138 kV Cable System Qualification to IEC 60840-2011 / … · 138 kV Cable System Qualification to...

• Jicable’15,21‐ 25June 2015‐ Versailles‐ France• Jicable’15,21‐ 25June 2015‐ Versailles‐ France

138 kV Cable System Qualification to IEC 60840-2011 / ICEA S-108-

720-2012 / AEIC CS-9-06Ravi Ganatra, Milan Uzelec,

Jose Zamudio, Joshua Perkel

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• Jicable’15,21‐ 25June 2015‐ Versailles‐ France

Reliable Underground Cable System

CABLE

ACCESSORIES

INSTALLATION

COMMISSIONING

In the field Cables and Accessories are required to work together as a System

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Cable System Testing

CABLE

ACCESSORIES

INSTALLATION

COMMISSIONING

Cable / Accessories: Tested & Qualified, preferably as a System

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ComponentAEIC CS9 requires component testing through:

Cable IEC 60840 ICEA S-108-720Joints IEC 60840 IEEE 404Terminations IEC 60840 IEEE 48

TAT and PQT Requirements for Cable Systems

36< kV ≤150 46< kV ≤150IEC AEIC

Cable System TAT: IEC 60840

TAT: AEIC CS9 through (IEC 60840 + ICEA S-108-720) - Not required, but preferred.

150< kV ≤500 150< kV ≤345IEC AEIC

TAT and PQT: IEC 62067

TAT and PQT: AEIC CS9 through IEC 62067 + ICEA S-108-720

No TAT or PQT for Individual Component.

There is more emphasis on System Qualification for Cable System up to 150 kV.

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ComponentAEIC CS9 requires component testing through:

Cable IEC 60840 ICEA S-108-720Joints IEC 60840 IEEE 404Terminations IEC 60840 IEEE 48

36< kV ≤150 46< kV ≤150IEC AEIC

Cable System TAT: IEC 60840

TAT: AEIC CS9 through (IEC 60840 + ICEA S-108-720) - Not required, but preferred.

This paper describes the challenges encountered and addressed in the development of an IEC/AEIC/ICEA qualification test program for a 138 kV Cable System.

While assessing and addressing the complexities added by the required number of accessories per IEEE and other desired expectations.

TAT and PQT Requirements for Cable Systems

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Challenge 1: Component Types Needed Challenge 2: Loop Architecture for IEEE

2000 mm2 XLPE Cable with Smooth Aluminum Seam Welded Sheath (left) and

Wire & Tape and Aluminum Laminate Sheath (right)

Premolded Joints (Shown in Copper and Fiberglass Housing)

Terminations: Composite Outdoor, Dry GIS and Wet GIS

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Challenge 2: Architecture for IEEE/AEIC/IECObservations from Dummy Loop:• Current / temperature requirement for

separate IEC/AEIC/ICEA and IEEE are lower than IEEE/AEIC/IEC super combo.

• Effects of high loading currents on cable and connectors significantly increase challenge for the system and the laboratory.

Decided to accept an intermediate challenge of an IEC/AEIC/ICEA test program with the quasi-IEEE architecture.

Loop constructed such that the length and accessory architectures would be compatible with the “Super Combo Test” (SCT) approach.

Resulting loop comfortably exceeded the minimum size requirements of IEC.

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Challenge 3: Load Cycle RequirementsFeasibility Study

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Challenge 3: Load Cycle Requirements Feasibility Study

280:00276:00272:00268:00264:00260:00

120

100

80

60

40

20

4000

3000

2000

1000

0

Elapsed Time

Tem

pera

ture

[deg

C]

Curr

ent [

A]

95CurrentAmbient TempConductor Temp

116:00112:00108:00104:00100:0096:00

120

100

80

60

40

20

4000

3000

2000

1000

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Elapsed Time

Tem

pera

ture

[deg

C]

Curr

ent [

A]

Current

Conductor TempAmbient Temp

256:00252:00248:00244:00240:00236:00

120

100

80

60

40

20

4000

3000

2000

1000

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Elapsed Time

Tem

pera

ture

[deg

C]

Curr

ent [

A]

105

CurrentAmbient TempConductor Temp

96:0092:0088:0084:0080:0076:0072:00

120

100

80

60

40

20

4000

3000

2000

1000

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Elapsed Time

Tem

pera

ture

[deg

C]

Curr

ent [

A]

105

CurrentAmbient TempConductor Temp

IEC 60840 95–100C, 2 h window 8 h on AEIC/ICEA 100–105C, 2 h window 8 h on (IEC Compliant)

IEEE 100–105C, 6 h window, 12 h on(Heating Time Exceeds IEC & ICEA

Maximums)

Combined AEIC, ICEA, and IEEE 100–105C 6 h window, 8 h on

20

30

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Optimizing the Test Loop for AEIC/ICEA with Extra Accessories and Two Cable Designs

Recent ExperienceIncludes:230 kV TAT & PQT275 kV TAT138 kV TAT138 ICEA

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AEIC/ICEA/IEC Test Sequence & Results

Order Test Type Std. Test for 138 kV

1 Bend Test IECICEA 3 forward and 3 reverse bends

2 AmbientPD

IEC

Ambient – 114 kV (start at 133 kV)

3 Hot Tan δ 95-100 ºC @ 76kV

4

Aging – 20 cycles

IEC 100-105 ºC 2h8 h on

24 h cycle159.8 kVICEA

Ambient Tan δ ICEA Ambient – 80 kV

Hot Tan δ ICEA 100-105 ºC – 80 kV

Order Test Type Std. Test for 138 kV

5 Ambient PDIEC Ambient - 114 kV (start at 133

kV)

ICEA Ambient – 160 kV

6 Hot PD IEC 95-100 ºC, 114 kV (start at 133 kV)

7 HotImpulse

IECICEA

100-105 ºC 2h650 kV Peak

8 acWithstand

IECICEA 200 kV for 2 h

9 Ambient PDIEC Ambient - 114 kV (start at 133

kV)

ICEA Ambient – 160 kV

10 Dissection IECICEA Examination and tear down

Optimized Test Loop with Long Thermal Loop (Left) and Main Loop (Right)

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IEC Annex G 138 kV Cables and Shield Break Joint

Annex G - Setup for Thermal Cycling & As- Installed in Water Housing (Without Final Housing Seals)

Order TestType

Test Specifics for138 kV

1 Bend Test 3 forward and reverse bends

2 Pre-conditioning

3 Heating Cycles, 24 h8 h current, 16 h cooling

95 – 100 C 2h

3 Aging 20 CyclesWater at 70 – 75 C 5h

4dc

Withstand

25 kV for 1 min across joint sectionalizer

5 25 kV for 1 min sheath to grounded exterior of joint

6Impulse

60 kV between parts

7 60 kV each part to ground

8 Dissection Tear down to determine if there has been moisture ingress

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Examination

Visual Examination of Termination and Joint

Moisture Indicating Tape at Both Ends of Annex G Joint

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Extension to IEEE

ANSI C119.4 Connection Stability Test

• AEIC, ICEA, and IEC do not directly address connector performance in their Ranges of Approval.

• IEEE 404 refers users to ANSI C119.4.

• To better understand the behavior of connectors in HV cable systems when going to “Super Combo Test”, it was decided to undertake the Copper-Copper Connection Stability described in ANSI C119.4.

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Conclusions• Demonstrated the feasibility of adding the number of accessories

required in IEEE standards for accessories.

• Test program successfully completed all requirements for approval under AEIC, ICEA, and IEC with the following components:– 55 m of 138 kV XLPE cable with 2000 mm2 segmental copper conductor– 3 Premolded joints (1 shield break & 2 straight joints)– 2 Dry-type GIS terminations– 2 Wet-type GIS terminations– 1 Composite outdoor termination

• Cable system far exceeds the minimum number of accessories and cable length required for either AEIC, ICEA, or IEC.

• The “Super Combo Test” approach is technically feasible but imposes significant challenges on the cable, accessories, and laboratory.

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Future Challenges• This work has exposed the limitations of the extensions

made in IEEE from prior experience with MV accessories.

• Lessons learned could help understand: How to differentiate requirements for Medium Voltage and HV/EHV components in IEEE Standards?

• Experience gained during this work will help bring necessary changes in future IEEE standards so that they are more aligned with AEIC and IEC standards since the system testing is more favored by the users for HV/EHV Systems.

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• Jicable’15,21‐ 25June 2015‐ Versailles‐ France• Jicable’15,21‐ 25June 2015‐ Versailles‐ France

Merci, Beaucoup!

Thank You!

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138 kV Cable System Qualification to IEC 60840-2011 / … · 138 kV Cable System Qualification to...

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