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C&I Cables Tests
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Pratyusha Khandelwal
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These tests were performed in factory outlet of Thermo Cables Ltd, Hyderabad.
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C&I Cables Tests
1.
© LANCO Group,
All Rights Reserved© LANCO Group, All Rights Reserved POWEREPC INFRASTRUCTURESOLAR RESOURCES Lanco Babandh Power Ltd (C&I Cables Testing Methods) PRATYUSHA KHANDELWAL Source : Thermo Cables Limited, Hyderabad: 19.Nov.2012-23.Nov.2012
2.
© LANCO Group,
All Rights Reserved Types of Cables: • Power Cables/Control Cables • Instrument/TC/Signal Cables Note: Only Instrument cables have drain wires
3.
© LANCO Group,
All Rights Reserved Material used in Cables: • TYPE: Y13 = Conductor Insulation(VDE 0207PT4) • TYPE: A = Conductor Insulation • XLPE = Conductor Insulation • TYPE: YM1 = Inner Sheath (VDE 0207PT5) • ST1 = Outer Sheath • ST2 = Outer Sheath *Note: Credentials validity must be up to 5 yrs approved by CPRI/NABL/NTH etc
4.
© LANCO Group,
All Rights Reserved Nomenclature: Ex: 3C/P/T/Q 16 SQ MM 1100V FRLS TCL 2012 315M Job ID: XXXXXX Customer No. DVWS Job No./ASC: 303468 Size: 8P x 0.5 sq.mm DRM No. 1004883 QTY: 465 M *ASC= Armoured Screen Cable
5.
© LANCO Group,
All Rights Reserved Tests for Cables: Type/Routine Tests: (100% of the given lot) 1) HV Test/High Pot. Test 2) Conductor Resistance Test 3) Drain Wire Resistance Test 4) Insulation Resistance Test
6.
© LANCO Group,
All Rights Reserved Tests for Cables: Acceptance Tests: (10% of offered lot of each cable size as applicable) 1) Construction detail verification(Conductor/Insulation system/ Pairing/ Laying/Pair/Overall Shielding/Inner sheathing /Armoring/Outer sheathing) 2) Conductor Resistance Test 3) Capacitance, Inductance & L/R Ratio Test 4) Tensile strength and elongation at break for insulation and sheath before and after ageing 5) Thermal Stability Test 6) Cross Talk/Attenuation Test 7) Insulation Resistance measurement 8) Insulation thickness measurement 9) Color identification of cores 10) Annealing Test 11) Volume Resistivity Test 12) Hot Deformation Test
7.
© LANCO Group,
All Rights Reserved Acceptance Tests: FRLS & ART: 1) Oxygen Index Test. 2) Temperature Index Test. 3) Smoke Density Test. 4) Flammability. 5) Swedish chimney/Flame Retardant Test. 6) Acid gas generation test. 7) Anti rodent test.
8.
© LANCO Group,
All Rights Reserved HV Test: IS : 10810 Part 45 • HV Tester • ForControlCables: 3kV ACrms for 5 minutes(C-C) 3kV ACrms for 5 minutes(C-Armour) • ForTC/InstrumentCables: 1kV ACrms for 1 minutes(C-C) 1kV ACrms for 1 minutes(C-Screen) *Note: Drain wires are only present in Instrument cables
9.
© LANCO Group,
All Rights Reserved Conductor Resistance & Drain Wire Resistance Test: • BS: 5308 Part-2 • IS: 10810 Part-5 • Digital Ohm Meter • Probe Calibration Test- 0.0 at NTP • At 20°C, R= [Rx.k.1000/L]; Ω/km [max. 36.6] where, k= 250/(230+T) *Drain wire: 30 Ω,max /Conductor Wire: 36.6 Ω,max
10.
© LANCO Group,
All Rights Reserved Insulation Resistance Test: • IS: 10810 Part-43 • Insulation Tester • IRconstant = LxR/[1000Log10(D/d)]; MΩ-km • Min. 100MΩ/km • C-C • C-Shield • Insulation • L/R
11.
© LANCO Group,
All Rights Reserved Capacitance, Inductance & L/R Ratio Test: • BS: 5308 – I & II • Digital LCR Q Meter • Frequency is set at 1kHz • OC & SC test is done • Capacitance b/w cores= Cc x 1000/L in nf/km [max. 250] • Capacitance b/w core to shield + armor = Cs x 1000/L in nf/km [max. 400] • Inductance = L x 1000 x 1000/L in mH/km [max. 1] • L/R = obs. Inductance/loop resistance; µH/Ω [max. 25]
12.
© LANCO Group,
All Rights Reserved continued… PARAMETER PVC INSULATION XLPE/LDPE INSULATION Capacitance b/w cores Max. 250 nf/km Max. 100 nf/km Capacitance b/w core-shield Max. 400 nf/km Max. 400 nf/km Inductance for signal cables Max.1mH/km Max.1mH/km Inductance for TC cables Max. 4mH/km Max. 4mH/km L/R ratio up to 1 mm² Max. 25µH/Ω Max. 25µH/Ω L/R ratio 1- 1.5 mm² Max. 40µH/Ω Max. 40µH/Ω L/R ratio 2.5 mm² Max. 50µH/Ω Max. 50µH/Ω
13.
© LANCO Group,
All Rights Reserved Ageing Test: • IS: 10810 Part-11 • Tensile strength and elongation at break for insulation and sheath before and after ageing is done. • 7 Days test at specific temp. of 80°C, 100°C etc • Sheath-dumb-bell shape & Insulation-tubular shape; each sample of ≥ 100mm is taken. • 20 mm marking is done on each test sample and tested at 50kg wt. tensile & elongation tester. • Tubular Cross sectional Area, A = ∏/4[ D² – d²]; mm² • Dumb-bell Cross sectional Area, A = width x thickness; mm² • T.S. = BL x 9.8/ A; N/mm² • % Elongation = [L-L0]/L0 x 100 in % • Variation in T.S. = [TS0 – TSx]/TS0 x 100 in % • Variation in Elongation = [EL0- ELx]/EL0 x 100 in % Note: BL at fractured point shall not be greater than 250 mm/min. Material T.S. % Elongation PVC 12.5 N/mm² min. Min. 150 % LDPE 10 N/mm² min. Min. 300% XLPE 12.5N/mm² min. Min. 200%
14.
© LANCO Group,
All Rights Reserved Ageing Test: continued… Material Variation in T.S. Variation In Elongation TYPE A Max. ± 20% Max. ± 20% TYPE C Max. ± 25% Max. ± 35% TYPE ST1 Max. ± 20% Max. ± 20% TYPE ST2 Max. ± 25% Max. ± 25% TYPE ST2 with FR/FRLS Max. ± 25% Max. ± 25% XLPE Max. ± 25% Max. ± 25% Material Set Temperature Duration of Test TYPE A 80±2 °C 7 Days TYPE C 135±2 °C 7 Days TYPE ST1 80±2 °C 7 Days TYPE ST2 100±2 °C 7 Days TYPE ST2 with FR/FRLS 100±2 °C 7 Days XLPE 135±2 °C 7 Days
15.
© LANCO Group,
All Rights Reserved Thermal Stability Test: • IS : 5831-1984 • Digital Temperature Controller • Temp.: 200°C • Time: 40 Minutes • PH paper color changes Type of Material Test Duration TYPE A, FRLS, PVC 80 minutes( min.) TYPE C 100 minutes( min.) TYPE ST1, FRLS 40 minutes( min.) TYPE ST2, FRLS 80 minutes( min.)
16.
© LANCO Group,
All Rights Reserved Cross Talk/Attenuation Test: • LF Source & Selective Level Meter • Frequency is set at 800Hz, Voltage = 10mV • Attenuation = 20 log10[Vmax/Vmin]; dB • It should be ≤ 1.2 dB(max.) • Cross Talk ≥ 60 dB(min.)
17.
© LANCO Group,
All Rights Reserved Annealing Test: • Test Sample: L1 = 250 mm marked • %age = [(L2 – L1)/ L1] x 100 • Annealing Test for conductor must be min. 18% • Ex: L1 : 250, L2 : 310 24%
18.
© LANCO Group,
All Rights Reserved Volume Resistivity Test/Water Immersion Test: • IS: 10810 Part-45 • VR is tested at ambient temp. and at rated temp. of 70°C • Voltage = 500V • Test Sample, L = 3.5 mtrs • VR = [observed resistivity x 2∏ x L x e⁸]/ log(core dia./conductor dia.); MΩ-cm Material At ambient temp.(27°C) At rated temp.(70°C) PVC Type A Min. 1 x 10^13 Ω-cm Min. 1 x 10^10 Ω-cm at 70°C PVC Type A, FRLS Min. 1 x 10^13 Ω-cm Min. 1 x 10^10 Ω-cm at 70°C PVC Type C Min. 1 x 10^13 Ω-cm Min. 1 x 10^10 Ω-cm at 85°C XLPE Min. 1 x 10^14 Ω-cm Min. 1 x 10^12 Ω-cm at 90°C LDPE Min. 1 x 10^15 Ω-cm Min. 1 x 10^12 Ω-cm at 70°C
19.
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All Rights Reserved Smoke Density Test: • ASTM D 2843 • Smoke Density test apparatus • Pressure gauge pointer • Gas flow at 40 psi or 2.8 kg/cm² • % of light absorbed at 15 sec interval for 4 minutes ie 16 values. • Rating = [ (Sum of 1 to 15 values) x 2 + 16th value] / 32 in % • 60% for FRLS PVC (max.) • 20% for ZHFR (max.) • Vdc = 5.8V • Ex: For a sample, the absorption % is as follows: 1 min : 14% 2 min : 28% 3 min : 31% 4 min : 29%
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All Rights Reserved Swedish chimney/Flame Retardant Test: • IS: 10810 Part-61 & SS 424-1475 F3 • Specimen Length: 850 mm and ext. dia. should not exceed 35 mm • Stop watch • Unaffected portion from top shall be min. 300mm • Ex: Test Sample Dia, D =20 mm Ethanol Qty(ml) = Time(min) x 20 = [1+D/5] x 20 = 100 ml Total Length = 850 mm; Undamaged sample after test= 610 mm
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All Rights Reserved Oxygen Index Test/ Temperature Index Test: • ASTM D 2863 • Oxygen is 100% and N2 is 0% • Flame is inserted • OI = 29%(min.) and Temp. : 30°C; • At 32, 32.5, +0.5°C likewise increases it. • TI, at 50°C, 80°C • TI = 250°C(min.)
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All Rights Reserved Flammability: • IEC: 332 Part-3 • Ladder length : 4 meters • Cable length : 2.5 meters • Time : 20 minutes • LPG flow: 0.25 kg/cm² • Air flow: 2.4 kg/cm² • Sample Result: 1.35 mtrs burned
23.
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All Rights Reserved Acid gas generation test: • IEC: 60754-Part I • Test Sample: 1 gms • Electronic Balance • Digital Temp. Controller • Pressure air flow meter Procedure: • 4 gm NaOH+ 1 ltrs distill water is made • 440ml soln of NaOH is made. • 200ml soln is taken out seperately.(Original Sample) • One sample is put at 800°C for 40 minutes (Test Sample)
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All Rights Reserved Acid gas generation test: continued Titration: • 200ml soln. of each is taken out from 440ml NaOH+ 1000ml distill water • 4ml Nitric Acid is added in both samples • 3ml Nitro Benzene(C6H5NO2) is added in both samples • 20ml AgNO3 is added in both samples • 1ml (40% ferric ammonium) is added in both samples • 0.1 M Ammonium Tryo Cyanate, NH4CNS (50ml) filled in burate • Now, original sample is stirred, and burate valve is opened. • Original Soln. color changes at X ml and Test soln. color changes at X+Y ml • % of HCL can be max. 20 in mg/g
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All Rights Reserved Acid gas generation test: continued • Ex: Cable: 3C x 16 sq.mm • Test Sample: 1.0071 gms • Original Soln.: 23ml & Test Soln.: 37ml • HCL % = 3.65 x 0.1 x (B-T) x (1000/200)/Weight of test sample = 3.65 x 0.1 x (23-14) x (1000/200)/ 1.0071 = 16.30 %
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All Rights Reserved ART: Anti rodent & termite repulsion test: • IS : 5831-1984 • Ash of cable is taken. • Sodium Sulphide flakes(fused), Na2S.xH2O are mixed with distill water in other bowl. • Ammonium Acetate soln. + Distill water + Ash all the three are put in oven for 10 minutes at 80 °C • After 10 minutes, sample is filtered and mixed with H2SO4. • We get brown spots, it means Lead is present in the given sample.
27.
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All Rights Reserved Important Cable Testing Standards: • IS 5831: PVC Compound • BS 7655: ZHFR • IS 8784, IEC 60584-1&3, ANSI MC 96.1: TC Cables • IS 10810: Methods of tests for cables • BS 5308-I&II : L/R Ratio • BS 5308P2, IS 10810P5: Drain wire test • IS 5831, IS 10810P60: Thermal Stability • ASTM D 2863: Oxygen Index & Temp. Index Test • ASTM D 2843: Smoke Density Test • IEC-60754P1: HCL gas test • IS 10810P62, IEC 332P3: Flame Retardance Test for bunch of cables • IS 10810P61 & SS 424-1475: Swedish Chimney Test • IEC 332P1: Flammability Test • IEC 60331: Fire Survival Test • IS 10810P12: Shrinkage Test • IS 10810P10: Loss of mass • IS 10810P14: Hot shock Test Data Sheets Test Certificates
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All Rights Reserved PK p.khandelwal@lancogroup.com 9/14/2015 12:12 AM
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