Damped AC for Commissioning & Diagnostic Testing of HV Cable Circuits

Cables & Accessories, HV/HP Testing

November 21, 2020 17 min read

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Current IEC standards for power cable systems up to and above 150 kV rated
voltage are manufacturer standards and, according to experts, do not necessarily
provide adequate recommendations for testing after-installation. By contrast,
IEEE 400 and IEEE 400.4 recommend partial discharge monitored testing using
continuous or damped AC voltage (DAC). This edited contribution to INMR by
Paul Leufkens of Power Projects Leufkens in the United States along with Edward
Gulski and Rogier Jongen on onsite hv solutions in Switzerland, focuses on use of
DAC for after-laying testing and diagnostics of all types of transmission cables.
These recommendations are based on experience collected over more than 15
years from power grids across the globe.
Reliable energy transport is fundamental to all on and offshore infrastructure and
maintaining quality control regulations over newly-installed as well as service-
aged cable connections is of great importance. Key questions for any Transmission
Grid Operator (TSO) in regard to reliable network operation include:

1. How best to detect poor workmanship defects in newly installed cable circuits in
a sensitive yet non-destructive way?
2. How to perform non-destructive diagnostics of cable circuits already in service
in order to determine their actual condition?

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Based on present IEC standards for power cables up to and above 150 kV
operating voltage, after-installation test protocols are limited to manufacturer
minimum recommendations. But these do not necessarily always meet the need to
keep failure risk during operation as low as possible. As a result, when considering
responsible operation and asset management of transmission power cables, testing
newly installed cable systems should be able to reveal:

1. Manufacturing related defects → less probable due to the high level of quality
control in a factory;
2. Accessories parts delivery problems → more probable due to more
diversification in supply chains;
3. Installation related defects → highly probable due to diversification in
installation supply chains and practical difficulties when installing HV cable
systems on or offshore.

Moreover, maintenance and diagnostic testing of cable systems already in

operation should allow estimation of:

1. Operational damage as well as electrical and thermal over stresses → cannot be

neglected e.g. transients and over voltages;
2. Ageing processes → depend on many operational and local factors e.g. presence
of installation defects, load constrictions;
3. Remaining service life → goal of asset managers to keep CAPEX and OPEX at
an optimal level. Unfortunately, some traditional testing companies and contractors
and also some TSOs refer to IEC procedures to ensure quality.

But these documents (IEC 80840 & IEC 62067) were introduced 30 years ago,
were highly influenced by manufacturers and tend to discuss factory-testing
aspects. Only basic after-installation tests are mentioned. Moreover, no guidelines
are provided in regard to maintenance of cable circuits and also
maintenance/diagnostic testing. In particular, IEC 60840 and IEC 62067 only
recommend a ‘Go/No-Go’ decision as a result of breakdown during one of the
following tests:

• Soak test with Uo at 24 hours; or

• After-installation test with 1.73 Uo or 2.0 Uo for cables with rated voltages up to
150 kV;
• After-installation test with 1.7 Uo, 1.4 Uo or lower for cables with rated voltages
above 150 kV.
But these over voltage based destructive tests are not suitable to verify if there are
insulation weak spots in a newly installed cable section. In case of an installation
fault, breakdown occurs only in the case of an extremely serious defect (i.e. rarely).
Yet in a situation where no breakdown occurs, presence of defects in accessories
can still not be fully excluded. It is well known that breakdowns during such tests
seldom occur and that the major reason for cable failures (i.e. some 30% of all
failures after installation) are due to defects in or at the interface of joints and
terminations. Most such installation defects result from poor workmanship.
Moreover about 80% of insulation defects in power cables could be detected only
using advanced diagnostics e.g. sensitive partial discharge detection. Considering
the focus on reliability, the question is whether these failures could be avoided if
TSOs maintain and update their testing procedures based on the latest
developments. In this regard, the more recent IEEE 400 and IEEE 400.4,
developed in co-operation between power companies, manufacturers and testing
companies, can play an important role, in combination with other selected IEC
documents. IEC 60060-3 and IEC 60270, for example, represent the state-of-the-
art when it comes to modern, non-destructive methods for after-installation as well
as for maintenance testing and diagnostics.
On-Site Generation of DAC Voltages
For sinusoidal voltages in the frequency range 20 to 300 Hz, close to the 50/60 Hz
network stresses, testing is often conducted using a resonant test set (RTS). But an
alternative is application of damped AC (DAC) voltages, including standardized
conventional PD detection and analysis, which is now accepted worldwide for on-
site testing and diagnosis of HV and EHV power cables. DAC technology was first
introduced at the Jicable Conference in 1999 and now has some 20 years use in
testing and diagnosing MV and HV power cables across the globe. Nowadays the
DAC technology makes it possible to energize long lengths of power cable with a
high capacitance with a low input power demand. The characteristics of the applied
technology meet the specification of modern on-site testing systems:

• Lightweight modular system,

• Compactness in relation to the output voltage,
• Low effort for system assembling,
• Low power demand incl. long cable lengths,
• Low level of EM noises and possibility of sensitive PD detection and localization
as well as dissipation factor measurements.

DAC testing for newly installed and service-aged cables is almost always applied
in combination with partial discharge (PD) and dissipation factor (tan δ)
measurements. Moreover, use of DAC voltages for testing power cables complies
with relevant testing parameters derived from IEC, IEEE and Cigré standards and
guidelines.
The system consists of a digitally controlled high voltage power supply to energize
capacitive load of power cables with large capacitance, e.g. 10 µF (see Fig. 1).
Energizing time depends on maximum available load current of the high voltage
power supply, test voltage and capacitance of the test object but must remain less
than 100 seconds. During a number of AC voltage cycles, PD signals are initiated
in a way similar to 50/60 Hz inception conditions. In accordance with IEEE 400.4-
2015, no DC stresses are applied to the test object and the DAC stress can be
considered similar to factory testing conditions. Due to the continuous voltage
increase and the immediate transition to the DAC voltage after the maximum test
voltage is reached, no steady-state condition occurs. The low electric field strength
in the insulation (typically < 20 kV/mm) and the short duration of bipolar stresses
(i.e. less than a second up to tens of seconds) ensure no space charge accumulation
(see Fig. 2).

Fig. 1:
Schematic of damped AC (DAC) systems for on-site testing and PD detection of
transmission power cables.
CLICK TO ENLARGE

Fig. 2:
Examples of damped AC voltage excitations monitored by PD detection. PD
activity can be used to localize breakdown site.
CLICK TO ENLARGE

Fig. 3:
Monitored voltage withstand testing of 150 kV XLPE cable underground circuit
(4.5 km). Example of PD mapping as obtained during DAC voltage testing up to
1.0 Uo showing clear PD concentration on joint location at 2.6 km.
CLICK TO ENLARGE
 Fig. 4:
Example of dissipation factor diagnosis data as obtained for two different oil-filled
cable circuits: a)- b) 150 kV power cable aged 49 years, c)-d) 230 kV power cable
aged 33 years.
CLICK TO ENLARGE
Applying DAC voltage, sensitive PD detection and localization in power cables
becomes possible. Using time domain reflectometry (TDR), presence of PDs in
cable terminations, joints or cable parts can be localized (see Fig. 3).

Moreover, dissipation factor, tan δ, can be estimated using the decay characteristics
of the damped AC voltage. This can be especially valuable for detecting onset of
ageing in paper-oil insulated cable insulation (see Fig. 4).

DAC Voltage Withstand Testing

According to IEEE 400.4, 50 excitations should be repeated followed one after the
other in order to perform a voltage withstand test at the maximum test voltage (see
Fig. 5). Considering time from PD initiation until breakdown and also shorter
duration of the excitation and decaying characteristics of the voltage, DAC test
results might differ from those obtained by continuous AC withstand voltage
testing. Assuming that testing should not necessarily be destructive and that PD
inception indicates the presence of defects, the difference in time to breakdown has
to be considered an advantage of DAC testing.

Fig. 5: Monitored voltages withstand testing of 50 kV XLPE cable underground

circuit (12 km): a) example of PD pattern at 1.7Uo; b) DAC voltage withstand test
1h 2.5 Uo.
CLICK TO ENLARGE
Testing Long Length Cables
Sensitive detection and localization of PDs in long cable systems (e.g. 30 km) can
be improved by performing measurements at both sides of the cable circuit. In the
case of single sided PD localization, the overall PD pulse travelling distance is two
times the cable length. But with double-sided PD measurement, the near end PD
only has to travel to the far end to be detected there, thereby travelling only one
time the cable length. This can improve detection sensitivity by up to 200%.

A damped AC system for energizing the cable system is used for such a double-
sided measurement system (see Fig. 6). This dedicated solution uses a coupling
capacitor with PD detector at the near end side and a second PD detector at the far
end side (see Fig. 7).

Fig. 6: Setup for double-sided PD measurement with localization feasibility, DAC

excitation circuit and synchronized PD detector units.
Fig. 7: PD mapping resulting from double sided measurement (energizing 110 kV
XLPE cable with DAC system at near cable end and slave unit at remote cable
end) on 19.1 km cable indicating PD activity in Phase L1 joint at 13.7 km position.
CLICK TO ENLARGE
On-Site Testing of HVDC Cables
Apart from HVAC cables, DAC technology is also suitable for testing HVDC
cables. Installing an HVDC cable (e.g. submarine) is costly and challenging and
the technical interventions for repair in case of faults are also costly and difficult.
This makes effective commissioning testing even more desirable. Submarine
power cable circuits have typical characteristics, including:

• high capacitances of HVDC cables that require extremely high power demand for
conventional HVAC test systems;
• large number of (factory-installed) joints.

Testing with AC resonant test (ACRT) systems does not provide the desired
selection criteria to obtain overall assessment of cable condition and requires great
effort to generate the power requested on-site (i.e. numbers of ACRT sets).
Compared to HVAC cable systems and accessories, HVDC cables are also
designed differently. This could result in damage to HVDC cable and accessory
insulation in case of defect breakdown under regular AC voltage over stresses.
DAC testing, by contrast, makes it possible to energize very long lengths of AC as
well as HVDC power cable with a high capacitance due to its low input power
demand. In fact, only DAC voltage testing, including single- or dual-side partial
discharge detection at the terminations, is able to test a complete installed HVDC
cable length as well as detect and locate possible defects introduced either in the
factory or after transport and installation.

On-Site Testing of Subsea Cables

Rapid growth in the number of offshore wind farms has contributed to continuing
increase in renewable energy but repairing damage to such infrastructure can be
challenging and costly. Subsea cable damage most often arises from two areas:

1. External faults such as caused in the open sea by anchor strikes or dragging
fishing nets and due to erosion from jointer error or poor workmanship;
2. Poor planning at the start of the project coupled with inadequate risk
identification, sub-standard design or deficiencies in how procedures are applied.

Indeed, each year the offshore wind sector reports on average at least 10 subsea
cable failures. These incidents, while not frequent, still carry a high financial
impact that continues to grow and accounts for about 77% of global losses by
offshore wind farms. It has determined that some two-thirds of cable faults
recorded in insurance claim databases can be attributed to contractor errors during
installation – even if these do not become evident until a wind farms starts
operating or is operational for a period of time. Several technologies are available
to perform on-site testing of power cables. Tables 1 & 2 provide an overview of
these techniques, including assessing key aspects of each. As can be seen, DAC
monitored testing of offshore cables offers several advantages.

In general, an effective after-laying testing technology has to be suitable:

• for offshore testing, taking into account restrictions regarding e.g. size, weight,
weather protection;
• to provide adequate information: voltage testing and fingerprinting (e.g. PD, tan
δ) during the entire installation and operational process;
• to ensure reliable operation of inter-array cables;
• to provide contractors a basis for lowering risks during the warranty period;
• to allow service providers a solid basis for condition-based maintenance during
operation.

Moreover, risk management criteria for contractors (e.g. a 5-year warranty),

system operators and insurers have to be related to a quality control system applied
during construction, e.g.:

a. Soak Test (non-monitored)

Due to lack of information about operational reliability, this offers no warranty.
b. Non-monitored voltage withstand test only
Due to only locating extreme defects, this offers but limited warranty.
c. Monitored voltage withstand test (DAC resp. AC voltage test) with sensitive
(PD, TD) fingerprinting By providing complete information, this allows the fullest
possible warranty.

Table 1: Overview of Practical Test Technologies for Monitored Withstand Test of

66 kV Subsea Inter-Array Cables.
Table 2: Overview of Practical Test Technologies for Monitored Withstand Test of
Subsea Export Cables.
CLICK TO ENLARGE
Practical Case Histories
Offshore Inter-Array Cables
During a maintenance outage on a 15-year old 160 MW offshore wind farm, 10
complete strings of inter-array cables from the offshore substation to the wind
turbines were DAC tested as part of diagnostic testing. For this purpose,
switchgear in each wind turbine was switched in such a way that all the inter-array
cables between the wind-turbines were connected to one another (see Fig. 8). The
DAC test system was connected to the cable string under test via a special test
adapter in the switchgear on the offshore substation (OSS). Total lengths of cable
strings varied from 5.2 km to 9.5 km.
Fig. 8: Layout of array cable strings, each string consisting of total of 8 WTGs.
DAC test has been performed from OSS.
CLICK TO ENLARGE
The benefit in this case was that the test system did not need to be transported
between tests, i.e. all tests could be performed from the OSS (see Fig. 9).
Fig. 9: Measurement set-up of DAC offshore system connected to one phase of
array string via test adapter cable connected to switchgear on OSS.
CLICK TO ENLARGE
Partial discharges were detected and localized in an 8.4 km long string of inter-
array cables between the OSS and 9 wind turbines. Each phase was individually
tested using a damped AC offshore system with a DAC frequency of 100 Hz (i.e.
total cable capacitance 1.85 µF). Maximum applied test voltage level was 1.4 U0.
PD monitored withstand testing was performed of 50 DAC excitations at
maximum test voltage. Although no breakdown was observed during the withstand
test, as damped AC test voltage was increased starting from 1.4 U0, PD activity
was detected in phases L2 and L3 of the string (see Fig. 10).
PD mapping revealed the PD concentration at 5.9 km in phase L3 and at 6.5 km in
phase L2. These locations matched WTG locations where cable terminations enter
the switchgear of a wind turbine. Based on these PD results (i.e. PD inception
voltage and PD concentration at termination) it was advised to investigate/repair
the location that showed PD activity or to further monitor the situation by repeating
measurement on this string within a year. Since PD inception voltage in this case
was above the nominal operating voltage of the cable, the operator decided to
monitor PD behaviour and repeat the measurement in about one year during the
next maintenance stoppage.

Fig.
10: Phase resolved PD pattern at 1.4 U0 (top), PD mapping showing complete
string length with localized PD concentrations at wind turbines (WTG) at 5.9 km
and 6.5 km. The squares are locations of WTGs in string (bottom).
CLICK TO ENLARGE
HV Transmission Cable
After-installation testing was performed on a newly installed 161 kV XLPE
insulated underground cable circuit with length of 5.8 km (see Fig. 11). Maximum
test voltage applied was 1.7 Uo and test frequency was 66 Hz. PD was detected
starting already from 0.4 Uo in one of the total 6 phases (double circuit, see Fig.
12). Increase in test voltage resulted in increased PD activity. During the test, it
was decided not to increase voltage above Uo and not to perform a monitored
withstand test on this phase. Location of the PD defect could be determined with
TDR analysis.

Fig. 11: Onsite after-laying test of 161 kV cable.

PD mapping revealed the concentration at 5.0 km and indicated their position in

the cable (see Fig. 13), which was at the location of a joint. The other 5 phases
fulfilled after-laying conditions and successfully passed the test. There was no
internal PD activity in cable insulation or accessories and no breakdown occurred
during tests on the other phases.

Fig. 12:
Damped AC voltages and PD patterns observed during damped AC test at phase
L3.
 Fig.
13: PD mapping as made up to 1.0 Uo during damped AC on-site testing of 161 kV
5.8 km long cable circuit. PD concentration at 5.0 km distance indicates PD
location of phase L3.

Concentrated PD activity below the operating voltage in phase L3 was sufficient

reason to advise replacing or investigating the joint location. However, since this
PD evaluation was not part of the original commissioning agreement, in this case
the contractor decided not to immediately replace the joint. Unfortunately, after
half a year subsequent operation, failure occurred in the joint of phase L3 at the
5000 m position.

Summary & Conclusions

Based on international experience over many years, the following conclusions can
be drawn in regard to after-installation cable testing:

1. Present IEC 60840 and IEC 62067 standards do not fully cover the needs of
modern TSOs by recommending over-stresses to create a breakdown in a newly
installed cable section;
2. Performing sensitive non-destructive testing offers a solid basis for condition
assessment and future life estimation of transmission power cables;
3. Damped AC (DAC) PD monitored voltage withstand testing is now common
practice in many countries. PD measurements, including PD-pattern information
and time domain reflectometry (PD localization), can help detect and locate
discharge defects in power cable insulation and accessories;
4. DAC is a suitable technology to test long lengths of on- and offshore HVAC and
HVDC power cables, with low on-site power demand needed and with sensitive
PD detection and localization;
5. Case studies consistently demonstrate the value of applying damped AC testing,
including PD detection and estimation of dissipation factor, to predict risk of
failure prior to in service operation.

References
[1] F.J. Wester, E. Gulski, J.J. Smit, “Electrical and acoustical PD on-site
diagnostics of service aged medium voltage power cables”, 5th International
Conference on Power Insulated Cables, Jicable 1999
[2] IEC 60840: Power cables with extruded insulation and the accessories for rated
voltages above 30kV up to 150kV Test methods and requirements;
[3] IEC 62067: Power cables with extruded insulation and the accessories for rated
voltages above 150kV
[4] IEEE 400.4-2015: Guide for Field-Testing of Shielded Power Cable Systems
Rated 5 kV and Above with Damped Alternating Current Voltage (DAC)
[5] E. Gulski, R. Jongen, R. Patterson, Modern Testing and Diagnosis of Power
Cables using Damped AC Voltages, NETA World, Spring 2015
[6] R. Jongen, B. Quak, E. Gulski, P. Cichecki, F. de Vries, “On-site testing and
diagnosis of long medium voltage cables”, Condition Monitoring and Diagnosis
(CMD) conference, 2012, p. 659-662.
[7] R. Jongen, B. Quak, E. Gulski, S. Tenbohlen, “New developments in on-site
testing of long lengths of (E)HV power cable”, Condition Monitoring and
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on-site testing of long length transmission power cables, IEEE Transactions on
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1087
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of-offshore-wind-losses-528959
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