Plant Support Engineering-Advanced Diagnostics and Life Estimation of Extruded Dielectric Cable

Plant Support Engineering:
Advanced Diagnostics and Life

Estimation of Extruded Dielectric Cable
Nonproprietary Results Related to Cross-Linked Polyethylene

and Ethylene Propylene Rubber Insulated Shielded Cables
This report describes research sponsored by EPRI and the U.S. Department of Energy
(Award No. DE-FC07-03ID14536).
Technical Report
Effective December 6, 2006, this report has been made publicly available in accordance
with Section 734.3(b)(3) and published in accordance with Section 734.7 of the U.S. Export
Administration Regulations. As a result of this publication, this report is subject to only
copyright protection and does not require any license agreement from EPRI. This notice
supersedes the export control restrictions and any proprietary licensed material notices
embedded in the document prior to publication.
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Plant Support Engineering:
Advanced Diagnostics and Life
Estimation of Extruded Dielectric
Cable
Nonproprietary Results Related to Cross-Linked
Polyethylene and Ethylene Propylene Rubber
Insulated Shielded Cables
1013085
Final Report, March 2006
Cosponsor
U.S. Department of Energy
Washington, DC
EPRI Project Manager

G. Toman
ELECTRIC POWER RESEARCH INSTITUTE

3420 Hillview Avenue, Palo Alto, California 94304-1395 • PO Box 10412, Palo Alto, California 94303-0813 • USA
800.313.3774 • 650.855.2121 • askepri@epri.com • www.epri.com
9988853
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9988853
CITATIONS
This report was prepared by
Electric Power Research Institute (EPRI)

1300 W. T. Harris Blvd.
Charlotte, NC 28262
Principal Investigator
G. Toman
This report describes research sponsored by the Electric Power Research Institute (EPRI) and the
U.S. Department of Energy (Award No. DE-FC07-03ID14536, FY03 Task 2).
Any opinions, findings, and conclusions or recommendations expressed in this material are those
of the author(s) and do not necessarily reflect the views of the Department of Energy.
The report is a corporate document that should be cited in the literature in the following manner:
Plant Support Engineering: Advanced Diagnostics and Life Estimation of Extruded Dielectric
Cable: Nonproprietary Results Related to Cross-Linked Polyethylene and Ethylene Propylene
Rubber Insulated Shielded Cables. EPRI, Palo Alto, CA and U.S. Department of Energy,
Washington, D.C.: 2006. 1013085.
iii
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REPORT SUMMARY
Aging of extruded medium-voltage cable insulation under wet conditions is of concern to

utilities for cables used in power plants and for distribution of power to customers. Distribution
companies have large amounts of cable assets. Nuclear power plants have much smaller amounts
of medium-voltage cable by comparison, but failure of these circuits can affect the function of
safety systems or operation of the plant. Both the nuclear and distribution industries are
searching for diagnostic tests that can be applied to extruded cables to indicate the degree of
degradation and remaining life of the cable insulation.
Background
This report describes research on accelerated aging and diagnostic testing of cross-linked
polyethylene (XLPE) insulation and an earlier test program on ethylene propylene rubber (EPR)
cables. The XLPE research subjected cable specimens to accelerated cable life tests (ACLTs)
and assessed the specimens with six nondestructive electrical tests and two destructive tests. The
EPR program subjected EPR insulation to a similar accelerated aging protocol but focused on
breakdown voltage to assess aging.
Objectives
• To correlate advanced diagnostic test data with time-to-failure data as a means of
determining the value of each diagnostic test for cable condition assessment and future life
predictions (XLPE program)
• To develop mathematical aging models from the ACLT time-to-failure data and
mathematical degradation models using advanced diagnostic test results (XLPE program)
• To perform accelerated aging tests of EPR insulated cables under various controlled
conditions of temperature and voltage stress in a wet environment (EPR program)
• To ascertain the relative influence of temperature and voltage stress on aging (EPR program)
Approach
In each of the programs, cable specimens were subjected to accelerated aging under wet
conditions at differing levels of applied voltage and elevated temperature cycling. In the XLPE
program, four groups of three cables were subjected to each aging regimen. When the first
specimen in the group of three failed, the remaining two were subjected to each of the diagnostic
tests, starting with the test having the least likelihood of damaging the specimen and ending with
the test having the most severe conditions. After the specimens had been subjected to the
complete diagnostic series, they were subjected to breakdown voltage testing; wafers taken at the
breakdown site were then evaluated for water treeing. In the EPR tests, 12 specimens were
subjected to each accelerated aging regimen. After eight specimens had failed during aging, the
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remaining four were subjected to breakdown testing to establish the degree of degradation. Then
the samples were aged to half and one quarter of the geometric mean of the times to breakdown
for each aging regimen.
Results
For the XLPE program, the data to date show that dissipation factor through the use of both
dielectric spectroscopy and 0.1-Hz dissipation factor testing correlates well with the degree of
aging. Other tests show promise but will require the data from the specimens subjected to the
lowest degree of voltage stress and temperature cycling. The aging of these specimens continues.
There was no strong correlation of water treeing with breakdown sites. In the EPR program, the
nature of the accelerated aging of EPR was determined to be distinctly different from that of
XLPE. XLPE ages most quickly when water is present at the interior and exterior surface of the
insulation. EPR ages most quickly when water is at one of the two surfaces and even then ages
much more slowly than XLPE. The aging program for the EPR was terminated for practical
reasons after an extended period when too few specimens had failed under the various aging
regimens.
Keywords
Cable diagnostic testing
Medium-voltage cables
XLPE cables
EPR cables
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CONTENTS
1 INTRODUCTION ................................................................................................................. 1-1

Background ........................................................................................................................ 1-1
Acronyms Used in This Report ........................................................................................... 1-3
2 DESCRIPTION OF CABLES AND CABLE AGING REGIMENS ......................................... 2-1

Cable Descriptions ............................................................................................................. 2-1
Cable Aging Regimens....................................................................................................... 2-1
3 XLPE TEST PROGRAM DIAGNOSTIC TESTS .................................................................. 3-1

XLPE Cable Program Diagnostic Tests .............................................................................. 3-1
Isothermal Relaxation Current ....................................................................................... 3-1
Return Voltage .......................................................................................................... 3-3
Recovery Voltage Results .................................................................................... 3-5
Oscillating Wave Test System................................................................................... 3-6
OWTS Results...................................................................................................... 3-7
Dielectric Spectroscopy............................................................................................. 3-7
Dielectric Spectroscopy Results ........................................................................... 3-7
Modeling............................................................................................................... 3-8
0.1-Hz Dissipation Factor .......................................................................................... 3-9
0.1-Hz Dissipation Factor Results......................................................................... 3-9
0.1-Hz Partial Discharge ..........................................................................................3-10
0.1-Hz Partial Discharge Results .........................................................................3-10
AC Breakdown Tests ...............................................................................................3-10
AC Breakdown Test Results................................................................................3-11
Treeing Analysis.......................................................................................................3-14
Trees at Breakdown Sites....................................................................................3-15
Trees at Other Than Breakdown Sites.................................................................3-17
Vented Trees.......................................................................................................3-19
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4 ETHYLENE PROPYLENE RUBBER PROGRAM ............................................................... 4-1
EPR Accelerated Aging Results ......................................................................................... 4-2
Results of Breakdown Strength Tests ............................................................................ 4-4
5 CONCLUSIONS .................................................................................................................. 5-1

XLPE Insulated Cable ........................................................................................................ 5-1
Diagnostic Measurements ............................................................................................. 5-1
Aging Regimen Effects .................................................................................................. 5-2
Ethylene Propylene Rubber Program ................................................................................. 5-4
Inferences of Results with Respect to Nuclear Plant Cables............................................... 5-5
6 REFERENCES .................................................................................................................... 6-1
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LIST OF FIGURES
Figure 3-1 Isothermal Relaxation Current Basic Measuring Circuit.......................................... 3-2

Figure 3-2 IRC Residual Strength Factors (M) for Field Pre-Aged Specimens ........................ 3-3
Figure 3-3 Equivalent Circuit Diagram of a Cable Under a Return Voltage Test...................... 3-4
Figure 3-4 Recovery Voltage Linearity Factors for Field Pre-Aged Cables .............................. 3-6
Figure 3-5 Correlation Between 0.1-Hz DF at 1 Uo Versus Aging Time of Field-Aged
Cables at Each Aging Condition ...................................................................................... 3-8
Figure 3-6 Correlation Between 0.1-Hz DF at 2 Uo and Aging Time of Field-Aged Cables
Post Accelerated Aging ..................................................................................................3-10
Figure 3-7 Breakdown Voltages and Time to Failure for Field Pre-Aged Specimens..............3-13
Figure 3-8 Breakdown Voltages and Time to Failure for Shelf Pre-Aged Specimens .............3-14
Figure 3-9 Largest Bow-Tie Length for Field Pre-Aged Specimens ........................................3-18
Figure 3-10 Largest Bow-Tie Length for Shelf Pre-Aged Specimens......................................3-19
Figure 4-1 Breakdown Strength Versus Time at Stress Run 1 and 2 EPRs............................. 4-9
Figure 4-2 70-Day Wet Testing of Run 2 EPR........................................................................4-10
Figure 4-3 Change in Breakdown Strength of Five Commercially Available Mid-1990s
EPR Insulated Cables from Wet Aging at 2.5 Times Rated Voltage ...............................4-11
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LIST OF TABLES
Table 2-1 Accelerated Aging Matrix for XLPE and EPR Research Programs.......................... 2-2
Table 3-1 Cable Diagnoses for Various Linearity Factors........................................................ 3-5
Table 3-2 Baur Criteria for Assessment of XLPE Insulated Cables ......................................... 3-9
Table 3-3 Summary of Aging Conditions Versus Average Life for Field Pre-Aged Cables......3-11
Table 3-4 Summary of Aging Conditions Versus Average Life for Shelf Pre-Aged Cables .....3-12
Table 3-5 Comparison of Average Times to Failure Between Field and Shelf Pre-Aged
Conditions (Number of Days of Aging Before Failure) ....................................................3-12
Table 3-6 Tree Observance near ACLT Failures and AC Breakdown Sites for Field Pre-
Aged Specimens ............................................................................................................3-15
Table 3-7 Tree Observance near ACLT Failures and AC Breakdown Sites for Shelf Pre-
Aged Specimens ............................................................................................................3-16
Table 3-8 Relationship of Length of Aging Period to Tendency of Treeing at Failure Sites.....3-16
Table 3-9 Average Length of Longest Bow-Tie Trees ............................................................3-17
Table 3-10 Number of Specimens with Vented Trees and Size of Largest Tree in the
Aging Group – Field Pre-Aged Specimens .....................................................................3-20
Table 3-11 Number of Specimens with Vented Trees and Size of Largest Tree in the
Aging Group – Shelf Pre-Aged Specimens.....................................................................3-20
Table 4-1 EPR Run 1 Time-to-Failure Results ........................................................................ 4-2
Table 4-2 Summary of Breakdown Strengths for EPR Run 1 Cables (Ordered by
Increasing Aging Time).................................................................................................... 4-5
Table 4-3 Summary of Breakdown Strengths for EPR Run 1 Cables (Ordered by
Decreasing GMBD) ......................................................................................................... 4-6
Table 4-4 Summary of Breakdown Strengths for Run 2 EPR Cables (Ordered by
Increasing Aging Time).................................................................................................... 4-7
Table 4-5 Summary of Breakdown Strengths for Run 2 EPR Cables (Ordered by
Decreasing GMBD) ......................................................................................................... 4-8
Table 5-1 Order of Severity of Test Regimen Based on Bulk and Localized Degradation
– Field Pre-Aged Specimens ........................................................................................... 5-3
Table 5-2 Order of Severity of Test Regimen Based on Bulk and Localized Degradation
– Shelf Pre-Aged Specimens........................................................................................... 5-3
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1
INTRODUCTION
Background
This report summarizes research performed on power distribution cable with solid dielectric
insulation and provides inferences and insights on related cables used in nuclear power plants.
Although the cable designs used for power distribution are somewhat different from those used
in nuclear power plants, the basic insulation systems are the same—and most of the insights
gained in the research work apply to nuclear power plant service. The key differences between
nuclear plant and distribution medium-voltage cables are related to insulation shield (IS) system
and the use of jackets. The importance of these differences is discussed further next.
Medium-voltage cables (4 kV and above) used in nuclear plants that are subjected to long-term
wet operating conditions will age more rapidly than those that are dry, given that other service
conditions are similar. Although many nuclear plant cables are in dry applications, most plants
have at least a few underground cables that have been or may be wet for some period of their
operating life. Two things are desirable for the management of aging of medium-voltage cables
under wet conditions: a model of the rate of degradation related to the stress parameters and a
method for monitoring the degradation. A model allows an estimate of the life of the cable to be
made for a specific set of conditions. A monitoring technique allows the condition of the
insulation to be assessed with respect to the degradation model. The research attempted to
develop aging models in relation to emerging electrical test methods.
The two key stress factors in the aging of wet medium-voltage cable insulation are applied
voltage and temperature. Increasing either should increase the rate of degradation. Given that
much of the degradation of medium-voltage cable under wet conditions is induced by voltage
stress, acceleration of the degradation can be achieved by increasing the voltage. However,
there are limits to the degree to which voltage stress may be increased without causing
nonrepresentative degradation mechanisms to be initiated. Accordingly, the applied voltage
during accelerated aging must be limited to 3 to 4 times normal applied voltage, which limits the
rate of accelerated aging. With respect to in-service aging, the small variations in applied voltage
(for example, 5–10%) are not likely to significantly alter the life of the cable. However, double
and triple voltage should accelerate aging, especially under wet conditions.
Changes in load may cause the temperature of a cable to change cyclically during the day or
during portions of the year. Cyclic large temperature swings (that is, >50°C) could be an
additional factor in the aging of materials such as cross-linked polyethylene (XLPE) if the peak
temperature is near the rating of the insulation. For conservatively loaded cables with significant
margins between peak load current and the ampacity limit, the operating temperature of a cable
will be low, and any effects of cycling would be minimal. For cables loaded closer to the
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Introduction
ampacity limit, thermal aging and cycling would have a greater effect. Short periods of
energization as occur for safety system testing are not a significant concern with respect to
thermal aging or cycling. The full temperature rise would not occur during the short load cycle.
Development of a model of degradation requires the identification of a monitorable attribute that

proceeds with or leads the aging of the cable insulation. Accelerated aging experiments that
progressively degrade the cable are then performed, and the attribute is measured on the aged
cable specimens. The test program must be devised to allow diagnostic monitoring tests to be
applied at various points in the exposure such that information for devising an aging model is
developed. Accordingly, the development of an aging model goes hand in hand with identifying
an acceptable diagnostic monitoring technique.
This report describes two test programs: one on XLPE insulated cables [1] and one on ethylene
propylene rubber (EPR) insulated cables [2]; it also provides insights from a third program
related to EPR insulation [3]. The goal of the XLPE research was to develop an aging model for
wet cable that includes voltage stress level and cycled temperature. The EPR research (an earlier
program) had a similar purpose. Both research programs are described here. More details on the
research and additional information not pertinent to the goals of this report are provided in the
EPRI reports 1011499 [1] and TR-108405-V2 [2]. The XLPE results provide insights into the
most recent research on modeling of aging and condition monitoring diagnostic techniques. The
EPR research provides insights into the most commonly used insulation system for nuclear plant
medium-voltage cable.
Because the research programs relate to distribution cable, there are basic differences between
the research specimens and the cable used in the nuclear industry. The research program cables
have similar conductor, conductor shields (CSs), insulation, and ISs as would occur in a nuclear
plant application. However, the research specimens use a concentric neutral (that is, a number of
strands of wire helically wrapped around the IS) and generally had no overall jacket. A nuclear
plant cable generally has a helical copper tape shield over the IS with an overall jacket covering
the tape shield. For nuclear application, the results of the research are either directly applicable
or somewhat conservative because the specimen shields were directly exposed to water when the
specimens were subjected to submerged aging. Most nuclear cables have a jacket over the shield
system1. Water diffusion into the insulation in the research specimens should be more rapid than
if the water had to diffuse through the jacket and past the helical copper tapes before entering the
surface of the IS. For the XLPE cable specimens, water was also placed between the strands of
the conductor because past tests confirmed that water on the outside and inside surface of the
insulation system produced the highest accelerated aging for XLPE insulated cables. In the EPR
research, water on the inside and outside surface of the insulation system did not produce the
highest degradation acceleration rate. Rather, wetting either of the two surfaces while keeping
the other dry produced higher acceleration rates and indicated that EPR ages differently than
XLPE. The dominant insulation in the nuclear industry is EPR. However, the XLPE results with
respect to test methods provide insights on emerging test methods and their applicability to
medium-voltage cable.
1
One EPR cable design used in some nuclear plants employs a compact construction where the extruded shield
serves as the jacket as well. Strands of wire are located in the shield of this cable. For this design, the EPR test
results from the research should be directly applicable.
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Introduction
Acronyms Used in This Report

ac alternating current
ACLT accelerated cable life test
AWG American wire gauge
CS conductor shield
dc direct current
DF dissipation factor
DS dielectric spectroscopy
EPR ethylene propylene rubber
GMBD geometric mean breakdown
GMTF geometric mean time to failure
HV DC high-voltage direct current
Hz hertz
IS insulation shield
IRC isothermal relaxation current
kV kilovolt
mil 0.001 in.
OWTS oscillating wave test system
PD partial discharge
RV return voltage
tan δ dissipation factor
TD tan δ
Uo normal operating voltage line-to-ground
VLF very low frequency
XLPE cross-linked polyethylene
°F = (°C x 9/5) + 32
1 m = 3.28 feet
1 mil = 0.0254 mm
1 V/mil = 0.0394 kV/mm
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2
DESCRIPTION OF CABLES AND CABLE AGING
REGIMENS
Cable Descriptions
In the XLPE program [1], the cable specimens were rated at 15 kV and were specifically
produced for a previous test program. The cable had an unfilled2 1/0 American wire gauge
(AWG), class B stranded aluminum conductor, 4.4 mm (175 mils) of insulation with a CS
thickness of 0.51 mm (20 mils), and an IS of 1.02 mm (40 mils). CPI was the manufacturer, and
HFDE 4201 NT EC insulation was used. The concentric neutral consisted of 16 #14 AWG bare
copper wires. The cable was unjacketed. These cables were manufactured in 1987. The cables
identified as shelf pre-aged had been stored on a reel outdoors in the hot Texas sun for
approximately 10 years at the start of the test program. The cables identified as field aged had
been subjected to actual underground field use for approximately 15 years between the time of
manufacture and the start of the test program.
In the EPR program [2], the cable specimens were rated at 15 kV and were produced specifically
for the program. The cable had an unfilled 1/0 AWG, class B stranded aluminum conductor,
4.4 mm (175 mils) of insulation with a CS thickness of 0.51 mm (20 mils), and an IS of 1.02 mm
(40 mils). The concentric neutral consisted of 16 #14 AWG bare copper wires. The cable was
unjacketed unless the results specifically state otherwise. Hendrix was the manufacturer, and
Schulman Superohm 3728 insulation was used.
Cable Aging Regimens
Accelerated aging of cables with two variables (voltage and temperature) can lead to a large
matrix of test conditions. In both test programs, a test matrix with three different voltages (two,
three, and four times normal phase-to-ground operating voltage [17.3, 26.0, and 34.6 kV]) and
three temperatures (60, 75, and 90°C) were considered. As a shorthand method for describing the
test conditions, a two-digit code was established: the first digit refers to the voltage level by the
multiplier to the nominal operating voltage (2, 3, and 4 for 17.3, 26.0, and 34.6 kV) and the
second digit to the temperature during cycling (2, 3, and 4 for 60, 75, and 90°C). Thus, “44”
meant 34.6 kV applied voltage with temperature cycles to 90°C, and “33” meant 26.0 kV with
75°C cycling. Using each of the voltages and temperatures results in a 3 by 3 matrix with nine
aging conditions. The complete aging matrix is shown in Table 2-1.
2
The spaces between strands were purposely not filled, allowing a path for water to migrate along the length of the
conductor.
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Description of Cables and Cable Aging Regimens
Table 2-1
Accelerated Aging Matrix for XLPE and EPR Research Programs
4 x Vg (34.6 kV) 90°C 4 x Vg (34.6 kV) 4 x Vg (34.6 kV) 60°C

(Both programs) 75°C (Both programs)
(EPR only)
3 x Vg (26.0 kV) 3 x Vg (26.0 kV) 75°C 3 x Vg (26.0 kV)

90°C (Both programs) 60°C
(EPR only) (EPR only)
2 x Vg (17.3 kV) 90°C 2 x Vg (17.3 kV) 2 x Vg (17.3 kV)

(Both programs) 75°C 60°C
(EPR only) (Both programs)
In each program, the voltage was applied for 24 hours a day with current applied for 8 hours
each day to create the elevated temperature for 8 hours a day. The temperature surrounding the
test vessels was held at 35°C ±2°C (95°F ±3.6°F). In the XLPE program, the cables were
accelerated aged in water with the water also forced between the strands of the conductor, which
past programs indicated was the most severe accelerated aging regimen for XLPE insulated
cables. In the EPR program [2], two additional aging regimens were applied to some specimens:
water on the IS surface only and water through the conductor strands only. These experiments
were performed to determine whether the XLPE regimen applied to the EPR. Additional
experiments were also performed in the EPR research when unexpected aging results occurred
and when many of the long-term tests did not result in failures.
To create statistically sound results, numerous specimens must be evaluated at each test
condition. This causes the number of test specimens to be very large. In the earlier EPR program,
specimens were subjected to all nine conditions in the matrix. The more recent XLPE program
eliminated some of the conditions through test design. In the XLPE program, the matrix was
evaluated to determine the best set of conditions to simulate that was likely to provide useful
results. Design-of-experiment techniques were used to further reduce the number of aging
conditions to the point where the program was possible, given the amount of cable available and
the number of aging levels required. Table 2-1 shows the test matrix used in both research
programs. For the XLPE program, the results are available for all but the lowest stress cables
(condition 22 [17.3 kV, 60°C]). The aging of these specimens is not complete because of the low
level of acceleration induced by the stresses.
There was one significant difference between the specimens in the XLPE program and those in
the EPR program. For the more recent XLPE program, the specimens were pre-aged either by
use in actual underground service or by exposure to long-term outdoor storage in the Texas sun.
Although all of these cables were from the same 1985 manufacturing run, some were used by a
utility for actual service. These were removed from service and provided for use in the program.
These were designated field pre-aged. The cables stored on a reel outdoors were designated shelf
pre-aged.
In the EPR program, no pre-aging was performed prior to the laboratory aging. However, cables
of the same manufacturing runs were installed by utilities in actual service. During the seven-
year program, none of the in-service cables failed. Two EPR cables—one unjacketed and the
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Description of Cables and Cable Aging Regimens
other jacketed—were also installed in the Marshall Technology Center in Marshall, Texas. The
first was 405 m (1330 ft) long; the second was 332 m (1090 ft) long. Both were energized at
14.4 kV (1.7 times rated phase-to-ground voltage), and 70 amperes was applied to the conductor
for 8 hours per day. Neither of these cables failed during the seven-year program.
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3
XLPE TEST PROGRAM DIAGNOSTIC TESTS
XLPE Cable Program Diagnostic Tests
The XLPE program focused on developing aging models related to diagnostic assessment of the
insulation. The following diagnostic test methods were under consideration:
• Isothermal relaxation current
• Return voltage (RV) method
• Oscillating wave partial discharge (PD) testing
• Dielectric spectroscopy
• Hz dissipation factor
• Hz PD
• AC breakdown strength
• Water treeing assessments
The cables under test in the program came from cable sections that were manufactured at the
same time but subjected to two different pre-aging conditions. One set of specimens was
removed from underground circuits, and the other specimens were from long-term field storage.
Four groups of three cable specimens were aged under each of the “44,” “42,” “33,” “24,” and
“22” conditions3 for both the field pre-aged and shelf pre-aged cable. When the first cable of a
group of three failed during the aging, the remaining two cables were removed from the aging
and subjected to the diagnostic tests, starting with the least stressful test and progressing toward
the destructive ac breakdown strength, followed by dissection for the water tree assessment. The
following summarizes the tests that were performed.
Isothermal Relaxation Current
This depolarization current technique was developed by Biegert et al. [4] at the University of
Wuppertal in Germany. The technique measures the isothermal relaxation current (IRC) (that is,
depolarization current remaining in a cable after a brief discharging time) in the time domain and
uses a computer-based artificial neural network to provide an estimate of the aging status of the
polymeric cable insulation. The test unit, a commercially available HDW Electronics KDA-1
3
The aging of the 22 specimens was not completed at the time of issuance of the EPRI report 1011499 [1] and is
expected to extend into 2006.
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XLPE Test Program Diagnostic Tests
Isothermal Relaxation Current Unit, also employs fuzzy logic to estimate the remaining life in
terms of breakdown strength. The time-dependent IRC can be approximated as a superposition of
three exponential components, each with different relaxation times, τi, and coefficients αi, as
shown in the equation below. These components are distinct and depend on specific mechanisms
of charge trapping and aging [5] and are strongly correlated with the material properties of the
cable.
i ( t ) = α O + ∑ α i × e − t / τi
Figure 3-1 shows the basic measuring circuit. The cable sample is polarized with a dc voltage of
1000 volts for 30 minutes. It is then temporarily grounded through a resistor, RD, for five
seconds to discharge the depolarization current due to geometric cable capacitance. The final
step is the 30-minute IRC measurement.
Figure 3-1
Isothermal Relaxation Current Basic Measuring Circuit [1]
The current during the relaxation measurement is plotted by showing (i(t) × t) versus ln(t). The
plot for unaged cable has a bell-shaped curve that starts close to the origin. As the cable ages, the
bell-shaped curve shifts to the right and then has a distorted collapsed peak. The KDA-1 test unit
also provides an automated analysis based on fuzzy logic to provide a residual strength prognosis
related to the destructive breakdown strength as measured by a German FGH step test
breakdown procedure [6]. The factor is expressed as a multiple of line-to-ground voltage. In this
test, the residual strength factor was expressed as a function of aging voltage, aging temperature,
and aging time.
The residual strength factor data generated in the program for the specimens removed from test
tanks at the time of the failure of the first specimen in a group of three are shown in Figure 3-2.
No strong correlation of the factor was observed with time in tank or any of the other aging
factors. Other factors generated by the KDA-1 test set were evaluated, and those had little
correlation with the various aging factors.
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Figure 3-2
IRC Residual Strength Factors (M) for Field Pre-Aged Specimens
Return Voltage
RV is another variation on measuring dielectric response in the time domain [7, 8, 9]. The RV
can be derived from the depolarization current using Maxwell’s equations if the conductivity of
the insulation is low (<10-18 Ω-m) and the response is independent of the applied voltage (that is,
linear) [10]. A SebaKMT CD31 Return Voltage Unit was used in the test program to measure the
RV of each sample. Instead of measuring the depolarization current following the initial charging
and discharging steps, a voltmeter with high input impedance was connected between the cable
conductor and shield to record the RV. Figure 3-3 shows an equivalent circuit diagram of a cable
under test. When the cable is shorted for the brief period, the cable capacitance, Co, discharges.
However, the remaining capacitors, Cpn, retain most of their charge due to their long time
constants. As soon as the shorting switch is opened and the voltmeter is connected across the
cable insulation, the voltage across Co again rises because all of the capacitors will try to
equalize—and eventually will do so if enough time passes.
When insulation is charged and then discharged, the various polarization mechanisms (such as
electronic, ionic, molecular, and dipole polarization) will dictate the magnitude and rate-of-rise
of the recovery voltage. Moisture and contamination in the cable insulation also influence the
recovery voltage spectrum. Recovery voltage measurements on XLPE insulated cables are used
to determine the extent of water tree deterioration, primarily reflecting the existence of large
water trees. If large water trees exist, the recovery voltage response will be nonlinear as a
function of applied voltage, but the charging voltage must be high enough to allow the
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nonlinearity to be observed. If a linear response exists, the recovery voltage at 2 Uo (normal

operating voltage line-to-ground) will be two times the recovery voltage when 1 Uo is applied.
For a cable with large water trees, a nonlinear response will occur, with the recovery voltage at
2 Uo being more than two times the recovery voltage when 1 Uo is applied. In this test, much
higher dc voltages than those used in the IRC test cause an increased risk of damage to the cable
during the test. However, no adverse effects of this test were observed in the program.
Figure 3-3
Equivalent Circuit Diagram of a Cable Under a Return Voltage Test [7, 8, 11]
In this test program, the XLPE cable samples were charged for 15 minutes and discharged for
2 seconds to ground through a resistor, and then the RV was measured and recorded for 15
minutes. The charge/discharge sequence was repeated four times with the dc charging voltage
increased each time, starting at a dc value equivalent to the peak value of a sinusoidal waveform
with an rms value of 0.5 Uo and then increasing to the peak value at 1 Uo, 1.5 Uo, and 2.0 Uo.
The ratio of the peak RV measured at 2 Uo charging voltage to that at 1 Uo is called the linearity
factor and was automatically calculated by the CD31 software of the test system. The linearity
factor is typically used to characterize damage due to large water trees in XLPE insulated cables.
Table 3-1 shows the ranges of linearity factor results with respect to cable condition. In this
research, the linearity factor was evaluated with respect to aging time, cycling temperature, and
applied voltage to model aging.
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Table 3-1
Cable Diagnoses for Various Linearity Factors [11]
Linearity Factor Range Cable Diagnosis
2.0–2.5 Good cable quality
2.5–3.0 Medium cable quality
>3.0 Heavily damaged cable
<2.0 External influence on measurement (for

example, dirty termination or cable not isolated)
Recovery Voltage Results
Figure 3-4 shows the linearity factors for the field pre-aged specimens that were removed from
aging at the time of the first failure within each group of specimens. For most specimen
groupings, there is a tendency toward higher linearity factors with an increase in aging time. The
strongest trend was experienced in the 42 grouping (34.6 kV, 60°C aging), which led to the
longest aging time. The apparent exception was the 33 condition (26.0 kV, 75°C aging).
However, the initial linearity factor test results in this group were high for a few of the specimens
(that is, 2.5, 2.6, and 2.7), indicating that during field service, water trees may have developed.
Indeed, the specimens with initial 2.6 and 2.7 linearity factors failed during laboratory aging at
146 days. If these high values were excluded from the results for the initial value, the average
initial value would have been 2.1. While two of the specimens with 2.6 and 2.7 factors failed
during the test, others with values of 2.3, 2.4, and 2.5 each had test results (when removed from
aging) of 2.0, indicating that results may vary significantly between measurements and do not
necessarily increase linearly.
Although the linearity factors were similar between aging groups after aging, the 24 (17.3 kV,
90°C) groups had significantly different 1 Uo and 2 Uo results from the other groups. For the 24
specimens, the recovery voltages were approximately at least five times larger than related
voltages from the other groups (this occurred for both the field pre-aged and shelf pre-aged
specimens). This did not purely relate to aging time in the tanks because other specimens had
longer periods in the tank.
An attempt to use the linearity data in an aging model resulted in poor fits of the regressions
curves. Additionally, the recovery voltage at Uo was plotted and found to have a somewhat
better, although still not adequate, correlation.
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Figure 3-4
Recovery Voltage Linearity Factors for Field Pre-Aged Cables
Oscillating Wave Test System
Work performed at the Delft University of Technology in the Netherlands by Gulski et al. [12,
13] demonstrated a sensitive PD test technique for locating discharge sites using a damped
oscillating wave as a voltage source. The technique is attractive for two reasons:
• The use of a damped oscillating wave allows a significant reduction in the kVA requirements
for the power supply when testing long cables.
• An indication of the PD extinction voltage is given as the voltage wave diminishes during
damping.
The oscillating wave test system (OWTS) test set consists of a remotely controlled high-voltage
direct current (HV DC) supply, a specially designed solid-state switch, an air core
inductor/voltage divider/PD coupler, and an industrial computer as a control unit. Digital data
acquisition and signal storage as well as the analysis and evaluation of the PD signals take place
in the control unit. The PD location is based on time domain reflectometry.
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During the test, the HV DC supply is used to charge the cable sample to a user-selectable dc
level (36 kV maximum). The solid-state switch is then closed (<1 microsecond closure time)
after disconnecting the HV DC supply to create a series resonant circuit (air-core inductor in
series with the cable capacitance). The circuit has a resonant frequency of:
1
f=
2π × (L × C)
where L is the fixed inductance of the air-core inductor and C is the capacitance of the cable
sample. Because the inductance of the air-core inductor is fixed at ~8 henry, the resonant
frequency is determined by the cable capacitance. The short 9.14-m lengths of cable in the test
required placing a 62-m section of cable of the same construction in series with the cable under
test and placing a 1.0-µf capacitor in parallel with the cables to lower the frequency of the test.
The cable segment was added to facilitate PD location rather than to add capacitance. The
resulting frequency was 197 Hz. The OWTS tests started with 6-kV dc charging and increased in
6-kV increments to 24-kV charging. This allowed a detection point for the inception of PD as
well as detection of the extinction voltage. The effective ac rms voltage for each test increment is
the applied charging voltage times the square root of 2.
OWTS Results
None of the samples either at the start of the test or upon removal from the aging tanks exhibited
PD beyond background noise. None of the specimens had PD inception voltages below the
24-kV peak charging voltage. Accordingly, no age-related modeling could be developed for
OWTS-generated PD.
Dielectric Spectroscopy
In dielectric spectroscopy (DS), measurements of capacitance and dielectric loss were performed
over the range of frequency between 0.1 and 1 Hz. A special test set was used to provide high-
voltage ac while measuring the dissipation factor (DF) at multiple frequencies. The maximum
voltage in these tests was 1 Uo, starting from 0.25 Uo and increasing in 0.25-Uo steps.
Measurements were made at 0.1, 0.2, 0.5, and 1.0 Hz. Swept frequency measurements were then
performed at 0.5, 0.75, and 1 Uo. Finally, a swept frequency measurement was performed at 0.5
Uo. The procedure allowed the observation of both voltage- and frequency-dependent behaviors
of the cable’s dissipation factor.
Dielectric Spectroscopy Results
Prior to the accelerated aging, the results for nearly all of the cable specimens were essentially
identical. At every voltage level, the DF increased from 0.1 Hz to 0.2 Hz, followed by a decrease
from 0.2 Hz to 0.5 Hz and from 0.5 Hz to 1 Hz. There was a relatively weak dependence of DF
on voltage across the frequency spectrum. In addition, there was no significant difference
between the shelf pre-aged specimens and the field pre-aged specimens. Some difference was
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expected because some water tree development should have occurred in the field pre-aged
specimens. The field pre-aged specimens may have dried between the time of removal and the
time of testing, leading to similar results. The results indicated that the cables were of good
quality.
After accelerated aging, general trends in the DS plots were not easy to recognize. There were
larger variations in the DF values as functions of both voltage and frequency than on the samples
prior to accelerated aging. Longer aging times did not always result in higher DF values. Each
aging condition showed different DS results, with some aging conditions showing little change in
absolute magnitudes before and after laboratory aging and others showing large changes.
Modeling
The DS data are both frequency and voltage dependent, making the selection of a single DF
measurement parameter from each set of DF curves for use in an aging model difficult. A
number of parameters were evaluated. For the field-aged cables, good correlations were observed
for 0.1-Hz DF results at 1.0 Uo for most conditions except the 44 and 42 conditions. Figure 3-5
shows these correlations. Other test points for the field pre-aged specimens did not correlate as
well, and no points for the shelf pre-aged cables had good correlations.
Figure 3-5
Correlation Between 0.1-Hz DF at 1 Uo Versus Aging Time of Field-Aged Cables at Each
Aging Condition
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0.1-Hz Dissipation Factor
In this program, DF (tan δ) measurements were made using a Baur PHG 80 TD/PD Unit. As
long as no unacceptably high DF measurements were encountered, 0.1-Hz DF measurements
were made at 0.5 through 2.0 Uo in 0.5-Uo increments. The assessment criteria from Baur are
provided in Table 3-2.
Table 3-2
Baur Criteria for Assessment of XLPE Insulated Cables
Tan δ at 2 Uo Difference of Tan δ Between 2 Uo and 1 Uo Assessment

-3 -3
<1.2 x 10 <0.6 x 10 Good cable
-3 -3
≥1.2 x 10 ≥0.6 x 10 Aged cable
-3 -3
≥2.2 x 10 ≥1.0 x 10 Highly degraded cable
0.1-Hz Dissipation Factor Results
Prior to accelerated aging, the vast majority of the samples—regardless of whether they were
shelf or field pre-aged—had a flat or decreasing DF between 0.5 Uo and 1.5 Uo followed by an
increasing DF at 2 Uo. A few specimens had DF values that exceeded 1.2 x 10-3, which (by Baur
criteria) would indicate an aged cable. Again, there was little difference in DF between the shelf
and field pre-aged specimens, possibly because the field pre-aged cables had dried before testing.
After aging, most cable samples, regardless of the aging condition, had higher DF values at all
test voltages. Higher test voltages usually resulted in higher DF values. However, there was not
always a consistent trend between longer aging times and higher DF values. Each aging
condition showed different DF results, with some aging conditions showing small changes and
some very large changes. Most notably, the 24 condition showed huge changes after accelerated
aging for the shelf and field pre-aged specimens. Similarly, the 24 condition showed the greatest
differences in DF between 1 Uo and 2 Uo.
When plotted against aging time, the 0.1-Hz DF at 2.0 Uo provided the best linear correlations
for both the shelf and field pre-aged specimens. The correlation was much stronger for the field
pre-aged specimens than for the shelf-aged specimens. Figure 3-6 shows the correlation for the
field-aged specimen.
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Figure 3-6
Correlation Between 0.1-Hz DF at 2 Uo and Aging Time of Field-Aged Cables Post
Accelerated Aging
0.1-Hz Partial Discharge
Very low frequency (VLF) PD testing was performed using a Baur PHG 80 TD/PD Unit, which
included a VLF voltage generator and a PD measuring system. Digital data acquisition and PD
signal storage take place in the PD measuring system. The system uses time domain
reflectometry to locate identified PD. The tests started at 1 kV, with the voltage increased in
1-kV increments until PD was detected or the maximum test voltage of 17 kV was reached.
0.1-Hz Partial Discharge Results
No PD in excess of background noise (10 to 20 pC) was identified on the specimens before and
after the start of the accelerated aging. This indicates that electrical trees, if present in the aged
samples, were too small to generate a PD signal that could be detected by the test unit within the
limit of the maximum voltage applied (17 kV).
AC Breakdown Tests
An ac breakdown test was the final electrical test performed on the surviving specimens removed
from aging when the first specimen in the group failed during accelerated aging. Due to the
limited amount of cable available for the field and shelf pre-aged specimens, only five shelf pre-
aged specimens were available for breakdown testing. No breakdown tests were performed on
any field pre-aged specimens. Data were also available for the cables when originally purchased
in 1987. For the new cable, the results ranged from 875 to 1295 V/mil. The Weibull
characteristic breakdown value (rank regression method) was 1175 V/mil (63.2% probability
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breakdown value) with a Weibull shape parameter of 11.01. For the five shelf pre-aged
specimens, the breakdown results ranged from 596 to 755 V/mil. The Weibull characteristic
breakdown value was 699.3 V/mil with a shape parameter of 10.43. The shelf aging resulted in a
significant drop in breakdown strength.
AC Breakdown Test Results
Detailed evaluation of the ac breakdown test data, including time to failure and breakdown
levels, is provided here because breakdown voltage provides the clearest indication of
degradation of the insulation of the specimens.
Time to Breakdown
Table 3-3 summarizes the breakdown voltage times for the field pre-aged cables. Starting from
the high-voltage, high-temperature stress point 44 (34.6 kV, 90°C) condition, the aging is the
fastest (13.7 days). The first increase in life occurs at the lowest voltage, highest temperature 24
(17.3 kV, 90°C) condition, indicating that reducing voltage has a large effect on life at elevated
temperature (increases to 120.3 days). At the intermediate voltage and temperature 33 (26.0 kV,
75°C) condition, a modest additional increase occurs (increases to 142 days), and another
significant increase in life occurs (total of 246 days) at the highest voltage and lowest
temperature 42 (34.6 kV, 60°C) condition. This indicates that lowering cycling temperature has a
stronger effect on life than lowering voltage.
Table 3-3
Summary of Aging Conditions Versus Average Life for Field Pre-Aged Cables
Condition Voltage (kV) Temperature (°C) Average Life [Range] (days)
44 34.6 90 13.7 [11.8–15.8]
24 17.3 90 120.3 [62–158.3]
33 26 75 142.0 [132.7–146.7]
42 34.6 60 246.6 [159–339.1]
Table 3-4 summarizes the breakdown voltage versus aging condition data for the shelf pre-aged
cable. These results differ from those for the field pre-aged data. The starting points are similar,
with the high-voltage, high-temperature 44 (34.6 kV, 90°C) condition causing the shortest life.
However, the intermediate-voltage, intermediate-temperature 33 (26.0 kV, 75°C) condition,
instead of causing a relatively long life, causes a relatively short life (68.6 days) in comparison
with the 33 results for the field pre-aged condition. The low-voltage, high-temperature 24
(17.3 kV, 90°C) condition gives a longer life (159 days). The high-voltage, low-temperature 42
(34.6 kV, 60°C) condition gives the longest life again (182 days), as did the 42 condition for the
field pre-aged cable, but the shelf pre-aged cable has a much shorter average life (182 versus 246
days). The shelf pre-aging thermal damage has predisposed this cable to early failure in
comparison to the field pre-aged specimens under all conditions except the low-voltage, high-
temperature condition, which has 1.25 times longer average life than the field pre-aged
condition. As with the field pre-aged cables, lowering temperature during cycling leads to the
longest life.
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Table 3-4
Summary of Aging Conditions Versus Average Life for Shelf Pre-Aged Cables
Condition Voltage (kV) Temperature (°C) Average Life [Range] (days)
44 34.6 90 12.2 [9–14.8]
33 26.0 75 68.6 [64.8–72.2]
24 17.3 90 159.4 [88–212.9]
42 34.6 60 182.2 [167–209]
The shelf pre-aging has affected the average accelerated life of the cable due to thermal aging
during outdoor storage. In three out of the four cases, comparison of the individual points
between the two sets of specimens confirms that thermal aging in storage had an effect. Table
3-5 shows the comparison of the breakdown results for the shelf and field pre-aged specimens.
For the 44, 33, and 42 specimens, the times to failure for the shelf pre-aged specimens are
significantly shorter. For the 24 specimens, the shelf pre-aged specimens had a longer life than
the field pre-aged specimens. The 44, 33, and 42 results indicate that the effect of the difference
between operational (field) aging and storage (shelf) aging is significant and that shortened
service lives are likely for cables that have been stored outdoors in the sun for a significant
period. However, the 24 specimen results may indicate that the thermal damage from the shelf
pre-aging is less important as test voltage is reduced. Although definitive data are not available
for EPR cables, the effect of long-term outdoor aging may also be significant.
Table 3-5
Comparison of Average Times to Failure Between Field and Shelf Pre-Aged Conditions
(Number of Days of Aging Before Failure)
90°C 75°C 60°C
Field Shelf Field Shelf Field Shelf
34.6 kV 13.7 12.2 246.6 182.2
26.0 kV 142.0 68.6
17.3 kV 120.3 159.4
Breakdown Levels
AC breakdown voltage tests were performed by applying an average electrical stress of
3.9 kV/mm (100 V/mil) across the cable insulation and then increasing the voltage in 1.6-kV/mm
(40-V/mil) steps every five minutes. The steps in voltage continued until breakdown occurred,
and the breakdown voltages were recorded. After breakdown, the thickness of insulation at the
breakdown site was measured, and the average electrical stress at the time of failure was
calculated.
Figure 3-7 shows the breakdown stresses for the field pre-aged cables during the accelerated
aging test and for the specimens removed from the test upon failure of the first cable in the test
group. The 44 (34.6 kV, 90°C) specimens failed first. The specimens removed for testing after
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each failure had breakdown voltages between 329 and 395 V/mil. The specimens that failed
during aging failed at an aging voltage of approximately 198 V/mil. The 24 (17.3 kV, 90°C)
specimens began failing next in the test, but the distribution of failure times completely overlaps
the 33 (26.0 kV, 75°C) group. The breakdown voltages for the 24 specimens decrease with
length of aging time and range from 302 V/mil to 204 V/mil. The failures during aging of the 24
specimens occurred at approximately 99 V/mil. The 33 (26.0 kV, 75°C) group had breakdown
voltages ranging from 287 to 356 V/mil with a tendency to drop with length of the aging period.
The failures during aging of the 33 specimens occurred at approximately 149 V/mil. The group
with the longest life was the 42 (34.6 kV, 60°C) specimens, having breakdown voltages between
346 and 460 V/mil.
No obvious trend with aging time appears in the data. The failures during aging occurred at 198
V/mil. Interestingly, Figure 3-7 indicates that when failures occur at higher aging voltages, the
breakdown voltages for the related specimens tend to be higher. Similarly, the breakdown
voltages for the related specimens are proportionally lower at the 17.3- and 26.0-kV levels. It is
interesting that reducing cycling temperatures by 30°C has the greatest effect on life even when
the operating voltage is four times nominal.
Figure 3-7
Breakdown Voltages and Time to Failure for Field Pre-Aged Specimens
Note: Aging voltage is shown for failures occurring during accelerated aging.
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Figure 3-8 shows the breakdown stresses for the shelf pre-aged specimens. The initial breakdown
stress prior to accelerated aging for these specimens (670 V/mil) is also shown in Figure 3-8. The
44 (34.6 kV, 90°C) specimens again have the shortest life. The highest average breakdown stress
of the “removed from test” specimens was 521 V/mil for the 44 (34.6 kV, 90°C) specimens. By
contrast, the 24 (17.3, 90°C) specimens had the lowest average breakdown stress (229 V/mil)
and an average life of 159 days. The 24 specimens had a very broad failure distribution, ranging
from 88 to 212.9 days. The breakdown strength of the 24 specimens removed at 88 days was 250
to 310 V/mil. The 24 specimens that were removed from the test between 140 and 212 days had
breakdown voltages between 200 and 220 V/mil—the lowest in the breakdown tests for the shelf
pre-aged specimens. The 42 (34.6 kV, 60°C) specimens and 33 (26.0 kV, 75°C) specimens had
similar breakdown stresses (389 V/mil versus 418 V/mil) even though the average life of the 33
specimens was considerably shorter than that of the 42 specimens.
Figure 3-8
Breakdown Voltages and Time to Failure for Shelf Pre-Aged Specimens
Note: Aging voltage is shown for failures occurring during accelerated aging.
Treeing Analysis
Following the breakdown tests, all of the specimens were analyzed for vented and bow-tie water
trees in the vicinity of the breakdowns. This analysis included the specimens that failed during
the accelerated aging tests. A total of six to seven wafers were cut from each specimen at the
accelerated cable life test (ACLT) failure site and each ac breakdown site. The tree counting
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procedure consisted of making a generalized assessment (of both size and density) of the bow-tie
trees, the vented trees from the CS, and the vented trees from the IS of each cable specimen. In
addition, the largest bow-tie tree, the largest vented tree from the CS, and the largest vented tree
from the IS were measured. If a tree was observed near the failure site, its size and type were
recorded.
Trees at Breakdown Sites
Tables 3-6 and 3-7 show whether trees were observed at the failures that occurred during ACLT
and at the breakdown sites of the samples removed at the time of the ACLT failure for the field
and shelf pre-aged specimens. Interestingly, few trees were observed at failure and ac breakdown
sites. For the field pre-aged cables, only 4 of 51 specimens (that is, 8%) had trees in the vicinity
of the failure sites. For the shelf pre-aged cables, only 2 of 48 specimens (that is, 4%) had trees
in the vicinity of the failure site. Both the field and shelf pre-aged groups had some trees at
failure sites in the 42 (34.6 kV, 60°C) aging groups. The 42 field pre-aged group had its ACLT
failures at 157 to 339 days. Specimens aged for 157 (ALCT fault site), 265.8 (single ac
breakdown site), and 339 days (single ac breakdown site) had one or more trees near the
breakdown site. The other specimens were aged for similar periods and did not have trees at the
breakdown site. The 42 shelf pre-aged group had its ACLT failures at 166 to 209 days. The
observed trees at failure sites occurred in specimens aged for 166.5 and 172.5 days on one of
each of the specimens that did not fail during the ACLT. None of the ACLT fault specimens
from the 42 shelf pre-aged group had trees at the fault site.
Table 3-6
Tree Observance near ACLT Failures and AC Breakdown Sites for Field Pre-Aged
Specimens
Aging Trees at ACLT Failure Trees at AC Breakdown No. % of

Group Site (size in mils) Site (size in mils) Specimens Group
44 0 0 12 0.0
42 1 (>20) 2 (18, >12) 12 25.0
33 0 12 0.0
24 1 (>40) 0 12 8.3
22 0 0 3 0.0
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Table 3-7
Tree Observance near ACLT Failures and AC Breakdown Sites for Shelf Pre-Aged
Specimens
Aging Trees at ACLT Failure Trees at AC Breakdown No. % of

Group Site (size in mils) Site (size in mils) Specimens Group
44 0 0 12 0.0
42 0 2 (15, >20) 12 16.7
33 0 0 12 0.0
24 0 0 12 0.0
The 24 field pre-aged group had its ACLT failures at 62 to 158 days, with the specimen having a
tree near the ACLT site occurring in the 158-day group (ACLT fault site).
Table 3-8 shows the age groupings by time to failure and whether treeing was identified near
failure and breakdown points. The treeing that was observed at failure sites occurred in groups
having longer aging periods before the first failure. The trees at failure sites were observed
mostly with the 42 group, which had the highest voltage (34.6 kV) and lowest aging temperature
(60°C). However, a tree was observed for the 24 (17.3 kV, 90°C) field pre-aged group in a
specimen with the longest aging time. For the aging regimens in this aging program, the data
indicate that heavy treeing did not occur in the vicinity of the failure and breakdown sites and
that, when it did occur, significant aging periods were required. The intensity of the voltage
applied to the specimen does seem to play a role in whether trees were in the vicinity of the
failure site, but the 24 group field-aged specimen that had a tree at the failure site indicates that
other factors beyond voltage stress allow trees to form at lower stress levels.
Table 3-8
Relationship of Length of Aging Period to Tendency of Treeing at Failure Sites
Group Aging Range (days) Trees at Failure/Breakdown Site
44 field pre-aged 11.8–15.8 No
24 field pre-aged 62–158 Yes (in 158-day group, 1 of 12 specimens)
33 field pre-aged 133–147 No
42 field pre-aged 159–339 Yes (3 of 12 specimens)
22 field pre-aged 315 No (only one group's data were available)
44 shelf pre-aged 9–14.8 No
33 shelf pre-aged 65–72 No
24 shelf pre-aged 88–213 No
42 shelf pre-aged 167–209 Yes (2 of 12 specimens)
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Under the aging regimens in this test program, the data indicate that points of failure and ac
breakdown do not necessarily correlate with the location of trees in the specimens.
Trees at Other Than Breakdown Sites
Although only a limited number of failure and breakdown sites had trees observed in their
vicinity, trees were observed farther from the failure site in many specimens. Every specimen
had observable bow-tie trees, and all specimens had medium to high counts of bow-tie trees.
Table 3-9 provides the average length per aging group of the longest bow-tie tree observed in
each specimen. The field pre-aged specimens tended to have longer bow-tie trees than the shelf
pre-aged specimens, which is consistent with the field-aged cables having been exposed to
approximately 15 years of wet, energized service as opposed to the non-energized, thermal aging
for the shelf pre-aged specimens that were stored outdoors in the Texas sun. There is no clear
correlation of the length of the bow-tie trees with the duration of the exposure, voltage, or cyclic
temperature. The largest trees (69 mils average) for the field pre-aged cables were observed in
the 24 group, which had the lowest voltage and highest cycling temperature. The next largest tree
sizes occurred in the 44 group, which had both high-voltage and high-temperature cycling.
Somewhat smaller trees occurred in the 42 and 22 field pre-aged groups that had lower cycling
temperatures but the highest and lowest voltage stresses. The data indicate that elevated cycling
temperatures promote larger trees. For the shelf pre-aged condition, the longest length trees (74
mils average) were associated with the 24 condition (lowest voltage, highest temperature),
indicating that the temperature of cycling has a strong effect on bow-tie growth in the shelf pre-
aged group as well. The 42 condition (highest voltage, lowest cycling temperature) produced
shorter bow ties, again indicating that bow ties are generated more slowly at a lower temperature
for a given voltage stress.
Table 3-9
Average Length of Longest Bow-Tie Trees
Aging Average Length of Bow-Tie Trees – Average Length of Bow-Tie Trees –

Group Field Pre-Aged Specimens (mils) Shelf Pre-Aged Specimens (mils)
44 42.5 30.3
42 24.5 15.5
33 36.2 29.2
24 69 74
22 23 (3 specimens) -
Figure 3-9 shows bow-tie length versus aging time for the four field pre-aged groups. The large
bow-tie trees associated with the 24 group tend to increase in size with aging time. Such a trend
does not appear with the other groups. Interestingly, the 42 specimens with the highest voltage
have much smaller trees even though these specimens have longer aging times than the 24 group.
The result indicates that elevated cycling temperatures correlate with larger trees rather than
longer periods at elevated voltage.
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Figure 3-9
Largest Bow-Tie Length for Field Pre-Aged Specimens
Figure 3-10 shows bow-tie length versus aging time for the four shelf pre-aged groups. The large
bow-tie trees associated with the 24 shelf pre-aged group also tend to increase in size with aging
time. Such a trend does not appear with the other groups. Interestingly, the 42 specimens with
the highest voltage seem to have a reverse trend in tree length versus time and have much
smaller bow-tie trees than the other groups. The data for the shelf and field pre-aged specimens
indicate that tree growth in the test program was much more affected by cycling at elevated
temperatures than by length of exposure to elevated voltage.
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Figure 3-10
Largest Bow-Tie Length for Shelf Pre-Aged Specimens
Vented Trees
The number of vented trees starting from the CS and from the IS was counted and the largest size
determined. Table 3-10 summarizes the results for the field pre-aged specimens. Most of the
specimens had low counts of vented CS and vented IS trees. The remainder had no observed
vented trees. The nominal insulation thickness was 175 mils such that the largest tree affected
14% of the thickness of the insulation. It is not clear whether any of the vented CS and IS trees
were opposite each other such that 28% of the wall was affected. Each aging group had 12
specimens. The results indicate that nearly all specimens had some vented CS or IS vented trees.
The 44 aging group had vented CS trees. The size of the trees tended to be equal or larger at the
CS as compared to the IS.
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Table 3-10
Number of Specimens with Vented Trees and Size of Largest Tree in the Aging Group –
Field Pre-Aged Specimens
Aging Specimens CS Vented, Specimens with IS IS Vented, Largest

Group with CS (Low)* Largest (mils) (Low)* (mils)
44 5 23 11 9
42 11 15 11 15
33 11 27 7 5
24 9 25 12 25
22** 1 12 0 -
* “Low” indicates fewer than five and often fewer than three trees per wafer.
** Data from only one of four sets of specimens in the 22 group.
Table 3-11 summarizes the results for the shelf pre-aged specimens. Again, the counts of vented
trees are low for most specimens, with a similar number of specimens having vented CS trees.
The number of specimens having no IS trees is much higher for the shelf pre-aged specimens
than for the field pre-aged specimens, possibly because the shelf pre-aged cable saw no wet,
energized service before the start of the program. The data indicate a difference in the presence
of vented IS trees in the shelf pre-aged specimens compared to those in the field pre-aged
specimens. The shelf pre-aged specimens had a much lower number of specimens having vented
IS trees than the field pre-aged specimens, and the size of the tree is much smaller. The data
indicate that, during the 15-year field pre-aging, some IS vented trees had already formed. A
clear difference is not seen between the two groups for the CS vented trees.
Table 3-11
Number of Specimens with Vented Trees and Size of Largest Tree in the Aging Group –
Shelf Pre-Aged Specimens
Aging Specimens CS Vented, Specimens with IS IS Vented, Largest

Group with CS (Low)* Largest (mils) Shield (Low)* (mils)
44 6 7 1 1
42 9 16 3 12
33 11 22 4 4
24 6 72** 3 3
* “Low” indicates fewer than five and often fewer than three trees per wafer.
** This length is an outlier. The remaining five have lengths between 3 and 14 mils.
Overall, no trends useful in assessing aging were identified from the analysis of vented trees.
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4
ETHYLENE PROPYLENE RUBBER PROGRAM
Although the EPR cable research described in the EPRI report TR-108405-V2 [2] had similar
aging regimens to those used in the XLPE research described in the EPRI report 1011499 [1],
this earlier work strove to understand aging processes and the development of aging regimens
that were more closely related to field cable than toward the development of advanced diagnostic
assessment techniques. Accordingly, the tests incorporated laboratory testing, in-service field
aging of cables, and simulated in-service underground aging at the test laboratory under
controlled conditions. The data described here relate only to the cables that were aged in the
laboratory. A high-voltage time test (HVTT) was performed at 60 Hz ac per Reference [14]. The
HVTT breakdown voltage per mil of the unaged specimens ranged from 620 to 1020 V/mil,
which exceeded the required minimum of 500 V/mil. Given the nominal insulation thickness of
175 mils, the applied voltages at breakdown ranged from 108,500 to 178,500 V.
The goal of the program was to determine the geometric mean breakdown (GMBD) strength
versus aging time for the various voltage and cyclic temperature conditions under wet aging
conditions. From the start, the researchers realized that relating failures in the breakdown tests at
relatively high stress to the life of cables in the field that experience relatively low stresses was
not necessarily possible. The failure mechanism under high stress is likely to be different from
the failure mechanism under lower stress. The research was to generate data for assessing models
that had been proposed to determine if a relationship could be reasonably established.
Step-rise ac tests were performed on unaged specimens using five-minute steps according to
section L.1.2 of Reference [14] to determine the as-manufactured condition. The protocol for the
aging program was performed differently from that of the XLPE program. Although a total of 12
specimens were subjected to each aging condition, they were not separated into 4 groups of 3.
Instead, when 8 of the 12 specimens failed during the aging, the remaining 4 specimens were
subjected to step-rise ac breakdown tests to determine the GMBD voltage at an aging time
closely approximating the geometric mean time to failure (GMTF). Then, an additional set of 12
specimens was subjected to the same aging for 1/2 of the GMTF aging value from the first series
of tests. Then, these specimens were subjected to ac breakdown tests. Finally, another set of 12
specimens was subjected to 1/4 of the GMTF aging and breakdown tested.
After the initial set of tests was performed, an additional set of tests was performed using cable
from a second manufacturing run. Accordingly, the initial cable was called EPR Run 1 and the
additional cable EPR Run 2.
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Ethylene Propylene Rubber Program
EPR Accelerated Aging Results
The EPR Run 1 specimens behaved differently than expected. Previous tests of XLPE insulation
and parallel tests of XLPE indicated that relatively early failure should occur under the 44
condition (34.6 kV, 90°C cycling) with the cables submerged and water in the conductor.
However, rather than failures occurring in a few weeks, the first EPR insulation failure occurred
after 890 days (2.4 years), indicating behavior significantly different from that of XLPE. Table
4-1 provides a partial listing of the time-to-failure results. To determine if different accelerated
test methods should be used for EPR, two further experiments were performed at the 44
condition:
• Submergence with no water in the strands
• Water in the strands without submergence
The results were dramatically different, with the shortest lives occurring under the submerged
but dry strand condition. Even under that condition, 7 failures took 511 days (1.4 years) to occur,
resulting in excessively long accelerated aging periods.
Table 4-1
EPR Run 1 Time-to-Failure Results
Test Group Notes Failure Times Lognormal Weibull Statistics

2
(days) Statistics (α, β, r )*
2
(GMTF, sdF, r )*
44 7 failures after 890, 1360, 1549, NA NA

2568 days; test 1720, 1721, 1948,
terminated at 3195 2568**
days (8.7 years)
44 "dry-wet" (no Testing terminated 493, 1.16, 0.971 518, 8.87, 0.938
water in strands) at 511 days with 7
failures
44 "wet-dry" Testing terminated 704, 3.76, 0.923 1297, 0.801, 0.930

(water in strands, at 1548 days
no external
water)
43 Testing terminated
after 509 days with
no failures; 12
breakdown tests
performed
42 Terminated after 132, 2.13, 0.917 188, 1.40, 0.856

832 days
41 Begun in response 66, 2.58, 0.878 92, 1.39, 0.856

to failures at 42 123, 1.63, 0.934 150, 2.50, 0.914
level 82, 1.37, 0.868 90, 4.97, 0.904
* Maximum likelihood estimates
** Termination failure
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Although failures took extensive times at the 44 condition (34.6 kV, 90°C cycling), earlier
failures occurred at the 42 condition (34.6 kV, 60°C cycling). To determine the effect of
reducing the temperature, testing at the 41 condition (34.6 kV, 45°C cycling) was initiated.
Shorter specimens were placed in smaller tanks for the first test, and failures occurred in much
shorter times. Because the specimens were shorter and more tightly bent, further experiments
were performed and showed that the 41 condition definitely led to earlier failure, with the GMTF
ranging from 66 to 124 days in the various experiments.
While failures occurred relatively early in the 41 and 42 conditions, very few failures were
occurring at the 44, 43, 34, 33, 32, 31, 24, 23, and 22 conditions:
• The 43 condition (34.6 kV 75°C) was terminated at 509 days with no failures.
• The 34 condition (26.0 kV, 90°C) was terminated at 1523 days with one failure at 1153 days.
• The 33 condition (26.0 kV, 75°C) was terminated at 2267 days with no failures.
• The 31 condition (26.0 kV, 45°C) was terminated at 1100 days with 1 failure at 153 days.
• The 24 condition (17.3 kV, 90°C) was terminated at 2268 days with three failures.
The cables from the 41 condition that failed early were subjected to extensive microscopic
examinations that showed that treeing was not the direct cause of the failures. There were no data
from the qualification testing and characterization data performed as part of the research that
indicated that the cables were poorly made or substandard in any way. Elimination of defects in
the cables and evaluation of the results for the other conditions indicate that the early failures in
the 41 condition are associated with the test condition rather than the overall capability of the
cable. Lowering the voltage from 34.6 kV to 26.0 kV while using 45°C resulted in only 1 failure
in 1100 days (3 years). That failure occurred at 153 days, after which no further failures
occurred. The 32 condition (26.0 kV, 60°C) resulted in no failures after 1506 days (4.1 years).
Another set of tests was subsequently performed on an additional manufacturing run of EPR
cable. The results were similar to those of the first program, with no failures on most groups up
to 1123 days. The exception was the 42 condition, but rather than cable insulation failures, 8
termination failures occurred. The interesting difference in this experiment was that after 459
days, no failures had occurred in the 41 condition cables. The EPR Run 1 cable material was
compared to the EPR Run 2 cable. The significant difference was that the residual dicumyl
peroxide (dcp) in the Run 1 cable was below the level of detectability (<30 ppm) while the Run 2
EPR had higher levels (80 to 150 ppm). Dicumyl peroxide is a cross-linking agent during
processing. The evaluation indicated that there may have been slightly greater thermal treatment
during manufacture on the Run 1 cable than on the Run 2 cables.
Two additional EPRs with different compounds were used in additional tests. These compounds
did not exhibit a tendency for early failure at the 41 condition.
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Overall, the tests of EPR insulated cables indicated the following:

• The conventionally most severe “wet/wet” (wet outer surface/wet conductor surface) aging
conditions developed for XLPE insulated cables are not the most severe for EPR insulated
cables.
• For most aging conditions in the test program, the accelerations achieved for the EPR
insulations were inadequate to cause failures in short enough periods to be of practical use in
developing aging models.
• EPR cables from one EPR manufacturing run (Run 1) failed relatively rapidly under elevated
voltage and low-temperature aging conditions while cables from another run and with
different formulations did not. Under less severe and more severe aging conditions, the Run 1
cables have either no or insufficient numbers of failures in extended periods to allow
meaningful aging trends to be identified.
• The different compounds of EPR tested behaved differently under “wet/dry” conditions.
The aging of EPR cables is different from that of XLPE cables and takes significantly longer,
making accelerated aging impractical under the aging regimens used in the program.
Results of Breakdown Strength Tests
The EPR cable in this program did not fail with any regularity in the test matrix other than the
EPR Run 1 at the 41 and 42 conditions using the standard time-to-failure test protocol. Because
protracted test times were encountered, aging of the cables had to be terminated for practical
considerations. When the aging was terminated, ambient temperature step-rise ac breakdown
tests were performed on the remaining samples in an attempt to develop data from the test
program. One of the goals of the program was to develop an aging model for the EPR cable. The
results of the aging made it obvious that this would not happen for EPR insulated cables due to
the inability to obtain time-to-failure information via the conventional test matrix conditions in a
reasonable period. Table 4-2 shows the summary of the GMBDs ordered by the number of days
of aging. Table 4-3 shows the same data but in order of decreasing breakdown strength. As can
be seen, there is an obvious difference in the GMBD from the unaged condition (877 V/mil) to
the various aged conditions. Although Table 4-3 shows that the lowest GMBDs occur for the
longest aging times, a strong correlation between breakdown strength and severity of the aging
condition does not appear to exist. A significant drop in breakdown voltage from the unaged
condition does, however, exist for all of the wet aged specimens: the unaged value is 877 V/mil,
and the breakdown strengths for all of the aged specimens are between 310 and 477 V/mil.
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Table 4-2
Summary of Breakdown Strengths for EPR Run 1 Cables (Ordered by Increasing Aging
Time)
Aging Condition Aging Time (days) GMBD (V/mil)
Unaged 0 877
41 69 477
41 91 404
41 100 398
41 172 400
43 509 424
44 (water external, not in strands) 511 470
42 832 379
31 1100 367
32 1506 382
23 1515 382
34 1523 375
44 (no water external, water in strands) 1548 440
22 2240 335
33 2267 348
24 2268 310
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Table 4-3
Summary of Breakdown Strengths for EPR Run 1 Cables (Ordered by Decreasing GMBD)
Unaged 0 877
41 69 477
44 (water external, not in strands) 511 470
44 (no water external, water in strands) 1548 440
43 509 424
41 91 404
41 172 400
41 100 398
32 1506 382
23 1515 382
42 832 379
34 1523 375
31 1100 367
33 2267 348
22 2240 335
24 2268 310
Tables 4-4 and 4-5 show similar data for the tests performed on the EPR Run 2 cables. As with
Run 1, there is a marked decrease in breakdown strength within the first month or so of
submersion in water. Thereafter, the breakdown strength seems to stabilize for a long period.
Figure 4-1 shows plots for the 41 aging regimen of the EPR Run 1 and the 41 and 44 aging
regimens for the EPR Run 2. These three plots show a consistent drop in breakdown strength
shortly into the aging exposure with stabilization thereafter. A few additional data points from
other Run 2 aging regimens are shown, which strengthens the indication that the GMBD of the
wetted EPR insulation consistently drops to approximately 1/2 of its original value and stabilizes.
The only data point that indicates a possible further drop is the lone Run 1, 24 (17.4 kV, 90°C)
value of 310 GMBD (V/mil).
An additional set of tests was performed on Run 2 cables to determine the change in breakdown
strengths in the first 70 days of exposure. This set of tests involved a cable that was wet, not
energized, and not temperature cycled as well as cables that were exposed to 41 and 44 aging.
Figure 4-2 shows the results. The 41 and 44 aging conditions resulted in a reduction of
breakdown strength, with the 41 condition causing the greatest reduction and the earliest decline.
The wet-only condition caused essentially no change in breakdown strength. It is not clear if
additional exposure to wetting only would ultimately have caused a drop in breakdown strength.
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As shown in Figure 4-1, there is variability in the degree of change and the onset of the drop.
However, there is a strong indication that the breakdown strength will decrease significantly and
then stabilize for a long period.
Reference [15] exposed five different commercially available EPR insulated cables
manufactured between 1994 and 1995 to long-term wet aging, both in laboratory and actual field
applications. The test program tried to simulate the same conditions in the laboratory as in the
underground field conditions. Both the laboratory and field cables were energized at 2.5 times
the rated voltage. The temperature of the field cables was monitored, and the temperature of the
laboratory cables was adjusted to simulate the condition of the field cables. Figure 4-3 shows the
change in breakdown strength with time. Within the first 100 to 200 days, the breakdown
strength of each cable type decreased by approximately 50%, at which point the breakdown
strength stabilized. It should be noted that the remaining breakdown strength far exceeds the
normal operating stress. Figure 4-3 also shows the percent water in the insulation near the
conductor prior to and after wet aging. The percent water approximately doubles for most of the
insulations. Interestingly, Cable E, which retains the highest percentage of initial breakdown
strength (75%), absorbed the most water.
Table 4-4
Summary of Breakdown Strengths for Run 2 EPR Cables (Ordered by Increasing Aging
Time)
Unaged 0 858
41 9.1 512
44 9.6 852
41 28.8 431
44 29.2 745
44 39.1 591
41 49.1 471
44 68.5 578
41 68.6 445
41 459 448
42 641 407
24 1109 319
44 1121 481
33 1123 452
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Table 4-5
Summary of Breakdown Strengths for Run 2 EPR Cables (Ordered by Decreasing GMBD)
Unaged 0 858
44 9.6 852
44 29.2 745
44 39.1 591
44 68.5 578
41 9.1 512
44 1121 481
41 49.1 471
33 1123 452
41 459 448
41 68.6 445
41 28.8 431
42 641 407
24 1109 319
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Figure 4-1
Breakdown Strength Versus Time at Stress Run 1 and 2 EPRs
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Figure 4-2
70-Day Wet Testing of Run 2 EPR
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Figure 4-3
Change in Breakdown Strength of Five Commercially Available Mid-1990s EPR Insulated
Cables from Wet Aging at 2.5 Times Rated Voltage
Note: Cable C was an XLPE cable, and its data are not shown here.
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5
CONCLUSIONS
XLPE Insulated Cable
Diagnostic Measurements
These conclusions are based on the sudden-death accelerated aging protocol with elevated
voltages and wet conditions used in the test and may not be relevant in other contexts. The data
from only a limited number of diagnostic test types resulted in a correlation with the aging
conditions in the ACLT program.
The results for each of the tests applied in the program are as follows:
Isothermal relaxation current: The samples in the program were short (9.14 m), making
automated IRC measurements difficult because of noise. However, on the samples for which
automated cable diagnoses could be achieved, the α3 × τ3 magnitude was found to be the most
relevant parameter for evaluating XLPE insulation degradation but still had a relatively weak
correlation with aging. The predicted residual breakdown strength provided by the KDA-1 unit
was not as good an indicator of XLPE cable degradation as the α3 × τ3 parameter.
Return voltage method: The CD-31 unit was consistently able to provide automated RV
measurements, even on the short 9.14-m cable samples. The peak RV value at 2 Uo—not the
linearity factor—was the most relevant parameter for evaluating the cable degradation. The
linearity factor may not have been applicable for the cables tested in this program because the
water trees were not large enough to cause a nonlinear dielectric response.
Oscillating wave partial discharge testing: PD in excess of the background noise at 197 Hz,
using the OWTS unit, was not observed on any of the ACLT samples either before or after aging
in the tanks. This indicates the absence of electrical trees in the samples that were removed
during the sudden-death ACLT. Because no PD has been observed, development of a
degradation model for the OWTS unit was not possible.
Dielectric spectroscopy: The dielectric spectroscopy measurement using the Baur unit was still
being investigated at the time of the issuance of the EPRI interim report, Advanced Diagnostics:
Life Estimation of Extruded Dielectric Cables [1]. One parameter that seems to be a good
indicator of cable degradation is the dissipation factor value at 0.2 Hz-1 Uo. There are other
combinations of voltage and frequency encompassed by this diagnostic technique, and one may
be a more relevant indicator of cable aging or degradation. It is possible that more than one
5-1
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Conclusions
parameter is necessary to adequately describe the degradation response, and thus the
development of multiple degradation models may be appropriate.
0.1 Hz dissipation factor: 0.1 Hz dissipation factor measurements using the Baur unit have
shown that those obtained at 2 Uo are a good indication of cable degradation, although
measurements obtained at 1 Uo are also acceptable.
0.1 Hz partial discharge: PD in excess of background noise at 0.1 Hz, using the Baur unit, was
not observed on any of the ACLT samples either before or after aging in the tanks. Because no
PD has been observed, development of a degradation model for PD at 0.1 Hz was not possible.
The result also indicates the absence of electrical trees in the samples that were removed during
the sudden-death ACLT.
AC breakdown strength: When compared with other diagnostic measurement techniques, ac

breakdowns performed on the removed samples were a good indicator of aging. The most
degraded cables, as indicated by the diagnostic measurements, result in the lowest ac breakdown
values.
Water treeing assessments: Water tree assessments on the removed samples indicate cable
degradation that, when ranked with the other diagnostic measurement techniques, is for the most
part consistent with the other diagnostic measurement techniques. The most degraded cables, as
indicated by the diagnostic measurements, have the longest bow-tie water trees. Interestingly,
there was no strong correlation of water treeing at the breakdown sites, indicating that
breakdowns in these tests were not necessarily related to water tree damage.
Aging Regimen Effects
The 24 (17.3 kV, 90°C) aging condition consistently provided cables that, when removed from
the tanks under the sudden-death test protocol, resulted in the most cable degradation even
though the aging times were not always the longest. This was demonstrated with each diagnostic
technique on both the field-aged and shelf-aged cables. AC breakdown tests and treeing analysis
confirmed the assessment by the diagnostic instruments. This does not mean that the 24
condition provides the most accelerated aging conditions. However, it does mean that under the
24 conditions in a sudden-death test protocol, the most degradation to the cables will occur in the
aging time permitted by the test voltage and temperature at this aging condition. Cables aging at
a 44 (34.6 kV, 90°C) condition will fail more quickly but will incur less bulk damage in the
aging time permitted by the test voltage and temperature of a 44 condition.
For field-aged cables, all of the diagnostic instruments ranked the cable degradation for the
various aging conditions in the following order from the highest level of bulk degradation based
on breakdown strength: 24 (17.3 kV, 90°C), 33 (26.0 kV, 75°C), 44 (34.6 kV, 90°C), and 42
(34.6 kV, 60°C). Time to breakdown in the ACLT from the shortest to the longest was 44, 24,
33, and 42—indicating that localized degradation can occur at a rate different from that of bulk
deterioration. The comparison of the effects of the aging regimens on bulk and localized aging is
shown in Table 5-1.
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Conclusions
Table 5-1
Order of Severity of Test Regimen Based on Bulk and Localized Degradation – Field
Pre-Aged Specimens
Severity Bulk Degradation Localized Degradation
Highest 24 44
33 24
44 33
Lowest 42 42
For shelf-aged cables, the degradation rankings for the various aging conditions were not as
clearly defined. However, for a majority of the diagnostic techniques, the order of the cable
degradation by aging condition, starting with the most severe, was 24 (17.3 kV, 90°C), 42
(34.6 kV, 60°C), 33 (26.0 kV, 75°C), and 44 (34.6 kV, 90°C). The implication for the reversal of
the rankings for localized degradation for the 33 and 44 conditions on the shelf-aged cables,
when compared to the field-aged cables, is not fully understood. The storage in the Texas sun
appears to have caused thermal aging that affected the results. Localized damage occurred most
quickly with the 44 specimens, followed by 33, 24, and 42 (in that order), based on the average
time to breakdown. Table 5-2 compares the effects of the aging regimens on bulk and localized
damage.
Table 5-2
Order of Severity of Test Regimen Based on Bulk and Localized Degradation – Shelf
Pre-Aged Specimens
Severity Bulk Degradation Localized Degradation
Highest 24 44
42 33
33 24
Lowest 44 42
The sudden-death ALCT technique provides a consistent and reproducible means of rapidly
aging XLPE cables and evaluating diagnostic techniques designed to detect cable degradation.
Unlike cable aging in the field on very long cable runs, the short (9.14-m long) samples are
uniformly aged in tanks along their entire immersed length under carefully controlled conditions.
The program continues, and the completion of the aging of the 22 (17.3 kV, 60°C) specimens
may provide additional insights regarding the ability of the diagnostic tests to assess the long-
term aging of cables. It is obvious that some of the aging regimens (for example, 44) increase the
rate of local deterioration, while others (for example, 24) elevate the bulk degradation as
indicated by the monitoring techniques and water tree counts. Localized degradation appears to
be heavily influenced by the temperature during cycling periods, with the highest temperature
leading to earliest breakdown in the ALCT. The pre-aging conditions are likely to have affected
the specimens in that the field pre-aging specimens may have had some water trees and the shelf
pre-aged specimens have experienced thermal aging.
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Conclusions
Although the aging regimens in the EPR program described in the EPRI report TR-108405-V2
[2] were similar to those of the XLPE program, the EPR specimens behaved totally differently.
EPR insulated cables do not age in the same manner as XLPE insulated cables under the
accelerated aging conditions used in the test program. While the aging rate of XLPE insulated
cables is highest when water is on both the exterior and interior of the insulation, this is not true
for EPR insulation that was tested. Failures during accelerated aging were made to occur more
rapidly for Run 1 EPR cable at the highest stress, highest cycling temperature (44) condition by
either not placing deionized water in the conductor strands (dry/wet aging) or not placing
deionized water on the outside of the cable (wet/dry aging). Both of these experiments seem to
indicate that diffusion of water into the insulation at the 44 condition plays a significant role in
the time-to-failure test results.
The Run 1 and Run 2 EPR cable insulations aged differently. The only identifiable difference in
the cables was that the Run 2 cables had residual cross-linking agent (dicumyl peroxide), while
Run 1 had no detectable residual. The earliest Run 1 EPR failures in the time-to-failure protocol
consistently occurred in the highest stress, lowest cycle temperature condition (41). This result
was not replicated for the Run 2 cables. Step-rise ac breakdown tests of unaged cables revealed
no differences between the runs. Under all other test conditions, the results were similar with
only scattered failures during aging after very long aging periods. The lack of failures in the
time-to-failure test protocol made the development of a meaningful EPR aging model impossible
in a reasonable period. Based on the data generated in the program, a well-defined relationship
does not appear to exist between the ambient temperature GMBD values, aging time, and aging
condition for EPR.
For the Run 1 and Run 2 EPR cables, a decrease in the GMBD with increased aging time was
noted. For the various aging conditions, this decrease from the unaged GMBD values (858–877
V/mil range) to the 310–512 V/mil range occurred after aging times of 70 to 2270 days. The
exact nature of the decrease in GMBD versus aging time was not determined in this program.
The data from these tests indicate that when EPR is aged under wet conditions, the breakdown
strength decreases significantly in the first few months of exposure and then stabilizes. This
indication was confirmed during the testing of five commercially available cable insulations
reported in the EPRI report 1009017, In-Service Performance Evaluation of Underground
Distribution Cables [15].
A short-term aging experiment on the Run 2 EPR cables showed that the 41 (34.6 kV, 45°C)
aging condition results in a much more rapid drop in the ambient temperature, step-rise ac
breakdown results than does the 44 (34.6 kV, 90°C) aging condition. A 37% drop in the step-rise
ac breakdown strength occurred after only 10 days at the 41 condition. Also at the 41 condition,
a 45% drop was noted after 70 days of aging. Only a 29% drop was noted after 70 days of aging
at the 44 condition. These short-term breakdown results indicate that despite continued aging at
various test conditions without failures, GMBD values decrease much more rapidly than first
thought for EPR insulated cables. In the 70-day experiment, no significant drop in GMBD
occurred under wet-only conditions. However, it is not clear if GMBD would have dropped had
the wet-only exposure continued. As stated previously, GMBD does stabilize after the initial
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Conclusions
drop to about 50% of original value under wet, energized conditions. The breakdown strength of
the insulation at 50% of original far exceeds the value needed to withstand operating voltages
and expected surges during operation.
Continued aging of the Run 1 cable at the 44 condition (8.8+ years) has shown that failures can
be obtained only after extended aging times. The failures during accelerated aging, which are
necessary to develop an aging model for EPR, can be obtained only with aging periods far in
excess of periods that are cost effective.
Inferences of Results with Respect to Nuclear Plant Cables
According to the Nuclear Energy Institute [16], the nuclear industry uses both EPR and XLPE
cables; EPR is the dominant insulation. Given that many of the plants were constructed in the
1970s, black EPR cables are most common—some plants have early XLPE insulated cables and
some have brown EPR. A few of the latest plants have red EPR insulated cables, which is also
the most common replacement material. The research described in this report indicates that
progress is being made in diagnostic testing of XLPE insulation. However, the research was not
fully successful in modeling the aging of XLPE based on the diagnostic test results. Dissipation
factor testing was affirmed as useful, and the additional data being generated under the 22 (17.3
kV, 60°C) aging condition may indicate that other techniques will be useful as well. The aging
under the 22 condition should be completed in 2006.
The test results also indicate that localized degradation, which could lead to early failure, does
not necessarily progress at the same rate as bulk degradation and may not be related to water
treeing. Under the various regimens, conditions that produced the most rapid times to breakdown
(the 44 condition) did not produce the most bulk degradation, as indicated by the diagnostic tests.
Conditions that produced the less rapid localized degradation led to much more bulk
deterioration. Interestingly, the temperature seems to be a stronger driver of bulk deterioration
than elevated accelerated aging voltage, given that the highest temperature coupled with the
lowest voltage consistently produced the largest amount of bulk degradation.
With respect to EPR insulation, the research indicates that accelerated aging of specimens is not
practical: even under the highest practical level of acceleration, very long periods (in fact, years)
are required to cause failure of specimens. Accordingly, evaluation of cables removed from long-
term service is likely to be a more successful route as long as cables can be obtained for
evaluation. The research described in the EPRI reports TR-108405-V2 [2] and 1009017 [15]
indicates that EPR, when subjected to wet aging, has a characteristic significant drop in
breakdown voltage a short while (that is, weeks to months) after the start of aging. But even
when subjected to 2.5 times rated voltage, the breakdown voltage remains stable at the lower
value through long periods of accelerated aging. It should be noted that the research described in
1009017 [15] was stopped because of a lack of a failures at eight years. It should also be noted
that while the breakdown strength of the wet EPR insulation drops, it remains 6 to 10 times
higher than the operating voltage and much higher than any high-potential proof test that has
been suggested.
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6
REFERENCES
1. Advanced Diagnostics: Life Estimation of Extruded Dielectric Cables. EPRI, Palo Alto, CA:
2005. 1011499.
2. Aging of Distribution Cable in Controlled Temperature Tank Tests. EPRI, Palo Alto, CA:
1997. TR-108405-V2.
3. In-Service Performance Evaluation of Underground Distribution Cables. EPRI, Palo Alto,
CA: 2003. 1009017.
4. M. Beigert, Mikrodielectromterische zertorungfreie Alerungsdiagnose von PE - und VPE -
Isolierten Mittelspannungskablen, Ph.D. thesis, BUGH Wuppertal, Germany, 1995.
5. R. Hoffmann, H.-G. Kranz, and D. Steinbrink, “IRC Analysis: Destruction Free Dielectric
Diagnosis of Mechanical and Service Aged Polymeric Insulation,” ISH 99, London, UK,
paper 5.102.S14.
6. M. Kuschel, Diagnose des Alterungszustandes von PV/VPE-islierten kabeln mittels
Verlustfaktormessung bei niedrigfrequenz (VLF) und Depolarisationstrom- bzw.
Rückkerhrspannungsmessung, Doctoral Thesis, Berlin, Germany, 1999.
7. W. Zaengl, “Application of Dielectric Spectroscopy in Time and Frequency Domain for HV
Power Equipment,” IEEE Electrical Insulation Magazine, Vol. 19, No. 6, pp. 9–22, 2003.
8. W. Zaengl, “Dielectric Spectroscopy in Time and Frequency Domain for HV Power
Equipment, Part I: Theoretical Considerations,” IEEE Electrical Insulation Magazine,
Vol. 19, No. 5, pp. 5–19, 2003.
9. G. Hoff, H.-G. Kranz, “Correlation Between Return Voltage and Relaxation Current
Measurements on CLPE Medium Voltage Cables,” ISH 99 London, UK.
10. Condition Assessment of Water Tree Aged XLPE Cables – Comparison of Four Commercial
Methods. SINTEF Energy Research Project Report TR-A5072, September 2000.
11. Instructional Manual, Diagnosis System CD31, Hagenuk KMT Kabelmesstechnik GmbH,
March 2001.
12. E. Gulski, J. J. Smit, P. N. Seitz, and J. C. Smit, “PD Measurements On-Site Using
Oscillating Wave Test System,” IEEE International Symposium on Electrical Insulation,
Washington, D.C., June 7–10, 1998.
13. E. Gulski, B. R. Hamerling, F. J. Wester, J. J. Smit, E. Groot, and P. Schikarski, “Insulation
Condition Assessment of Medium Voltage Power Cables Using On-Site PD Detection and
Analysis Techniques,” Paper 1-51, CIRED 2001, Amsterdam, Netherlands.
6-1
9988853
References
14. AEIC Publication CS6-87, “Specification for Ethylene Propylene Rubber Insulated Shielded
Power Cables Rated 5 through 69 kV (5th Edition),” The Association of Edison Illuminating
Companies, Birmingham, AL, October 1987.
15. In-Service Performance Evaluation of Underground Distribution Cables. EPRI, Palo Alto,
CA: 2003. 1009017.
16. 2005 Nuclear Energy Institute Survey of Information Related to Wet Underground Cables,
Preliminary Results, Nuclear Energy Institute, Washington, D.C., 2005.
6-2
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Advanced Diagnostics and Life

Nonproprietary Results Related to Cross-Linked Polyethylene

Final Report, March 2006

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Aging of extruded medium-voltage cable insulation under wet conditions is of concern to

1 INTRODUCTION ................................................................................................................. 1-1

2 DESCRIPTION OF CABLES AND CABLE AGING REGIMENS ......................................... 2-1

3 XLPE TEST PROGRAM DIAGNOSTIC TESTS .................................................................. 3-1

5 CONCLUSIONS .................................................................................................................. 5-1

6 REFERENCES .................................................................................................................... 6-1

Figure 3-1 Isothermal Relaxation Current Basic Measuring Circuit.......................................... 3-2

Development of a model of degradation requires the identification of a monitorable attribute that

Acronyms Used in This Report

Cable Aging Regimens

4 x Vg (34.6 kV) 90°C 4 x Vg (34.6 kV) 4 x Vg (34.6 kV) 60°C

3 x Vg (26.0 kV) 3 x Vg (26.0 kV) 75°C 3 x Vg (26.0 kV)

2 x Vg (17.3 kV) 90°C 2 x Vg (17.3 kV) 2 x Vg (17.3 kV)

XLPE Cable Program Diagnostic Tests

Isothermal Relaxation Current

nonlinearity to be observed. If a linear response exists, the recovery voltage at 2 Uo (normal

Linearity Factor Range Cable Diagnosis

2.0–2.5 Good cable quality

2.5–3.0 Medium cable quality

>3.0 Heavily damaged cable

<2.0 External influence on measurement (for

Recovery Voltage Results

Oscillating Wave Test System

Dielectric Spectroscopy Results

0.1-Hz Dissipation Factor

Tan δ at 2 Uo Difference of Tan δ Between 2 Uo and 1 Uo Assessment

0.1-Hz Dissipation Factor Results

0.1-Hz Partial Discharge

0.1-Hz Partial Discharge Results

AC Breakdown Test Results

Condition Voltage (kV) Temperature (°C) Average Life [Range] (days)

44 34.6 90 13.7 [11.8–15.8]

24 17.3 90 120.3 [62–158.3]

42 34.6 60 246.6 [159–339.1]

Condition Voltage (kV) Temperature (°C) Average Life [Range] (days)

44 34.6 90 12.2 [9–14.8]

33 26.0 75 68.6 [64.8–72.2]

24 17.3 90 159.4 [88–212.9]

42 34.6 60 182.2 [167–209]

90°C 75°C 60°C

Field Shelf Field Shelf Field Shelf

34.6 kV 13.7 12.2 246.6 182.2

26.0 kV 142.0 68.6

17.3 kV 120.3 159.4

Trees at Breakdown Sites

Aging Trees at ACLT Failure Trees at AC Breakdown No. % of

42 1 (>20) 2 (18, >12) 12 25.0

Aging Trees at ACLT Failure Trees at AC Breakdown No. % of

42 0 2 (15, >20) 12 16.7

Group Aging Range (days) Trees at Failure/Breakdown Site

44 field pre-aged 11.8–15.8 No

24 field pre-aged 62–158 Yes (in 158-day group, 1 of 12 specimens)