Maintaining Underground Cable Systems

TNB Distribution Division Maintenance Manual : Underground Cable System Page |i
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TNB Distribution Division
Maintenance Manual :
Underground Cable System
2007
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Acknowledgement

We would like to express our deepest gratitude to TNB Distribution Division especially to
Mr. Halim Osman, Chief Engineer, TNB Distribution Engineering Services for giving us the
opportunity to develop TNB Distribution Division Maintenance Manual: Underground Cable
System. Acknowledgement also goes to Muhammad Azizi Abdul Rahman and Jazimah Abd
Majeed for their valuable contribution and assistance in developing this manual.
The project team would also like to express its highest gratitude to the TNBR Management
team for their supports starting from the initiation until its completion as well as the various
groups/units in TNBR especially to IT for their support in developing this manual.
Our deepest expression also to Dr. Prodipto Sankar Ghosh, RUP Consultant Plus Inc. (M)
Sdn. Bhd for his guidance, patience, support and encouragement towards the successful
completion of this manual development.
Special thanks to Huzainie Shafi Abd Halim, Radzlan Hisham Mohd Arifin and Zairul Aida
Abu Zarim for their valuable contribution and support towards the smooth execution of this
manual development.
Lastly we would like to extent our indebtedness to ILSAS whose valuable input has been a
great help for the successful development of this manual.

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I. Purpose of the Manual
This manual outlines sets of recommended maintenance practices for underground cable
system and to be used as a reference in the execution of related maintenance tasks by in-
house of external service providers.
Analysis of test results or interpretation, decision criteria and recommendations are generally
based on available industry standards and experiences of subject matter experts (SME) in
TNB Distribution. However, owing to unique equipment system design and characteristics,
failure modes and performance as experienced by TNB Distribution, expert judgments must
be exercised when finally applying these recommendations. In this respect, there is also a
need to refer to other related documents namely manufacturers recommendations and other
documented evidences related to operational historical performance of specific equipment as
additional inputs to the decision-making process.
II. Scope and Validity
This manual covers full scope of maintenance, testing and diagnostics tasks for MV and LV
underground cable system at three critical stages of the asset life namely: commissioning, in
–service and re-commissioning after failure. Although the motivation in the development of
this manual is more for the standardization of advanced diagnostic testing related to
condition-based maintenance, the more routine inspections and maintenance tasks are also
included for completeness and to ensure further standardization of these maintenance tasks.
The contents, or parts thereof, of the manual shall remain valid until such time further
revision is made. The custodian of this Manual is Engineering Services, Engineering
Department, and TNB Distribution.
III. Relevant Standards and References
Users of this Manual are advised to refer to the following set of standards and references so
as to acquire more in-depth understanding of the relevant standards being quoted in this
Manual and related subject matter.
1. IEEE 400-1991 – IEEE Guide for Making High Direct Voltage Tests on Owner Cable
Systems in the Field
2. IEEE 400.2 – 2004 – IEEE Guide for Field Testing of Shielded Power Cable Systems
Using Very Low Frequency (VLF)
3. IEEE 400 – 2001 – IEEE Guide for Field Testing and Evaluation of the Insulation of
Shielded Power Cable Systems
4. IEEE STD 1425 – 2001 IEEE Guide for the Evaluation of the Remaining Life of
Impregnated Paper Insulated Transmission Cable Systems
5. IEEE NO.83 -1963 – Radial Power Factor Tests on Insulating Tapes in Paper Insulated
Power Cable
6. Condition Assessment of Power Cables using Partial Discharge Diagnostic at Damped
AC Voltages – Frank Westler, SEBA KMT
7. Electric Cables Handbook, third edition – G.F. Moore BICC Cables
8. Electrical Power Equipment Maintenance and Testing - Paul Gill, Marcel Dekker Inc.
9. Tan Delta Cable Testing: Overview and Frequently Asked Questions – High Voltage Inc.
10. Condition Monitoring using Partial Discharge Method on Cable Mapping – Final Report
TNBR - Huzainie Shafi, John Foo, 2002.
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List of Abbreviations

A Ampere
AC Alternating Current
AM Ampere Meter
ASTM American Society for Testing and Materials
BS British Standard
CBM Condition Based Maintenance
CM Condition Monitoring
CMMS Computerised Maintenance Management System
CRO Cathode Ray Oscilloscope
CTC Critical Technology Challenges
CTCs Critical Technological Challenges
DC Direct Current
DGA Dissolve Gas Analysis
DS Dielectric Spectroscopy
emf Electro Magnetic Field
EPDM Ethylene Propylene Diane Monomer
ERMS Enterprise Resource Management System
F Farad
FMECA Failure Mode Effect And Criticality Analysis
GIS Geographical Information System
HV High Voltage
HVDC High Voltage Direct Current
Hz Hertz
IEC International Electrotechnical Commission
IEEE Institute of Electrical Electronic Engineer
IR Insulation Resistance
km kilometre
kV Kilo Volt
LGB Laporan Gangguan Bekalan
LV Low Voltage
MIL-STD United States America Military Standard
MTBF Mean Time Between Failures
MV Medium Voltage
NASA National Aeronautics and Space Administration
nC Nano Coulomb
O&M Operation and Maintenance
O/C Open Circuit
OWTS Oscillating Wave Testing System
pC Pico Coulomb
PD Partial Discharge
PDEV Partial Discharge Extinction Voltage
PDIV Partial Discharge Inception Voltage
PE Polyethylene
PILC Paper Insulated Lead Cable
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PM Preventive Maintenance
PRN Probability Risk Number
PT&I Predictive Testing And Inspection
PVC Poly Vinyl Chloride
RCM Reliability Centred Maintenance
RPN Risk Priority Number
SCADA Supervisory Control And Data Acquisition
SF6 Sulphuric Hexafluoride
TDR Time Domain Reflectrometry
UG Underground
VLF Very Low Frequency
VM Volt Meter
XLPE Cross Linked Polyethylene
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Table of Contents
Acknowledgement ii
I. Purpose of the Manual iii
II. Date Completed and Period Covered iii
III. Recommended Standards and References iii
List of Abbreviations iv
Table of Contents vi
List of Figures and Tables x
1 Introduction......................................................................................................................13
1.1 Background ...............................................................................................................13
1.2 Maintenance Practice in United States Bureau of Reclamation, Denver, Colorado .15
1.2.1 Power Cables .....................................................................................................16
1.2.2 Circuit Breakers .................................................................................................16
1.2.3 Transformers ......................................................................................................16
1.3 Maintenance Practice in NASA ................................................................................17
1.3.1 Transformers ......................................................................................................19
1.3.2 Circuit Breakers and Switchgear .......................................................................19
1.4 TNB Distribution Division’s journey toward Best Maintenance Practice................21
2 Maintenance Management ...............................................................................................24
2.1 Background ...............................................................................................................24
2.2 Failure Patterns..........................................................................................................24
2.3 Maintenance Techniques...........................................................................................26
2.3.1 Reactive Maintenance........................................................................................27
2.3.2 Preventive or Calendar Based Maintenance ......................................................27
2.3.3 Predictive or Condition Based Maintenance......................................................28
2.3.4 Proactive Maintenance.......................................................................................28
2.4 Failure Modes, Effects and Criticality Analysis (FMECA)......................................29
2.4.1 Types of FMECA...............................................................................................30
2.4.2 Standards Related to FMECA............................................................................30
2.4.3 Prerequisites of FMECA....................................................................................30
2.4.4 Preparation of FMECA ......................................................................................30
2.4.5 Limitations of FMECA ......................................................................................32
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2.5 Frequency or Periodicity of Condition Based Maintenance Task.............................32

3 Cable Asset Category.......................................................................................................36
3.1 Categorization of Underground Cable and its Accessories in TNB Distribution
Division System ...................................................................................................................36
3.2 Construction of Cables and its Accessories ..............................................................38
3.2.1 XLPE Cable .......................................................................................................38
3.2.2 PILC Cable.........................................................................................................40
3.2.3 LV Cable............................................................................................................41
3.2.4 Joint....................................................................................................................43
3.2.5 Termination........................................................................................................44
3.2.6 Electrical Stresses in Joints and Terminations...................................................44
3.3 Severity, Probability and Detectability Ranking used in FMECA Exercise.............46
3.4 Failure Modes, Effects and Criticality Analysis (FMECA) for MV Cables.............47
3.5 Failure Modes, Effects and Criticality Analysis (FMECA) for MV Joints and
Terminations ........................................................................................................................50
4 Cable Maintenance Testing..............................................................................................55
4.1 Background ...............................................................................................................55
4.2 Maintenance Matrix ..................................................................................................55
4.3 General Description of Identified On-Site Testing for Assessing the Integrity of
Insulation..............................................................................................................................57
4.3.1 Non-Destructive/Diagnostic Test.......................................................................57
4.4 General Description of Identified On-Site Testing for Assessing the Integrity of
Current Carrying Paths (Conductors, connectors and earthing shields) ..............................69
4.4.1 Contact Resistance Measurement of Joints and Terminations ..........................69
4.4.2 Continuity of Phase Conductor and Metallic Sheath.........................................69
4.5 Soaking Test..............................................................................................................70
5 Cable Maintenance Testing Procedure ............................................................................72
5.1 Background ...............................................................................................................72
5.2 Testing Equipment Specification ..............................................................................72
5.2.1 Testing Equipment Calibration ..........................................................................74
5.3 Commissioning, In-service and After Repair Maintenance Guidelines....................75
5.3.1 Commissioning Testing Guideline for Low Voltage Cables.............................75
5.3.2 In-service Maintenance Testing Guideline for Low Voltage Cables.................75
5.3.3 After Repair Testing Guideline for Low Voltage Cables ..................................76
5.3.4 Commissioning Testing Guideline for Medium Voltage XLPE Cable .............77
5.3.5 In-service Maintenance Testing Guideline for Medium Voltage XLPE Cable.78
5.3.6 After Repair Testing Guideline for Medium Voltage XLPE Cable ..................79
5.3.7 Commissioning Testing Guideline for Medium Voltage PILC Cable...............80
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5.3.8 In-service Maintenance Testing Guideline for Medium Voltage PILC Cable ..81
5.3.9 After Repair Testing Guideline for Medium Voltage PILC Cable....................82
5.4 Testing Procedure for Insulation Integrity ................................................................82
5.4.1 Tan Delta Test for MV Cables...........................................................................82
5.4.2 VLF Partial Discharge Mapping System ...........................................................85
5.4.3 Oscillating Wave Test System (OWTS) For PD Mapping & Tan-Delta...........87
5.4.4 Dielectric Spectroscopy .....................................................................................89
5.4.5 Insulation Resistance (IR) Testing Procedure....................................................92
5.5 Sheath Integrity Test .................................................................................................93
5.6 Testing Procedure for Current Carrying Path (Phase Conductors, connectors and
earthing shields) ...................................................................................................................94
5.6.1 Contact Resistance for Joints and Terminations................................................94
5.6.2 Continuity Test for Metallic Sheath...................................................................95
5.6.3 Thermography Survey for Exposed Termination ..............................................96
5.7 Fault Location ...........................................................................................................97
5.7.1 Cable Fault Location..........................................................................................97
5.7.2 Sheath Fault Locator ..........................................................................................99
5.8 Test Sheet Templates ..............................................................................................102
5.8.1 LV Cables Inspection and Test Data Sheet......................................................103
5.8.2 MV XLPE Cables Inspection and Test Data Sheet .........................................105
5.8.3 MV PILC Cables Inspection and Test Data Sheet...........................................109
6 Cable Maintenance Testing Results’ Interpretation.......................................................113
6.1 Background .............................................................................................................113
6.2 Condition and Data Quality Indicators and Cable Condition Index........................113
6.3 Scoring ....................................................................................................................114
6.4 Weighting Factors ...................................................................................................114
6.5 Mitigating Factors ...................................................................................................114
6.6 Documentation ........................................................................................................115
6.7 Condition Assessment Methodology ......................................................................115
6.8 Tier 1 Condition Indicators of MV XLPE and PILC Cables ..................................117
6.8.1 Contact Resistance ...........................................................................................117
6.8.2 Cable Condition Indicator 1 – Thermography .................................................117
6.8.3 Cable Condition Indicator 2 – Tan Delta Test .................................................118
6.8.4 Cable Condition Indicator 3 – Insulation resistance test .................................119
6.8.5 Cable Condition Indicator 4 – Operation and Maintenance Performance.......120
6.8.6 Cable Condition Indicator 5 – Age ..................................................................120
6.8.7 Tier 1 - Cable Condition Index Calculations ...................................................121
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6.8.8 Tier 1 – Cable Data Quality Indicator..............................................................122

6.9 Tier 2 – Tests and Measurements of MV XLPE and PILC Cables.........................123
6.9.1 Partial Discharge Test ......................................................................................124
6.9.2 Dielectric Spectroscopy Test ...........................................................................125
6.9.3 Tier 2 – Total Cable Condition Index Calculations .........................................126
6.10 Combined Tier 1 and Tier 2 Cable Condition-Based Alternatives .........................127
7 Record Management of Cable Maintenance Testing Results ........................................129
7.1 Background .............................................................................................................129
7.2 Flow Chart for Record Management of Raw Waveform and Processed Data........129
7.3 Record Management of Raw Waveform and Processed Data of VLF PD .............131
7.4 Record Management of Raw Waveform and Processed Data of OWTS PD..........132
7.5 Record Management of Raw Waveform and Processed Data of DS ......................136
7.5.1 XLPE................................................................................................................136
7.5.2 PILC.................................................................................................................138
7.6 Record Management of Raw Waveform and Processed Data of Thermography ...140
7.7 Record Management of IR and Tan Delta ..............................................................142
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List of Figures and Tables
Figure 2.1 Growing Expectation of Maintenance....................................................................24

Figure 2.2 Probability of Failure with Age..............................................................................25
Figure 2.3 Failure Patterns.......................................................................................................26
Figure 2.4 Schematic Representation of Proactive Maintenance ............................................29
Figure 2.5 P-F Curve................................................................................................................33
Figure 2.6 P-F Interval.............................................................................................................33
Figure 2.7 Periodicity of Condition Based Maintenance.........................................................34
Figure 3.1 Construction of single core XLPE cable ................................................................39
Figure 3.2 Construction of three core XLPE cable..................................................................39
Figure 3.3 Construction of triplex XLPE cable .......................................................................40
Figure 3.4 Construction of PILC cable ....................................................................................41
Figure 3.5 Construction of PVC LV cable...............................................................................42
Figure 3.6 Construction of XLPE LV cable ............................................................................42
Figure 3.7 Construction of Premoulded type Joint .................................................................43
Figure 3.8 Types of connectors (a) mechanical (b) crimped ...................................................43
Figure 3.9 Construction of Termination ..................................................................................44
Figure 3.10 Electrical Stress at End of Cable Semi-Conductive Screen .................................45
Figure 3.11 Geometric Stress Control .....................................................................................45
Figure 3.12 High Dielectric Constant Stress Control ..............................................................45
Figure 4.1 Electric circuit of insulation under dc voltage test .................................................57
Figure 4.2 Insulation Current Characteristics ..........................................................................59
Figure 4.3 Representation of Cable .........................................................................................61
Figure 4.4 Comparison between new and old cable ................................................................62
Figure 4.5 Tangent delta in frequency sweep ..........................................................................63
Figure 4.6 Comparison between new and old cable under dielectric spectroscopy ................63
Figure 4.7 Equivalent circuit diagram of cable insulation with voids .....................................65
Figure 4.8 Occurrences of internal discharges.........................................................................66
Figure 4.9 PD Test Setup .........................................................................................................67
Figure 4.10 PD Pulse Generation in Cables.............................................................................67
Figure 4.11 PD Pulse Characteristic in Cables ........................................................................68
Figure 4.12 Contact Resistance Test Setup..............................................................................69
Figure 5.1 Connection between Analyzer and PILC Cable.....................................................83
Figure 5.2 Connection between HV Unit, Analyzer and XLPE Cable....................................85
Figure 5.3 Schematic of Test Circuit .......................................................................................87
Figure 5.4 Schematic of Test Circuit .......................................................................................89
Figure 5.5 Connection between Analyzer and PILC Cable.....................................................90
Figure 5.6 Connection between Analyzer, HV Unit and XLPE Cable....................................91
Figure 5.7 Connection of IR Testing Equipment.....................................................................93
Figure 5.8 Test set up for Sheath Integrity Test.......................................................................94
Figure 5.9 Connection of Test Leads to Cable Joint................................................................95
Figure 5.10 Shock wave discharge ..........................................................................................98
Figure 5.11 Fault Location Procedure Flowchart ....................................................................99
Figure 5.12 Sheath fault pre-location by the voltage drop method........................................100
Figure 5.13 Sheath fault location with DC voltage................................................................101
Figure 6.1 Flowchart for Calculating Cable Condition Index ...............................................116
Figure 7.1 Flow Chart of Raw Waveform and Processed Data.............................................130
Figure 7.2 Raw Waveform of PD VLF..................................................................................131
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Figure 7.3 Processed Data (PD Mapping) of PD VLF ..........................................................132
Figure 7.4 Raw Waveform of OWTS PD..............................................................................133
Figure 7.5 Raw Waveform of OWTS PD..............................................................................134
Figure 7.6 Processed Data (PD Mapping) of OWTS PD.......................................................135
Figure 7.7 Processed Data (Histogram) of OWTS PD ..........................................................135
Figure 7.8 Raw Waveform (Good Response) of XLPE DS ..................................................136
Figure 7.9 Raw Waveform (Non Deteriorated Response) of XLPE DS ...............................137
Figure 7.10 Raw Waveform (Voltage Dependent Response) of XLPE DS ..........................137
Figure 7.11 Raw Waveform (Leakage Current Response) of XLPE DS ..............................138
Figure 7.12 Raw Waveform of PILC DS...............................................................................139
Figure 7.13 Processed Data (Moisture Content) of PILC DS................................................140
Figure 7.14 Raw Waveform of Thermography......................................................................141
Figure 7.15 Processed Data of Thermography ......................................................................141
Table 1.1 Criticality Ranking...................................................................................................17

Table 1.2 Sample Maintenance Approach Table.....................................................................18
Table 3.1 Types of Underground Cables and its Accessories .................................................36
Table 3.2 Cable components and their function ......................................................................38
Table 3.3 Failure Severity Ranking and Definition .................................................................46
Table 3.4 Failure Probability Ranking and Definition.............................................................46
Table 3.5 Failure Detectability Ranking and Definition..........................................................47
Table 3.6 FMECA for MV Cables...........................................................................................48
Table 3.7 FMECA for MV Joints ............................................................................................51
Table 3.8 FMECA for MV Terminations ................................................................................52
Table 4.1 Cable Maintenance Matrix.......................................................................................56
Table 5.1 MV XLPE Cable for Insulation Integrity Test ........................................................72
Table 5.2 MV PILC Cable for Insulation Integrity Test..........................................................73
Table 5.3 LV Cable for Insulation Integrity Test ....................................................................73
Table 5.4 MV XLPE Cable for Sheath Integrity Test .............................................................73
Table 5.5 MV XLPE, MV PILC & LV for Integrity of Connections......................................73
Table 6.1 Contact Resistance.................................................................................................117
Table 6.2 Thermography........................................................................................................117
Table 6.3 Tan delta ................................................................................................................118
Table 6.4 Insulation resistance...............................................................................................119
Table 6.5 Operation and Maintenance Performance Scoring ................................................120
Table 6.6 Age Scoring ...........................................................................................................121
Table 6.7 Tier 1 Cable Condition Index ................................................................................121
Table 6.8 Cable Data Quality Indicator Scoring....................................................................122
Table 6.9 Final Tier 1 Cable Condition Index Value.............................................................122
Table 6.10 Cable Tier 1 Condition-Based Alternatives.........................................................123
Table 6.11 Partial Discharge Test Score Adjustment ............................................................124
Table 6.12 Dielectric Spectroscopy Test Score Adjustment .................................................125
Table 6.13 Total Cable Condition Index Value .....................................................................126
Table 6.14 Cable Condition Based Alternatives....................................................................127
Table 7.1 Processed Data of XLPE DS .................................................................................138
Chapter 1
Introduction
1 Introduction
1.1 Background
Electrical distribution equipment is generally designed for a certain economic service life.
Equipment life is dependent on operating environment, maintenance program and the quality
of the original manufacture and installation. Beyond this service life period they are not
expected to render their services up to expectation with desired efficiency. However, certain
equipments are found to operate satisfactorily even after the expected economic life span
which may be attributed to good site conditions and good maintenance.
However, generally due to poor quality of raw material, workmanship and manufacturing
techniques or due to frequent system faults, over loading, environmental effect, unexpected
voltage swings and over voltage stresses on the system during the operation, many equipment
fail much earlier than their expected economic life span. Moreover, due to the above cited
reasons, the failure of vital equipment has become a regular feature and the high rate of
failure has become a cause of concern for electrical utilities. The concept of simple
replacement of power equipments in the system either before or after their economic service
life, considering it as weak or a potential source of trouble, is no more valid in the present
scenario of financial constraints.
Today the paradigm has changed and efforts are being directed to explore new
approaches/techniques of monitoring, diagnosis, life assessment and condition evaluation,
and possibility of extending the life of existing assets (i.e. circuit breaker, cables, oil filled
equipment like transformers, load tap changer etc., which constitute a significant portion of
assets for distribution system). Minimization of the service life cycle cost is one of the stated
tasks of the electrical power system engineers. For electrical utilities this implies for example
to fulfill requirements from customers and authorities on reliability in power supply at a
minimal total cost.
The main goal is therefore to reach a cost effective solution using available resources which
is captured by the concept of Asset Management. Maintenance is one of the areas where
higher effectiveness is sought for, and utilities are implementing new strategies for
maintenance and management of assets. The pressure to reduce operational and maintenance
costs is already being felt and the concept of Preventive Maintenance is undergoing change.
In practice, the traditional understanding of maintenance is to "fix it when it breaks". This is a

good definition for repair, but not maintenance. This style of maintenance is reactive. In
modern and forward thinking utilities, it has been realized that proactive, rather than reactive
maintenance management brings the best results. Adopting a proactive approach to
maintenance will improve maintenance effectiveness dramatically within the confines of the
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organizational and cultural environment of an existing, predominantly reactive maintenance

program.
Most equipment require regular and effective maintenance to operate correctly and meet their
design specifications. The consequences of ineffective equipment maintenance can be huge in
terms of system reliability indices, revenue loss and organizational image. Therefore, the
importance of effective maintenance through condition monitoring of electrical equipment in
the system is gaining importance to reduce the occurrence of such incidents. Assessing the
condition and thereby reducing failures of equipment is a key to improving reliability and
also effectively extending the life of equipment. Hence utilities are continuously in search of
best maintenance practices other than traditional methods/techniques to assess the condition
of equipment in service so that remedial measures can be taken in advance to avoid disastrous
consequences thereby saving lot of valuable resources.
The potential cost savings of Best Maintenance Practices can often be beyond the
understanding or comprehension of management. Unfortunately, in some people's minds, the
words "Best Practices" evoke some difficulty to understand, ever-changing and unachievable
goal towards which they are supposed to focus without hope of ever attaining. "Best
Maintenance Practices in Power Utilities" can be benchmarking standards, which are real,
specific, achievable and proven standards for maintenance management and by adopting this
will make any maintenance department more efficient to reduce operating and maintenance
costs, improve reliability, and increase morale. Best Maintenance Practices comprise of
standards and methods. Standards are the measurable performance levels of maintenance
execution and methods and strategies are procedures that must be practiced in order to meet
the standards. Overall, the combination of standards, and methods and strategies are elements
of a Planned Maintenance Management system.
This manual will introduce you to "Best Maintenance Practices in Power Utilities", define the
standards and show you how to set target and reach the performance levels of Best
Maintenance Practices. It will also provide you with detailed study on failure modes,
criticality assessment, strategies and actions to be taken, maintenance procedures and
analyses needed to execute Best Maintenance Practices. It has been shown that when
maintenance is planned and scheduled, a twenty-five person maintenance force operating
with proactive planning and maintenance scheduling can deliver the equivalent amount of
work of a maintenance team of forty persons working in a reactive maintenance organization.
A CMMS is critical to an organized, efficient transition to a proactive maintenance approach.

The types of reports and data tracking that can be obtained from CMMS are work orders and
all kinds of reports. A final item to consider when incorporating Best Maintenance Practices
is integrating the use of contractors into the maintenance activity of the organization and
following the same format of information/data to be collected and entered into CMMS.
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The process of transition from a reactive maintenance organization to a totally proactive

structure is not an overnight project. It will take time, effort and planning to accomplish. The
transition requires commitment from all levels of the organization.
1.2 Maintenance Practice in United States Bureau of
Reclamation, Denver, Colorado
Bureau of Reclamation has developed a document on their maintenance practices on

electrical equipment owned and operated by them. Maintenance recommendations are based
on industry standards and experience in Reclamation facilities. However, equipment and
situations vary greatly, so Reclamation suggests other sources of information to be consulted
(e.g., manufacturer’s recommendations, unusual operating conditions, personal experience
with the equipment, etc.) in conjunction with these maintenance recommendations.
Reclamation follows Preventive Maintenance (PM) practice of maintaining equipment on a

regular schedule based on elapsed time or meter readings. The intent of PM is to “prevent”
maintenance problems or failures before they take place by following routine and
comprehensive maintenance procedures. The goal of Reclamation is to achieve fewer,
shorter, and more predictable outages focused on the most important equipment. Reclamation
categorized electrical maintenance activities into three types:
Routine Maintenance – Activities that are conducted while equipment and systems are in
service. These activities are predictable and can be scheduled and budgeted. Generally, these
are the activities scheduled on a time-based or meter-based schedule derived from preventive
or predictive maintenance strategies. Some examples are visual inspections, infrared scans,
cleaning, functional tests, measurement of operating quantities, lubrication, oil tests,
governor, and excitation system alignments.
Maintenance Testing – Activities that involve the use of testing equipment to assess condition
in an off-line state. These activities are predictable and can be scheduled and budgeted. They
may be scheduled on a time or meter basis but may be planned to coincide with scheduled
equipment outages. Since these activities are predictable, some offices consider them “routine
maintenance” or “preventive maintenance.” Some examples are Doble testing, insulation
resitance testing, relay testing, circuit breaker trip testing, alternating current (AC) hipot tests,
high-voltage direct current (HVDC) ramp tests, battery load tests.
Diagnostic Testing -Activities that involve use of testing equipment to assess condition of
equipment after unusual events such as faults, fires, or equipment failure/repair/replacement
or when equipment deterioration is suspected. These activities are not predictable and cannot
be scheduled because they are required after a forced outage. Each office must budget for
these events. Some examples are Doble testing, AC hipot tests, HVDC ramp tests, partial
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discharge measurement, wedge tightness, core magnetization tests, pole drop tests, turns
ratio, and core earth.
Failure analysis studies complemented by industry standards and the preventive maintenance
schedule practiced by Reclamation on their primary equipment are presented below.
1.2.1 Power Cables
The cables used are either solid dielectric or oil-filled. In the case of critical circuits, periodic
maintenance tests are justified during the life of the cable to determine whether or not there
has been significant insulation deterioration due to operational or environmental conditions.
Cables are tested in accordance with manufacturer’s recommendations and industry
standards. When done properly, maintenance tests can detect cables that are approaching
failure without accelerating the deterioration process. Direct current (DC) high potential tests
effectively reduce in-service failures from faults of the cable or its accessories. Periodic
direct-current maintenance tests are not practiced for XLPE cables. Except for infrared
scanning, the cable circuit is de-energized before maintenance. For Oil filled cables oil
analysis including DGA are done annually. Refer Appendix 1.1 for details of maintenance
schedule for power cables.
1.2.2 Circuit Breakers
Most breaker maintenance except infrared scanning are performed with equipment de-
energized. Breakers are tested in accordance with manufacturer’s recommendations and
industry standards. Contact resistance and motion analyzer tests are highly recommended for
in-service breakers on a regular basis to monitor condition of the operating mechanism.
Power factor and ac high potential tests with contacts open are also practiced but with lesser
frequency. Moisture tests on gas in SF6 gas breakers are also done periodically. Meters and
gauges are calibrated annually. Manufacturer’s instructions are strictly followed in
performing ac high potential test on vacuum bottle to avoid X-radiation. Overhauling of
breakers with new seals and contacts are done based on number of operations, load and
timing analyzers information and/or guidelines. Refer Appendix 1.1 for details of
maintenance schedule for vacuum and SF6 breaker.
1.2.3 Transformers
Transformers are tested in accordance with manufacturer’s recommendations and industry

standards. Bushings are tested based on Doble Guideline and the periodicity of test is
adjusted depending on the condition. Annual infrared scanning for bushing is also practiced.
Based on DGA results several electrical tests for the main windings and core earthing are
recommended as per industry standards. Cooling accessories are also tested periodically for
condition assessment. Pressure relief device and gas relays are also included in their
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preventive maintenance schedule. Tap changer failure has been identified as one of the
dominant failure modes and its maintenance schedule has also received prime importance.
Refer Appendix 1.1 for details of maintenance schedule for oil-filled power transformers.
1.3 Maintenance Practice in NASA
NASA Center has developed a guide to perform preventive maintenance tasks for facilities
systems and sets initial Predictive Testing and Inspection (PT&I) alarm limits. In their
journey of RCM they felt the necessity of the understanding of the selected machine's failure
modes and the consequences of that failure. The maintenance approach followed by NASA
is based upon identifying, mitigating, and/or preventing failure. For each equipment category
the most common (the dominant) failure modes of the item with the highest probability of
occurring are being identified. In addition to the failure mode NASA has also considered the
consequence of failure.
Table 1.1 provides the method used to rank system criticality based upon the consequences
of failure. For the lowest ranked systems (identified as Rank Number 1 on Table 1.1), a run-
to-failure approach is often used. And in the highest ranked systems (Ranking Number 5), a
redesign effort is usually undertaken to shift the consequence of failure to a lower rank. The
recommended strategy identified in the table is adjusted based upon stressful operating
conditions and system redundancies.
Table 1.1 Criticality Ranking
Ranking Effect Consequence
The loss of function will be so minor that it would have

1 Negligible
no discernible effect on the facility or its operations.
The loss will cause minimal curtailment of operations or

may require minimal monetary investment to restore full
2 Minimal
operations. Normal contingency planning would cover
the loss.
The loss will have noticeable impact on the facility. It

may have to suspend some operations briefly. Some
3 Marginal
monetary investments may be necessary to restore full
operations. May cause minor personal injury.
Will cause personal injury or substantial economic

damage. Loss would not be disastrous, but the facility
4 Critical would have to suspend at least part of its operations
immediately and temporarily. Reopening the facility
would require significant monetary investments.
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Ranking Effect Consequence
Will produce death or multiple death or injuries, or the

impact on operations will be disastrous, resulting in long-
5 Catastrophic term or permanent closing of the facility. The facility
would cease to operate immediately after the event
occurred.
NASA Reliability-Centered Maintenance Guide provides Predictive Testing and Inspection

(PT&I) schedule including sample procedures. To determine the most effective intervals for
maintenance tasks NASA follows age related maintenance actions in order to reduce the cost
of unnecessary and/or ineffective maintenance. PT&I monitoring intervals are set in order to
determine the onset of failure and to take an action before the failure occurs. According to
NASA like all time/cycle tasks, if the interval is too short, there will be wasted effort (labor
and material) and if the interval is too long, failures will occur. For each equipment category
NASA has developed a table that identifies the maintenance approach for the Equipment
Items within the category. The table includes the Equipment Item, the applicable procedures,
and three Periodicity Codes. The Periodicity Codes are provided to assist the NASA Centers
in determining how often to perform the maintenance task based upon the consequences of
failure.
Table 1.2 Sample Maintenance Approach Table
Periodicity
Procedure By Criticality
Equipment Item Rank
Number Description 2 3 4
Brkr-02 Inspect and Test Vacuum 3A 3A A
or Oil Filled Circuit
Medium Voltage Circuit Breaker
Breaker, Vacuum
PT&I-05 Test Insulation 3A 3A A
PT&I-08 Power Factor Test 3A 3A A
Brkr-03 Inspect and Test SF6 3A 3A A
Medium Voltage Circuit Circuit Breaker
Breaker, SF6
PT&I-05 Test Insulation 3A 3A A
___________________________________________________________________________
Periodicity Codes
The Periodicity Codes used by NASA are described below:
D = Daily
W = Weekly
M = Monthly
Q = Quarterly
S = Semi-Annually
A = Annually
OC = On Condition: usually based upon results of a Predictive Testing and Inspection (PT&I)
test
Multiples of the above are sometimes used and are identified by a number followed by a
letter. For example, 5A indicates a procedure is scheduled every 5 years. Maintenance
schedule for transformers and circuit breakers practiced by NASA is presented here as
sample.
1.3.1 Transformers
Transformer dominant failure modes identified by NASA are deterioration of the electrical
insulation, deterioration of the electrical connections, and exterior corrosion. Over time, heat
generated internally slowly breaks down the paper insulation in all types of transformers. For
oil filled transformers, the oil insulation system also deteriorates, also due to heat. In dry
type units, moisture contamination contributes to the insulation deterioration. Repeated
heating and cooling cycling can loosen connections, both internal (tap connections, winding
termination points) and external (bushing connections). Harsh ambient conditions can
corrode transformer tanks, cooling fins, and attached accessories such as control panels and
conservator tanks. Most of the above failure modes progress slowly over time. Consequently
go/no-go tests such as turns-ratio testing are ineffective at finding failure patterns. Trending
test data is necessary to identify these failure patterns. The maintenance approach for
transformers therefore focuses on using applicable PT&I technologies such as infrared
thermography, oil testing and insulation power factor testing. The periodicity of condition
monitoring tasks according to criticality ranking for all types of distribution transformers are
detailed in Appendix 1.2.
1.3.2 Circuit Breakers and Switchgear
Circuit breakers used in NASA are as follows:

• Moulded Case – a sealed breaker with self-contained tripping and overload mechanisms.
• Oil Filled – mineral oil is the primary insulating medium. Normally medium and high
voltage range.
___________________________________________________________________________
• Vacuum – a ceramic cylinder contains the operating contacts. The insulating medium is a
lack of air in the bottle, which allows for close contacts. This type of breaker is normally
only used for medium voltage systems.
• Sulfur Hexafluoride (SF6) – SF6 is used as the insulating medium. Operating voltage can
be as high as 500 kV rated.
Dominant failure modes for circuit breakers identified by NASA are binding in the operating
mechanism, control circuitry failure, development of high resistance in the power
connections, exterior corrosion, and deterioration of the electrical insulation. Of these failure
modes, binding operating mechanism and control circuitry failure are the most common,
resulting in a circuit breaker that will not open or close as required. For oil filled breakers the
oil system also deteriorates due to repeated operations, and for SF6 breakers (SF6 gas is the
insulating medium) leaks in the SF6 containment is a dominant failure mode.
It should be noted in the periodicity section of the table in Appendix 1.2 that some breakers
have recommended maintenance frequencies of no longer than three years, and only low
voltage molded case breakers should be run to failure. The limiting factors for these
determinations are both cost and reliability. Medium and high voltage units (especially SF6
and air breakers) also benefit from maintenance cycles of three years or less. The periodicity
of condition monitoring tasks according to criticality ranking for all types of breakers is
detailed in Appendix 1.2.
Dominant failure modes for switchgear identified by NASA are high resistance at mechanical
connections, control relay failure, and corrosion for units installed outdoors or in harsh
environments. Additional failure modes that cause operational difficulties include racking
mechanism failure (not allowing a breaker to be racked in/out) and shutter
assembly/insulation barrier failure (which would not allow a breaker to be racked in or leave
energized bus connection uncovered). Typically the bar made from copper bar stock is bent
into specific angles and various lengths to fit the configuration of the switchgear. A failure at
one of the mechanical connections normally results in a bus bar that becomes greatly
distorted and not able to be reused. Replacement times depend on availability of the proper
copper bar stock and then manufacturing it into the proper configuration.
As a result the use of PT&I technologies, Infrared Thermography and Ultrasonic testing,
become very important for long term reliability. The periodicity of condition monitoring
tasks according to criticality ranking for all types of switchgears is detailed in Appendix 1.2.
___________________________________________________________________________
1.4 TNB Distribution Division’s journey toward Best
Maintenance Practice
The main themes for the TNB Electricity Technology Roadmap have been postulated as
follows:
• Reliable and efficient delivery system
• Intelligent power delivery systems
• Value added electricity products and services
• Enhance environmental management
Technology will play an important role to enable the improvements in reliability and
operational efficiency on the existing electricity delivery infrastructure. The critical
technological challenges (CTCs) during this period are described below:
• Improvement in operational efficiency
• Application of modern maintenance techniques
• Enhancement of grid system reliability
• Improvement in quality of equipment, components, fuel, infrastructure and
systems design
It therefore envisions that the following technologies can provide significant improvements to
the operational efficiency of the power delivery systems:
• Condition-based monitoring and Risk-based Inspection of critical components
• Basic SCADA for distribution systems
• GIS-based network information systems and applications
The drive to enhance the utilization of utility assets requires significant improvements in
maintenance techniques. In a highly competitive business environment, utilities are required
to utilize their assets for longer periods, while reducing downtime or outages. One way in
which this can be achieved is through the optimization of maintenance strategies.
In the past, maintenance strategies have usually been dictated by the original equipment
manufacturers to be time-based. These strategies are usually rather conservative. New
sensing technologies have now enabled condition based monitoring and opened new
dimensions in maintenance techniques and strategies. Data and information obtained from
condition based monitoring can be analyzed for anomalies and trends. These analyses form
the basis for predicting potential failures and scheduling maintenance strategies that would
maximize on the operating hours, while minimizing failure.
Therefore, the combination of sensing technologies together with information analyses and
statistics provide the opportunity for what is called reliability centered maintenance. This
technology allows for flexibility in maintenance strategies and allows utilities the ability to
maximize the potential of their assets, while reducing unplanned outages and down times.
___________________________________________________________________________
TNB Distribution Condition Based Maintenance (CBM) Program has been divided into
following tasks:
I. Task 1: Maintenance assessment

i. Review existing asset maintenance processes and work practices
ii. Identify operation and maintenance cost improvement opportunities through
CBM application
iii. Cite relevant industry’s best practices in CBM application
II. Task 2: Review existing asset management tools and systems

i. Assess sufficiency of data elements
ii. Assess integration possibilities
of existing asset management tools (i.e.: ERMS, LGB, GIS)
III. Task 3: Develop CBM processes, methodologies and models

i. Develop the CBM processes and methodologies
ii. Conduct network risk and criticality analysis
iii. Conduct equipment and network Failure Modes, Effects, and Criticality
Analysis (FMECA)
IV. Task 4: Define CBM implementation objectives, strategies and measures

i. How to identify critical/high risk equipment to be prioritized
ii. What CM technologies are relevant as identified through economic and risk
assessment
iii. How to measure the cost effectiveness of the CBM strategies
V. Task 5: CBM network architecture, hardware and software

i. Define the architecture and functional specification of the computerized CBM
system (CMMS)
ii. Identify interfacing possibilities with existing asset management system
VI. Task 6: Identify tangible benefits and evaluation measures related to CBM
i. Define the tangible benefits of the CBM program (in terms of improved
system/component reliability and reduced/maintained operation and maintenance
expenses)
ii. Specify the methodology to evaluate the effectiveness of the CBM program
VII.Task 7: CBM implementation master plan

i. Conduct a pilot implementation of the master plan
VIII.Task 8: Propose implementation approach and work plan

i. Identify key activities, tasks, schedule and manpower requirements for
implementing the TNB Distribution Division CBM Master Plan
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Chapter 2
Maintenance
Management
___________________________________________________________________________
2 Maintenance Management
2.1 Background
With the increasing age of the population of assets, complex designs and changing
expectations, organizations are making efforts to assess the internal condition of the
equipment while in service before catastrophic failures can take place to ensure higher
availability and reliability. Key challenges faced by maintenance engineers are as follows:
• To select the most appropriate techniques to deal with each type of failure process in
order to fulfil all the expectations of the owners of the assets, the users of the assets
and of society as a whole.
• In the most cost-effective and enduring fashion.
• With the active support and co-operation of all the people involved.
At the wake of this avalanche of change, maintenance engineers are continuously in search
for a new approach to maintenance that can be adopted to ensure that the physical asset will
continue to do whatever its users want it to do in its present operating context and also
strategies to maximise the life of the equipment at a minimal cost.
Maintenance management is also responding to changing expectations. Since the 1930’s, the
evolution of maintenance can be traced through three generations (shown in Figure 1) to
capture growing expectations of the industries and more importantly maintenance engineers.
Third Generation
• Higher plant availability and reliability

Second Generation • Greater safety
• Better product quality
First Generation • Higher plant availability • No damage to the environment
• Longer equipment life • Longer equipment life
• Fix it when it is broken • Lower costs • Greater cost effectiveness
1940 1950 1960 1970 1980 1990 2000
Figure 2.1 Growing Expectation of Maintenance
2.2 Failure Patterns
Traditional perception recommends that the best way to maximize the performance of assets
is to overhaul or replace them at fixed intervals. This is based on the premise that there is a
direct relationship between the amount of time equipment spends in service and the
likelihood that it will fail, as shown in Figure 2.2, which suggests that most assets are
___________________________________________________________________________
expected to operate reliably for a period "X", and then wear out. Traditional thinking suggests
that X could be determined from historical failure records and manufacturer’s guidelines.
This relationship between age and failure relationship is applicable for some failure modes
that are typically associated with fatigue and corrosion.
Figure 2.2 Probability of Failure with Age
Today’s equipment is much more complex causing remarkable changes in equipment failure
patterns. Figure 2.3 shows failure probability against age for a wide variety of assets. Pattern
A is the well-known bathtub curve, and pattern B is the same as Figure 2.2. Pattern C shows
slowly increasing failure probability with no specific wear out age. Pattern D shows low
failure probability at start then a rapid increase to a constant level, while Pattern E shows a
constant failure probability at all ages. Pattern F starts with high infant mortality and then
drops to a constant or very slowly increasing failure probability.
___________________________________________________________________________
Figure 2.3 Failure Patterns
2.3 Maintenance Techniques
There has been tremendous growth in new maintenance concepts and techniques. They are
broadly classified into following categories:
• Reactive maintenance
• Preventative or Calendar based maintenance
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• Predictive or Condition based maintenance

• Proactive maintenance
2.3.1 Reactive Maintenance
Corrective maintenance means fixing things either when they are found to be failing or when
they have failed. It includes:
• Breakdown maintenance
• Repair-when-fail
• Run-to-failure
Strategy of reactive maintenance assumes that failure is equally likely to occur. Major
downside of reactive maintenance is unexpected and unscheduled equipment downtime if
failed or repair parts are not available. Both labour and materials are used inefficiently.
Replacement parts are stocked at high levels which incurs high inventory cost.
2.3.2 Preventive or Calendar Based Maintenance
Preventive maintenance usually means overhauling items or replacing components at fixed

intervals. It includes activities like:
• scheduled inspection
• adjusting alignments
• cleaning and lubrication parts
• replacement
• calibration
• repair of parts
The above tasks are performed at pre-defined intervals without regard to equipment condition
or degree of use. It will reduce serious unplanned machine failure. The scheduled
maintenance is based on MTBF (or failure rate). The major weakness is that in reality failures
are equally likely to occur at random times and with a frequency unrelated to the average
failure rate. Thus calendar-based maintenance can be costly and ineffective when it is the sole
type of maintenance practiced. Although many ways have been proposed for determining the
correct frequency of scheduled maintenance tasks, none are valid unless the in-service age-
reliability (i.e. failure rate versus age) characteristics of the systems are known. To determine
periodicity, the following techniques are recommended:
• Anticipating failure from experience
• Failure distribution statistics
• Conservative approach (due to lack of information)
___________________________________________________________________________
2.3.3 Predictive or Condition Based Maintenance
Predictive or condition based tasks entail checking if something is failing. It includes:
• Non-intrusive testing
• Visual inspection
• Operational data to assess machinery condition
To check whether something is failing the "failure-finding tasks" are carried out using
various on-site testing methods. The data collected from on-site testing are called Condition
Monitoring (CM) data. A few examples of CM data are:
• Flow rates
• Temperature
• Pressure
• Electrical parameter
• Ultrasonic testing
• Vibration monitoring
• Oil analysis
• Optical sensing
• Thermography
Usually FMECA is being practiced to identify condition monitoring techniques appropriate

for different failure modes of equipment to assess their condition.
The CM data are analysed using the following techniques to identify the precursors of failure:
• Trend analysis
• Pattern recognition
• Comparing tests results against specified limits
• Statistical process analysis
Through trending or other predictive analysis methods, the maintenance interval is decided.
For trending purposes a minimum of 3 monitoring points will be required before failure. CM
does not give all types of equipment failure modes and therefore should not be the sole type
of maintenance practiced.
2.3.4 Proactive Maintenance
This is the capstone of Reliability Centred Maintenance philosophy. It improves maintenance
through better:
• Design
• Installation
• Maintenance procedures
• Workmanship
• Scheduling spare parts
___________________________________________________________________________
It is characterised by an effective feedback system between the maintenance technician and
design engineer. One must ensure that design mistakes made in the past are not repeated in
future design. The equipment is viewed from life-cycle perspective. Constantly maintenance
procedures are re-evaluated to find optimal mix. Its main objective is to extend machinery
life and to obtain zero breakdown. The activities undertaken are schematically represented in
Figure 2.4.
Figure 2.4 Schematic Representation of Proactive Maintenance
2.4 Failure Modes, Effects and Criticality Analysis (FMECA)
Initially, the FMECA was called FMEA (Failure modes and effects analysis). The C in
FMECA indicates that the criticality (or severity) of the various failure effects are considered
and ranked. Today, FMEA is often used as a synonym for FMECA. These are methodologies
designed to identify potential failure modes for an equipment or system, to assess the risk
associated with those failure modes, to rank the issues in terms of importance and to identify
and carry out corrective actions to address the most serious concerns.
Failure modes, effects, and criticality analysis (FMECA) is a methodology to identify and
analyze:
• All potential failure modes of the various components of a system
• The effects these failures may have on the system
• How to avoid and/or mitigate the effects of the failures on the system
___________________________________________________________________________
FMECA is a very structured and reliable technique for failure analysis developed by the U.S.
Military. FMECA is used during the early design phases to assist in selecting design
alternatives with high reliability and high safety potential to ensure that all conceivable
failure modes and their effects on operational success of the system have been considered. It
also provides a basis for maintenance planning and provides a basis for quantitative reliability
and availability analyses.
2.4.1 Types of FMECA
FMECA are of three types:

• Design FMECA is carried out during equipment design phases to eliminate all
conceivable failures that can happen during the whole life-span of the equipment.
• Process FMECA is focused on problems stemming from how the equipment is
manufactured, maintained or operated.
• System FMECA looks for potential problems and bottlenecks in larger processes,
such as entire production lines.
2.4.2 Standards Related to FMECA
FMECA standards are:

• MIL-STD 1629 “Procedures for performing a failure mode and effect analysis”
• IEC 60812 “Procedures for failure mode and effect analysis (FMEA)”
• BS 5760-5 “Guide to failure modes, effects and criticality analysis (FMEA and
FMECA)”
2.4.3 Prerequisites of FMECA
Prerequisites for FMECA studies are:

1. Defining the system to be analyzed and dividing it into manageable units called
functional elements.
2. Collecting available information that describes the system to be analyzed; including
drawings, specifications, schematics, component lists, interface information and
functional descriptions.
3. Collecting information about previous and similar designs through interviews with
design personnel, operations and maintenance personnel and component suppliers.
2.4.4 Preparation of FMECA
FMECA worksheets (Appendix 2.1):

___________________________________________________________________________
A suitable FMECA worksheet for the analysis has to be designed which can easily fit into the
maintenance management system. A typical FMECA worksheet covering the most relevant
columns is discussed below.
Task No. Task Description

1. In the first column a unique reference is assigned to a functional element.
2. The functions of the element are listed in the second column. Functions are also
categorized according to various operational modes for the element.
3. For each function of the element the potential failure modes are then identified and listed
in column three. Failure mode is defined as a functional failure or in other words a non
fulfillment of the functional requirements of the functions specified in column 2.
4. The failure modes identified in column three are studied one-by-one. The failure
mechanisms or causes that may contribute to a failure mode are identified and listed.
Some failure modes are evident, others are hidden.
5. The effects each failure mode may have on other elements in the same subsystem (local
effects) and/or on the system (global effects) are listed in column four. The resulting
operational status of the system after the failure can be recorded, that is, whether the
system is functioning or not, or is switched over to another operational mode.
6. In some cases consequences such as safety consequences, environmental consequences,
operational consequences and economic consequences are also listed in separate columns
in the worksheet.
7. The severity index rank corresponding to the failure mode is then assigned in column
five. The severity classes and the ranks can be described in various ways. A typical
example is shown below:
Rank Description
10 Catastrophic Failure results in major injury or death of personnel.
7-9 Critical Failure results in minor injury to personnel.
4-6 Major Failure results in a low level of exposure to personnel, or activates
alarm system.
1-3 Minor Failure results in minor system damage but does not cause injury to
personnel.
8. The likelihood that the failure will be detected is then listed in column six. An example
of detectability ranking is given below:
Rank Description
1-2 Very high probability that the defect will be detected
3-4 High probability that the defect will be detected
5-7 Moderate probability that the defect will be detected
8-9 Low probability that the defect will be detected
10 Very low (or zero) probability that the defect will be detected
9. Failure rate or probability of failure for each failure mode is then listed in column seven.
___________________________________________________________________________
An example of a classification is shown below:
Rank Description
Very unlikely Once in 1000 years
Remote Once in 100 years
Occasional Once in 10 years
Probable Once per year
Frequent Once per month
More sophisticated numerical value of probability of failure can also be calculated and
assigned using past record of failure data and using appropriate statistical modeling
technique.
10. The various possibilities for detection of the identified failure modes are listed in column
eight. These may involve on-line and off-line diagnostic testing and proof testing.
11. Possible actions to correct the failure and restore the function or prevent serious
consequences are listed in column nine. Actions that are likely to reduce the frequency of
the failure modes should also be recorded.
12. The risk related to the various failure modes is presented in column ten by
Probability/Risk number (PRN). Sometimes it is called criticality assessment. A PRN is
derived by assigning a numerical value to the frequency/probability of the failure mode
and another value to the severity of the failure mode. More sophisticated PRN can be
calculated by attaching different numerical weightings to different categories of failure
consequences (safety, environmental, operational and economic). If historical failure
rates and costs are available, these rankings can be refined using Pareto analysis.
Some methodology recommends computation of Risk Priority Numbers as shown below:
XXXXXRPN (risk priority number) = Fr x Cr x DetXXXXX
where, Fr = probability of occurrence, Cr = criticality or severity and Det = detectability
2.4.5 Limitations of FMECA
In spite of being so popular FMECA also has downsides and they are:
• It is a tedious, time-consuming and expensive process
• It is not suitable for multiple failures
2.5 Frequency or Periodicity of Condition Based
Maintenance Task
Traditionally, the periodicity of condition based maintenance tasks used to be decided based
on two factors; the frequency of the failure and/or severity of the failure. Sometimes these
two are combined together and expressed as the criticality of the equipment. Recent studies
___________________________________________________________________________
have shown that periodicity of condition based maintenance tasks should be based on more
appropriate factor called failure period also known as the "P-F interval". Figure 2.5 illustrates
this in the form of P-F curve, which shows how a failure starts and deteriorates to the point at
which it can be detected (the potential failure point "P"). Thereafter, if it is not detected and
suitable action taken, it continues to deteriorate - usually at an accelerating rate - until it
reaches the point of functional failure ("F").
Figure 2.5 P-F Curve
The amount of time which elapses between the point where a potential failure occurs and the
point where it deteriorates into a functional failure is known as the P-F interval, as shown in
Figure 2.6. The P-F interval will vary with the failure modes.
Figure 2.6 P-F Interval
The P-F interval governs the periodicity with which the condition based maintenance tasks
should be undertaken. The periodicity must be significantly less than the P-F interval if we
___________________________________________________________________________
wish to detect the potential failure before it becomes a functional failure. Unless there is a
good reason to do otherwise, it is usually sufficient to select a periodicity equal to half the P-
F interval. If the P-F interval is too short for it to be practical to monitor for the potential
failure, or if the nett P-F interval is too short for any sensible action to be taken once a
potential failure is discovered, then the condition based task is not appropriate for the failure
mode under consideration. For instance, Figure 2.7 shows how a P-F interval of 9 months
and a periodicity of 1 month give a nett P-F interval of 8 months.
Figure 2.7 Periodicity of Condition Based Maintenance

Chapter 3
Cable Asset
Category
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3 Cable Asset Category
3.1 Categorization of Underground Cable and its
Accessories in TNB Distribution Division System
The power cables have been subdivided into 4 voltage levels i.e. 33kV, 22kV, 11kV and
0.433 kV. Underground cables are further subdivided according to their insulation medium of
various sizes and number of cores. The subdivision for joints is the same for underground
cables. Assets that are critical to the system have been short-listed as per Table 3.1.
Table 3.1 Types of Underground Cables and its Accessories

Category Types Size
2
Cables 630mm 1 core Aluminium
300 mm2 1 core Copper
33kV XLPE 500mm2 1 core Copper
70 mm2 3core Aluminium
PILC 185 mm2 3core Aluminium
22kV 70 mm2 1core Aluminium
XLPE
70 mm2 1 core Aluminium
95 mm2 Aluminium Triplex
XLPE
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Category Types Size

2
300 mm 1core Aluminium
PVC
500 mm2 1core Copper
630 mm2 1core Copper
XLPE 120 mm2 4core Aluminium
LV
630mm2 1 core Aluminium
33kV XLPE
500mm2 1 core Copper
XLPE
Termination
XLPE
Joints 630mm2 1 core Aluminium
33kV XLPE
500mm2 1 core Copper
XLPE
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Category Types Size

2
120 mm 3core Aluminium
XLPE
185 mm2 - 150 mm2 3core
185mm2 - 240 mm2 3core
22 kV PILC - XLPE
400 mm2 - 240 mm2 3core
Transition Joints 400 mm2 - 500 mm2 3core
120 mm2 - 95 mm2 3core
11kV PILC - XLPE 185 mm2 - 150 mm2 3core
300 mm2 - 240 mm2 3core
3.2 Construction of Cables and its Accessories
Generally the major component and its function in power cables and accessories are as
follows:
Table 3.2 Cable components and their function

Component Function
Conductor / Ferrule Carrying current. The important criterion is the current
carrying capacity of the conductor.
Insulation High resistance to the flow of current. Often referred to
as dielectric.
Metallic Sheath To provide return path for fault current. Size depending
on short circuit rating of the particular circuit.
Outer Sheath To provide mechanical protection.
3.2.1 XLPE Cable
In TNB Distribution network there are single core, three core and triplex XLPE cables.
3.2.1.1 Single Core Cable
The typical construction of single core XLPE cable is shown in Figure 3.1.
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No. Designation
1. Conductor
2. Conductor screen
3. Insulation Insulation
4. Insulation screen
5. Metallic sheath
6. Outer protection
Figure 3.1 Construction of single core XLPE cable
• Conductor: Aluminum or Copper. Size varies as shown in Table 3.1.

• Insulation: XLPE sandwiched between semi-conductive materials that are conductor
screen and insulation screen using vulcanizing technique.
• Metallic Sheath: Copper tape is applied helically with at least 15% overlap.
• Outer Protection: Usually Polyethylene (PE).
3.2.1.2 Three Core Cable
The typical construction of three core XLPE cable is shown in Figure 3.2.
No. Designation
1. Conductor
2. Conductor screen
5. Metallic sheath
6. Filler
7. Core wrapping Outer
8. Outer sheath protection
Figure 3.2 Construction of three core XLPE cable

screen and insulation screen using vulcanizing technique.
• Filler: To fill in the gap between conductors with polypropylene material to make it
round shape.
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3.2.1.3 Triplex Cable
The typical construction of triplex XLPE cable is shown in Figure 3.1.
No. Designation
1. Conductor
2. Conductor screen
5. Metallic sheath
6. Outer protection
Figure 3.3 Construction of triplex XLPE cable
• It is actually single core cable construction for each core but grouped together.
screen and insulation screen using vulcanizing technique. Currently in TNB only
11kV with triplex construction is in use.
3.2.2 PILC Cable
In TNB Distribution network, PILC is used for 11kV and 22kV.
The typical construction of PILC cable is shown in Figure 3.4.

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No. Designation
1. Stranded aluminium conductor
2. Paper insulation
3. Filler paper
4. Manufacturer label
5. PVC tape
6. Bedding
7. Textile serving
8. Perforated metallic
9. Jute fillers
10. Copper-woven fabric tape
11. Lead sheath
12. Voltage label
13. Steel armour
Figure 3.4 Construction of PILC cable
• Conductor: Aluminum or Copper. Size varies as shown in Table 3.1. Are often
wrapped in insulation paper.
• Insulation: Paper with impregnated oil.
• Filler: Paper impregnated with oil.
• Belt Insulation: Paper impregnated with oil. To provide extra insulation required
corresponding to ((VL/√3) - (VL/2)) volt.
• Metallic Sheath: Lead shield.
• Perforated Metallic Paper: Used for 22kV only.
• Outer Protection: Usually jute with steel type armor.
3.2.3 LV Cable
In TNB Distribution Division Network, there are two types of LV Cables: PVC and XLPE.
3.2.3.1 PVC LV Cable
The typical construction of PVC LV cable is shown in Figure 3.5.

___________________________________________________________________________
No. Designation
1. Sheath
2. Binder tape
3. Filler
4. Insulation
5. Conductor
Figure 3.5 Construction of PVC LV cable

• Insulation: PVC. Usually colored according to the phase.
• Binder Tape.
round shape.
• Outer Protection/Sheath: Usually Polyethylene (PE).
3.2.3.2 XLPE LV Cable
The typical construction of XLPE LV cable is shown in Figure 3.6.
No. Designation
1. Conductor
2. Insulation
3. Filler
4. Core Wrapping
5. Inner Sheath
6. Metallic Screen
7. Outer Sheath
Figure 3.6 Construction of XLPE LV cable
• Conductor: Aluminum. Size varies as shown in Table 3.1.

• Insulation: XLPE. Usually colored according to the phase.
round shape.
• Metallic Screen: Copper tape
• Inner/Outer Sheath: Usually Polyethylene (PE).
___________________________________________________________________________
3.2.4 Joint
The typical construction of cable joint is shown in Figure 3.7.
Figure 3.7 Construction of Premoulded type Joint
• Connector: Aluminum or Copper depending on conductor type. For crimped type the
size depends on conductor size whereas mechanical type has range taking capability.
• Semi-conducting conductor shield: Same function as conductor shield of cable.
• Insulation: Usually EPDM (Ethylene Propylene Diene Monomer) rubber material and
silicone.
• Semi-conducting insulation shield: Same function as insulation shield of cable.
• Metallic Shield: Breaded Copper Strip or Copper stocking bonded with the main cable
copper tape at both ends.
• Outer Protection: Resin to protect joint body from mechanical damage.
3.2.4.1 Different Types of Connectors
Currently, two types of connectors, Mechanical and Crimped Connector, are in use in TNB
Distribution System as shown in Figure 3.8.
(a) Mechanical connector (b) Crimped connector
Figure 3.8 Types of connectors (a) mechanical (b) crimped

___________________________________________________________________________
3.2.4.2 Different Joint Design
1. Taped Resin – See Appendix 3.1

2. Heat Shrink – See Appendix 3.2
3. Premoulded – See Appendix 3.3
4. Liquid Transition – See Appendix 3.4
5. Dry Transition – See Appendix 3.5
3.2.5 Termination
The typical construction of termination is shown in Figure 3.9.
Figure 3.9 Construction of Termination
• Connector/Lug: Aluminum or Copper depends on conductor type, sometimes bimetal.

Size also depends on conductor size.
• Insulation: Skirted shed if outdoor. Unskirted for indoor type.
• Semi-conductive material: High K for both conductor and insulation screen.
• Outer protection: Must have environmental sealing if outdoor type.
3.2.6 Electrical Stresses in Joints and Terminations
In joint and termination build-up, the most important criterion is insulation screen cut back.
This is where the high electrical stress lay (Figure 3.10). To control it, there are 2 ways either
with geometric stress control or dielectric stress control as shown in Figure 3.11 and Figure
3.12 respectively. It depends on manufacturer’s design and preference.
___________________________________________________________________________
Figure 3.10 Electrical Stress at End of Cable Semi-Conductive Screen
Figure 3.11 Geometric Stress Control
Figure 3.12 High Dielectric Constant Stress Control

___________________________________________________________________________
3.3 Severity, Probability and Detectability Ranking used in
FMECA Exercise
The important features of FMECA exercise are ranking of the severity index, detection factor
and failure probabilities corresponding to various failure modes. All the above indices are
ranked in a 10 point scale with their respective descriptions and are presented in Table 3.3,
Table 3.4, and Table 3.5.
Table 3.3 Failure Severity Ranking and Definition

Effect Severity of Effect Ranking
Hazardous (without Very high severity ranking when a potential failure
10
warning) mode affects safe system operation without warning
Hazardous (with Very high severity ranking when a potential failure
9
warning) mode affects safe system operation with warning
System inoperable with destructive failure without
Very high 8
compromising safety
High System inoperable with equipment damage 7
Moderate System inoperable with minor damage 6
Low System inoperable without damage 5
System operable with significant degradation of
Very low 4
performance
System operable with some degradation of
Minor 3
performance
Very minor System operable with minimal interference 2
None No effect 1
Table 3.4 Failure Probability Ranking and Definition

Failure Probability Failure Probability in 1 Year Ranking
Very High: Failure is almost >1 in 2 10
inevitable 1 in 3 9
1 in 8 8
High: Repeated failures
1 in 20 7
1 in 80 6
Moderate: Occasional failures
1 in 400 5
1 in 2,000 4
Low: Relatively few failures
1 in 15,000 3
1 in 150,000 2
Remote: Failure is unlikely
<1 in 1,500,000 1
___________________________________________________________________________
Table 3.5 Failure Detectability Ranking and Definition
Detectability Likelihood of Detection Ranking
Absolute Control cannot detect potential cause/mechanism and
10
Uncertainty subsequent failure mode
Very remote chance the control will detect potential
Very Remote 9
cause/mechanism and subsequent failure mode
Remote chance the control will detect potential
Remote 8
Very low chance the control will detect potential
Very Low 7
Low chance the control will detect potential
Low 6
Moderate chance the control will detect potential
Moderate 5
Moderately Moderately high chance the control will detect potential
4
High cause/mechanism and subsequent failure mode
High chance the control will detect potential
High 3
Very high chance the control will detect potential
Very High 2
Almost The control will detect potential cause/mechanism and
1
Certain subsequent failure mode
for MV Cables
Medium Voltage Cable’s dominant failure modes identified by TNB Distribution Division
are critical mechanical damage to cable insulation, damaged oversheaths due to corrosion,
increase in power factor/decrease in insulating resistance due to ageing and water-treeing,
localized defect due to increase in electrical stresses and localized defect/insulation ageing
due to thermal ageing. Due to continuous and cyclical dielectric and thermal stresses most of
the above failure modes progress slowly over time the insulation system further deteriorates.
Consequently go/no-go tests such as spot reading of insulation resistance value and tan delta
value at fixed voltage and frequency are ineffective at finding failure patterns. Trending test
data is necessary to identify these failure patterns. The maintenance approach for cables
therefore focuses on using applicable condition monitoring technologies such as polarization
index, tan delta with voltage sweep, dielectric spectroscopy and partial discharge testing. The
appropriate condition monitoring technologies corresponding to various failure modes are
being identified through detailed FMECA exercise. The FMECA for cables is shown in Table
3.6. The periodicity of condition monitoring tasks according to criticality ranking for all
types of failure modes are also detailed in Table 3.6.
____________________________________________________________________________________________________________________
Table 3.6 FMECA for MV Cables
Current
Failure Failure Failure Recommended
Failure mode Sev Prob design Det CN RPN Freq.
effects cause mechanism activities
controls
To map cable
Critical Reduction/damage Continuous
Severe Hard impact route
mechanical of insulating
damage to 7 due to sharp 4 None 8 28 224 Multi purpose
damage to materials (due to
cable object tunnel
cable insulation 3rd party digging)
Armored cable
Corrosion of
metal
sheath; 3rd party
water damage, After laying,
ingress - brittleness, Degradation and then after 5
HVDC
Damaged leading to external damage to years, then
4 5 None 8 20 160 oversheath
oversheaths ageing water contamination insulating depending
integrity test
trees on of solvents, materials on test
cable oils, bitumen, results
without etc.
radial water
barrier
2 mths. after
Water ingress in laying, then
insulation area Dissipation after 10
through damaged factor years, then
Ageing,
4 Water ingress oversheath or 6 None 8 24 192 measurement depending
water treeing
through conductor on test
Increase in
on damaged results
power
cable/accessories Dielectric
factor/decrease
Spectroscopy
in insulating
resistance 2 mths. after
laying, then
Decrease of Overheating due Dissipation after 10
insulation 4 Overheating to soil dry out or 3 None 8 12 96 factor years, then
strength current overload measurement depending
on test
results
Defect not
detected during 2 mths. after
acceptance test laying, then
Local
and factory quality after 5 years,
Localized increase in Manufacturing PD
4 control - leading to 2 None 8 8 64 then
defect electrical defect measurement
localized increase depending
stresses
of electrical on test
defects as cable results
gets older
____________________________________________________________________________________________________________________
Current
Failure Failure Failure Recommended
Failure mode Sev Prob design Det CN RPN Freq.
effects cause mechanism activities
controls
2 mths. after
laying, then
Dissipation after 10
factor years, then
measurement depending
on test
Thermal results
ageing of 2 mths. after
Abnormal cable
insulation; External laying, then
Localized bending
Local stresses due after 5 years,
defect and (mechanical PD
increase of 3 to cable 3 None 8 9 72 then
insulation damage); increase measurement
electrical environment depending
ageing in soil thermal
stressess; changes on test
resistivity
Damaged results
oversheath 2 mths. after
laying, then
after 10
Dielectric
years, then
Spectroscopy
depending
on test
results
___________________________________________________________________________
for MV Joints and Terminations
Medium Voltage Cable joints dominant failure modes identified by TNB Distribution
Division are localized defect caused by assembly error, localized defect caused by material
defect and insulation ageing. For terminations additional dominant failure modes identified
by TNB Distribution Division are localized defect caused by environmental stresses,
localized defect caused by insulator tracking and insulation ageing due to water penetration.
Most of the above failure modes progress slowly to deteriorate the condition of the joints and
terminations over time. The maintenance approach for joints and terminations therefore
focuses on using applicable condition monitoring technologies such as tan delta measurement
with voltage sweep, partial discharge testing and contact resistance measurement. The
appropriate condition monitoring technologies corresponding to various failure modes are
being identified through detailed FMECA exercise. The FMECA for joints and terminations
are presented in Table 3.7 and Table 3.8 respectively. The periodicity of condition
monitoring tasks according to criticality ranking for all types of failure modes for joints and
terminations are also detailed in Table 3.7 and Table 3.8 respectively.
____________________________________________________________________________________________________________________
Table 3.7 FMECA for MV Joints
Current
Failure Failure Failure Failure Recommended
Sev Prob design Det CN RPN Freq.
mode effects cause mechanism activities
controls
Improper
assembly
leading to
After laying,
bad
Localized then after 5
connection,
Localized increase of Assembly PD yrs., then
6 which in turn 4 - 8 24 192
defect electrical error measurement dependant
results in
stresses on test
increase of
results
localized
electrical
stresses
After laying,
then after 5
PD yrs., then
measurement dependant
on test
Assembly
Reduced results
Insulation Assembly error leading
insulating 6 4 - 8 24 192 2 mths. after
ageing error to imperfect
property laying, then
sealing
Dissipation after 10 yrs.,
factor then
measurement dependant
on test
results
After laying,
Localized Defective then after 5
Localized increase of Material prefabricated PD yrs., then
6 3 - 8 18 144
defect electrical defect joints measurement dependant
stresses installed on test
results
____________________________________________________________________________________________________________________
Table 3.8 FMECA for MV Terminations

Current
Failure Failure Recommended
Failure mode Failure effects Sev Prob design Det CN RPN Freq.
cause mechanism activities
controls
2 yrs. or
External leakage External longer,
Surface
current. Insulator surface dependant
pollution
Localized chalking (leading to conductivity on site
7 Pollution degrading 2 - 8 14 112
defect loss of hydrophobicity) measurement pollution
insulating
for polymeric type level
material
terminations Visual
inspection
2 yrs. or
Pollution
longer,
providing
Localized Increase of electrical Insulator Visual dependant
7 current path 2 - 8 14 112
defect stresses tracking inspection on site
for tracking
pollution
to occur
level
Mechanical
damage
leading to
Localized Increase of electrical Improper localized Visual
7 2 - 8 14 112 After laying
defect stresses application electrical inspection
stresses at
the point of
damage
2 yrs. or
Degradation PD activity
longer,
Localized increase of of external leads to
Localized Visual dependant
electrical/environmental 7 and internal degradation 2 - 8 14 112
defect inspection on site
stresses insulating of insulating
pollution
surfaces surfaces
level
After laying,
Mechanical then after 5
Localized Localized increase of Assembly damage due PD yrs., then
6 4 - 8 24 192
defect electrical error to assembly measurement dependant
error on test
results
PD
Imperfect After laying,
measurement,
sealing due then after 10
Insulation dissipation
Assembly to assembly yrs., then
ageing/localized Water penetration 6 4 - 8 24 192 factor
error error causing dependant
defect measurement,
water on test
visual
penetration results
inspection
____________________________________________________________________________________________________________________
Current
Failure Failure Recommended
Failure mode Failure effects Sev Prob design Det CN RPN Freq.
cause mechanism activities
controls
Internal
insulating
compound
leaking
causing
Internal uneven
Localized Uneven voltage insulating insulation, Visual
7 3 - 8 21 168 Every 2 yrs.
defect distribution compound which leads inspection
leaking to uneven
voltage
distribution
(only for
porcelain
insulators)
Chapter 4
Cable
Maintenance
Testing
___________________________________________________________________________
4 Cable Maintenance Testing
4.1 Background
The commissioning of any power cables, regardless of its sizes or significance, is a routine
but a critical phase of asset management function so as to ensure non-problematic or effective
introduction and integration of power cable to the power delivery system. A lack of
knowledge and experience in dealing with commissioning and possible arising technical
issues could result in delays in commissioning in power cables and associated power delivery
systems with consequential revenue losses. Whilst in service, asset managers of electric
utilities have an even bigger responsibility to operate and maintain the power cable in such a
way so as to derive optimal return on investment and service reliability. The asset managers
are therefore in search of successful cable diagnostic techniques commercially available for
performing test in the field on distribution power cables. The objective of any diagnostic test
is to identify in a non-destructive way a potential problem that may exist in the power cables
so that preventive action can be taken to avoid possible in service failure of that cables
circuit. This is applicable to both cables and associated accessories.
4.2 Maintenance Matrix
The maintenance matrix summarises the list of maintenance testing identified for various
categories of cables in TNB Distribution System under different conditions, such as
commissioning, in-service and after repair. The maintenance matrix is shown in Table 4.1.
____________________________________________________________________________________________________________________
Table 4.1 Cable Maintenance Matrix
Condition Monitoring
XLPE PILC LV
Technologies
2 3
1 In- After In- After In- After
Purpose Technologies Commissioning Commissioning Commissioning
Service Repair Service Repair Service Repair
Insulation
9 9 9 9 9 9 9 9 9
Resistance
Tan-delta 9 9 9 9 9 9
Insulation Partial
Integrity Discharge 9 9 9 9 9 9
Mapping
Dielectric
9 9 9 9 9 9
Spectroscopy
Sheath HVDC Sheath
9 9 9
Integrity Test
Contact
Resistance 9 9 9 9 9 9
Test
Integrity of
Metallic
Connections
Sheath 9 9 9 9 9 9 9 9 9
Continuity
Thermography 9 9 9
1
Newly installed cables prior to first energization
2
Condition-based maintenance practice
3
After replacement of faulty section
___________________________________________________________________________
4.3 General Description of Identified On‐Site Testing for
Assessing the Integrity of Insulation
The field testing methods identified in the maintenance matrix for commissioning, in-service
and after repair are non-destructive or diagnostic test.
4.3.1 Non‐Destructive/Diagnostic Test
Non-destructive electrical tests are usually carried out on the equipment insulation to ensure
that its electrical characteristics comply with the specification without destroying or
jeopardizing the insulation. In most cases, the non-destructive testing is also referred as
diagnostic testing where result interpretation is required. In practical this testing method
is widely used for condition monitoring activity whereby trending of the test results will be
monitored closely thus giving more information compared to spot test reading. The most
popular non-destructive test includes Insulation Resistance, Polarization Index, Tangent
Delta/Dissipation measurement, Dielectric Spectroscopy measurement, Partial Discharge, etc
many more that will not be discussed in this guideline.
4.3.1.1 HVDC test
When dc voltage is applied to insulation, the electric field stress gives rise to current
conduction and electrical polarization. Consider an elementary circuit as shown in Figure 4.1
below, that shows a dc source, a switch and insulation specimen. When the switch is closed,
the insulation become electrified and a very high current flows at the instant the switch is
closed. However, these currents immediately drop in value, and decreases at slower rate until
it reaches a nearly constant value. The current drawn by the insulation may be analyzed into
several components namely Capacitance charging current, Dielectric absorption current,
Surface leakage current, Partial Discharge current and volumetric leakage current.
C – Represents charging current

RA – Represents absorption current
RL – Represents volumetric leakage current
Figure 4.1 Electric circuit of insulation under dc voltage test

___________________________________________________________________________
4.3.1.1.1 Capacitance Charging Current
The capacitance charging current is high as the dc high potential is applied and this charging
current is a function of time and will decrease as the time of the application of voltage
increases. It is the initial charging current when voltage is applied and therefore not of any
value for test evaluation. Test readings should not be taken until this current has decreased to
a sufficient low value.
4.3.1.1.2 Dielectric Absorption Current
The dielectric absorption current is also high as the test voltage is applied and decreases as
the voltage application time increases, but at slower rate than the capacitance charging
current. This current is also high but not as high as the capacitance charging current. The
absorption current can be divided into two currents called “reversible” and “irreversible”
charging currents. The irreversible charging current is of the same general form as the
reversible charging current, but is much smaller in magnitude. The irreversible charging
current is lost in the insulation and thus is not recoverable. Again, sufficient time should be
allowed before recording test data so that the reversible absorption current has decreased to a
low value.
4.3.1.1.3 Surface Leakage Current
The surface leakage current is due to the conduction on the surface of the insulation where
the conductor emerges and point of earth potential. This current is not desired in the test
results and should therefore be eliminated by carefully cleaning the surface of insulation to
eliminate the leakage paths, or should be captured and guarded out of the meter reading.
4.3.1.1.4 Partial Discharge Current
The partial discharge current, also known as corona current, is caused by over stressing the
air at sharp edges of the conductor due to high voltage test. This current also not desirable
and should be eliminated by the use of stress control shielding at such points during test.
However this current does not occur at lower voltages, such as insulation resistance test
voltages.
4.3.1.1.5 Volumetric Leakage Current
The volumetric leakage current that flows through the insulation volume itself is of primary
importance. This is the current that is used to evaluate the conditions of the insulation system
under test. Sufficient time should be allowed for the volumetric current to stabilize before test
reading is recorded. The total current, consisting of various leakage currents as described
above is shown in Figure 4.2.
___________________________________________________________________________
Figure 4.2 Insulation Current Characteristics
4.3.1.1.6 Dielectric Phenomenon and Polarization
Generally dielectric has the property of both temporary and permanent absorption of
electrical charges and property of conduction. When a voltage is applied to a dielectric, forces
on the positive and negative charges inherent in the particles that make up the dielectric tend
to orient the particles in line with the applied field. Some dielectric materials have molecules
that have an uneven number of atoms that is, having asymmetrical arrangement of charges.
When such molecules are placed in an electric field, they will migrate in an electric filed, thus
becoming polarized with the electric field. Such molecule is called “dipole”. Dipole plays an
important role in the electrical characteristics of such insulation. A dipole may be represented
by a particle having a small positive charge at one end and a small negative charge at the
other end. When these dipoles are subjected to dc voltage, they are polarized and become
aligned with respect to positive and negative polarity of the dc voltage. This phenomenon is
known as dipole polarization. Polarization phenomenon is influenced strongly by the material
properties, structure and condition of insulation. On the other hand, charged particles, i.e.
particles with positive and negative charges, which are not interrupted by interfacial barriers
and can travel through the dielectric from one electrode to the other, constitute the leakage
current and are not part of the polarization phenomenon.
___________________________________________________________________________
4.3.1.1.7 Insulation Resistance Testing
In general this test may be conducted at applied voltage of 250 – 15,000 V. The testing
equipment used is a megohmmeter, either hand cranked, motor driven or electronic, which
indicates the insulation resistance in Mega ohms or Giga ohms. The quality of insulation is
variable, dependent upon temperature, humidity and other environmental factors. Therefore,
all readings must be corrected to standard temperature for the class of equipment under test.
The insulation resistance measurement can be useful in giving an indication of deteriorating
trends in the insulation system. However the insulation resistance value alone does not
indicate the weakness of neither the insulation nor its total dielectric strength. The reading
only allows a rough check of the insulation condition. Therefore, comparison of this value
with previous values is of utmost importance. A continued reducing value trend, exhibited the
deterioration of insulation. Hence it is of great importance to record each interval value with
corrected to the specific temperature reference for consistency purposes.
4.3.1.1.8 Polarization Index
The polarization index test is a specialized application of the dielectric absorption test. A
good insulation system shows a continued increase in its insulation resistance value over a
period of time in which voltage is applied. On the other hand, an insulation system that is
contaminated with moisture, dirt and the like will show a low insulation resistance value. In
good insulation, the effect of absorption current decreases as time increases. In bad
insulation, the absorption effect is prevailed by high leakage current. The time resistance
method is less dependent of temperature and equipment size. It can provide conclusive results
as to the condition of the insulation. The ratio of time-resistance readings can be used to
indicate the condition of insulation system.
Polarization index is carried out at applied voltages of DC volts which slightly below the
phase voltage of particular cable rating. Using an electronic megohmmeter will give an
indication of insulation resistance in Mega ohms or Giga ohms. Cable terminations at both
ends are cleaned before making the measurement in which special cleaning solvent is used.
Subsequently after the cleaning, earthing mechanism via cable sheath was also checked and
verify through the conductor resistance measuring devices. To get an accurate reading guard
connection can be used to eliminate the presence of surface leakage current that might affect
the measurement. Insulation resistance measurement values are recorded at 1 minute and 10
minutes of voltage application. The ratio at 10 minutes to 1 minute will determine the
polarization index value.
4.3.1.1.9 Tangent Delta
Tan Delta, also called Loss Angle or Dissipation Factor testing, is a diagnostic method of
testing underground cables to determine the quality of the cable insulation. Cable approaches
the properties of perfect capacitor provided that the insulation is free from defect. In a perfect
___________________________________________________________________________
capacitor, the voltage and current are phase shifted 90º. If there is an impurity or defects
resistance of the cable will decrease resulting in an increase in resistive current. Therefore it
will no longer be a perfect capacitor and the voltage and current will no longer be shifted 90º.
It will be less than 90º. The angle between the phase shift is called delta ( δ ) or loss angle.
Figure 4.3 Representation of Cable
Figure 4.3 shows a representation of the cable. The tangent of δ is measured. This will
indicate the level of resistance in the insulation. The greater the angle means the worse the
cable is.
The tangent delta essentially provides the same qualitative assessment as a power factor test.
With power factor the cosine of the angle between the voltage and current is measured,
yielding the power factor. Meanwhile the tangent delta is the tangent of the complimentary
angle. For slight angle, the tangent delta readings will be the same as the power factor. As the
angle, hence loss, increases the tangent delta and the power factor will not be the same.
Below is the calculation of Dielectric Loss,
Pd = V2ωCtanδ …………………………………………Equation (4.1)
From the equation above, it’s clearly shown that tangent delta can be measured by varying
the voltage or frequency. By varying the voltage called Tip-up whereas by varying the
frequency it is called dielectric spectroscopy. If the insulation of the cable is perfect, the tan
delta will not change as applied voltage is increased. If the cable has water tree
contamination, thus changing the capacitive nature of the insulation, then the tangent delta
will be higher at the higher voltages. The increase in loss angle with the increasing voltage
indicates high resistive current element in the insulation as shown in
Figure 4.4.
___________________________________________________________________________
Figure 4.4 Comparison between new and old cable
The tan delta testing equipment has an AC high voltage source. This high voltage is needed
to energize the cable. The length of the cable that can be tested will depends on the AC
voltage source used. It is generally advantageous to test shorter length rather than a long
cable, the more precise we can be in determining whether the cable is bad or good. Usually
VLF voltage source is used. The standard VLF source can test 4-6 km.
4.3.1.1.10 Dielectric Spectroscopy
It is a measurement of tan delta over a range of voltage and frequency. By varying the
frequency and the voltage, the response can provide more information about the insulation
than varying only one factor. The tangent delta below 1Hz is sensitive to degradation due to
water trees in XLPE cables. The tangent delta also offers a comparative assessment of the
aging of PILC. Tangent delta will decrease if the frequency is raised as shown in Figure 4.5.
When the voltage is varied, the tangent delta remains relatively the same, thus indicating the
good condition of cable.
___________________________________________________________________________
Figure 4.5 Tangent delta in frequency sweep
From Figure 4.6, when looking at new cable the voltage is varied from 3kV to 6kV, the
tangent delta stays relatively the same, thus indicating the good condition of the cable.
Whereas in old cable when the voltage is varied from 3kV to 6kV, the tangent delta increases
with voltage, thus indicating that water tree is present in this cable.
Figure 4.6 Comparison between new and old cable under dielectric spectroscopy
When making dielectric spectroscopy measurements on cable circuits containing accessories,

users should be aware that the presence of certain types of accessories could dominate the
___________________________________________________________________________
results obtained. In particular, accessories that utilize stress grading materials may results in
high value of tangent delta at elevated voltage.
Using tangent delta measurement test it is not possible to find the location of the cable
defects. For any value of tangent delta, there could be many minor defects or a few major
defects, it cannot discriminate since it is not a fault finding tool.
For varying the voltage, AC high voltage source is required. Due to the voltage source
limitations, this test can only be applied for medium voltage cables with maximum length of
2-3 km.
4.3.1.2 Partial Discharge
4.3.1.2.1 Definition
Electric discharges which do not bridge electrode are called partial discharge. Between the
electrodes a sound dielectric is present in the form of solid, liquid, or gaseous insulator.
Examples of this type of discharge are discharges in a cavity in a solid dielectric (both
electrodes are shielded from the discharges by the solid), discharge on a surface (at least one
electrode is shielded by a solid dielectric), and discharges around a sharp point at high
voltage (the discharge is shielded from one electrode by column of non-ionized gas).
Although the magnitude of such discharge is usually small they can cause progressive
deterioration and ultimate failure, so that it is essential to detect their presence as a non-
destructive control test.
Partial discharge belongs to a far greater group of gas discharges. In all these discharge gas
molecules are ionized by impact of electrons. The newly formed electrons gain speed in an
electric field, ionizing more molecules by impact, so that an avalanche of electrons is formed.
The electrons in the avalanche and the ions left behind move towards the electrodes, thereby
forming a passage of current through the gas.
4.3.1.2.2 Classification
The term ionization is often used for partial or internal discharges. This is incorrect the scope
of this term is far broader according to its definition: a process by which an atom becomes
electrically charged due to losing or gaining one or more of extra nuclear electrons. There are
generally three classification of partial discharges namely corona discharge, surface discharge
and internal discharge. Corona discharges are discharges taking place around an electrode
placed in a highly non-uniform field. Corona discharge is usually observed as a bluish glow
accompanied by hissing sound. These discharges cause ionisation of the air and produces
ozone. The combined action of bombardment of ions and the chemical compounds formed
during corona discharge leads to the degradation of the insulation.
___________________________________________________________________________
The second type of partial discharge is the surface discharge. Surface discharges are
discharges that take place along an interface between two dielectric media. The formation of
surface discharge normally preceded with the sufficient flow of surface leakage current in the
presence of moisture and impurity or imperfections of the surface. Flow of this current along
the interface causes surface heating (I2R heating). This heating action then causes drying of
the moisture and thus dry bands are formed due to the imperfections or impurities on the
surface islands. When the potential difference across these dry bands exceed its breakdown
strength, surface discharge or scintillations will take place. These discharges when left alone
are able to bridge the conductors and hence total failure of the insulation system.
The third classification and by far the most common in power cable insulation is internal
discharge. Internal discharges are partial discharges occurring internal to the insulation
system. This is usually caused by the presence of voids or cavities within the insulation
system. These voids when experience a potential gradient greater than its breakdown strength
will cause a discharge bridging the two affected surfaces of the particular void. A discharge
internal to the void will cause localised burning of the insulation and when left alone, these
voids will grow on to form an electrical tree, and hence causing failure of the insulation.
Insulation of power cables can be modeled by its equivalent capacitance and resistances.
Lumped parameters are employed in this case for ease of analysis. The equivalent electrical
circuit of the insulation system can be modeled as Figure 4.7 below.
Figure 4.7 Equivalent circuit diagram of cable insulation with voids

___________________________________________________________________________
As shown in Figure 4.7, a void is typically represented by a parallel resistor and capacitor.
When the total insulation systems see the applied voltage, a voltage drop will be impressed
upon this parallel combination of resistance and capacitance representing the void. In the
event where the voltage drop across the void exceeds its respective breakdown voltage,
termed Inception Voltage (Vi), a discharge will take place thus, bridging the void. When the
void is bridged the voltage across the void collapses until the point of extinction where the
discharge is extinguished. The voltage at this point of extinction is termed as the extinction
voltage (Ve). Once this discharge is extinguished, the voltage across the void resumes
increases in the direction of the applied voltage until the next inception voltage is reached and
hence a repetition of the above cycle.
Figure 4.8 Occurrences of internal discharges
The requirement for an increasing build-up of voltage across the void before the inception
voltage is reached gives partial discharge the characteristic traits of only occurring either in
the first and third quarter of the test voltage waveform. Partial discharges occurring in the
first quarter (positive rising voltage) is termed as negative polarity discharge whereas
discharges occurring in the third quarter (negative rising voltage) are termed positive polarity
discharges. This is represented in Figure 4.8. This notation of discharges is derived from the
fact that the classical method of detection measures partial discharges as voltage pulses.
4.3.1.2.3 Partial Discharge Location Using Travelling Wave Technique
Partial discharges occurring within the insulation of the power cables will result in charge
accumulation at the point of discharge. This charge accumulation in turn creates two
travelling waves that travel in opposite direction to each other, towards the two ends of the
cable. The voltage wave can be described as:
Zo × i(t)
Vi = …………………………………..….. Equation (4.2)
2
where Zo is the surge impedance of the cable under test and i(t) reflects the rate of charge
accumulation. This voltage wave can be detected through the following test setup and
equipment as shown in Figure 4.9.
___________________________________________________________________________
Figure 4.9 PD Test Setup
The voltage wave can be effectively measured by ensuring that the effective detection
impedance of the system equals the surge impedance of the test cable. By measuring these
discharge pulses and comparing their time of arrival, quantification of discharge magnitude
and the number of discharges, as well as, determination of the location of the various
discharges can be made.
In determining the location of the discharge, the time of arrival of the discharge pulse would
have to be closely monitored. For a discharge, two pulses will be generated and will travel
towards the two ends of the cable as shown in Figure 4.10. By effectively measuring the
time of arrival of the first and second pulse, together with the arrival of the third pulse which
is a reflection of the first pulse that travels twice the whole length of the cable, the discharge
location can be deduced.
Figure 4.10 PD Pulse Generation in Cables
Considering End A as the measurement end, then the first pulse propagating towards this end
would serve as the reference pulse. The second pulse would travel towards
End B and be reflected back along the length of the cable towards End A. The time this pulse
reaches End A is recorded as tB. The first pulse after having reached End A would also be
reflected and transverse towards End B where again it is reflected towards End A. This pulse
when detected at End A is called the third pulse. Figure 4.11 depicts the phenomenon
described above. The time by which this third pulse is detected at End A (referenced to the
first pulse) is recorded and for the purpose of our analysis denoted as tC.
___________________________________________________________________________
Figure 4.11 PD Pulse Characteristic in Cables
The location of the discharge can be easily computed by the following ratio:
tC − tB
X = × 100 ………………….………………….Equation (4.3)
tC
where X is the location of the discharge in percentage of cable length from the detection end,
End A.
A characteristic feature of the discharge signal is indicated by the attenuation of the discharge
pulses measured. The attenuation of the pulses as it transverse the cable conductor leads to
the general characteristic of discharges as indicated below, where the magnitude of the pulses
decreases from the first pulse to the last.
4.3.1.2.4 High Voltage Source
• VLF (0.1 Hz) Test:

VLF testing at 0.1 Hz, and lower frequencies for longer cable lengths, has been used
successfully to measure dissipation factor and PD levels in cables and their accessories, is
less damaging to the insulation than dc testing and can locate potential failure sites
reliably. VLF has the advantage that the energy requirements are 1/600 for 60 Hz
voltages and 1/500 for 50 Hz voltages, so the test sets can be much smaller than for
normal operating frequency test sets. Portability is of utmost importance for field testing.
VLF PD detection has been successfully employed to find major defects in cable
accessories.
• The Oscillating Wave Test System (OWTS):

The Oscillating Wave Test System was developed as a non-destructive, after laying test,
standardized by the IEC. Further development has led to a diagnostic suitable for off-line
applications in noisy environments. The OWTS produces ac voltages in the range of 20 to
1000 Hz depending upon the cable length and can be used for PD pattern analysis
provided there are no high disturbances present. This is also used for dissipation factor
measurements.
Refer Appendix 4.1 for details on Partial Discharge Theory.

___________________________________________________________________________
4.4 General Description of Identified On‐Site Testing for
Assessing the Integrity of Current Carrying Paths
(Conductors, connectors and earthing shields)
This kind of test is conducted to check the low resistance ohmic values of the connections
and the continuity of the phase conductor and also metallic sheath.
4.4.1 Contact Resistance Measurement of Joints and Terminations
This test is to assist in determining poor connection in installing conductor to conductor

jointing for both straight through joints and terminations. A limit for acceptable value varies
with the ferrule types, procedures used and tools used. A reading exceeding 50 µΩ indicates
that a poor connection exists. The manufacturers usually recommend that a 10-100 amperes
testing equipment be used. This test should be conducted after the installation of ferrule and
before the build up of insulation in joints and terminations. Figure 4.12 shows the set-up for
contact resistance measurement.
Figure 4.12 Contact Resistance Test Setup
4.4.2 Continuity of Phase Conductor and Metallic Sheath
This also uses the same principal of the contact resistance measurement but with the lower
value of ampere. The value of resistance may vary from hundreds of milliohm to few ohms
depending on the length of the circuit, type of conductor material and type of joints. The
measurement set-up is same as shown in Figure 4.12.
___________________________________________________________________________
4.5 Soaking Test
The recommendation is to follow detail commissioning tests for Medium Voltage power
cables. Alternative to detail commissioning test can be the following:
(a) The insulation test shall be applied for 1 minute between each phase conductor and
sheath
(b) The circuit shall be under soak for at least 24 hours
To bypass (b), the work conditions shall be considered as emergency or as determined by the
Engineer-in-Charge.
The soak test is basically to energize the cable at the rated voltage without any load.
Chapter 5
Cable
Maintenance
Testing
Procedure
___________________________________________________________________________
5 Cable Maintenance Testing Procedure
5.1 Background
This chapter will discuss testing equipment required, commissioning & in-service
maintenance guidelines, detail testing procedures for all the identified tests and CMMS data
capturing templates for both underground Medium Voltage and Low Voltage Cables. The
detail guidelines for cable fault locating will also be discussed toward the end of this chapter.
5.2 Testing Equipment Specification
The following testing equipments are required to perform the testing requirements for
commissioning, in-service, and after repair maintenance tasks are shown in Table 5.1 – Table
5.5.
Table 5.1 MV XLPE Cable for Insulation Integrity Test

Task Maintenance Test Testing equipment Minimum Technical Specification
Max voltage: 57kVrms
Max current: 90mA
Tan-delta Test Set with Freq range: 0.01Hz – 1.0Hz
Tan-delta Test
VLF HV Source Max Load: 2µF at 0.1 Hz
Waveform: Sinusoidal
Tan Delta Range: 0.1 to 1000 10-3
Max voltage: 40kV
Max current: 40mA
PD Mapping Test Set
Freq range: 0.01Hz – 1.0Hz
with VLF HV Source
Max Load: 2µF at 0.1 Hz
Partial Discharge Waveform: Sinusoidal
Insulation
Mapping Test Max voltage: 60kVpeak
Integrity
Max current: 7mA
PD Mapping Test Set
Freq range: 50Hz-500Hz
with OW HV Source
Max Load: 2.0 µF
Min PD: 1pC-100nC
Max Output Volt: 30kVpeak
Tan-delta Test Set with
Max current: 15-40mApeak at the rate
Dielectric sweep frequency
of 0.01-2.5Hz
Spectroscopy Test analyzer
Max Load: 10µF
Freq Range: 0.0001-100Hz
Max voltage: 10kV dc
Insulation Megohmeter Test Set
Max current : 2mA
Resistance Test (3 Terminal Tester)
Max resistance: 5TΩ (digital meter)
___________________________________________________________________________
Table 5.2 MV PILC Cable for Insulation Integrity Test
Max voltage: 200V
Power Frequency Tan-
Tan-delta Test Max current: 50mA
delta Test Set
Frequency: 50Hz
Max voltage: 40kVpeak
Max current: 40mA
PD Mapping Test Set
Freq range: 0.1Hz – 1.0Hz
with VLF HV Source
Max load: 2µF at 0.1Hz
Partial Discharge Waveform: Sinusoidal
Mapping Test Max voltage: 60kVpeak
Insulation
PD Mapping Test Set Max current: 7mA
Integrity
with OW HV Source Freq range: 50Hz-500Hz
Max Load: 2.0 µF
Min PD: 1pC-100nC
Tan-delta Test Set with Max voltage: 200Vpeak
Dielectric
sweep frequency Max current: 50mApeak
Spectroscopy Test
analyzer Freq range: 0.0001 – 1kHz
Max voltage: 10kV dc
Insulation Megohmeter Test Set
Max current : 2mA
Resistance Test (3 Terminal Tester)
Table 5.3 LV Cable for Insulation Integrity Test

Max voltage: 10kV
Insulation Insulation Megohmeter Test Set
Max current : 2mA
Integrity Resistance Test (3 Terminal Tester)
Table 5.4 MV XLPE Cable for Sheath Integrity Test

Output voltage: 20kV DC
Sheath
HVDC Sheath Test DC Pressure Test Set Output current: 20mA
Integrity
Maximum Testing Duration: 30 min
Table 5.5 MV XLPE, MV PILC & LV for Integrity of Connections

Max current : 0-200A
Integrity of Contact Resistance Milliohmmeter Test Set
Resistance Range: 0-500 µΩ
Connections Test (4 Terminal Tester)
Resolution: 1 µΩ
Measurement Ranges:
Max Voltage: 600Vrms
Metallic Sheath
Digital Multimeter Max Current: 10Arms
Continuity
Resistance Range: 400Ω – 40MΩ
Capacitance range : 5nF – 5µF
___________________________________________________________________________
Max current:10A
Milliohmmeter
Resistance range: 0-5 Ω
resistance Test Set
Continuity Selection Mode
Temperature Range: 0oC – 500oC
Sensitivity: ± 0.3oC
Focal range: 0.4m to infinity
Should be able to measure:
1. Absolute value of hot spot
temperature
2. Colour thermal image of focused
Thermography InfraRed Camera
object
3. Isotherm temperature
4. Dual spot delta temperatures
5. Measured temperatures shall be
corrected for effects of solar
emittance, atmospheric
temperature.
All testing equipment shall be in good mechanical and electrical condition. Accuracy of
metering in testing equipment shall be appropriate for the test being performed but not in
excess of two percent of the scale used. Waveshape and frequency of testing equipment
output waveforms shall be appropriate for the test and the tested equipment.
5.2.1 Testing Equipment Calibration
• There has to be a calibration program which assures that all applicable testing
equipment is maintained within rated accuracy.
• The accuracy shall be directly traceable to TNB approved accredited test laboratory
following International Standard.
• Testing equipment shall be calibrated in accordance with the following frequency
schedule:
– TNB testing equipment: every 12 months
– Contractor testing equipment: every 12 months, where contractor must ensure
the evidence of calibration test certificate
• Dated calibration labels shall be visible on all testing equipment.
• Records, which show date and results of testing equipment calibrated or tested, must
be kept up to date.
• Up-to-date testing equipment calibration instructions and procedures shall be
maintained for each testing equipment.
• Calibrating standard shall be of higher accuracy than that of the testing equipment
being tested.
___________________________________________________________________________
5.3 Commissioning, In‐service and After Repair
Maintenance Guidelines
5.3.1 Commissioning Testing Guideline for Low Voltage Cables
5.3.1.1 Inspection
1. Inspect for signs of physical damage.

2. Inspect for loose screws, bolts and nuts.
3. Inspect for damaged core.
4. Ensure that the surface markings are legible.
5. Inspect ends of cable for proper seals.
6. Inspect for discolored, cracked or brittle insulation and/or jacket.
7. Inspect for signs of sharp bends.
8. Inspect for signs of corrosion, discoloration and oxidation of metallic shield.
9. Inspect compression-applied connectors for correct cable match and indentation.
10. Note if there is any cable core crossing.
11. Record results on the appropriate test sheet (See Section 5.8.1).
5.3.1.2 Testing
1. Inspect all crimped electrical connections for high resistance using low-resistance
ohmmeter in accordance with Section 5.6.1.
2. Perform continuity tests on each cable phase using multimeter or low resistance
ohmmeter in accordance with Section 5.6.2.
3. Perform insulation-resistance tests on each cable phase-to phase and phase-to-earth.
Applied voltage should be 1000V dc for one minute in accordance with Section 5.4.5.
Note
All the above identified tests should be carried out on de-energized cables.
5.3.2 In‐service Maintenance Testing Guideline for Low Voltage
Cables
5.3.2.1 Inspection

2. Inspect for evidence of overheating.
___________________________________________________________________________

7. Note if there is any cable core crossing.
5.3.2.2 Testing
1. Inspect all crimped electrical connections for high resistance using thermographic
survey in accordance with Section 5.6.3 as and when required.
2. Perform continuity tests on each phase using ohmmeter in accordance with Section
5.6.2 as and when required.
3. Perform insulation-resistance tests on each cable phase-to phase and phase-to-earth.
Applied voltage should be 1000V dc for one minute in accordance with Section 5.4.6
as and when required.
Note
Thermographic survey should be performed on energized cables.
All other identified tests should be carried out on de-energized cables.
5.3.3 After Repair Testing Guideline for Low Voltage Cables
5.3.3.1 Inspection

10. Inspect compression-applied connectors for correct cable match and indentation.
5.3.3.2 Testing
1. Same group of tests to be followed as listed under commissioning of Section 5.3.1.

___________________________________________________________________________
5.3.4 Commissioning Testing Guideline for Medium Voltage
XLPE Cable
5.3.4.1 Inspection

9. Inspect compression-applied or mechanical connectors for correct cable match and
indentation.
10. Inspect for shield grounding and cable support.
5.3.4.2 Testing
1. Inspect all bolted or crimped electrical connections for high resistance using low-
resistance ohmmeter in accordance with Section 5.6.1.
2. Perform a shield continuity test on each power cable by ohmmeter method in
accordance with Section 5.6.2.
3. Perform sheath integrity test using high voltage DC in accordance with section 5.5.
4. Perform tan delta test with voltage sweep ranging between 0.5UO and 2UO using 0.1Hz
AC voltage waveform in accordance with section 5.4.1.2.
5. Perform tan delta test with frequency sweep at varying voltages (dielectric
spectroscopy test) in accordance with section 5.4.4.2.
6. Perform partial discharge test at 1.7UO using either 0.1 Hz AC voltage waveform in
accordance with Section 5.4.2 or oscillating voltage waveform for all the phases in
7. Perform an insulation-resistance test utilizing a megohmmeter with a voltage output of
at least 2500 volts. Individually test each conductor with all other conductors and
shields grounded in accordance with Section 5.4.5. Test duration shall be one minute.
Note
___________________________________________________________________________
5.3.5 In‐service Maintenance Testing Guideline for Medium
Voltage XLPE Cable
5.3.5.1 Inspection

5.3.5.2 Testing
1. Inspect all exposed bolted or crimped electrical connections using thermographic

survey in accordance with Section 5.6.3, 24 months after commissioning for new
installation. Thereafter follow the guideline given in Chapter 6 for appropriate
frequency of monitoring based on health condition.
accordance with Section 5.6.2 after 24 months from commissioning. Thereafter follow
the guideline given in Chapter 6 for appropriate frequency of monitoring based on
health condition.
3. Perform sheath integrity test using high voltage DC in accordance with section 5.5
after 24 months of commissioning. Thereafter follow the guideline given in Chapter 6
for appropriate frequency of monitoring based on health condition.
4. Perform tan delta test with voltage sweep ranging between 0.5UO and 2UO using 0.1Hz
AC voltage waveform in accordance with section 5.4.1.2 after 24 months of
commissioning. Thereafter follow the guideline given in Chapter 6 for appropriate
spectroscopy test) in accordance with section 5.4.4.2. Follow the guideline given in
Chapter 6 for appropriate frequency of monitoring based on health condition.
accordance with Section 5.4.3. Follow the guideline given in Chapter 6 for appropriate
shields grounded in accordance with Section 5.4.5 after 24 months of commissioning.
___________________________________________________________________________
Thereafter follow the guideline given in Chapter 6 for appropriate frequency of
monitoring based on health condition. Test duration shall be one minute.
Note
To obtain the first set of testing data for cables already in-service the prioritized
maintenance plan should be referred. Thereafter follow the guideline given in Chapter 6
for appropriate frequency of monitoring based on health condition.
5.3.6 After Repair Testing Guideline for Medium Voltage XLPE
Cable
5.3.6.1 Inspection

9. Inspect compression-applied and mechanical connectors for correct cable match and
indentation.
5.3.6.2 Testing

___________________________________________________________________________
5.3.7 Commissioning Testing Guideline for Medium Voltage
PILC Cable
5.3.7.1 Inspection

indentation.
5.3.7.2 Testing
1. Inspect all bolted or crimped electrical connections for high resistance using low-
resistance ohmmeter in accordance with Section 5.6.1.
Perform tan delta test with low voltage 50 Hz AC voltage waveform in accordance with
section 5.4.1.1.
Perform tan delta test with frequency sweep at varying voltages (dielectric
spectroscopy test) in accordance with section 5.4.4.1.
shields grounded in accordance with Section 5.4.5. Test duration shall be one minute.
Note
___________________________________________________________________________
5.3.8 In‐service Maintenance Testing Guideline for Medium
Voltage PILC Cable
5.3.8.1 Inspection

5.3.8.2 Testing
1. Inspect all exposed bolted or crimped electrical connections using thermographic

survey in accordance with Section 5.6.3, 24 months after commissioning for new
installation. Thereafter follow the guideline given in Chapter 6 for appropriate
accordance with Section 5.6.2 after 24 months from commissioning. Thereafter follow
the guideline given in Chapter 6 for appropriate frequency of monitoring based on
health condition.
3. Perform tan delta test with low voltage 50Hz AC voltage waveform in accordance with
section 5.4.1.1 after 24 months from commissioning. Thereafter follow the guideline given in
spectroscopy test) in accordance with section 5.4.4.1. Follow the guideline given in
accordance with Section 5.4.3. Follow the guideline given in Chapter 6 for appropriate
shields grounded in accordance with Section 5.4.5 after 24 months of commissioning.
Thereafter follow the guideline given in Chapter 6 for appropriate frequency of
monitoring based on health condition. Test duration shall be one minute.
___________________________________________________________________________
Note
For cables already in-service should follow the prioritized maintenance plan to obtain
the first set of testing data. Thereafter follow the guideline given in Chapter 6 for
appropriate frequency of monitoring based on health condition.
5.3.9 After Repair Testing Guideline for Medium Voltage PILC
Cable
5.3.9.1 Inspection

indentation.
5.3.9.2 Testing

5.4 Testing Procedure for Insulation Integrity
5.4.1 Tan Delta Test for MV Cables
5.4.1.1 Tangent Delta for MV PILC
1. This test should be performed on de-energized cable.

2. Switching should be done by Authorised Person (AP) in accordance with TNB Safety
___________________________________________________________________________
Rules. Before going into operation, local safety regulations and safety precautions for
the protection against direct or indirect contact of live parts have to be met
accordingly.
3. Remove cable terminations (if possible). Make sure that zero voltage condition exists.
4. Ensure that the application of the diagnostic voltage does not lead to flashovers to
other nearby items of the cable station which are in service.
5. Keep all phases earthed at near end except the one under test. Remove the earth at far
end (open).
6. Clean the terminations with cotton cloth and appropriate cleaning solvent.
7. Before making any measurement, analyzer should be calibrated. Usually manufacturer
will supply calibration box. Connect the calibration box to the analyzer.
8. Connect the Negative/Ground lead to cable shield as shown in Figure 5.1.
9. Connect Positive lead to one core (e.g. Red core) as shown in Figure 5.1.
10. Set the frequency to 50Hz (power frequency).
11. Set the voltage to 200 V peak (or the maximum voltage of the testing equipment that
recommended by the manufacturer).
12. After all the necessary safety action are done, then start the measurement.
13. Take measurement:
• Tangent delta and
• Capacitance value.
14. Stop the measurement.
15. When the measurement is completed, record the value of the identified data in the
appropriate test sheet.
16. Repeat steps 9-15 for the remaining phases.
Figure 5.1 Connection between Analyzer and PILC Cable
For interpretation of results refer section 6.8.3.
Refer Appendix 5.2 for testing equipment details.

___________________________________________________________________________
5.4.1.2 Tangent Delta for MV XLPE

accordingly.
end (open).
7. Connect testing equipment protective earth lead to station earth.
8. Connect the phase to be diagnosed to the HV unit as shown in Figure 5.2.
9. Connect the guard ring with braided shield around the bottom of the sealing ends as
shown in Figure 5.2. The guard must not have any contact with earth.
10. Connect the power supply.
11. Switch ON the power supply and testing equipment.
12. Set the frequency to 0.1Hz.
13. Set the Step Test Voltage as below:
Step 1: 0.5*Uo
Step 2: 1*Uo
Step 3: 2*Uo
14. Take measurement:
• Capacitance value.
16. Switch OFF the high voltage unit.
17. Disconnect and Discharge the tested phase.
appropriate test sheet.

___________________________________________________________________________
Figure 5.2 Connection between HV Unit, Analyzer and XLPE Cable
5.4.2 VLF Partial Discharge Mapping System

accordingly.
end (open).
8. Check the power supply and detection system prior to connecting the cable.
9. Set up the power supply and connect the detection filter ready for use but do not
connect the final link to the cable under test as shown in Figure 5.3.
10. Ensure that the filter unit is earthed as shown in Figure 5.3.
11. A buffer amplifier should be used in the signal lead connecting between the detection
filter and measuring terminal as shown in Figure 5.3.
12. Energize the system.
13. Connect HV supply to cable via HV Coupling filter as shown in Figure 5.3.
14. Calibrate cable length using TDR.
15. Connect a pulse calibrator at the cable end.
16. Capture a waveform which consists of two pulses, one direct from the pulse generator
and the other, a reflection from the far end. Measurement of the difference between
the leading edges of these pulses gives the travel time.
___________________________________________________________________________
17. Once the travel time has been noted capture the cable length into analyzer.
18. Disconnect the pulse calibrator.
19. Repeat steps 15-18 on the other two phases (Yellow phase to earth, Blue to earth) and
phase to phase (Red phase to Yellow phase, Yellow phase to Blue phase and Blue
phase to Red phase).
20. Set up measuring equipment so that the trigger level is slightly in excess of the
background noise level.
21. The time base should be set so that the pulse travel time covers the majority of the
display width, allowing maximum accuracy.
22. After all the necessary safety actions are taken energize the cable.
23. Slowly increase the voltage on the cable until partial discharge is observed. Minor
adjustment of the measuring equipment triggering may be required.
24. If partial discharge occurs, record inception voltage (PDIV), PD frequency and other
relevant data giving a filename.
25. Slowly increase the voltage until Uo voltage and record all PD data and give the
filename.
26. If partial discharge occurs in more than one locations record the data in separate file
names.
27. Increase the test voltage until 1.3Uo for in-service test and 1.7Uo for commissioning
test and record the data in separate file names.
28. Slowly decrease the voltage until partial discharge not being observed.
29. Record Extinction Voltage (PDEV)
30. Slowly decrease the voltage until 0 Volt.
32. Switch the high voltage button OFF.
34. Repeat steps 20-33 for other two phases.
35. Analyze the data.
36. When the analysis is completed, record the value of the identified data in the
appropriate test sheet (Refer Section 5.8).
37. Produce, annotate and store partial discharge raw data including maps with
appropriate File name in accordance with guideline stated in Section 7.3.
___________________________________________________________________________
Figure 5.3 Schematic of Test Circuit
5.4.3 Oscillating Wave Test System (OWTS) For PD Mapping &
Tan‐Delta

accordingly.
end (open).
8. The OWTS HV Unit connection terminal with the earth connector must be connected
to earth as shown in Figure 5.4.
9. Connect the HV unit cable to the power cable termination.
10. Calibrate cable length using TDR.
11. Connect a pulse calibrator at the cable end.
12. Capture a waveform which consists of two pulses, one direct from the pulse generator
and the other, a reflection from the far end. Measurement of the difference between
the leading edges of these pulses gives the travel time.
13. Once the travel time has been noted capture the cable length into analyzer.
14. Disconnect the pulse calibrator.
15. Repeat steps 11-14 on the other two phases (Yellow phase to earth, Blue to earth) and
phase to phase (Red phase to Yellow phase, Yellow phase to Blue phase and Blue
___________________________________________________________________________
phase to Red phase).

16. Calibrate of PD magnitude and PD pulse velocity* / cable length using the IEC 60270
PD calibrator.
17. Connect the PD pulse calibrator across the test object (cable termination).
18. Connect the calibrator connector (+) to the OWTS HV unit or directly on the cable
termination.
19. Connect the calibrator connector (-) to the earth connection of the OWTS HV unit or
on an earthed part of the cable termination.
20. Select PD calibration value higher than the value which could be expected during the
measurement, e. g.
• for PD measurements on service aged paper/oil insulated cables, or service aged
polymeric cables with discharging faults a PD calibration value in the range of
1nC....100 nC could be used,
• for PD measurements on polymeric insulted cable without insulation faults a PD
calibration value in the range 100pC...5000pC could be used.
21. After all the necessary safety actions are taken energize the cable.
22. Switch on the HV power supply.
23. Set the voltage [kV] to a preferable value between 0.5Uo ~ 2Uo.
24. Start with a low voltage level e.g. 2 kV and slowly increase the voltage.
25. In the case at the particular voltage level no PD activity has been observed, there is no
necessity to store the data.
26. If partial discharge occurs, record inception voltage (PDIV), PD frequency and other
relevant data giving a filename.
27. Slowly increase the voltage until Uo voltage and record all PD data and give the
filename.
28. Increase the test voltage until up to 1.3Uo for in-service test and 1.7Uo for
commissioning test and record the data in separate file names.
29. Slowly decrease the voltage until partial discharge cannot be observed.
30. Record Extinction Voltage (PDEV).
31. Save all the data.
32. Slowly decrease the voltage until 0 Volt.
34. Switch off the HVDC Power Supply Unit.
36. Repeat steps 23-35 for other two phases.
37. Analyze the data.
39. Produce, annotate and store partial discharge raw data including maps with
appropriate file name in accordance with guideline stated in Section 7.4.
___________________________________________________________________________
Figure 5.4 Schematic of Test Circuit
5.4.4 Dielectric Spectroscopy
5.4.4.1 MV PILC Cable

accordingly.
end (open).
___________________________________________________________________________
Figure 5.5 Connection between Analyzer and PILC Cable
10. Set the frequency from 50Hz (or the maximum frequency of the testing equipment that
recommended by the manufacturer) to 0.01Hz. In some equipment the frequency is
already preset.
11. Set the voltage to 200 V (or the maximum voltage of the testing equipment that
recommended by the manufacturer).
12. After all the necessary safety actions are done, then start the measurement.
13. Perform the measurement:
• Capacitance value at 50 Hz.
17. Produce, annotate and store tan delta and capacitance raw data with appropriate file
name in accordance with guideline stated in Section 7.5.2.
5.4.4.2 MV XLPE Cable

accordingly.
end (open).
___________________________________________________________________________
Figure 5.6 Connection between Analyzer, HV Unit and XLPE Cable
10. Set the frequency from 100Hz (or the maximum frequency of the testing equipment that is
recommended by the manufacturer) to 0.01Hz. In some equipment the frequency range is
already preset.
11. Set the testing voltage in the following sequence 0.25Uo, 0.5Uo, 1Uo, 0.5Uo and 0.25Uo, e.g.
• 11kV: 1500 3000 6000 3000 1500,
• 33kV: 4500 9000 19000 9000 4500
12. After taking all the necessary safety actions are done, then start the measurement.
13. Perform the measurement:
• Minimum tangent delta and
• Capacitance value at 0.01 Hz.
15. Switch off the high voltage unit.
16. When the measurement is completed, record the value of the identified data in the appropriate
test sheet (Refer Section 5.8).
19. Produce, annotate and store tan delta and capacitance raw data with appropriate file name in
accordance with guideline stated in Section 7.5.1.
For interpretation of the results see section 6.9.2.
Refer Appendices 5.2 and 5.3 for Testing equipment details.

___________________________________________________________________________
5.4.5 Insulation Resistance (IR) Testing Procedure

accordingly.
3. Remove cable terminations (if possible). Make sure that zero voltage condition exists
using phasing stick (MV) or voltage indicators (LV).
end (open).
7. Clean the other end of cable with cotton cloth and appropriate cleaning solvent.
8. Connect the Guard (G) terminal to insulation using copper band as shown in Figure
5.7.
9. Connect the positive (+) terminal to Red core and the negative (-) terminal to shield as
shown in Figure 5.7.
10. Apply voltage according to:
• LV Cable : 0.5kV
• MV 11kV Cable : 2.5kV
• MV 22/33kV Cable : 5.0kV
11. After all the necessary safety actions are done, then start the measurement.
12. Apply recommended test voltage.
13. Wait for the measurement to stabilize according to:
• LV Cable : 1 minute
• MV XLPE Cable : 1 minute
• MV PILC Cable :10 minutes
Note: If there is a mixed cable i.e. XLPE and PILC, follow the time for XLPE
cables.
14. Record IR readings for :
• LV Cable and MV XLPE : 30 seconds and 1 minute
• MV PILC : 1 minute and 10 minutes.
17. Switch off the testing equipment.
18. Disconnect, short the tested core with the earthing sheath for at least 10 seconds.
20. Once completed all the phases of the tested cable should be shorted to earth for at least
5 minutes for LV cables and 30 minutes for MV cables before energization.
___________________________________________________________________________
Figure 5.7 Connection of IR Testing Equipment
5.5 Sheath Integrity Test
1. This test should be performed on de-energized cable. This test is applicable to single
core cable only. This test can be performed on cable with graphite coating.
accordingly.
3. Make sure that zero voltage condition exists using phasing stick (MV) or voltage
indicators (LV).
end (open).
6. Remove the earthing shields at both near and far ends.
8. Clean the other end of cable with cotton cloth and appropriate cleaning solvent.
9. Ensure that the input voltage to the test set is regulated. Current
10. Connect the near end earthing shield to the HV terminal (+) of the HVDC Test Set and
the (-) terminal of the HVDC Test Set to substation earth as shown in Figure 5.8.
___________________________________________________________________________
Figure 5.8 Test set up for Sheath Integrity Test
11. Set the timer to 2 minute.

12. Apply 5.0 kV DC test voltage.
13. After taking all the necessary safety actions then start the measurement.
14. Stop the testing after 2 minute.
15. When the testing is completed, record the value of the identified data in the appropriate test
sheet (Refer Section 5.8).
16. Switch off the testing equipment.
17. Reconnect the earthing shield to the substation earthing.
If any fault exists then it will be indicated by the high leakage current value and it would
be difficult to raise the voltage to 5.0 kV. This fault can be located by sheath fault locater
as discussed in Section 5.6.2.
5.6 Testing Procedure for Current Carrying Path (Phase
Conductors, connectors and earthing shields)
5.6.1 Contact Resistance for Joints and Terminations
1. This test is performed for new installation or after repair. The cable should be in de-energized
condition. The test is carried out after installation of connectors and before insulation build-up
of joints or terminations.
2. Clean the test leads, ferrule and lug with appropriate solvent using cloth.
___________________________________________________________________________
3. Connect the power supply cable of the testing equipment (if applicable).
4. Connect the test leads to the C1, C2, P1 and P2 terminals of the testing equipment.
5. Make connection on to the joint/termination under test as shown in Figure 5.9.
Figure 5.9 Connection of Test Leads to Cable Joint
6. Switch on the power supply (if applicable).

7. Set the current to 100A.
8. Start the measurement. Usually an audible BLEEP will sound during this time to warn the
operator that measurement is still in progress.
9. Observe the indication as shown below:
Display Indication Action to be taken

---- Indicates Over range
Select a lower range
---- with O/C lead lighted. Indicates Open circuit
Measurement should not be made if this
warning message is displayed.
10. When the measurement is completed, record the micro ohm value in the appropriate test sheet
(Refer Section 5.8).
11. Switch off the testing equipment and the power supply (if applicable).
12. Repeat steps 5-11 for the remaining joints/terminations.
5.6.2 Continuity Test for Metallic Sheath
1. This test is performed for both new installation, in-service after repair conditions.
accordingly.
4. Ensure that zero voltage condition exists using phasing stick (MV) or voltage
indicators (LV).
5. Make sure the other end of cable is shorted to earth.
6. This test uses multimeter with two test leads. Connect one lead at Voltage terminal and
another lead at ground.
___________________________________________________________________________
7. Put the meter at ohm reading.

8. Check core to core continuity. In order to do that one test lead connected to Red core
and another test lead connected to Yellow core. Then change to another core until all
combination listed below has been tested.
• For LV Cables, there are 6 combinations:
– Red-Yellow
– Red-Blue
– Red-Neutral
– Yellow-Blue
– Yellow-Neutral
– Blue-Neutral
• For MV Cables, there are 3 combinations:
– Red-Yellow
– Red-Blue
– Yellow – Blue
9. Check continuity for each core with sheath. One test lead connected to core and
another test lead connected to sheath. Repeat until all combination listed below has
been tested.
• For LV Cables, there are 4 combinations:
– Red-Sheath
– Yellow-Sheath
– Blue-Sheath
– Neutral-Sheath
• For MV Cables, there are 3 combinations:
– Red-Sheath
– Yellow-Sheath
– Blue-Sheath
10. When the measurement is completed, record the ohm value in the appropriate test
sheet (Refer Section 5.8).
5.6.3 Thermography Survey for Exposed Termination
1. The measurement should be performed on energized cable.

2. Identify load conditions at time of inspection.
3. Thermographic test should be performed during periods of maximum possible loading but not
less than 40 percent of rated load of the electrical equipment being inspected.
4. Switch on the Infra Red Camera.
5. Calibrate the camera with a known source.
6. Select the appropriate emissivity for the test.
7. Adjust the focal length.
8. Shoot the laser on the phase under test.
9. Record the temperature difference between the area of concern and the reference area.
10. Save all the data that can be obtained from the camera.
11. When the measurement is completed, record the value of the identified data in the appropriate
test sheet (Refer Section 5.8).
12. Repeat steps 7-11 for other phases.
___________________________________________________________________________
13. Produce, annotate and store thermal imaging raw data including profile with appropriate File
name in accordance with guideline stated in Section 7.6.
5.7 Fault Location
5.7.1 Cable Fault Location
The steps in a correct approach for cable fault location are in the proper sequence as
follows:
• Analysis of fault
• Prelocation
• Pin Pointing
• Confirmation and re-test
1. Collect and record all information related to the faulty cable and the circumstances.
2. Analysis of Cable Fault

• Insulation Resistance Tests in accordance with 5.3.6
• Continuity Tests in accordance with 5.5.2
• Burning of the Fault
3. Prelocation of Cable Faults

• Conventional methods of prelocation of cable faults is by bridge
• The Pulse Echo, Impulse Current and Arc Reflection and Secondary Impulse
Method are working on the principle of travelling wave.
4. Bridge or Loop Method

This conventional method is largely based on various forms of bridge circuit where
the DC or low frequency parameters of cables were measured.
Limitations:
i. Great difficulty in detecting intermittent or flashing faults.
ii. Requires very accurate & up-to-date cable route record to ensure reliable
results for fault on feeder which consists of a number of different conductor
sizes or materials.
iii. Induced voltages from power plants or feeders in proximity would cause
disturbance in the measuring equipment.
iv. Accuracy of the results obtained is very much affected by the test leads and
contact resistance.
___________________________________________________________________________
5. Pulse Echo Time Domain Reflectometry (TDR) Method

A simple method which works on travelling wave principles. It is applicable to all
series faults and for shunt faults with Rf > Zo/10 & Rf< 10Zo respectively.
6. Impulse Current Method

Working on traveling wave principles, it is applicable to all types of faults.
7. Arc Reflection or Secondary Impulse Method G~ I' It)

The equipment consists of three (3) main components, i.e. the Pulse Echo Equipment
(with built-in Transient Recorder), the Filter Unit and the Surge Voltage Generator.
8. Pin Pointing
The exact location of cables and conductors is an essential aspect of modern cable
fault finding and helps to save existing cable networks from damage. Pin-pointing is
the application of a test that positively confirms the exact position of the fault. Before
the commencement of pin-pointing, the prelocated fault distance should be marked on
the cable route which is measured by means of a trumeter. Pin-pointing is normally
carried out by the shock wave discharge method as shown below in Figure 5.10.
9. The fault can be detected by the use of a semisphone.
Figure 5.10 Shock wave discharge
10. Confirmation & Re- Test

After the pin-pointed position of the fault has been marked & exposed, check for
physical signs of fault. If there is, then the fault is confirmed. Quite often there are no
physical signs, then the exposed cable or joint is confirmed again by means of the
semisphone. After confirmation, the fault should be cut away, insulation resistance
and continuity test should be carried out on the two remaining cable sections to
determine the soundness of these cable sections. The insulation resistance &
continuity tests are again carried out after jointing, followed by pressure test before
supply can be restored.
___________________________________________________________________________
Figure 5.11 Fault Location Procedure Flowchart
Details of Cable Fault Location is given in Appendix 5.8.
5.7.2 Sheath Fault Locator
1. Establish a low resistance connection between the two cores and the faulty screen at
the far end of the cable.
2. In order to carry out the measurement from one point of the cable, two healthy cores
of the same cable system are used as auxiliary leads and are connected to the faulty
screen at the far end of the cable with very low resistance connection in order to keep
the voltage drops occurring there at a minimum. The connection diagram is as shown
in Figure 5.6.2.
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3. These auxiliary leads serve as “test leads” the resistances of which do not influence
the measurement since the test current flowing to earth does not flow on them.
Figure 5.12 Sheath fault pre-location by the voltage drop method
4. Connect the MFM 5 to safety earth by means of the earthing lead supplied.
5. Switch on the MFM 5 and, in the first stage, increase the voltage until a constant
current flows – note down current value and test voltage U1.
6. As per figure 5.6.2, in the test mode 1 the DC generator feeds a current via screen and
fault resistance into the earth.
7. On the section A-B, a DC voltage drops and is measured by means of the built-in mA-
meter. One pole of the testing equipment is directly connected to A. The potential of
B is fed to the testing equipment via the screen section B-C and core 1.
8. In the second stage, increase the voltage until an equal current as in stage 1 is
obtained. Note down test voltage 2.
9. In the second stage, the feed-in voltage is fed to the end of the screen via core 2. Now,
the test current flows via section C-B and the fault into the earth, whereby the
resulting voltage drop reaches the testing equipment via the screen B-A on the one
hand via core 1 on the other hand.
10. Calculate the fault distance by the formula mentioned below.

___________________________________________________________________________
• A DC voltage that is connected between earth and screen, driver a current into the
earth at the insulation fault.
• This current which flows through the screen from the point of entry to the point of
exit, cause a voltage drop U1 on the screen.
• If this measurement is carried out from the far end of the cable, then a voltage
drop U2 is present on this section of the screen.
• If the length of the cable is known, the fault distance can be calculated by a simple
ratio equation into which the two component voltage U1 and U2 are to be
inserted:
Lx = Lg ___U1___
U1 + U2
Lx = Fault distance
Lg = Total cable length
U1= Component voltage A-B
U2= Component voltage C-B
11. Pinpoint Location of Sheath Faults with DC Voltage
12. Disconnect the screen from earth at both ends. Joints must be floating.
Figure 5.13 Sheath fault location with DC voltage
13. Connect the BT 500/IS or the MFM 5 to the screen of the cable and to system earth.
Use maximum 2 kV for PVC and maximum 5 kV for PE sheaths.
___________________________________________________________________________
14. As shown in Figure 5.6.3, a DC voltage of suitable value which is connected between
screen and earth, induces a current into the earth at the point of insulation damage and
thus causes a voltage peak at the point of exit.
15. The measurement of this voltage peak leads to a pinpoint location of the point of
damage since the centre of the peak lies directly over the sheath fault.
16. In the practical measurement, there will be change in polarity of the voltage over the
fault. This should be borne in mind especially in the event of stray currents or the
formation of electrolytic elements.
17. The use of a pulsed DC voltage is of great help since only the rate of increase is to be
evaluated on the meter.
18. Additionally, a pulsed DC voltage involves a lower thermal load at the fault, thus
avoiding damage to the insulation of the cable end neighboring cable systems during
the test.
19. The two earth spikes of the ESG 80-2 are to be inserted into the earth over the track of
the cable in the pre-located area. If the earth is too hard, they can also be positioned
alongside the track.
20. The use of pulsed voltage is to be recommended. In the area around the voltage peak,
a pointer deflection is visible on the meter. Now the direction and the value of
increase are to be observed. If the two earth spikes are equidistant to the fault, then a
Zero value will be obtained on the meter. If however an extraneous voltage is present,
then the point of fault can only be recognized by the absence of the pulsed voltage. A
second measurement with the earth spikes turned through 90° gives a second
coordinate, thus leading to a final pinpoint location.
Details of Sheath Fault location is given in Appendix 5.9.
5.8 Test Sheet Templates
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5.8.1 LV Cables Inspection and Test Data Sheet
___________________________________________________________________________
___________________________________________________________________________
5.8.2 MV XLPE Cables Inspection and Test Data Sheet
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
5.8.3 MV PILC Cables Inspection and Test Data Sheet
___________________________________________________________________________
___________________________________________________________________________
Chapter 6
Cable
Maintenance
Testing Results’
Interpretation
___________________________________________________________________________
6 Cable Maintenance Testing Results’ Interpretation
6.1 Background
Determining the existing condition of power cables is an essential step in analyzing the risk
of failure. This chapter provides a process for arriving at a Cable Condition Index. This
condition index may be used as an input to the risk-and-economic analysis computer model
where it adjusts cable life expectancy curves. The output of the economic analysis is a set of
alternative scenarios, including costs and benefits, intended for management decisions on
replacement or rehabilitation.
6.2 Condition and Data Quality Indicators and Cable
Condition Index
The following condition indicators are generally regarded by TNB Distribution Division as
providing a sound basis for assessing cable condition:
Tier 1:
Maintenance Tests/Condition Condition Indicator

Thermography 1
Tan delta 2
Insulation resistance 3
Operation and maintenance performance 4
Age 5
Tier 2:
Maintenance Test
Dielectric spectroscopy
Partial discharge
These indicators are based on Tier 1 tests and measurements conducted by utility staff or
contractors over the course of time. The indicators are expressed in numerical terms and are
used to arrive at an overall Cable Condition Index. Additional information regarding cable
condition may be necessary to improve the accuracy and reliability of the Cable Condition
Index. Therefore, in addition to the Tier 1 condition indicators, this Manual describes a
“toolbox” of Tier 2 tests and measurements that may be applied to the Cable Condition Index,
depending on the specific issue or problem being addressed. Tier 2 tests are considered non-
routine. However, if Tier 2 data is readily available, it may be used to supplement the Tier 1
assessment. Alternatively, Tier 2 tests may be deliberately performed to address Tier 1
findings. Results of the Tier 2 analysis may either increase or decrease the score of the Cable
___________________________________________________________________________
Condition Index. The Cable Condition Index may indicate the need for immediate corrective
actions and/or follow-up testing. The Cable Condition Index is also suitable for use as an
input to the risk-and-economic analysis model.
This manual assumes that tests and measurements are conducted and analyzed by staff
suitably trained and experienced in cable diagnostics. In the case of more basic tests, this may
be qualified staff those who are competent in these routine procedures. More complex tests
and measurements may require a cable diagnostics “experts”.
This manual also assumes that tests and measurements are conducted on a frequency that
provides accurate and current information needed by the assessment. It will be necessary to
conduct tests prior to this assessment to acquire current data. Results of the cable condition
assessment may cause concern that justifies more frequent monitoring. TNB
DISTRIBUTION DIVISION should consider the possibility of taking more frequent
measurements or the installation of on-line monitoring systems that will continuously track
critical parameters. This will provide additional data for condition assessment and establish a
certain amount of reassurance as cable alternatives are being explored.
Note: A zero score of ANY Tier 1 test or measurement may be adequate in itself to require
immediate call for Tier 2 test to be conducted. A negative Total Cable Condition Index
Value would require immediate de-energization, or prevent re-energization, and planning
for replacement.
6.3 Scoring
Cable condition indicator scoring is somewhat subjective, relying on cable condition experts.
Relative terms are used and compared according to industry accepted levels; or to baseline or
previous (acceptable) levels on this cable; or to cable of similar design, construction, or age
operating in a similar environment.
6.4 Weighting Factors
Weighting factors used in the condition assessment methodology recognize that some
condition indicators affect the Cable Condition Index to a greater or lesser degree than other
indicators. These weighting factors were arrived at by consensus among cable design and
maintenance personnel with extensive experience.
6.5 Mitigating Factors
Every cable is unique and, therefore, the methodology described in this chapter cannot
quantify all factors that affect individual cable condition. It is important that the Cable
Condition Index arrived at is scrutinized by engineering experts. Mitigating factors specific to
___________________________________________________________________________
the utility may determine the final Cable Condition Index and the final decision on cable
replacement or rehabilitation.
6.6 Documentation
Substantiating documentation is essential to support findings of the assessment, particularly

where a condition indicator score is less than 3 (i.e., less than normal). Test results and
reports, photographs, O&M records, or other documentation should accompany the Cable
Condition Assessment Summary Form.
6.7 Condition Assessment Methodology
The condition assessment methodology consists of analyzing each condition indicator

individually to arrive at a condition indicator score. The scores are then weighted and
summed to determine the Tier 1 Cable Condition Index. The Tier 1 Cable Condition Index is
then adjusted by data quality adjustment score to arrive at final Tier 1 Cable Condition Index
value. The final Tier 1 Cable Condition Index is applied to the Cable Condition-Based
Alternatives in Table 6.10, to determine the recommended course of action. Reasonable
efforts should be made to perform Tier 1 tests and measurements. The Tier 2 tests will be
performed based on Cable Condition-Based Alternatives. The Tier 2 adjustment scores will
further modify the final Tier 1 Condition Index value to arrive at the Total Cable Condition
Index value. The Total Cable Condition Index value is applied to the cable condition based
alternatives in Table 6.14. This strategy must be used judiciously to prevent erroneous results
and conclusions. An example of the above methodology for MV cables is illustrated in Figure
6.1.
___________________________________________________________________________
Figure 6.1 Flowchart for Calculating Cable Condition Index

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6.8 Tier 1 Condition Indicators of MV XLPE and PILC
Cables
6.8.1 Contact Resistance
Contact resistance is the most important factor in determining the condition of the
terminations/joints because, being performed at the time of commissioning or after repair.
These tests can identify internal arcing, bad electrical contacts, hot spots, partial discharge, or
overheating of conductors. The “health” of the connections is reflective of the health of the
cable itself.
Results of the contact resistance analyses are applied to Table 6.1 to arrive at an appropriate
mitigating action.
Table 6.1 Contact Resistance

This test is done during installation. If any concern identified then it is rectified before putting the
cable into service. Therefore this test results are not consider for condition assessment while the
cable is in service.
Results Score Remarks/Action
Less than 50 µΩ in all the - The connection is healthy and
phases can be put into service
> 50 µΩ but less than 100 µΩ - The connection can be put into
in any particular phase or all service with caution
the phases
> 100 µΩ in any particular - The connection must be
phase or all the phases replaced
6.8.2 Cable Condition Indicator 1 – Thermography
Thermography is important factor in determining the condition of the exposed terminations

because, being performed periodically it may be the first indication of a problem. These tests
can identify internal arcing, bad electrical contacts, hot spots, partial discharge, or
overheating of conductors. The “health” of the connections is reflective of the health of the
cable itself.
Table 6.2 Thermography

This test is done on exposed terminations during cable in-service at every 24 months interval
under normal condition. This test results are considered for condition assessment while the cable
is in service.
Results Score Action
The hot spot temperature 3 Normal. The monitoring
difference between phases is frequency of 24 months can be
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less than 5 degree centigrade maintained.
The hot spot temperature 2 The monitoring frequency
difference between phases is > should be revised to 12
5 degree centigrade but less months.
than 10 degree centigrade
The hot spot temperature 1 The monitoring frequency
difference between phases is > should be revised to 3 months.
10 degree centigrade but less
than 20 degree centigrade
The hot spot temperature 0 Remove the cable from
difference between phases is > service and perform tan delta
20 degree centigrade tests immediately.
6.8.3 Cable Condition Indicator 2 – Tan Delta Test
Table 6.3 Tan delta

This test is done on cables at regular interval of 24 months under normal condition. This test
results are considered for condition assessment while the cable is in service.

XLPE: 3 Normal. The monitoring
tan δ (2 U0) < 1.2 E-3 and [tan frequency of 24 months can be
δ (2 U0) - tan δ (U0)] < 0.6 E-3 maintained.
PILC:
tan δ (50Hz) < 2.3 E-3
XLPE: 2 The monitoring frequency

1.2 E-3 ≥ tan δ (2 U0) < 2.2 E- should be revised to 6 months.
3 and
0.6 E-3 ≥ [tan δ (2 U0) - tan δ
(U0)] < 1.0 E-3
PILC:
2.3 E-3 < tan δ (50Hz) < 3.0
E-3
XLPE: 1 The monitoring frequency

2.2 E-3 ≥ tan δ (2 U0) < 2.8 E- should be revised to 3 months.
3 and
1.0 E-3 ≥ [tan δ (2 U0) - tan δ
(U0)] < 1.5 E-3
PILC:
3.0 E-3 < tan δ (50Hz) < 3.5
E-3
___________________________________________________________________________
XLPE: 0 Remove the cable from

tan δ (2 U0) ≥ 2.8 E-3 or [tan δ service and perform Tier 2
(2 U0) - tan δ (U0)] ≥ 1.5 E-3 tests (whichever applicable)
immediately.
PILC:
tan δ (50Hz) ≥ 3.5 E-3
6.8.4 Cable Condition Indicator 3 – Insulation resistance test
Table 6.4 Insulation resistance

This test is done on cables at regular interval of 24 months for MV cables and 60 months for LV
cables under normal condition. This test results are considered for condition assessment while the
cable is in service.

XLPE: 3 Normal. The monitoring
DAR value ≥ 1.6 periodicity of 24 months for
MV cables and 60 months for
PILC: LV cables can be maintained.
PI value ≥ 3.0
XLPE: 2 The monitoring periodicity

1.1 < DAR value < 1.5 should be revised to 6 months
for MV cables and 24 months
PILC: for LV cables.
1.5 < PI value < 3.0
XLPE: 1 The monitoring periodicity

1.0 < DAR value < 1.1 should be revised to 3 months
for MV cables and 12 months
PILC: for LV cables.
1.0< PI value < 1.5
XLPE: 0 Remove the Cable from

DAR value < 1.0 service and perform Tier 2
tests (if applicable)
PILC: immediately for MV cable.
PI value < 1.0 Replace LV cables.
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6.8.5 Cable Condition Indicator 4 – Operation and Maintenance
Performance
Operation and maintenance (O&M) history may indicate overall cable condition. O&M
history factors that may apply are:
• Sustained overloading.
• Abnormal temperatures indicated by infrared scanning.
• Nearby lightning strikes or through-faults.
• Abnormally high partial discharge detected.
• Increase in breakdown maintenance or difficulty in acquiring spare parts.
• Anomalies determined by physical inspection
• Previous failures on this cable.
• Failures or problems on cable of similar design, construction, or age operating in a
similar environment.
Qualified personnel should make a subjective determination of scoring that encompasses as
many operation and maintenance factors as possible under this Indicator. Results of the O&M
history are analyzed and applied to Table 6.5 to arrive at an appropriate Condition Indicator
Score.
Table 6.5 Operation and Maintenance Performance Scoring

Operation and Maintenance 3 -
are normal
Some abnormal operating 2 -
conditions experienced and/ or
additional maintenance above
normal occurring
Significant operation outside 1 -
normal and/or significant
additional maintenance is
required.
Severe abnormal operating 0 -
conditions experienced and/ or
additional maintenance above
normal occurring
6.8.6 Cable Condition Indicator 5 – Age
Cable age is an important factor to consider when identifying candidates for cables
replacement. Age is one indicator of remaining life and upgrade potential to current state-of-
the-art materials. During the life of the cable, the insulating properties of materials which are
used for electrical insulation, especially XLPE, deteriorate. Although actual service life varies
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widely depending on the manufacturer’s design, quality of assembly, materials used,

operating history, current operating conditions, and maintenance history, the average
expected life for a large population of cables is statistically about 40 years. Apply the cable
age to Table 6.6 to arrive at the Condition Indicator Score.
Table 6.6 Age Scoring

XLPE: 3 -
Under 10 years
PILC:
Under 20 years
XLPE: 2 -
Between 11 to 20 years
PILC:
XLPE: 1 -
PILC:
XLPE: 0 -
Above 30 years
PILC:
Above 40 years
6.8.7 Tier 1 ‐ Cable Condition Index Calculations
Enter the condition indicator scores from the tables above into the Cable Condition
Assessment Summary form at the end of this Chapter. Multiply each condition indicator
score by the Weighting Factor, and sum the Total Scores to arrive at the Tier 1 Cable
Condition Index. The value of the individual weighting factor of the Tier 1 Condition
Indicator is determined by the expert. The sum of all the weighting factors should be equal to
3.33.
Table 6.7 Tier 1 Cable Condition Index

No Condition Indicator Score Weighting Total Score
Factor
1 Thermography 0.70
2 Tan Delta 0.80
3 Insulation Resistance 1.00
Operation and Maintenance
4 0.53
Performance
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Factor
5 Age 0.30
Tier 1 Cable Condition Index
(Sum of Individual Total score)
(Condition Index should be between 0 and 10)
6.8.8 Tier 1 – Cable Data Quality Indicator
The Cable Data Quality Indicator reflects the quality of the test and measurement results used
to evaluate the cable condition under Tier 1. The more current and complete the tests and
measurements, the higher the rating for this indicator. The normal testing frequency is
defined as the organization’s recommended frequency for performing the specific test or
inspection. Qualified personnel should make a subjective determination of scoring that
encompasses as many factors as possible under this indicator. Results are analyzed and
applied to Table 6.8 to arrive at a Cable Data Quality Indicator Score.
Table 6.8 Cable Data Quality Indicator Scoring

Results Score Adjustment Action
All Tier 1 testing equipment were calibrated Subtract 0 -
within the recommended calibration
frequency AND results are reliable.
One or more of the Tier 1 testing equipment Subtract 0.5 -
were calibrated between 0 and 6 months past
the recommended calibration frequency.
were calibrated between 6 and 12 months
past the recommended calibration frequency.
were calibrated more than 12 months past the
recommended calibration frequency.
The Tier 1 Cable Condition Index is adjusted by the Cable Data Quality Indicator Score to
attain the final Tier 1 Cable Condition Index Value as shown in Table 6.9.
Table 6.9 Final Tier 1 Cable Condition Index Value

Factor
1 Thermography 0.70
2 Tan Delta 0.80
4 Operation and Maintenance History 0.53
5 Age 0.30
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Factor
Cable Data Quality Indicator Score Adjustment
6
(value can be 0, -0.5 ,-1.0 or -1.5)
Final Tier 1 Cable Condition Index Value
Based on the final Tier 1 Cable Condition Index Value the suggested recommendations on
the testing frequency of Tier 1 and proposal for Tier 2 tests are mentioned below in Table 6.9.
Table 6.10 Cable Tier 1 Condition-Based Alternatives

Final Tier 1 Cable Condition Index Value Suggested Course of Action
≥ 7.0 and ≤ 10.0 (Good) Maintain the normal frequency of Tier 1 test.
≥ 3.0 and < 7.0 (Fair) Revise frequency of Tier 1 tests to 6 months
interval. Make arrangements for Tier 2 tests.
≥ 0.0 and < 3.0 (Poor) Perform Tier 2 tests immediately.
6.9 Tier 2 – Tests and Measurements of MV XLPE and PILC
Cables
Tier 2 tests and measurements generally require specialized equipment or training, may
require an extended outage to perform. A Tier 2 assessment is not considered routine. Tier 2
inspections are intended to affect the Cable Condition Index number established using Tier 1
but also may confirm or refute the need for more extensive maintenance, rehabilitation, or
cable replacement. Note that there are many tests that can give information about the various
aspects of cable condition. The choice of tests should be made based on known information
gathered by O&M history, other test results, company standards, and Tier 1 assessment.
Many Tier 2 tests are used to detect or confirm a defect in the cable. Since Tier 2 tests are
being performed by, and/or coordinated with, knowledgeable technical staff, the decision on
which test is most significant and how these tests overlap in application is left to the experts.
For Tier 2 evaluations, apply only the applicable adjustment factors per the instructions above
and recalculate the Cable Condition Index using the Cable Condition Assessment Survey
Form at the end of section 6.8. An adjustment to the Data Quality Indicator score may be
appropriate if additional information or test results were obtained during the Tier 2
assessment.
___________________________________________________________________________
6.9.1 Partial Discharge Test
This test is performed with the cable de-energized and may show the necessity for further
investigation on the location of the defects or removal from service. Results are analyzed and
applied to Table 6.10 to arrive at a Cable Condition Index adjustment.
Table 6.11 Partial Discharge Test Score Adjustment

Severity Index < 2 Subtract 0 Normal. The monitoring periodicity of
all Tier 1 tests can be maintained at 24
months. Practice partial discharge test
if necessary.
Subtract 0.5 Retest the cable for partial discharge
2 < Severity Index < 5 after 6 months. The monitoring
periodicity of all Tier 1 tests should be
revised to 6 months.
5 < Severity Index < 7 Subtract 1.0 Retest the cable for partial discharge
after 3 months. Arrange for
replacement of defective section(s).
Severity Index > 7 Subtract 1.5 Indicates serious problem requiring
immediate evaluation, additional
testing and consultation with experts.
Recommendation is to remove from
service immediately and replace the
cable.
6.9.1.1 Severity Index Calculation
The related parameters are shown in equations 6.1 – 6.6.

K=k1*k2………….………….. Equation (6.1)
k1 = Vi/Vo………….………….. Equation (6.2)
k2 = Ve/Vo………….………….. Equation (6.3)
where,
k1 = Inception Voltage Factor
k2 = Extinction Voltage Factor
Vi = Inception Voltage
Ve = Extinction Voltage
Vo = Phase Voltage
A = Qm/Qa………….………….. Equation (6.4)

where,
A = Discharge Factor
Qm = Maximum Discharge
Qa = Average Discharge
___________________________________________________________________________
D = Nm/NT………….………….. Equation (6.5)

where,
D = Density Factor
Nm = Number of Discharges @ L ± 10m
NT = Total Number of Discharges
L = Location of Highest Discharge
S = (A·D)/K………….………….. Equation (6.6)

where,
S = Severity Factor
K = Critical Factor
6.9.2 Dielectric Spectroscopy Test
This test is performed with the cable de-energized and may show the necessity for further
investigation on the location of the defects or removal from service. Results are analyzed and
applied to Table 6.12 to arrive at a Cable Condition Index adjustment.
Table 6.12 Dielectric Spectroscopy Test Score Adjustment

XLPE: Subtract 0 Normal. The monitoring periodicity
Good response: of all Tier 1 tests can be maintained
No significant gap between the at 24 months. Practice partial
frequency sweep responses at
different voltages. discharge test if necessary.
PILC:
% Moisture Content < 0.5
XLPE: Subtract 0.5 Retest the cable for dielectric
Non deteriorated response: spectroscopy after 6 months. The
Significant gap between the monitoring periodicity of all Tier 1
frequency sweep responses at tests should be revised to 6 months.
different voltages with no
hysteresis effect.
PILC:
0.5 < % Moisture Content < 2.0
XLPE: Subtract 1.0 Retest the cable for Dielectric
Voltage dependent response: Spectroscopy after 3 months.
Significant gap between the Arrange for replacement of
frequency sweep responses at
different voltages with hysteresis defective section(s).
effect.
PILC:
2.0 < % Moisture Content < 2.5
___________________________________________________________________________
XLPE: Subtract 1.5 Indicates serious problem requiring
Leakage current response: immediate evaluation, additional
Wide gap between the frequency testing and consultation with
sweep responses at different
voltages with hysteresis and experts. Recommendation is to
leakage current effects. remove from service immediately
and replace the cable.
PILC:
% Moisture Content > 2.5
The sample examples of Non-Deteriorated, Voltage Dependent and Leakage Current

responses are illustrated in section 7.5.1.
6.9.3 Tier 2 – Total Cable Condition Index Calculations
Enter the Tier 2 adjustments from the tables above into the Total Cable Condition Index
Value Form as shown in Table 6.12. Subtract the sum of these adjustments from the Final
Tier 1 Cable Condition Index to arrive at the Total Cable Condition Index. The value of the
individual weighting factor of the Tier 1 Condition Indicator is determined by the expert. The
sum of all the weighting factors should be equal to 3.33.
Table 6.13 Total Cable Condition Index Value

No Condition Indicator Score Weighting Factor Total Score
1 Thermography 0.70
2 Tan Delta 0.80
4 Operation and Maintenance 0.53
Performance
5 Age 0.30
6 Cable Data Quality Indicator Score Adjustment
(value can be 0, -0.5, -1.0 or -1.5)
Final Tier 1 Cable Condition Index Value
7 Tier 2 Partial Discharge Score Adjustment
(value can be 0, -0.5, -1.0 or -1.5)
8 Tier 2 Dielectric Spectroscopy Score Adjustment
(value can be 0, -0.5, -1.0 or -1.5)
Total Cable Condition Index Value
A negative Total Cable Condition Index Value would require
immediate de-energization, or prevent re-energization, and
planning for replacement.
___________________________________________________________________________
6.10 Combined Tier 1 and Tier 2 Cable Condition‐Based
Alternatives
The Cable Condition Index – either modified by Tier 2 tests or not – may be sufficient for
decision making regarding cable condition based alternatives as shown in the Table 6.14. The
Index is also suitable for use in the risk and-economic analysis model, which will be
discussed in the Maintenance Planning Manual.
Table 6.14 Cable Condition Based Alternatives

Total Cable Condition Index Value Suggested Course of Action
≥ 7.0 and ≤ 10.0 (Good) Continue O&M without restriction. Maintain
the normal frequency of Tier 1 test. Repeat Tier
2 test as needed.
≥ 3.0 and < 7.0 (Fair) Repeat both Tier 1 & Tier 2 test after 6 months
from this condition assessment activity.
≥ 0.0 and < 3.0 (Poor) Reduce the load based on expert judgment and
arrange for replacement of section(s). If
necessary online condition assessment such as
partial discharge monitoring can also be
undertaken while waiting for the replacement.
Chapter 7
Record
Management of
Cable
Maintenance
Testing Results
___________________________________________________________________________
7 Record Management of Cable Maintenance Testing
Results
7.1 Background
This section of the manual deals with the record management of various identified tests. Tests
that generate waveforms and processed data are archived either in floppy drive or in separate
server. The processed data are transferred to CMMS via recommended test data sheet. The
tests that yield numerical data are directly fed into the CMMS via recommended test data
sheet.
7.2 Flow Chart for Record Management of Raw Waveform
and Processed Data
The raw waveforms of PD VLF, PD OWTS, DS and Thermography image are saved using
unique file name for each cable circuit. These waveforms can only be read with the help of
analyzing software provided by the testing equipment manufacturers. The saved raw
waveforms should be archived either in floppy drives or in a separate server. The raw
waveforms are further processed using the respective analyzing software to obtain “processed
data”. These processed data usually presented in tabular form and are possible to be copied
and pasted in either as word document or excel document. The data from these processed data
are then extracted and filled into the recommended test data sheet for further processing by
the Computerized Maintenance Management Software (CMMS). The CMMS also has input
from other tests such as IR and Tan Delta via test data sheet as shown in the Figure 7.1.
___________________________________________________________________________
Figure 7.1 Flow Chart of Raw Waveform and Processed Data

___________________________________________________________________________
7.3 Record Management of Raw Waveform and Processed
Data of VLF PD
The sample raw waveforms of VLF PD test is shown in Figure 7.2 below. These raw data
waveforms for all the phases should be saved with appropriate filenames and stored either in
floppy drives or in a separate server. These raw waveforms can only be viewed using the
appropriate analyzing software provided by the manufacturer of the testing equipment.
Figure 7.2 Raw Waveform of PD VLF
The above three pulse raw waveforms are further processed by the analyzing software to
generate the PD mapping plot and several PD parameters such as amplitude, counts and
location. A sample of such output data is shown in the Figure 7.3. The numerical values of
the identified parameters can be extracted from the following processed output and can be
recorded into the test data sheet. After this these values can be keyed into CMMS for
interpretation. The periodicity of archiving the test data sheet information should be same as
the service life of the respective cables.
___________________________________________________________________________
Figure 7.3 Processed Data (PD Mapping) of PD VLF
Data of OWTS PD
The sample raw waveforms of OWTS PD test is shown in Figures 7.4 and 7.5 below. These
raw data waveforms for all the phases should be saved with appropriate filenames and stored
either in floppy drives or in a separate server. These raw waveforms can only be viewed
using the appropriate analyzing software provided by the manufacturer of the testing
equipment.
___________________________________________________________________________
Figure 7.4 Raw Waveform of OWTS PD

___________________________________________________________________________
Figure 7.5 Raw Waveform of OWTS PD
The above three pulse raw waveforms are further processed by the analyzing software to
generate the PD mapping plot and several PD parameters such as amplitude, energy, counts
and location. A sample of such output data is shown in the Figure 7.6 and Figure 7.7. The
numerical values of the identified parameters can be extracted from the following processed
output and can be recorded into the test data sheet. After this these values can be keyed into
CMMS for interpretation. The periodicity of archiving the test data sheet information should
be same as the service life of the respective cables.
___________________________________________________________________________
Figure 7.6 Processed Data (PD Mapping) of OWTS PD
Figure 7.7 Processed Data (Histogram) of OWTS PD

___________________________________________________________________________
Data of DS
The sample raw waveform of the DS test is shown in Figure 7.8 below. These raw data
waveforms for both XLPE and PILC should be saved with appropriate filenames and stored
either in floppy drives or in a separate server. These raw waveforms can only be viewed
using the appropriate analyzing software provided by the manufacturer of the testing
equipment.
7.5.1 XLPE
The sample raw waveforms of DS test of XLPE Cables for non deteriorated response, voltage
dependent response and leakage current response are shown below in Figures 7.8, 7.9, 7.10,
and 7.11.
Figure 7.8 Raw Waveform (Good Response) of XLPE DS

___________________________________________________________________________
Figure 7.9 Raw Waveform (Non Deteriorated Response) of XLPE DS
Figure 7.10 Raw Waveform (Voltage Dependent Response) of XLPE DS

___________________________________________________________________________
Figure 7.11 Raw Waveform (Leakage Current Response) of XLPE DS
The above raw waveforms are further processed by the analyzing software to generate the
deviation between the frequency sweeps at different voltages and also the hysterisis effect. A
sample of such output data is shown in the Table 7.1. The numerical values of the identified
parameters can be extracted from the following processed output and can be recorded into the
test data sheet. After this these values can be keyed into CMMS for interpretation. The
periodicity of archiving the test data sheet information should be same as the service life of
the respective cables.

Table 7.1 Processed Data of XLPE DS
Response Gap between the frequency Hysterisis Leakage
sweep responses at Effect Current
different voltages Effect
Good response No No No
Non deteriorated response Yes No No
Voltage Dependent response Yes Yes No
Leakage Current response Yes Yes Yes
7.5.2 PILC
The sample raw waveform of the DS test for PILC Cable is shown in Figure 7.11 below.
These raw data waveforms should be saved with appropriate filenames and stored either in
floppy drives or in a separate server. These raw waveforms can only be viewed using the
appropriate analyzing software provided by the manufacturer of the testing equipment.
___________________________________________________________________________
Figure 7.12 Raw Waveform of PILC DS
moisture content in paper insulation. To estimate the moisture content of paper insulation,
several internal files are used by the software to extract the required information. A sample of
such output analysis is shown in the Figure 7.13. The numerical values of the identified
parameters can be extracted from the following processed output and can be recorded into the
test data sheet. After this these values can be keyed into CMMS for interpretation. The
periodicity of archiving the test data sheet information should be same as the service life of
the respective cables.
___________________________________________________________________________
Figure 7.13 Processed Data (Moisture Content) of PILC DS
Data of Thermography
The sample raw waveform of the Thermography image for exposed Cable Terminations is
shown in Figure 7.14 below. These raw data waveforms should be saved with appropriate
filenames and stored either in floppy drives or in a separate server. These raw waveforms can
only be viewed using the appropriate analyzing software provided by the manufacturer of the
testing equipment.
___________________________________________________________________________
Figure 7.14 Raw Waveform of Thermography
temperature by the software using several internal files. A sample of such output analysis is
shown in the Figure 7.15. The numerical values of the identified parameters can be extracted
from the following processed output and can be recorded into the test data sheet. After this
these values can be keyed into CMMS for interpretation. The periodicity of archiving the test
data sheet information should be same as the service life of the respective cables.
Figure 7.15 Processed Data of Thermography

___________________________________________________________________________
7.7 Record Management of IR and Tan Delta
The test data for IR and Tan Delta are numerical values and can be recorded directly into the
test data sheet without further processing. After this these values can be keyed into CMMS
for interpretation. The periodicity of archiving the test data sheet information should be same
as the service life of the respective cables.

Maintaining Underground Cable Systems

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TNB Distribution Division Maintenance Manual : Underground Cable System Page |i

I. Purpose of the Manual iii

II. Date Completed and Period Covered iii

III. Recommended Standards and References iii

List of Figures and Tables x

2.5 Frequency or Periodicity of Condition Based Maintenance Task.............................32

6.8.8 Tier 1 – Cable Data Quality Indicator..............................................................122

Figure 2.1 Growing Expectation of Maintenance....................................................................24

Table 1.1 Criticality Ranking...................................................................................................17

In practice, the traditional understanding of maintenance is to "fix it when it breaks". This is a

organizational and cultural environment of an existing, predominantly reactive maintenance

A CMMS is critical to an organized, efficient transition to a proactive maintenance approach.

The process of transition from a reactive maintenance organization to a totally proactive

Bureau of Reclamation has developed a document on their maintenance practices on

Reclamation follows Preventive Maintenance (PM) practice of maintaining equipment on a

Transformers are tested in accordance with manufacturer’s recommendations and industry

Table 1.1 Criticality Ranking

Ranking Effect Consequence

The loss of function will be so minor that it would have

The loss will cause minimal curtailment of operations or

The loss will have noticeable impact on the facility. It

Will cause personal injury or substantial economic

Ranking Effect Consequence

Will produce death or multiple death or injuries, or the

NASA Reliability-Centered Maintenance Guide provides Predictive Testing and Inspection

Table 1.2 Sample Maintenance Approach Table

The Periodicity Codes used by NASA are described below:

Circuit breakers used in NASA are as follows:

I. Task 1: Maintenance assessment

II. Task 2: Review existing asset management tools and systems

III. Task 3: Develop CBM processes, methodologies and models

IV. Task 4: Define CBM implementation objectives, strategies and measures

V. Task 5: CBM network architecture, hardware and software

VII.Task 7: CBM implementation master plan

VIII.Task 8: Propose implementation approach and work plan

• Higher plant availability and reliability

1940 1950 1960 1970 1980 1990 2000

Figure 2.1 Growing Expectation of Maintenance

Figure 2.2 Probability of Failure with Age

Figure 2.3 Failure Patterns

• Predictive or Condition based maintenance

Preventive maintenance usually means overhauling items or replacing components at fixed

Usually FMECA is being practiced to identify condition monitoring techniques appropriate

Figure 2.4 Schematic Representation of Proactive Maintenance

FMECA are of three types:

FMECA standards are:

Prerequisites for FMECA studies are:

FMECA worksheets (Appendix 2.1):

Task No. Task Description

Some methodology recommends computation of Risk Priority Numbers as shown below:

XXXXXRPN (risk priority number) = Fr x Cr x DetXXXXX

where, Fr = probability of occurrence, Cr = criticality or severity and Det = detectability

Figure 2.5 P-F Curve

Figure 2.6 P-F Interval

Figure 2.7 Periodicity of Condition Based Maintenance

Table 3.1 Types of Underground Cables and its Accessories

Category Types Size

Category Types Size

Table 3.2 Cable components and their function

Figure 3.1 Construction of single core XLPE cable

• Conductor: Aluminum or Copper. Size varies as shown in Table 3.1.

Figure 3.2 Construction of three core XLPE cable

• Conductor: Aluminum or Copper. Size varies as shown in Table 3.1.