TYPE TEST REPORT - Hes · PDF fileTYPE TEST REPORT NO. 3149.2090352.0530 SHEET 2 This test...

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 „Prüffeld für elektrische Hochleistungstechnik“ GmbH (IPH Berlin) is a subsidiary of CESI S.p.A, Milan.

Independent, accredited testing station · Member laboratory of STL and LOVAG

TYPE TEST REPORT

NO. 3149.2090352.0530

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

CLIENT

HES Hacilar Elektrik Sanayi ve Ticaret A.Ş.

MANUFACTURER

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

TEST OBJECT

YXC7V-R (N2XSY) 1x35/16 mm² 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.Ş.

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 δ 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 ST2.......................................................................................................................................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 mm² 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 δ 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)

Ck = 1 nF

Output 10 pC

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

Zs

2

Zm

1

HE HE

PO

E PTr Ck

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)

1.73xU0 = 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 diameterin 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 The calibration was at 5 pC.

Test voltage

in kV

Noise level

in pC

PD initiation

in kV


PD interruption

in kV


in pC 2xUo 40.6 1)

1.73xU0 = 35.2 ≤ 1 pC - 1.2 pC also - ≤ 5 pC

1) Measured value during 2Uo 40.6 for 10 sec. Test results The test has been PASSED.


4.3 Tan δ measurement at 5 °C to 10 °C above the maximum conductor temperature

Normative document


Technical data of test circuit Test transformer: Rated voltage 100 kV Rated power 100 kVA Rated frequency 50 Hz Technical data of measuring circuit 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 δ 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 δ tan δ required

3 kV 10.3 x 10-4 ≤ 40 x 10 - 4

Test results

The test has been PASSED.

Tr C-T.

P

HT

C PO

tan

TDummy


4.4 Heating cycle test followed by a partial discharge test

Normative document


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

The calibration was at 5 pC.

Test voltage

in kV

Noise level

in pC

PD initiation

in kV


PD interruption

in kV


in pC 2xUo 40.6 1)

1.73xU0 = 35.2 ≤ 1 pC - 1.2 pC also

- ≤ 5 pC

1) Measured value during 2Uo 40.6 for 10 sec. 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, Up = 190 kV (2.62/49.6 μs). Normative document

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

Impulse voltage test at high temperature followed by a voltage test

Technical data of test circuit Impulse circuit: Number of stages n = 2 Impulse capacitance CS = 70 nF Loading capacitance CB = 1.5 nF Damping resistance RD = 130 Discharge resistance RE = 1100

Technical data of measuring circuit

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 CB Loading capacitance CS Impulse capacitance PO Test object ZFS Spark gap 1 Measuring point RE Discharge resistance HT Heating transformers RD Damping resistance T Temperature measurement

HT

PO

DummyT

CS RE CB

+ / -

Gl ZFS RD

~ 1


Measured values

Test voltage Up 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


Technical data of test circuit Single-phase AC voltage source Test transformer: Rated voltage 125 kV Rated power 100 kVA Rated frequency 50 Hz Damping resistance 0.67 kOhm Technical data of measuring circuit

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 RD 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

RD

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 ST2 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 mm² 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

Measured values Nominal values 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 sectioninclusive copper helix mm² 16.3 Min. 16


Semi conductive tape

Measured values Nominal values 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 required by manufacturer 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 required by manufacturer 8.2 0.6

Minimum value required by manufacturer -- 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 Ω/km at 20 °C

Max. permissible value Ω/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/mm²

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



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: ST2

Normative documents


Tensile test machine Zwick Z 1435, heating cabinet No. 14 Measured values before ageing



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

Treatment: 100 °C, 7 days



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 %




5.4 Ageing tests on pieces of complete cables to check compatibility of materials

Normative document


Tensile test machine Zwick Z 1435, heating cabinet No. 13 XLPE insulation

Treatment: 100 °C, 7 x 24 h



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 %

Requirements Max. 25 % Max. 25 % PVC oversheath

Treatment: 100 °C, 7 x 24 h



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 %




5.5 Loss of mass test on PVC oversheath of type ST2

Normative document


Laboratory balance, heating cabinet No. 4 Treatment: 100 °C, 7 days

Sample Loss of mass mg/cm²

Requirement mg/cm²

1 0.94 2 1.12 3 1.12

1.5

Test results


5.6 Pressure test at high temperature on the PVC oversheath


Normative documents


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


Normative documents


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)


Normative documents


Heating cabinet No. 22 Treatment: 150 °C, 1 h Test results

None cracks were seen. The test has been PASSED.


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


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

cm²

Result

mg/cm²

Requirement

mg/cm² 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


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 ELEKTRİK SAN. VE TİC. A.Ş.

- 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 (mm²) : 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 (mm²) : 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 mm2


Figure 3: Chart of heating cycle test

Conductor temperature

Sheath temperature


7. Photo

Figure 4: Cable samples after flame spread test

35 mm²

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