TEST FACILITIES CPRI

Cables lab has facilities to undertake type testing of all types of power cables of rating 1.1 kV up to 220 kV voltage rating and their accessories as per Indian and International standards .In addition the laboratory can undertake partial discharge test and dielectric loss power factor measurement on current transformers, bushings and surge arrestors etc. TESTING/EQUIPMENT FACILITY:o 600 kV, 600 KVA series Resonant test set. o 300 kV, 120 KVA Transformer o 100 kV, 20 KVA Partial discharge free test source and associated accessories. o 500 kV, 15 KJ Impulse voltage generator o 2000 Amps Current transformer o Robinson 803 Partial discharge discrimination System o Bonar Model 5 Discharge Detector o Transformer ratio arm bridges, 600 kV Standard capacitor o High Precision automatic insulation resistance measuring kit. o o o 500 kV water terminations for testing of EHV cables. Splicing machines for preparation of cable insulation samples for physical tests. Profile projector of magnification upto 100 Products/Apparatus Paper/PVC/XLPE/EPR Power Voltage rating up to 220 kV cables of Type of test All type test like partial discharge test, Tan delta measurement, Conductor Resistance Test, Tensile Test, Hot Deformation Test, Hot Set test, Shrinkage Test, Thermal Stability test etc All type test like partial discharge test, DC High Voltage Test, Impulse Test, Load Cycle Test Etc. Surge Partial discharge Test, Dielectric Loss Power Factor Test

Cable Accessories Current Transformers, Bushings, Arrestors etc up to 220 kV Rating

Products PILC cables up to 33 kV Elastomeric,& Polymeric insulated Power cables up to 220 kV Aerial bunched cables, Mining Cables Cable joints & Terminations Partial discharge testing on instrument transformers Partial discharge testing on Surge Arrestors

Standards IS 692, IEC 55-1, BS 6480 IS 7098 Part I,II, & III, IS 1554 Part I.& II, IS 694, IEC 60227, IEC 60245, IS 9968 Part I & II, IEC 60840, IEC 62067 ,IEC 60502 1,IEC 60502-2, BS 6622, BS 5467,BS 6346 IS 14255, IS 14494 C-81,IS 13573, IS 13705, IEC 60502-4,VDE 0278- 629, IEC 60044-1,IEC 60044-2, IEC 60044-3, IS 11322 , IS 3070, IEC 60099-4

Type Tests Bending test PD test amb. Diel. loss test Heating cycle test PD hot and PD amb. Impulse test hot AC test PD amb if not done before PD test amb Heat cycle test PD test amb and PD hot Impulse test hot Impulse test amb. AC test PD test amb. Insulating materials Dielectric properties of cable insulation: 1. 1. high insulation resistance 2. 2. high dielectric strength 3. 3. good mechanical properties 4. 4. immune to attacks by acids & alkalies 5. 5. non-hygroscopic Commonly used insulating materials are: a) a) Oil-impregnated paper b) b) Vulcanized India rubber(V.I.R) c) c) Polyvinyl chloride(P.V.C) d) d) SF6 gas e) e) Cross-linked polythene(XLPC) Void formation Voids (small pockets of air or gas) are formed in the insulation where constituent parts of the cable are expanded and contracted to different extents with heat evolved on load cycles. The stress across the voids is high and breakdown results.
Electrostatic stress in a single core cable The potential gradient is maximum at the surface of the conductor. Potential gradient art any point at a distance x from the centre of the conductor is G= V/ [x ln (R/r)] Where R is the inner radius of the sheath and, and r is the radius of the conductor. Grading of cables a) a) b) b) Capacitance grading Intersheath grading

Dielectric loss and loss tangent of a cable

The dielectric loss, due to leakage and hysterisis effects in the dielectric, is usually expressed in terms of the loss angle,H: H = 90- J where J is the dielectric power factor angle. Dielectric loss = [ C V tan H, Where C= capacitance to neutral V= phase voltage A typical value of tan H lies in the range 0.002 to 0.003. In low voltage cables the dielectric loss is negligible, but is appreciable in EHV cables.
2

Tests on Electrical Materials Type Tests Tests carried out to prove conformity with the specifications. These are intended to prove the general qualities and design of a given type of manufactured item. Routine Tests-Tests carried out on each part/item manufactured to check parameters (as per requirements0, which are likely to vary during production. Acceptance Tests- Tests carried out on samples taken at random from offered lot of manufactured item for the purpose of acceptance of lot. TYPE TESTS No. a Type test Tests on conductor 1. 1. Annealing test (for copper) 2. 2. Tensile test (for Aluminum) 3. 3. Wrapping test (for Aluminum) 4. 4. Resistance test Tests for armouring wires/strips Purpose To check softness of wire To check strength of Al wire To check hardness of Al wire To check cross-section of the conductor To check electrical , mechanical and chemical properties of armouring wire/strip To check capability of insulation to withstand voltage and its mechanical strength

Test for thickness of insulation and sheath

Physical test for insulation & sheath 1. Tensile strength & elongation at break 2. Ageing in air oven 3. Shrinkage test 4. Hot deformation 5. Loss of mass in air oven 6. Heat shock test 7. Thermal stability To check mechanical stress and strain during manufacturing and bending To check physical & chemical changes in insulation due to heat with age To prevent problem in termination To check resistance against deformation due to heat & mechanical pressure To check physical & chemical changes in insulation due to heat and time To check ability of cable against overheating To check thermal effect To check uniformities of insulation in dielectric To check ability of cable in water during service To check ability of cable against high voltage during service To check flame retardant properties

e f g h

Insulation resistance test High voltage test(Water immersion test) High voltage test at room temperature Flammability test

OPTIONAL TYPE TESTS No. a b Optional type test Cold bend test Cold impact test Purpose To check effect of low temperature during bending To check effect of low temperature on outer sheath in terms of hardness & softness To check electrical properties of armouring wire/strip

Armour resistance test (or other than mining cables

ROUTINE TESTS No. a b c Resistance test High voltage test at room temperature Armour resistance test (for mining cables) Test Purpose To check cross-section of the conductor To check ability of cable against high voltage during service To check conductivity of armouring materials

CROSS LINKED POLYETHYLENE INSULATED PVC SHEATHED CABLES [XLPE from 66 to 220 kV][IS: 7098 (Part-3)-1988]

TYPE TESTS: No. a Type Test Tests on conductor 1. Annealing Test (for Cu) 2. Resistance Test b Physical tests on insulation 1. Test for thickness & dimensions of insulation 2. Tensile strength & elongation at break 3. Thermal ageing in oven 4. Hot set test 5. Shrinkage test 6.Void & contaminants test c d Resistivity test for semi conducting layers Test for concentric metallic screen i) i) Test for concentric metallic screen ii) ii) Test for concentric copper tape Thickness of metallic sheath To check capability of insulation to withstand voltage and its mechanical strength To check mechanical stress & strain during manufacturing & bending To check physical & chemical changes in insulation due to heat with age To check cross-linking of insulating material To prevent problem in termination To check voids & contaminants To check resistance of semi-conducting layer To check capacity against short circuit Purpose To check softness of wire

To check cross-section of the conductor

To check capability of insulation to withstand voltage and its mechanical strength

To check that dimensions are within limits To check mechanical stress and strain during manufacturing and bending To check mechanical strength during bending To check resistance of armouring material To check mechanical strength To know the material used

Tests for armouring material 1. Dimensions 2.Tensile strength & elongation at break 3. Wrapping test 4. Resistivity test

g 1 2

Physical tests for outer sheath Measurement of thickness PVC Sheath

1. Tensile strength & elongation at break

To check mechanical stress and strain during manufacturing and bending To check physical & chemical changes in sheath due to heat with age To check physical & chemical changes in insulation due to heat and time To check ability of cable against overheating To check resistance against deformation due to heat & mechanical pressure

2. Thermal Ageing in air oven

3. Loss of mass 4. Heat shock test 5. Hot deformation test

6. Shrinkage test 7. Thermal Stability 3. PE SHEATH 1. Carbon black content 2. Tensile strength & elongation at break before & after ageing 3. Hot deformation

To prevent problem in termination To check thermal effect To know the material used To know the % of carbon To check mechanical stress and strain during manufacturing and bending To check resistance against deformation due to heat & mechanical pressure To check flame retardant properties

Flammability test (for PVC outer sheathed cable only) Water tightness test 1. Thermal ageing on complete cable sample

j k

To check penetration of water in cable To check physical &chemical changes in cable due to heat with age To check mechanical stress and strain during manufacturing and bending To know resistance of semi-conducting layer To check bending radius during bending while installation & handling To check rupturing capacity & voids

2. Tensile strength & elongation at break for insulation & outer sheath 3. Resistivity test for semi- conducting layers m Bending test followed by P. D. test

Dielectric power factor measurement at ambient temperature

Dielectric power factor measurement at elevated temperature Load cycle test followed by P.D measurement

To check impurities & voids

To check capacity of cable under loading conditions To check ability of insulating material to withstand lightning voltage

Impulse withstand test followed by HV test

NOTES: Tests from (n) to ( r ) shall be performed successively on the same test sample of complete cable, not less than 10 m length between test accessories Tests at (p) and (q) may be carried out on different samples.

OPTIONAL TYPE TEST:

No. Type Test Purpose

Cold impact test for outer sheath

To check effect of low temperature on outer sheath in terms of hardness & softness

ROUTINE TESTS
No. Routine Test Purpose

a b c

Conductor resistance test P. D. test HV test

To check cross-section of the conductor To check small voids and cavities in insulation To check ability of cable in service

ACCEPTANCE TESTS
No. 1 Acceptance Test Measurement of capacitance Purpose To check impurities & voids

The following Type Tests will be used as Acceptance Tests: a1,a2, b1, b4,b6,e, g1 The following Routine Tests will be used as Acceptance Tests: b, c Partial discharge test shall be carried out on full drum length

SCALE OF SAMPLING
No. of Drums in a Lot Up to 25 26 to 50 51 to 100 101 to 300 301 and above No. of Drums to be taken as sample 3 5 8 13 20 Permissible No. of Defectives 0 0 0 1 1

DRUMS FOR EECTRIC CABLES [IS: 10418-1982]

The tests under TYPE, ROUTINE and ACCEPTANCE categories are not specified in the Indian Standards. However, the following checks shall be made on DRUMS & their components. CHECKS FOR CONSTRUCTION OF DRUM:
S. No. 1 Description Mechanical strength Purpose (a) Transverse loading test (b) Impact test (c) Barrel batten test Free from protruding materials or Projections or unevenness capable of damaging the cable/hands a) For dia. Up to 1600mm- 2 ply OR 3 ply construction. b) For dia. Above 1600 mm- 2 full ply OR 3 full ply plus 1 segmental layer construction (Segments shall not be less than six) For flange dia up to 700mmDia 701 mm-1600mmDia above 1600 mm100 mm 150 mm 200 mm

2 3

Flange & outside surface Flanges (Main Discs) construction

Width of middle plank (Minimum)

Barrel end- supports

Shall be complete circular discs or of various segments. Securely fixed to inside of flanges by nailing Shall be complete circular construction of single/two ply layers (at 90 0) OR of various segments (Only for drums having transverse above 1000 mm). To be provided for drum sizes of 1206 mm and above mm +/- 20 +/-30 +/- 06 +/-09 +/- 20 +/-30 +/- 25 +/-3 +/-3 0 to+2 0 to +5

Barrel middle-supports

6 7

Stretchers (Core carrier planks) Tolerances in mm Drum flange dia ,up to & including 1600 mm Above 1600 mm Flange thickness up to & including 1600 mm Above 1600 mm Barrel dia. up to & including 1600 mm Above 1600 mm Overall & transverse widths Barrel battens thickness Stretchers thickness Centre hole dia. with bush Centre hole dia. without bush