220 KV Cable Inspection Learning points at KEI Industries, Chopanki

Cable Details {127/220 (245) KV, 1 C X 1000 Sqmm}:

It is comprising of stranded Miliken overall compact circular plain copper

conductor, Nonconductive water blocking in each stranding layer
longitudinally of conductor except outer layer, Semiconducting water
Swellable tape over each segment and over final layer of central
conductor.
Screened by a layer of extruded semiconducting compound, XLPE
insulated (Dry Cure) screened by an extruded semiconducting compound
with semiconducting water swellable tape.
Copper wires Metallic screen and copper tape in open helix, Semi
conducting water swellable tape, Lead alloy “E” Sheathed, Anti corrosive
layer with bedding tape, Non conducting water swellable tape
Extruded HDPE (ST-7) (Anti Rodent & Termite) outer sheathed with
Extruded semiconducting layer.

Test were conducted on randomly selected drums as per approved QAP/GTP

and IEC -62067.

Following test were conducted on selected drum:

1. Electrical Tests
2. Physical Dimension
3. Insulation Test
4. Test on HDPE (ST-7) Outer Sheath Black
1. Electrical Tests on Full Drum Length:
S. Test Descriptions Unit Specified Observed
No. Value Value
1 Electrical Resistance of conductor at 20 Ohm 0.176 (Max) 0.0172
deg. C /km
2 Partial Discharge (at 1.50 Uo Test pC 5 max 1.90
voltage i.e. 190 KV)
3 Capacitance measurement at ambient µf/Km 0.204 + 8 % 0.184
Temp (Max)
4 Power frequency voltage withstand test KV 318 KV for 30 Withstood
at Room Temp minutes
5 Electrical Test on Non-metallic overall KV To withstand withstood
sheath with conductive layer over /Minute 25 Kv DC for
1 minute
sheath
6 Metallic screen resistivity (Copper wire Ohm. 0.01786 Max 0.016490
screen) mm2/m
7 Tan Delta measurement ------ 0.0001 max 0.0001239
8 Lightning Impulse test for 10 +ve & 10 KV To withstand Max 02
–ve at 1050kV on sample sample per
contact as
per IEC-
62067 cl.
10.2
(Already
test
conducted
from first
two lots)
9 Longitudinal water tightness test Visual Water should Max 02
(Water Penetration Test) not emerge sample per
from ends of contact as
test piece per IEC-
62067 cl.
10.2
(Already
test
conducted
from first
two lots)
2. Physical Dimension:

S Test Descriptions Unit Specified Observed

No. Values Values
1 No. of wires per segment(IEC – 60228 Cl-2) No. 61 wires / 61 wires /
s/mm 5 segments 5 segments
+7 +7 = 312
2 Approx. Overall Diameter of Conductor mm 41.2 41.35
Approx.
3 Thickness of Semi Conducting over mm 0.10 0.17
conductor
4 Thickness of Extruded Semi Conducting mm 1.15 / 2.5 2.51/2.73
Conductor Screen
5 Radial Thickness of Extruded XLPE mm 20.7 / 23.0 23.2/23.40
Insulation
6 Eccentricity of Insulation % 10 2.41
7 Thickness of Extruded Semi Conducting mm 1.15 / 1.5 1.68/1.77
Insulation Screen
8 Ovality of Core % 5 (Max) 1.05
9 Thickness/ Number of Semi Conducting mm 2x0.40 2x0.42
Water Swellable Tape over Insulation
Screen
10 No. & Diameter of Copper wires No/mm 75/1.58 75/1.59-
1.60
11 Thickness of Copper Tape-Open Helix mm 0.1 0.103
12 Thickness of Semi Conducting Water mm 2x0.40 2x0.43
Swellable Tape over Metallic Screen
13 Thickness of Metallic Lead Alloy “ E” Sheath mm 3.04/3.30 3.23/3.38
14 Thickness of Non Conducting Water mm 0.40 0.45
Swellable Tape over Metallic Screen
15 Thickness of HDPE (ST-7) Outer sheath mm 3.6/4.30 5.78 / 6.05
16 Overall Diameter of Cable with Extruder mm 121 ±3.0 120.25
Semiconducting Layer
3. Tests on Insulation (Natural):
S Test Descriptions Unit Specified Observed
No. Values Values
1 a. Tensile Strength (Before N/mm2 12.5 Min 22.50
ageing)
b. Elongation at break (Before % 200 Min 613
ageing)
2 HOT Set Test (200±3 ° C for 15 minutes)
a. Elongation under load % 175 Max 60
b. Permament Elongation % 15 Max 0.15

4. Test on HDPE (ST-7) Outer Sheath Black:

S Test Descriptions Unit Specified Observed
No. Values Values
1 a. Tensile Strength (Before N/mm2 12.5 min 29.24
ageing)
b. Elongation at break (Before % 300 min 906
ageing)
2 Visual Check for Embossing & Visual KEI INDIA 127/220
Surface Finish KV 1C X100 SQMM CU
XLPE 2019
3 Sequential Length marking at every Visual Shall be Provided
meters provided