cable trenches are filled with dry sand in hazardous locations
6.4 Pre-commission tests
6.4.1 Insulation Resistance Test
All new cables shall be tested for insulation resistance before making joints /
connections. IR of cables is measured by means of insulation resistance testers. It is
preferable to use motorised insulation testers for measuring the IR of cables. The
recommended ratings of insulation tester is given below.
The above value of conductor resistance may be compared with the values given in
the test certificate of the manufacturer. Wide difference between the two values is
an indication of improper joints. Contact resistances are kept minimum by properly
clamping or bolting connections.
6.4.3 Measurement of Capacitance
Capacitance of cables is measured for voltages above 11 kV. The measurement is
made using a suitable capacitance bridge. In the case of screened cables the
capacitance is measured between the conductor and the screen. For unscreened
cables, the capacitance is measured between one conductor and others with the
metal sheath/armour connected to earth. The measured values are compared with
the values given in the test certificate.
6.4.4 High Voltage Test
After making joints and terminations, cables are subjected to High Voltage Test. The
condition of the insulation of the cable is evaluated by applying a voltage higher
than the rated voltage for a short duration. The cable shall withstand the test
voltages given in table 6.2 when applied for a period of 5 minutes.
The test can be conducted by applying dc voltage also. DC test equipments are
compact and portable and they require less power.
Test Procedure
The high voltage source is connected to the conductor of the core under test. The
cores not under test, screen and armour are connected to the earth terminal,
depending on the mode of connection (please see the figures below).
The voltage is now raised slowly, but not so slowly as to cause unnecessary
prolongation of the stress near the test voltage. The test voltage is raised to the
specific value given in table 6.2 and is maintained for the specified time of 5
minutes. After the specified time, the voltage is suddenly decreased but without
sudden interruption to avoid the possibility of switching transients. Insulation
resistance values of the cable before and after the HV test shall be measured and
compared. There shall not be wide variation in the IR values. Fig. 6.1
Points to note
1. The Cable cores must be discharged on completion of HV test and the cable
earthed before it is put into service.
2. For old cables, the test voltage may be limited to 1.5 times the rated voltage. But
in no case shall the test voltage be less than the rated voltage.
3. It is not desirable to conduct frequent HV tests on cable installations. The test
shall be carried out when the cable is first installed and thereafter only when
essential.
4. During the HV test on cables, other electrical equipments such as switches,
breakers etc. shall be earthed and adequate clearance maintained from the test
equipment and the cable under test to prevent any flash over.
5. In each test, the metallic sheath, screen and armour shall be connected to earth.