Independent test lab accredited for HV and LV equipment

Independent test laboratory, accredited by Deutsche Akkreditierungsstelle Technik (DATech) e.V. in the fields of h.v.
apparatus
and switchgear, power cables and power cable accessories, l.v. apparatus and switchgear, installation equipment and
switching and control equipment.
Institut Prffeld fr elektrische Hochleistungstechnik GmbH (IPH Berlin) is a subsidiary of CESI S.p.A, Milan.

I ndependent, accredi ted testi ng stati on Member l aboratory of STL and LOVAG

TYPE TEST REPORT

NO. 3149.2090352.0530

HES Hacilar Elektrik Sanayi ve Ticaret A..
Erciyes Mah. HES Cad. No:22
38210 Kayseri
TURKEY

CLIENT

HES Hacilar Elektrik Sanayi ve Ticaret A..

MANUFACTURER

Medium voltage cross-linked PE (SLPE) insulated power cable

TEST OBJECT

YXC7V-R (N2XSY) 1x35/16 mm 20.3/35 kV

TYPE

Test sample

SERIAL NO.

Rated voltage
Max. operating voltage
Uo/Um
Um
20.3/35
42
kV
kV

RATED
CHARACTERISTICS
GIVEN BY THE
CLIENT

IEC 60502-2: 2005-03

NORMATIVE
DOCUMENT

Type tests on cable

RANGE OF TESTS
PERFORMED

May 2009 to July 2009

DATE OF TEST

The tests have been PASSED.

TEST RESULT

H. ZINNBAUER
Head of Centre of Competence
High-Power/High-Voltage
G. BROSE
Test engineer in charge

Berlin, 21 October 2009

TYPE TEST REPORT NO. 3149.2090352.0530 SHEET 2

This test document consists of 28 sheets.

Distribution Copy No. 1

Copy No. 1 in English: HES Hacilar Elektrik Sanayi ve Ticaret A..

The test results relate only to the object tested.
This document is confidential. Its transfer to third parties as well as its reproduction in extracts require the consent of the client.
Contents Sheet
1. Present at the test............................................................................................................................................................. 3
2. Place of test ........................................................................................................................................................................... 3
3. Identity of test object...................................................................................................................................................... 3
4. Type tests, electrical on the cable......................................................................................................................... 4
4.1 Partial discharge test at ambient temperature.................................................................................................................................................... 5
4.2 Bending test followed by a partial discharge test ......................................................................................................................................... 6
4.3 Tan measurement at 5 C to 10 C above the maximum conductor temperature........................ 7
4.4 Heating cycle test followed by a partial discharge test......................................................................................................................... 8
4.5 Lightning impulse voltage test at a maximum conductor temperature ranging from
95 C to 100 C.................................................................................................................................................................................................................................................. 9
4.6 Power-frequency voltage test for 4 h............................................................................................................................................................................. 11
4.7 Resistivity of semi-conducting screens before and after the ageing treatment.......................................... 12
5. Type tests, non-electrical on the cable........................................................................................................... 13
5.1 Measurement of thicknesses and check of cable construction....................................................................................... 14
5.2 Tests for determining the mechanical properties of the insulation before and after
ageing............................................................................................................................................................................................................................................................................. 17
5.3 Tests for determining the mechanical properties of the PVC oversheath before and after
ageing............................................................................................................................................................................................................................................................................. 18
5.4 Ageing tests on pieces of complete cables to check compatibility of materials..................................... 19
5.5 Loss of mass test on PVC oversheath of type ST
2
....................................................................................................................................... 20
5.6 Pressure test at high temperature on the PVC oversheath.......................................................................................................... 20
5.7 Test on sheath at low temperature.................................................................................................................................................................................. 21
5.8 Test for resistance of PVC sheath to cracking (heat shock test) .......................................................................................... 21
5.9 Hot set test for XLPE insulations.............................................................................................................................................................................................. 22
5.10 Water absorption test on insulation................................................................................................................................................................................ 23
5.11 Flame spread test on single cables.................................................................................................................................................................................. 23
5.12 Shrinkage test for XLPE insulation........................................................................................................................................................................................ 24
6. Sketches/Drawings/Data sheet......................................................................................................................... 25
7. Photo....................................................................................................................................................................................... 28


1. Present at the test
Mr. Brose IPH test engineer in charge

2. Place of test
IPH, High-voltage test laboratory, test bay no. 1, test bay no. 3, high-voltage hall no. 2

3. Identity of test object
The tests were carried out on a cable sample with markings of manufacturer and year of
manufacture as follows:
00966 HES YXC7V-R 1x35/16 mm 20.3/35 kV TSEK 22/03/2009 01 TEDAS.

Construction, please see attached sketch.

4. Type tests, electrical on the cable
Tests performed

a) Partial discharge (PD) test
b) Bending test followed by a partial discharge test
c) Tan measurement at 5 C to 10 C above the maximum conductor temperature
d) Heating cycle test followed by a partial discharge test at ambient temperature
e) Lightning impulse test at elevated maximum conductor temperature followed by a voltage test
f) Power-frequency voltage test for 4 h
g) Resistivity of semi-conducting screens


4.1 Partial discharge test at ambient temperature
Normative document
IEC 60502-2: 2005-03, Sub-clause 18.1.4

Test and measuring circuits
Technical data of test circuit

Test transformer: Rated voltage 125 kV
Rated power 100 kVA
Rated frequency 50 Hz
Damping resistance 0.67 kOhm

Technical data of measuring circuit

Meas.
point
Measured quantity Measuring sensor/device Technical parameters
1 Test voltage Capacitive divider with MU11
(TuRD) peak voltmeter
Ratio 864
2 Partial discharge
level
- Coupling capacitor
- CPL 542A quatripole (mtronix)
MPD 540 PD measuring system
(mtronix)
- Calibrator of Cal 542 type
(mtronix)
C
k
= 1 nF

Output 10 pC

E Supply
PTr Test transformer with variable transformer connected in series
Z
s
Blocking impedance
C
k
Coupling capacitor
Z
m
Measuring impedance
C-T. Capacitive divider
HE Auxiliary sealing end
1, 2 Measuring points
PO Test object

Z
s

2
Z
m

1
HE HE
PO
E PTr C
k

C-T.

Measured values
The calibration was at 5 pC.

Test voltage

in kV
Noise level

in pC
PD initiation

in kV
PD at test
voltage
in pC
PD
interruption
in kV
Required
sensitivity
in pC
2xUo 40.6
1)

1.73xU
0
= 35.2
1 pC - 1.2 pC - 5 pC

1) Measured value during 2Uo 40.6 for 10 sec.

Test results
The test has been PASSED.

4.2 Bending test followed by a partial discharge test
Normative document
IEC 60502-2: 2005-03, Sub-clause 18.1.3

The test was carried out at IPH. The cable sample with a length of more than 10 m was three
times bended around a test cylinder and unwound in each direction around the required test
diameter at ambient temperature.. For this, each sample part was bend and afterwards unwound
and again bend and unwound in the opposite direction.

Required test parameters
The bending diameter was calculated using the equation D 20 (d + D) 5 %.

D = cable diameter
in mm
d = conductor diameter
in mm
Bending diameter
in mm
Chosen diameter
in mm
33.5 7.4 817 803

Partial discharge test at ambient temperature after bending test
Technical data of measurement circuit
See Sub-clause 4.1
Measured values

Test voltage

in kV
Noise level

in pC
PD initiation

in kV
PD at test
voltage
in pC
PD
interruption
in kV
Required
sensitivity
in pC
2xUo 40.6
1)

1.73xU
0
= 35.2
1 pC -
1.2 pC
also
- 5 pC


Test results

4.3 Tan measurement at 5 C to 10 C above the maximum conductor temperature
Normative document
IEC 60502-2: 2005-03, Sub-clause 18.1.5


Rated power 100 kVA


Measured quantity Measuring sensor/device Technical parameters
Test voltage HV divider (Haefely)
Inv. No. 11228/6, Cal. No. 12315
MU11 peak voltmeter (TUR Dresden)
-
Tan MWB measuring bridge
Cal. No. 7524
-
Standard capacitor Compressed gas capacitor
Cal. No. 12314
C = 57.02 pF

Tr High-voltage test transformer with variable transformer
C-T. Capacitive divider
P Peak voltmeter PO Test object
C Standard capacitor tan tan- measuring bridge
HT Heating transformer T Temperature measurement

Measured values
Test temperature: 95 C to 100 C

Test voltage Measured tan tan required
3 kV 10.3 x 10
-4
40 x 10
- 4

Test results
Tr
C-T.
P
HT
C
PO
tan
T
Dummy

4.4 Heating cycle test followed by a partial discharge test
Normative document
IEC 60502-2: 2005-03, Sub-clause 18.1.6


PO Test object S Copper screen
H T Heating transformers T Temperature measurement

Number of cycles: 20
Minimum 5-hours heating period, minimum 3-hours natural cooling
Test temperature: 95 C to 100 C at the conductor

The test set-up was subjected to 20 heating cycles. During the cyclic load, the cable was heated
to a minimum conductor temperature ranging from 95 C to maximum 100 C. The temperature
was maintained constant for 2 hours. Subsequently, the cable was naturally cooled during 3 hours.
The conductor temperature was continuously checked at the dummy.

Partial discharge test at ambient temperature after heating cycle
Technical data of measurement circuit
See Sub-clause 4.1

Measured values

Test voltage

in kV
Noise level

in pC
PD initiation

in kV
PD at test
voltage
in pC
PD
interruption
in kV
Required
sensitivity
in pC
2xUo 40.6
1)

1.73xU
0
= 35.2
1 pC -
1.2 pC
also
- 5 pC


Test results
HT
PO
Dummy T
HT
PO
Dummy T
S

4.5 Lightning impulse voltage test at a maximum conductor temperature ranging from
95 C to 100 C
The test circuit was heated to a conductor temperature of (95+5) C. After the conductor
temperature had stabilized at least 2 h, a lightning impulse voltage test according to IEC 60060
and IEC 60230 was carried out, i.e. the test circuit was subjected to 10 impulses of each polarity,
U
p
= 190 kV (2.62/49.6 s).

Normative document
IEC 60502-2: 2005-03, Sub-clause 18.1.7

Impulse voltage test at high temperature followed by a voltage test

Impulse circuit: Number of stages n = 2
Impulse capacitance C
S
= 70 nF
Loading capacitance C
B
= 1.5 nF
Damping resistance R
D
= 130
Discharge resistance R
E
= 1100


Measuring point Measured quantity Measuring sensor/device Technical parameters
1 Test voltage R divider of SMR 10/770 type (TuRD)
with digital measuring instrument of
DMI 551 type (Haefely) and TDS 220
digital oscilloscope (made by Tektronix)
Ratio 466.9

Gl Rectifier C
B
Loading capacitance
C
S
Impulse capacitance PO Test object
ZFS Spark gap 1 Measuring point
R
E
Discharge resistance HT Heating transformers
R
D
Damping resistance T Temperature measurement

HT
PO
Dummy
T
C
S
R
E

C
B

+ / -
Gl ZFS
R
D

~ 1

Measured values
Test voltage
U
p
in kV
Lightning impulse
voltage,
positive polarity
Lightning impulse
voltage,
negative polarity
Number of
impulses
Result
x 10
190
x 10
No disruptive,
no discharge

Power-frequency voltage test during the cooling
Test voltage AC 71 kV for 15 min.

Test results
No breakdown was occurred. The test has been PASSED.


4.6 Power-frequency voltage test for 4 h
Normative document
IEC 60502-2: 2005-03, Sub-clause 18.1.8


Single-phase AC voltage source

Rated power 100 kVA
Damping resistance 0.67 kOhm


Measuring point Measured quantity Measuring sensor/device Technical parameters
1 Test voltage Capacitive divider with MU11
(TuRD) peak voltmeter
Ratio 864

E Supply
PTr Test transformer with variable transformer connected in series
R
D
Damping resistance
P Peak voltmeter
PO Test object

Power-frequency voltage test
Test voltage AC 81.2 kV for 4 h

Test results

P
PTr
E
R
D
PO

4.7 Resistivity of semi-conducting screens before and after the ageing treatment
Normative document
IEC 60502-2: 2005-03, Sub-clause 18.1.9

Test arrangement
As described in IEC 60502-2, Annex C

Test equipment and measuring instruments
Heating cabinet No. 18 for ageing treatment, calibration No. 9977
Heating cabinet No. 21 for measurement, calibration No. 10060
DC voltage supply HP E 3610A, Inv. No. 10642/01
Multimeter Fluke 8050A Inv. No. 10866/02, calibration No. 9762

Measured values
Resistance in Ohm m Semi-conducting screen
Before ageing After ageing at 100 C Requirement
Inner 676 602 1000
Outer 44 43 500

Test results


5. Type tests, non-electrical on the cable
Test performed

a) Measurement of thicknesses and check of cable construction
b) Tests for determining the mechanical properties of insulation before and after ageing
c) Tests for determining the mechanical properties of the PVC oversheath before and after ageing
d) Ageing tests on cables to check compatibility of materials
e) Loss of mass test on PVC sheaths of type ST
2

f) Pressure test at high temperature on sheath
g) Test on sheath at low temperature
h) Test for resistance of PVC sheath to cracking (heat shock test)
i) Hot set test for XLPE insulations
j) Water absorption test on insulation
k) Flame spread test on single cables
l) Shrinkage test for XLPE insulation


5.1 Measurement of thicknesses and check of cable construction
Normative document
IEC 60502-2: 2005-03, Sub-clauses 19.1, 19.2

Measuring instruments
Profile projector

PVC oversheath
Marking
00966 HES YXC7V-R 1x35/16 mm 20.3/35 kV
TSEK 22/03/2009 01 TEDAS
Colour Red
Material PVC

Diameter
mm
Thickness
mm
Measured values 33.21 33.95 33.79
2.19 2.11 2.18
2.08 2.36 2.48
Required nominal value
by IEC 60502-2
Without 2.0
Required nominal value
by manufacturer
34 2 2.0
Measured average value 33.65 2.23
Measured minimum value 33.2 2.08
Required minimum value
by IEC 60502-2
Without 1.61

Tape
Measured values Nominal values
Number of tapes 1 No data
Width x thickness mm 60 x 0.05 No data
Overlap mm 8 No data

Copper screen
given by manufacturer
Wires
Diameter over screen mm 29 Approx. 30.2
Number of wires 60 60
Diameter of wires mm 0.57 0.55
Copper helix
Number of tapes 1 1
Width x thickness mm 10 x 0.1 10 x 0.1
Cross section
inclusive copper helix
mm 16.3 Min. 16


Semi conductive tape
Number of tapes 1 No data
Width x thickness mm 50 x 0.2 No data
Overlap 0 No data

Dimension of core
Measuring instruments
Profile projector inventory No. 10609/01 with calibration disk, inventory No. 10614/01

Outer semi-conducting screen

Diameter
in mm
Thickness
in mm
Measured values 27.41 27.49 27.79 0.57 0.59 0.54 0.48
0.46 0.58
Nominal value
required by manufacturer
27.4 0.6
Minimum measured value -- 0.46
Average 27.6 0.54
Maximum measured value -- 0.59

XLPE insulation

Diameter
in mm
Thickness
in mm
Measured values 26.36 26.44 26.66 8.78 8.89 9.25 9.53
9.32 9.17
Nominal value
Approx. 26.2 9.0
Minimum value
to IEC 60502-2
-- 8.0
Minimum measured value 26.36 8.78
Average measured value 26.5 9.13

Centricity -- 0.08
Requirement -- 0.15

Inner semi-conducting screen

Diameter
in mm
Thickness
in mm
Measured values 8.23 8.23 8.24 0.54 0.55 0.54 0.55
0.55 0.55
Nominal value
8.2 0.6
Minimum value
-- 0.3
Average measured value 8.23 0.6


Stranded copper conductor
Measured values Required values
by IEC 60228
Diameter measured value 7.17 mm 7.01 mm --
Diameter average value 7.09 mm Min. 6.6 mm Max. 7.5 mm
Number of core conductors 7 7

Conductor resistance
Normative document
IEC 60502-2: 2005-03; IEC 60228

Measured values at ambient temperature
Measured value
/km at 20 C
Max. permissible value
/km at 20 C
0.512 0.524

Test results

5.2 Tests for determining the mechanical properties of the insulation before and after
ageing
Type of compound: XLPE

Normative documents
IEC 60502-2: 2005-03, Sub-clause 19.3

Testing device
Tensile test machine Zwick Z 1435, heating cabinet No. 4

Measured values before ageing
Sample No. Tensile strength
in N/mm
Elongation at break
in %
1 17.16 455
2 22.76 503
3 17.05 451
4 16.45 437
5 20.21 483
6 18.99 477
Median 18.07 466
Requirements Min. 12.5 Min. 200

Measured values after ageing treatment
Treatment: 135 C, 7 days

in N/mm
Elongation at break
in %
1 18.55 493
2 21.07 510
3 17.60 490
4 19.41 503
5 18.99 496
6 20.06 505
Median 19.20 499

Measured variation 6.3 % 7.1 %
Requirements Max. 25 % Max. 25 %

Test results


5.3 Tests for determining the mechanical properties of the PVC oversheath before and
after ageing
Type of compound: ST
2

Normative documents
IEC 60502-2: 2005-03, Sub-clause 19.4

Testing device

Measured values before ageing
in N/mm
Elongation at break
in %
1 16.03 241
2 13.25 238
3 12.90 166
4 12.90 231
5 13.47 238
6 13.59 222
Median 13.36 234
Requirements Min. 12.5 % Min. 150 %

Measured values after ageing treatment

in N/mm
Elongation at break
in %
1 12.24 193
2 12.86 202
3 12.42 216
4 12.99 204
5 12.71 177
6 11.99 183
Median 12.56 197
Requirements Min. 12.5 Min. 150

Variation -6.0 % 15.8 %

Test results

5.4 Ageing tests on pieces of complete cables to check compatibility of materials
Normative document
IEC 60502-2: 2005-03, Sub-clause 19.5

Testing device

XLPE insulation
Treatment: 100 C, 7 x 24 h

in N/mm
Elongation at break
in %
1 15.71 434
2 15.26 423
3 16.21 431
4 16.98 448
5 18.47 463
6 16.52 444
Median 16.36 439

Variation -9.5 % -5.8 %

PVC oversheath
Treatment: 100 C, 7 x 24 h

in N/mm
Elongation at break
in %
1 14.05 2,15
2 14.36 218
3 12.00 177
4 12.14 142
5 13.00 166
6 13.93 203
Median 13.46 190
Variation -9.5 % -5.8 %

Test results

5.5 Loss of mass test on PVC oversheath of type ST
2

Normative document
IEC 60502-2: 2005-03, Sub-clause 19.6

Testing device
Laboratory balance, heating cabinet No. 4


Sample Loss of mass
mg/cm
Requirement
mg/cm
1 0.94
2 1.12
3 1.12
1.5

Test results

5.6 Pressure test at high temperature on the PVC oversheath
2

Normative documents
IEC 60502-2: 2005-03, Sub-clause 19.7

Testing device
Heating cabinet No. 21, measuring projector

Treatment: 90 C, 6 h

Sample No. Thickness of sheath Engaged depth
mm mm %
1 2.30 0.62 27
2 2.31 0.54 26
3 2.44 0.63 23
Requirements None None Max. 50

Test results


5.7 Test on sheath at low temperature
2

Normative documents
IEC 60502-2: 2005-03, Sub-clause 19.7

Testing device
Cooling chamber, elongation test machine

Treatment: -15 C

Length
pre elongation
Length
after elongation
Sample No.

mm mm %
1 20 34 70
2 20 40 100
3 20 41 105
4 20 44 120
5 20 44 120
6 20 34 70
Requirements -- -- --

Test results

5.8 Test for resistance of PVC sheath to cracking (heat shock test)
2

Normative documents
IEC 60502-2: 2005-03, Sub-clause 19.9

Testing device
Heating cabinet No. 22

Treatment: 150 C, 1 h

Test results
None cracks were seen.


5.9 Hot set test for XLPE insulations
Normative documents
IEC 60502-2: 2005-03, Sub-clause 19.11

Test temperature
200 C

Testing device
Heating cabinet No. 21, length measurement system (for example a steel measuring tape)

Measured values
Treatment: 200 C, 15 minutes, 5 minutes

Sample No.

Elongation
under load
Permanent elongation
after cooling
in % in %
1 38 4.8
2 33 2.4
3 38 2.4
4 32 2.4
5 32 2.4
6 33 2.4
Requirements Max. 175 Max. 15

Test results

5.10 Water absorption test on insulation
Type of compound: XLPE

Normative document
IEC 60502-2: 2005-03, Sub-clause 19.13

Testing device
Low-pressure oven No. 30, laboratory balance, inventory No. 1132/05

Measured values
Sample
No.

Weight
M1
of dry
pieces
Weight
M2
of wet
pieces
Weight
M3
of dry
pieces
Area

cm
Result

mg/cm
Requirement

mg/cm
1 0.3225 0.3245 0.3224 10.2672 0.20
2 0.3306 0.3317 0.3306 10.2880 0.11
< 1

Test results

5.11 Flame spread test on single cables
2

Normative document
IEC 60502-2: 2005-03, Sub-clause 19.14

Testing device
As described in IEC 60332-1-2

Test results
The PVC sheathed cable sample has PASSED the test.

5.12 Shrinkage test for XLPE insulation
Normative document
IEC 60502-2: 2005-03, Sub-clause 19.16

Testing device
Oven No. 21, steel tape measure

Measured values
Sample
No.

Distance
before ageing
mm
Distance
after cooling
mm
Result

%
Requirement

%
1 200 197.5 1.3 Max. 4

Test results


6. Sketches/Drawings/Data sheet

Figure 1: Sketch of the tested cable

POLYESTER TAPE
COPPER TAPE
SCREEN (COPPER WIRES)
SEMI CONDUCTIVE TAPE
INSULATION SCREEN(XLPE)
INSULATION (XLPE)
CONDUCTOR
OUTER SHEATH
COPPER CONDUCTOR

Figure 2: Data sheet of tested cable
1 - GENERAL
- Producer : HES HACILAR ELEKTRK SAN. VE TC. A..
- Cable Code : YXC7V-R (YE3SV)-N2XSY
- Aplied Standards : IEC 60502-2
- Rated Voltage (U0/Um) (kV) : 20.3/35
- Max. Operating Voltage (Um) (kV) : 42
2 - STRUCTURAL PROPERTIES
2.1 CONDUCTOR
. Type : Compacted Conductor
. Material : Annealed Electroltyic Copper
. Cross-sectional Area (mm) : 1x35/16
. Number of Wires : 7
. Type of Stranding : Circular
. Outer Diameter of Strand (max) (mm) : 7,0
2.2 INNER SEMICONDUCTING SCREEN
. Material : Semiconductive XLPE
. Nominal Thickness (mm) : 0,6
. Minimum Thickness (mm) : 0,3
. Outer Diameter of Screen (Approx.) (mm) : 8,2
2.3 INSULATION
. Material : XLPE
. Outer Diameter of Insulatio (Approx.) (mm) : 26,2
2.4 OUTER SEMICONDUCTING SCREEN
. Material : Semiconductive XLPE
. Outer Diameter of Screen (Approx.) (mm) : 27,4
2.5 METALLIC SCREEN
. Material : Copper
. Type : Wire & Tape
. Number & Diameter of Wires (mm) : 60x0.55
. Number of Copper Tape & Dimensions (mm) : 1 - (0.1x10)
. Geometrical Area (mm) : 16
. Outer Diameter (Approx.) (mm) : 30,2
2.6 OUTER SHEATH
. Material : PVC
. Colour : Red
.Outer Diameter of Cable (mm) : 34 2
MEDIUM VOLTAGE CROSS-LINKED PE (XLPE) INSULATED POWER CABLE 1x35/16 mm
2

Figure 3: Chart of heating cycle test
Conductor temperature
Sheath temperature

7. Photo

Figure 4: Cable samples after flame spread test

35 mm

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