Predictive analysis on cables,

Transformers, O/H Equipments &

RLE
Sanjeev Atri
9818100219
Maintenance Philosophy
• Corrective or Breakdown maintenance implies that repairs are
made after the equipment is failed and can not perform its normal
function anymore
• Preventive Maintenance (PM) provides them periodic/scheduled
inspections and minor repairs to reduce the danger of unanticipated
breakdowns.
• Condition based maintenance, machinery conditions are
periodically monitored and this enables the maintenance crews to
take timely actions, such as machine adjustment, repair or
overhaul
 Tools for Condition based maintenance

Detects the
Infrared
Human eyes real-time
Scanning
abnormality

Ultrasound Detect tracking/

Scanning Human ears arcing/
discharges

Electrical Detect change in

TDR Signal Impedance
Characteristics
 Predictive Maintenance of RMU

Ultrasound Technology

• Ultrasonic frequencies are high frequency signals

that are above the range of human hearing
• Audible range for humans is 20 Hz to 20 KHz.
• Ultrasound instruments sense 20 KHZ to 100 KHz
“Ultrasound is used for electrical inspection:
To detect discharge/ionization”
 Characteristic Phenomena
Three types of discharges in Power system that
generally produce ultrasonic frequency:-
Not possible
Not possible
to capture at No standard
to detect by
Arcing the initial guideline.
infrared
stage

Tracking

Corona

➢ They are more directional and travel in a straight line.

➢ Localized to the source of emission.
 CORONA IDENTIFICATION

• Hissing Noise
• Uniform peaks at equal intervals of
time
• Frequency domain pattern has
harmonics of the line frequency and
they are visible in its pattern
• Corona discharge happens at the
peak of the cycle
• Corona discharge produces ozone
and nitrous oxide
• Advantage: Early identification may
result in large scale protection.
 TRACKING IDENTIFICATION
• Low current pathway from top
to ground through the insulator.
• Can happen anywhere in the
positive cycle.
• Harmonics are not present.
• Less uniformity in pattern and
popping sound occurs.
• Advantage: In grids tracking
can be missed by infrared
camera scanners but
ultrasound is the best the
equipment to search for
tracking.
 ARCING IDENTIFICATION

• High Current pathway

from top to ground
through insulator which
don’t even require high
voltage.
• It is quick and abrupt with
buzzing sound.
• Burst of Energy
extending for large
periods of time.
• Most random pattern so it
is easily recognizable.
 PROBES
• There are two kinds of probes in this equipment:
• Contact type probe with frequency setting of 20 kilohertz
• Air borne probe with frequency setting of 40 kilohertz

Contact Probe Non- Contact

Probe
10

Partial Discharge detection on overhead line

11

Partial Discharge detection on overhead line

12

Partial Discharge detection on Insulator

 DD Fuse Assembly

Feedback from Zones: Increasing failure trend in DD insulators

Analysis: IR image reveals that

1) Partial discharge in the porcelain assembly is main culprit for failure of DD insulators
2) Hot spots due to Improper contact of barrel fuses.
3) Hot spots due to loose / oxidized Jumper connections.

CA: 1) Design may be reviewed by polymeric instead of porcelain.

2) Jumper connections at DD contacts may be cleaned & tightened properly.

35.9 °C
35

30
PD in DD Insulator

25

20

18.6
Condition Assessment through Infrared
Thermography
Role of Infrared Thermography in Electrical Network

• The main benefit of this technique is to find deteriorating

components prior to catastrophic failure

• Thermography provides diagnostic aid and problem

solving.

15
 Methodology
Methodology adopted for Identifying criticality in the network Equipments

• Detection of Hot spot on the contacts & joints

• Thermal Distribution profile analysis of the Equipments

16
Detection of Hot spots
• Measures adopted for hot spots
1) Reference based (i.e. Min. Temperature rise at any
phase & compared with others, at same load)
2) Temperature rise above Ambient

69.1 °C

ar3
60

ar2 40

ar1
20

0
17 -2.4 °C
 Categorization of Temperature rise

Temperature Rise Category Recommendations

above Ambient at
Rated Load

Less than 20ºC Normal Keep monitoring

Greater than Serious To be Scheduled

20ºC & Less in PM
than 50ºC
above 50ºC Critical Immediate
action

18
Thermal Distribution profile Analysis
• Measures adopted for Thermal Distribution profile analysis
– Auditing & Capturing the thermal signature of the equipment along with following data
1) Ambient Temperature
2) Date & Time
3) Load
– Review after six month

19
Identifying Criticality in 50MVA Power Transformer (Case study1)
Thermal Distribution profile Analysis

Name of Grid: Jahangir puri

Ambient Temperature: 34.ْ C
Case study -1: Location: 50MVA Power Tr.2 Load: 130Amps.
This is a case study wherein the thermo scanning was done in a routine exercise in the year 2006 which was found to
be normal. Subsequently the routine thermoscanning was again carried in 2007 and it was observed that there was a
perceivable difference in the thermal signature highlighting the development of abnormality over a period of time. This
abnormality was attended and the impending failure was averted.
This is a classic case of identifying criticality in the equipment through proactive thermo scanning exercise.
BEFORE: Normal Thermal Signature of the Equipment on 12.8.06
Identifying Criticality in 50MVA Power Transformer (Case study1)
Thermal Distribution profile Analysis

Name of Grid: Jahangir puri

Ambient Temperature: 37.ْ C
Location: 50MVA Power Tr.2 Load: 150Amps.
Max. Temperature captured at Tr. tank 52.2.ْ C
Max. Temperature captured at Radiator 50.9.ْ C
Max. Temperature captured at Tap changer 62.7.ْ C
Abnormal Thermal pattern observed at tap changer

ar1
64.6 °C

ar2 60

ar4
50
ar3

40

35.3 °C

Tap Collector
changer ring

Carbon
deposition
 Identifying Criticality in 20MVA Power Transformer (Case study2)
Thermal Distribution profile Analysis

Name of Grid: Rohtak Road

Ambient Temperature: 34ْ C
Heat distribution on Power Transformers
Power Transformer 1 Rating: 20MVA Load: 60A
S. no Description unit Status Remarks
1 Oil circulation in Radiators Normal
2 Heat distribution Pattern on Normal
Transformer & Radiators
3 Max temperature rise on °C 52.5
Transformer body
4 Winding Temp. in Gauge °C 56
5 Oil Temp. in Gauge °C 54
6 Cooling fans 6no. Working
7 Hot spots on Bushings & No. NIL
cable connections
Identifying Criticality in 20MVA Power Transformer (Case study2)
Thermal Distribution profile Analysis

Name of Grid: 33 KV Rohtak Road Grid

Ambient Temperature: 27°C
Image shows Non circulation of Oil in the Radiators
 Identifying Criticality in 20MVA Power Transformer (Case study2)
Thermal Distribution profile Analysis

Name of Grid: 33 KV Rohtak Road Grid

Date of Scanning: 19th Sept 2008
Time of Scanning: 12.00HRS
Ambient Temperature: 30°C

Thermal Image captured after corrective action:

Max. Temperature captured on the tank 45°C
Max. Temperature captured on the Radiator 44.3°C
Image shows circulation of Oil in the Radiators is normal
 Identifying Criticality in 20MVA Power Transformer (Case study3)
Thermal Distribution profile Analysis

This is an example of bringing forth the results of reactive thermo scanning being carried out from time to time as per the
requirement wherein it was in formed by the end user that the winding resistance of LV winding of 66 /11kV, 25 MVA was
found to be abnormal.
Thermo scanning was carried out to ascertain whether there was any abnormal temperature rise due to the
unsatisfactory test results.
ANAYLSIS:
1) At the outset it was brought to the notice that there was abnormal rise in the temperature on B phase LV bushing.
2) On a micro analysis it was revealed that the source of temperature rise was localized to the internal busing connection
and this was clearly depicted by the thermal grading.
3) Thereafter the bushing was opened and it was observed that there was a loose connection from the main winding to
the internal bushing which was leading to the rise in the temperature.
4) Corrective action was effected and again the winding resistance was checked and found to be within normal limits.
HT Overhead System with Components

1. Reinforced cement concrete poles (R.C.C. Poles) 11. Stay wire

2. Double pole structure 12. Stay insulators
3. Cross – arms 13. Anchor rod
4. Line conductors 14. Dead end clamps
5. Pin-type insulators
6. Strain insulators
15. Parallel grooved clamp (P.G. Clamp)
7. Earth wires 16. Earthing
8. Angle iron for earth wire 17. Lightning arrestors
9. Hooks for earth wire 18. Danger plates
10. Top hamper 19. Anti –climbing device
20. Tie wire
 Case Study -Top 5 Tripping Contributor Feeders
As per thermo
scanning Data

As per PSC Data Nature of Faults (As Per PSC Data)

Trunk feeder name

No. of
abnormalities BD & ESD
PSD HOURS TOTAL HRS
observed during HOURS
Thermo scanning
No. of
trippings
S.NO. YTM
1 RAMA RD-70 RAMA RD 53 48 148.2 54.23 202.43

2 RAMA RD- 51 RAMA RD

56 31 92.57 113.14 205.71

3 REWARI LINE -COLD HOLD

22 29 40.15 40.15

4 RAMA RD-BREAKFAST
30 23 26.5 51.51 78.01

5 SARASWATI GDN -DLF-3

22 23 27.37 34.16 61.53
294.64 587.63
 Polymeric Surge arrestor/ Lightening arrestor

Feedback from Zone 1301: Increasing failure trend in Newly installed Polymeric LA s

Analysis: IR image reveals that Leakage current flowing in the Polymeric LA.

38.6 °C

Ar1 35

30

25

20

18.2
 GO Switches

Feedback from Zone 1302: Increasing failure trend in GO insulators

Analysis: IR image reveals that

1) Hot spots observed due to loose connections/ Oxidation at jumper connections.
2) In some cases in Z1302, GO insulators on which jumper connections are done, found broken due
temperature rise on the insulator due to hot spots. No evidence observed due to partial discharge in the
insulators.

CA: Jumper connections at GO may be cleaned & tightened properly.

62.2 °C 72.2 °C
60
Ar1:max 197.1
Ar1:max 130.2 60

50

40
40

30
20

19.7 6.8
 Distribution Transformers

Feedback from Zones: Failure in DTs

Analysis: IR image reveals that

1) Hot spots at LV /HV side of DTs due to use of old bimetallic MS rivet type clamps
2) Hot spots due to Loose/ oxidized connections at LV/HV bushings in new tinned copper clamps.

CA: 1) old bimetallic MS rivet type may be replaced by tinned copper clamps.
2) Cable/ Jumper connections at LV/ HV bushing may be cleaned & tightened properly.

128.1 °C

120
Old bimetallic
MS Rivet type clamp
100

Ar1:max 117.7
80

60

40
New Tinned
Loose/oxidized copper clamp
cable connection:max 130.2 20

0.4
 Distribution Transformers

Feedback from Zones: failure in DTs

Analysis: IR image reveals that

1) Internal hot spots at LV bushings inside the DT tank.
2) No oil circulation in the Radiators
3) Oil Leakage through bushings due to hot spots at bushings which causes damage of bushing gaskets

CA: 1) Cable/ Jumper connections at LV/ HV bushing may be cleaned & tightened properly.
2) Thermo scanning may be conducted periodically.

38.8 °C
37.4 °C

36 No oil circulation through

front radiator unit 35
34

Oil Level 32
30
in DT
30

28
25

26

21.2
24.0
Identifying Criticality in RMUs Using Infrared Technology

Location: RMU ABB Makes at S/S 6 .

Sp1: Max. Temperature at O/G panel s/s 8 26.3°C Load: 80A
Sp2: Max. Temperature at O/G panel s/s 7 25.2°C Load: 23A
Sp3: Max. Temperature at spare panel 24.9°C Load: 17A
Sp4: Max. Temperature at IN/C panel SZB grid 25.2 ° C Load: 120A

27.0 °C
27

After Removing the boot caps.

sp4 sp3 sp2
sp1 26 ar1: Max. Temperature 65.3°C
ar2: Max. Temperature 34.3°C
ar3: Max. Temperature 54.4°C
25
67.4 °C

24 60
ar1
23.9 °C ar2
ar3

40

20

14.8 °C

32
Types of faults in 11kV OH lines

• 70% - 80% of faults are of a transient

(temporary) nature:
– Conductors clashing in the wind
– Tree branches falling on overhead
conductors
– Animals or birds getting caught in power
lines
– Lightning strikes

• An “auto-reclose” cycle should clear

the fault

• Some are more permanent:

– Careless motor vehicle drivers
– Downed power lines (fires, fallen trees,
storms)

• “lock out” (no further recloser

operation) of the faulted section; operator
intervention required

33
Auto re-closer and Sectionalizers

Autorecloser

34
Sectionalisers
Pole Mounting Arrangement

Switchgear unit

PT

Control Cubicle (PTCC or

ADVC)

35
 Sectionalizing function

• Supply Interruption Counter “counts” upstream

recloser (ACR) operation. Counts when:
– Downstream fault is detected
Substation – Current drops to zero
Logic – Loss of source side voltage
Fault occurs
• Detects downstream Phase, Earth and SEF faults
Both detect fault
• When a preset value is reached the switch (SEC)
ACR trips opens during the recloser dead time
ACR
SEC counts interrupt
• Fault conditions are isolated
ACR recloses
• Power is restored to fault-free sections
Both detect fault
ACR trips
SEC counts interrupt
SEC opens if set to 2
SEC ACR recloses
Power restored to
fault-free section

36
Reclosing function
• The primary function of a recloser is to detect
faults and turn the power off when faults occur

Substation • Monitors current, voltage, harmonics and

Logic frequency
Fault occurs
• Detects abnormal conditions (faults) such as:
Both ACRs detect fault – Electrical current: Phase overcurrent &
earth fault
ACR2, closest to fault trips – Voltage: Loss of phase & phase imbalance
ACR1 ACR1 remains in sequence – Advanced: Harmonics & frequency
ACR2 recloses • Reclose function:
Both ACRs detect fault – Switch closes automatically (trips if fault
still present)
ACR2 trips – Programmable repetitions (4 times max)
– Temporary faults – restores power after
Temporary fault disappears fault disappears
ACR2 recloses – Permanent faults – remains open and
operator intervention is required
ACR2 Power restored
Sequence reset in both ACRs

37
Fault Passage Indicators
Working Principle of FPI
Fault Identification through FPI

NOP
Importance of connectors in O/H line
Types of connectors used in O/H network

PG Clamp Binding connections

Shear off PG connectorWedge connectors

Mid span joints compression type

Mid span joint Plug in type
Jumper Connections using connectors
Hotspot on jumpers due to
Improp :
er
Binding ➢ Loose Connection
➢ Improper binding
➢ Improper size of Binding
Wire
➢ Jumper connected
P Gdirectly
Connector Benefits:
to conductor
➢ Jumper not same as
PG ➢ Low
maincost
linecompare to
conductor
Connect wedge connector
or ➢ Firm connection due to
shear-off mechanism
45
➢ Reduction in Technical
Loss compare to binding
P G Connector for Jumper connections to main conductor

Application of anti-oxidant
grease after cleaning on
jumper/ main conductor to
prevent Oxidation in between
Shear off head of
Joints
connector for firm
connection

46
 Wedge Connector Installation

Hook the “C” member Place the tap conductor in the Insert the wedge
on to the main conductor lower grove of the “C” member
between the two
conductors inside the
“C” member with the
catalogue number
appearing in front

Drive the wedge inside the “C” member by way of a

nylon hammer till the broader dimension of the Final
wedge flushes with the broader dimension of the “C”
47

member
Assem
Poly Pro Installation to mitigate bird faults
Wrong Practice- Corrective Action-
Binding connected Polypro should be
along the polypro covered on both sides
causes bird age due without opening the
to potential pin insulators & to be
developed on it tie with the help of
cable tie

48
HT Line Spacer to Mitigate shorting of conductors in long spans
Fuse Co-ordination

Tr. Voltage No. of Fuse Color Code

Rating Level in Phases Element
(KVA) KV (Amp)
16 11 1 5 Yellow
16 11 3 2 Yellow
25 11 3 2 Yellow
25 11 1 5 Red
63 11 3 5 Red
100 11 3 8 NDPL Blue
160 11 3 10 Green
Barrel Fuse installed 250 11 3 20 White
Barrel Fuse missing
315 11 3 20 White
400 11 3 30 Pink
 HTABC Failure
Symptoms prior to failure
At initial stage:
In Majority of cases, sparking &Hissing sound is developed between Copper screen & Messenger
wire of HT ABC.

Later stage:
Outer Sheath burnt along the Messenger wire & damage of XLPE insulation due to heat of
sparking.
Insulation damage
due to sparking
Sparking spot

Outer sheath burnt

Cause of Sparking
The design of ABC is such that a substantial voltage induced at copper screen and is capable to puncture
the outer sheath along the messenger wire which is at earth potential resulted in sparking &
discharging sound.

Don’ts:
1) Temporary joints must be restricted. In emergency case, while making temporary joint, copper
screen continuity must be maintained. Standard joint must be installed at the earliest possible.
2 ) Copper screens connected to messenger wire with fuse/ conductor strand wire.
 Partial discharge test of HT ABC
❑ HT ABC failure occurs mainly due to insulation failure, no proper earthing, hot spot generation, improper proper spacing between phase and
earth.

Symptoms prior to failure

At initial stage:
In Majority of cases, sparking &Hissing sound is developed between Copper screen & Messenger wire of HT
ABC.
Later stage:
Outer Sheath burnt along the Messenger wire & damage of XLPE insulation due to heat of sparking.

Insulation and Copper sheath

damage
Partial discharge
Detected

Outer sheath burnt

Bonding of HT ABC
HT ABC with AL. wire screen with fault
HT ABC with Cu tape screen. withstand 10KA for 1sec.

Metallic screens connected to

messenger wire at one end only
Metallic /copper screens of AB cable section(@500mtrs)
connected to messenger wire with PVC single core AL 2X50 or
at both ends of the AB cable 1X 95 sqmm cable ABC 10 KA
section (@500 mtrs) with PVC rating.
single core AL 25 sqmm cable
53
Installation of Rodent Disc Barrier

Animal GO Switch
Cantilever
Guards

Monkey Scare

The key features Sleeve Black

• Thickness -5 MM 11 KV Spacer Polyolefin
• Easy to install , just we need to insert the product in slot and screwed easily.
• Single product give protection from birdage / animal electrocution
• No modification or extension required in existing fittings, therefore installation time is less
• Enhance the separation / isolation from live parts.
Installation of Pole Protector
72% contribution of
pole broken in three
districts only. Industrial
Grade shock absorbent
material.

320 Pole protectors 0

were installed

The pole protector has four parts :

Inner Layer - clamped with high tension springs to absorb
shocks.
Middle part - filler with high density material to absorb hit
force.
Outer part made of high-density polyethylene which act as first
line of defense.
Installation of Pole Protector- Schematic Diagram

0
 Insulation on Iron Pole to restrict current leakage

Animal GO Switch
Cantilever
Guards

After Insulation

The key features Sleeve Black

• To avoid current leakage through Iron poles, we have identified a solution forPolyolefin
providing Bird Sp
insulation to iron pole.
• We have covered approximately 7 Ft. height of the pole.
• Reflective tape is used to protect the pole from inadvertent hitting,
Portable Earthing Device
It is proposed to use Portable earthing device for
creating safety zone. By using this device the lineman need not to
climb the pole to create safety zone thus there is a saving of time
by 20 min approx. This time can be utilized for maintenance
Safety
purpose. Time No
process
zone taken in provisi
of
creatio ladder on of
shortin
n in fixing shortin
g by
line g by
and reachin
outage staying
g at line
0
mainten removal at
. only
ance ground
 Rodent capacitive screen guard
Problem:-Rodent electrocution on DT
Introduction
• Ring structure made from silicon coated HDPE bushing
material & G.I spikes.
• Metallic spikes generates low voltage(due to
capacitive
Why we use effect) causing mild
Rodent shock to rodents
capacitive screen .
guard ?
• Used to prevent rodent to reach at live part of DT.
• Reduction in tripping due to animal electrocution.
• Reduces power outages due to animal
electrocution thereby improving reliability and Solution:- Rodent capacitive screen guard
reduces SAIDI, SAIFI.
• Prevents equipment from damage due to flashover
.
• Protects and teaches animals to avoid future
contact.
Envirogel-Cobalt Free
Background and purpose

Envirogel is the latest alternative of blue silica gel. Envirogel is cobalt free and having high absorbing capacity than blue silica
gel.

Orange Green
60

It indicate orange colour(as shown in pic) when active and changes to green when desiccant becomes saturated(after use pic
also shown)
Line Vegetation Dashboard

Line Vegetation
Dashborad
❖The dashboard with
daily data updation
by linkage with Daily
PSC report.
0
❖Dashboard is on
tableau for better
data visualization.
❖User can check the
poles where
repeated
tree/transient fault
occurred .
❖User can compare
Tree Trimming Activity

62
Overview of cable Types & components

Classification of Cables used in Utilities

• Low Tension cables
• Single Core
• Multi Core
• High Tension cable
• Super tension cables
• Screened
• Unscreened

63
Single Core Cable

• HDPE outer sheath

• Cu foil
• Wire fixation compound
• Cu-wire screen
• Swelling tape
• Semiconductive PE
• XLPE insulation
• Semiconductive PE
• Cu-Water barrier
• Cu/Al-Conductor
65
 Quality Design Requisites in Cables

Conductor:

S.No. Parameter Requirement

1 Conductor As per IS 8130
2 Class Class II
3 Material Plain Aluminium, grade H2/H4
4 Shape Stranded Compacted Circular
Max. DC Conductor
Nominal size Min.
resistance Short circuit
of conductor number of
@ 20 deg C current rating

Best Practices U/G Cable laying

mm2 strands
No. of strands & (Ohm/km) for 1 second
5 electrical 300 30 0.10 28.3 kA
parameters 400 53 0.0778 37.7 kA
630 53 0.0469 59.4 kA
1000 53 0.0291 94.3 kA
a) Non-conductive water swellable yarn/ tape/ combination of
both shall be provided in between interstices of the conductor.
Longitudinal water
b) Also, this water swellable tape and yarn shall be compatible
6 sealing of
to withstand conductor continuous temperature of 90 deg C
conductor
and short circuit temperature of 250 deg C without any decay.
c) It shall not affect the electrical conductivity of the conductor.
a) Before stranding, the cross-section of the Aluminium

7
Cleanliness and Date 23/02/2021
conductor shall be circular, and shall have uniform smooth
surface, free from sharp edges and free from any defects.
b) Stranded Conductor shall be free from oil traces & aluminum
uniformity
dust. Conductor (after stranding) shall be super cleaned
c) Traces of aluminum dust on conductor or conductor screen
shall not be acceptable.
Not acceptable in any strand or in any conductor after it is
8 Conductor jointing
stranded.
Raw material Conductor raw material shall be procured from reputed
9
supplier suppliers viz., BALCO/ HINDALCO/ NALCO/ Vedanta only.
Diameter of
10 To be specified by bidder
conductor
Nominal size of conductor Min. weight of conductor
mm2 (kg/km/core)
Min. weight of
11 conductor 300 780
(kg/km/core) 400 1080
630 1650
1000 2600
 Quality Design Requisites in Cables

Insulation:

S.No. Parameter Requirement

Material and extrusion XLPE insulation shall be applied through CCV/VCV line by triple
1
process extrusion process with ‘Dry Curing’ and Dry/‘Water Cooling’.

a) XLPE compound shall be super cleaned and procured from

reputed raw material suppliers viz., Dow/Borealis/Hanwa only.
2 Raw material supplier
b) Both XLPE and semi conductive compounds shall be used from
same raw material supplier.

a) Nominal thickness shall be 8.8 mm.

Thickness and
3 b) Minimum thickness shall be 7.82 mm at any point of measurement.
Eccentricity
c) Eccentricity of insulation shall not exceed 10%.

Date 23/02/2021
The insulation properties shall be stable under thermal conditions
4 Thermal stability arising out of continuous operation at conductor temperature of 90 deg.
C rising momentarily to 250 deg. C under short circuit conditions.

Interfacial region between insulation and insulation screen shall be

Cleanliness and
5 uniform. Protrusion/convolution/ other defects are not acceptable. Core
uniformity
shall be free from void and contamination.
Identifying criticality in Cable Terminations

50.7 °C
50
ar1

45

40

35
34.1 °C

Air jacket formed between

insulation sleeve & cable
insulation due to improper
shrinking of sleeve.

Dust particles deposited on

inner side of the sleeve.
During Termination
installation, dust free zone
was not created.
Identifying criticality in Cable Terminations
Single core cable

Name of Grid: 33KV SGT Nagar

Ambient Temperature: 40ْ C
Details of Hot Spots observed during scanning
Location: Tr.2

Sp1:L.V Cable earth connection Max. Temp. 86.2°C Load: 170 Amps.
Nature of problem: Hot spot at cable earth connection
Investigation: Earth braid was bolted at Tr. and touching to the panel at other end.

Degradation of Insulation at
the point of hot spot
Identifying criticality in Cable Terminations

60.4 °C
60

40

20
sp1

3.4 °C

Temp rise detected at

insulation semicon cut
back, due to absence of
stress pad
 Causes of Insulation Degradation

Electrical Stress:
• Untreated screen cut back during installation of cable termination
• Phase to Phase & Phase to earth clearance at cable termination.
• Core crossing above cut back area at cable termination
• Application of High voltage DC during testing

Mechanical Stress:
• Improper bending radius
• Mechanical vibrations
• Improper cable supports
• External Damage

Thermal Stress
• Overloading
• High thermal resistivity of soil
• Improper electrical connections

Chemical Attack due to environmental contamination

Water Ingress
Field Distribution at insulation screen cutback

Back
 Effect of Electrical Stress
• Effect of Space Charges During DC Testing in XLPE
Insulation :-

• XLPE insulation is a polymer, during manufacturing or cable laid with

damaged outer sheath, voids occur in the insulation.
• The negative test voltage injects electrons into the dielectric & creates
space charges around the weak-spot in the cable insulation. This space
charge stays in the insulation after the test voltage is shut off.

Point of
electrical
stress due
to crossing
of cable
cores above
the screen
cutback at
termination

Back
 Effect of Mechanical Stress
Bending radius is necessary to take care during fault repairs.

Abnormal
Temp. 62.5
Deg C due to Point of
sharp bend/ Stress
Mech. Stress
at joint

Stress at Sharp bends lead to cable failure

Minimum permissible Bending Radius

Failure due to thermal stress

Degrada
Point of
tion of
fault
insulatio
close to
n close
New
to fault
joint
point
 Degradation of insulation due to water
ingress
Moisture Detection in Cables at Jointing site
 Diagnostic testing

Various solutions have been studied to conduct a number of diagnostic tests may be
termed Condition Assessment Testing (CAT). CAT is not a single go/ no go test, but is
designed to provide a ranking of the cable system and assist in prioritizing future cable
maintenance and replacement. There is as yet no one specific test that determines
the condition of cable insulation. But by conducting the various diagnostic tests help
to predict the insulation condition, Location of Voids and Pre locate & pinpoint the
locations of joints.
we have grouped some tests with Signature Analysis to assess condition of
insulation in the cable section with existing available testing facilities used for fault
location in the TPDDL :
•Insulation Resistance Measurement
•Polarization Index
•Impedance characteristics Measurement
•Leakage current measurement at DC rated voltage
•Very Low Frequency testing
•Audio Frequency Testing
•Infrard Thermography
• Ultrasonic detection
 Diagnostic Testing:

Polarization Index
Polarization is the ability for a material’s dipoles (equal and opposite charges separated by some
distance) to line up in the presence of an electric field. As the dipoles align themselves absorption
current is created that decrease over time. Initially the absorption current is high, but as fewer and
fewer dipoles are left to align themselves with the applied field the current drops. Thus an IR
measurement taken after 1 second would yield a lower resistance than an IR measurement taken at
stay, 60 seconds. In fact, the most common test times are a 10 minute test divided by a 1 minute test.
The resulting ratio of the test measurement is known as the polarization index.
Polarization Index = Insulation Resistance after 10 minutes/
Insulation Resistance after 1 minute
A ratio of the 10 min. reading to the 1 min. reading (10 min./ 1 min.) is called the Polarization index.
Range of Polarization Index:-
Poor >> less than 1.0
Fair >> 1.0 – 1.25
Good >> 1.25 – 2.0
Excellent >> above 2.0
 Diagnostic Testing:

TDR Measurement Test:

Purpose:
This test is used to identify the change in impedance characteristics of the cable

Significance:
It is based on pulse reflection method. Suitable measuring pulses are transmitted into the cable being
tested. The pulses pass along the cable at a propagation velocity that is dependent on the connected test
object. The part of the transmission pulse are reflected wherever the electrical characteristics of the cable
change and travel back to TDR equipment
The most important advantage of the pulse reflection method is that it is possible to locate faults as well
as detect them.
Abnormality detection in Cables Using PD
 Diagnostic Testing

Very low frequency (VLF) testing

Purpose:
VLF testing methods utilize AC signals in the frequency range from 0.01Hz to 1 Hz. VLF testing methods can
be categorized as withstand testing or diagnostic Testing. Diagnostic testing by VLF allows the determination
of the relative amount of degradation of a cable system section.
Phase to Earth of cable.

Significance:
VLF testing methods utilize AC signals in the frequency range from 0.01Hz to 1 Hz. VLF testing method can be
categorized as withstand or diagnostic. In withstand testing; the test object must withstand a specified
voltage applied across the insulation for a specified period of time without breakdown of the insulation. The
magnitude of the withstand voltage is usually greater than that of the applied voltage. If the cable insulation
is sufficiently degraded a breakdown can occur. The cable system may be repaired and the insulation
retested until it passes the withstand test. Diagnostic testing allows the determination of the relative
amount of degradation of a cable system section and establishes, by comparison with figures of merit or
accumulated data, whether a cable system section is likely to continue to perform properly in service.
Diagnostic tests may be nondestructive and are usually performed at lower voltages than withstand tests.
However, when the cable system insulation is in advanced condition of degradation, the diagnostic tests can
cause breakdown before the test can be terminated.
Case Study – 1 (contd.)

8 A s/s
 CASE STUDIES
Case Study - 1
Cable section between Wazir Pur Grid 2 to 8A s/s
Type & size of cable: 3X300 sqmm XLPE
Length of section: 400 mtr. Approx.
Av Load: 220A
Failure Rate: 2 faults in 08-09, previous faults - unknown
Diagnostic Tests Measurements’

Measurement Values
S. no. Test Remarks
R ph- E Y ph- E B ph- E Rph-Yph Yph-Bph Bph-Rph

1 IR 120 MΩ 120 MΩ 130 MΩ N/A N/A N/A

2 PI 1 1 1 N/A N/A N/A

3 DD 0.9 0.9 1 N/A N/A N/A
4 SV 120-100- 120-100- 120-105-115- N/A N/A N/A
115-120- 111-120- 120-125
120 120

5 TDR Reflections of all ph are identical, 8joints are observed

6 DC 0mA 0mA 0mA
Leakage @
5KV DC
7 VLF withstood withstood withstood withstood withstood withstood
8 TDR after Reflections of all ph are identical
VLF
9 Repeated 8 nos joints are pinpointed at Ring Road near Bus stand (GIS Image)
Failure (93,106,117,124,128,203,213,240 Mtr from 8A s/s)
Zone
Tracing
 Diagnostic Testing

Audio Frequency Testing:

Purpose:

This test is conducted to pinpoint the location of cable joints on route of the cable.

Significance:

The AF generator is a low frequency generator for main operation. When combined with a suitable search
receiver is used to search for and follow cable/ joints laid underground.
The AF tracer is consist of two basic modules:
The transmitter — an ac generator which supplies the signal current on the underground cable/ joint to be
traced.
The receiver — detects the electromagnetic field produced by the transmitted ac current flow.
The test is used to pinpoint the previous failure spots by identification of joints.
TDR OF ‘R’ φ BEFORE & AFTER THE VLF
BEFORE VLF

AFTER VLF
 Case Study – 1 contd.

Conclusion:-

•After interpreting the measurement values, It is observed that TDR reflections before & After VLF testing
are identical. All measurement values are satisfactory.
•Previous failure zone is identified. 8 nos joints are pinpointed and uploaded in the GIS.

Recommendations:

It is under stood that joints prone to the weak spots and identified zone has congested joints. A major
digging activity had been done by other utilities on the identified zone.
So It is recommended that affected zone may be revived to enhance the life of cable section
 Case Study - 2

Case Study – 2
Cable section between s/s 4/3---- s/s 3/3
Type & size of cable: 3X300 sqmm PILCA + XLPE
Length of section: 390 mtr.
Av Load: 200A
Failure Rate: 2 faults in 08-09, previous faults - unknown
Diagnostic Tests Measurements’
Measurement Values
S. Test Remark
no. R ph- E Y ph- E B ph- E Rph-Yph Yph- Bph-Rph s
Bph

1 IR 110 MΩ 120 MΩ 50 MΩ

2 PI 1.25 1.25 0.98

3 DD 0.06 0.06 2

4 SV 65-90-105-100- 67-95-110- 20-26-32-40-

110 116-125 51

5 TDR Reflections of all ph are identical, 12 joints are observed

6 DC Leakage @ 0 0 0.3mA
5KV DC

7 VLF withstood withstood withstood N/A N/A N/A

8 TDR after VLF Deviation observed in B ph TDR reflection

@9 KV
9 DC Leakage @ 0 0 0.08
5KV DC
9 Repeated Failure 12 nos joints are pinpointed on cable route
Zone Tracing
 Case Study – 2 (contd.)

10 Joint Locations within 150m from s/s 3/3

TDR before VLF Testing

TDR after VLF Testing

Contaminated spot at 18 m from 4/3s/s. which is split during

VLF testing may be due migration of OIL in the dielectric.
 Case Study – 2 (contd.)

Conclusion:-

•After interpreting the measurement values, It is observed that TDR reflections of R & Y ph are identical and
deviation observed in TDR of B ph reflection wrt R&Y ph. before VLF testing.

•VLF testing is conducted at all phase. In B ph, it is observed that initially its showing increasing trend of
leakage and suddenly leakage comes down to zero value.

•After VLF testing, TDR reflection is taken and compared with the related phase of previous reflection and
Deviation observed in reflection of B ph.

•Leakage current value of B phase measured and observed improvement wrt previous value (0.3mA to 0.08
mA)

Recommendations:

Measurement values show the presence of contamination in the dielectric of the cable which requires close
monitoring.
 Case Study – 3 Preempting fault

Case Study – 3
Cable section between s/s 4/3---- s/s 3A/2
Type & size of cable: 3X300 sqmm PILCA +XLPE
Length of section: 1180 mtr.
Av Load: 180A
Failure Rate: 3 faults in 08-09, previous faults - unknown
Diagnostic Tests Measurements’
Measurement Values
S. Test Remarks
no. R ph- E Y ph- E B ph- E Rph-Yph Yph-Bph Bph-Rph

1 IR 10 MΩ 100 MΩ 120 MΩ N/A

2 PI 0.8 1 1.2

3 DD 2 1 0.9

4 SV 6- 9-10-10- 120-100-115- 120-100-

11 120-115 115-120-
115
5 TDR Reflections of all ph observed identical, 22 joints are observed
6 DC Leakage @5KV 0.3mA 0 mA 0 mA

7 VLF @ 9KV Breakdown withstood withstood withstood withstood withstood

8 TDR after VLF Deviation observed in R ph reflection at 26 mts distance from 4/3 s/s

DC Leakage @ 5KV 1.0 mA 0 0

9 Repeated Failure Zone 20 nos joints are pinpointed

Tracing (11,16,25,40,182,198,240,303,314,355,370,378,680,685,692,700,868,890,980,1160 Mtr
from 4/3 s/s
 Case Study – 3 (contd.)

TDR before VLF Testing

TDR after VLF Testing

Contaminated spot at
26 m from 4/3.
 Case Study – 3

Conclusion:-

•After interpreting the measurement values, It is observed that TDR reflections before VLF testing are
identical. But After VLF testing, breakdown occurred in R ph..

•Deviation observed at distance of 26 mtr from 4/3 s/s.

•Spot is pinpointed on the cable Route by AF testing for preventive maintenance.

Findings after Dissection

Ingress of water found at pinpointed location.

Innovative Application of Signature Analysis in Underground
Network Management

CAPEX Budget Project Planning Tool

Optimization

Condition assessment
Asset Management
Testing Decision-Making Tool

U/G Network Strengthening

Tool

Preempting Faults
Case 1 :The subject cable ( Raja Enclave - Aminabad) is one of the many sick cables to
be replaced under CAPEX Plan 2009-10. As per CEG details, total budget of INR
27.50 lacs is allocated to subject cable for replacing 550 meters from its full length of
590 meters.

Joint Clusters & Abnormalities between 10-300

meters.4 Fault located in this zone
R
A
AJ
M
A
I
N
E A
B
N
A
C
D
L
A
S
V
E /
S

SICK LENGTH (300 meters) HEALTHY LENGTH(290 meters)

SA Outcome : Only 300 meters within full length is sick. Saving of 250 meter of cable length which turns out
to be saving of Rs 12.5 lacs of CAPEX budget.
SOCB (Signature Optimized Capex Budget) Matrix
For Sick Cable Replacement CAPEX

Cable Section Details CAPEX 09-10 Details ( As per CEG) Signature Optimized CAPEX Budget (SOCB)

Saving in
Replacement Allocated Replacement Sick Length CAPEX Optimized
Replacement
Length Budget Cost/meter From SA Saving Budget
ID District Length
(A) (B) ( C= B/A) ( D) (F=E*C) (G=B-F)
( E=C-A)
In Meter In Lac In Rs In Meter In Lac In Lac
(In Meter)

D BLK MS GARDEN-7 BLK

RAMESH NAGAR
1303/MTN 700 35 5000 600 100 5 30

PUMPING STATION-17 BLK MTN 1301/MTN 600 30 5000 465 135 6.75 23.25

PHILIPS-30 DLF 1301/MTN 450 22.5 5000 370 80 4 18.5

RAJA ENCLAVE - AMINABAD 504/PPR Total Savings

550 27.5 (∑5000F) = Rs300 250 12.5 15

1.3725 Crores
WHS NO 1-WHS NO 2 1303/MTN 800 40 5000 650 150 7.5 32.5

Rampura Grid-Vishram Ngr 520/KPM 780 39 5000 580 200 10 34.8

520/KPM 1800 5000 1070 730 36.5 53.5

PD Vihar- Bijli Apartment 90

Prahladpur I/D S/stn to Sector- 516/BDL 1100 55 5000 Nil 1100 55 Zero
30 crossing DP

There are 103 Sick Cable replacement under CAPEX .SA can provide ample
CAPEX saving to improve bottom-line.
Challenges in HDD Trenchless cable laying
 Existing Trenchless Installation Technique
Problem 1 : Cable Damage during Pull- Back

98
 Problem in Existing Trenchless Installation Technique
Problem 2 : Performance Degradation by 20%

Cable Installation within HDPE pipe lower down

Thermal Conductivity & result in De-rating by 20%

Source : IEEE Paper on Soil Thermal Resisitivity

 Problem in Existing Trenchless Installation Technique
Problem 3 : Accurate Fault Location Not Possible Due to Echo
Effect of Fault Sound in HDPE Pipe

Cable within
HDPE Pipe

HDPE Pipe

Joint
Joint Joint
XLPE Cable
Fluidic Cable Installation

101
 Fluidic Cable Installation
Proposed Fluidic Cable
Parameter "As Is "(Trenchless with HDPE Pipe)
installation ( Na-Bentonite)
20 % additional power from
20% De-rating due to poor heat dissipation
Derating of cable enhancement in thermal
by HDPE
conductivity

K rho Temp Read

Measurement Time Sensor W/(m·K) °C·cm/W Err (°C) Time
7/6/2014 11:08 TR-1 1.592 62.8 0.0092 36.57 5
27/12/2014 1:28:00 PM TR-1 1.582 63.2 0.0096 36.42 5
21/3/2015 1:44:00 PM TR-1 1.602 62.4 0.0099 36.64 5

FCI : 20 % more Power

HDPE Installation : 20 % Less

102
Fluidic CCD Cable Installation

XLPE Cable

Slurry around Cable

FCI Installation without HDPE Pipe : Accurate Fault Location

Need for Innovation- Macro Challenges in Cable Networks

Ageing of U/G Cable- Untimely Failure High Repair & Replacement Cost ROW Permission

Regulator : Limited CAPEX/OPEX Reliability/Unexpected Power Cut Customer Dissatisfaction

 Need for Innovation- Macro Challenges in Cable Networks

❑ Cables once laid underground, it is supposed MU Losses/

to be maintenance free CAPEX/OPEX

❑ Presence of multiple utilities on the same

route leading to External Damage (ED)

❑ Moisture ingress leading to water

treeing/Insulation Failure/joint failure

❑ Oxidation of Al conductor & rise in Conductor

Resistance

❑ Frequent failure viz. high joint leads to

accelerated ageing of cable

❑ End of cable life before its useful life cycle

Many diagnostic technique available for power cables
❑ Indian scenario demands maintenance

No defined process / guideline for maintenance

of underground cables worldwide
 Need for Innovation- Macro Challenges in Cable Networks

❑ Cables once laid underground, it is supposed MU Losses/

to be maintenance free CAPEX/OPEX

❑ Presence of multiple utilities on the same

route leading to External Damage (ED)

❑ Moisture ingress leading to water

treeing/Insulation Failure/joint failure

❑ Oxidation of Al conductor & rise in Conductor

Resistance

❑ Frequent failure viz. high joint leads to

accelerated ageing of cable

❑ End of cable life before its useful life cycle

Many diagnostic technique available for power cables
❑ Indian scenario demands maintenance

No defined process / guideline for maintenance

of underground cables worldwide
 Challenges & Problem- Micro Analysis (Cable Fault Trend)
Moisture ingress leads to failure of Joint box & Cable. Moisture ingress
occur during External Damages or Installation/Commissioning

Cable Fault Fault in Run Joint Failure

1352
1400
1156 1186
1200 1118

1000 60-65 %
Failure due
800
to Moisture
600 ingress
355 326 358
400 315

200 352 313 336 287

Fy 17-18 18-19 19-20 20-21

 Need for Innovation (Why?)-Water Tree in XLPE Insulation

Long time effect of

water on insulation
causes water tree
formation

❑ Water trees are dendritic patterns which grow in hydrophobic

polymers in the presence of AC electric field and water.

❑ It causes a significant reduction in the breakdown strength of an

affected cable
 Proposed Solution- Residual Life Enhancement (RLE)

“As-Is” Philosophy for Ageing & Sick Cable “To- Be” Philosophy Proposed for Ageing & Sick Cable

Run
Run

Replace Repair

Replace Repair

Process +
RLE Product
Innovation
 Process Innovation- RLE Concept for Cables

Methodology In-House Developed for Cable Maintenance

❑ STEP 1: Selection Criteria– Prioritization matrix is prepared for the selection of the cable.

❑ STEP 2: Diagnostic Testing – Polarization Index (PI), DC Leakage Current & Signature
analysis using Time Domain Reflectometer (TDR) for identification of the abnormalities
/contamination

❑ STEP 3: Vacuumizing - Moisture Removal from Conductor, Screen & Outer Jacket

❑ STEP 4: Nitrogen Purging - For complete curing of the underground cable.

 Execution process - Layout

Vacuum Pressure: Nitrogen Pressure:

Pole 1.5 bar
0.2 to 0.6 bar
PVC Hose PVC Hose
Pipe Pipe Regulated
Pump Pressure
exhaust gauge
Vacuum
pressure
gauge

Silica gel
container is
Vacuum Nitrogen
fitted on
pump set Cylinder
affected cable
core.

Vacuumizing Nitrogen Purging

 Process I- Cable Vacuumization

Moisture Removal from Outer Sheath Process Outcome

Methodology

❖ Vacuum pump is used to extract the water

from outer sheath & Conductor

❑ Vacuum Pressure is around at 0.2- 0.6 bar

Moisture Removal from Conductor Process Outcome
❑ Time Period: Around 20 Min. per core
❑ Other end sealed with silica gel container to
prevent moist air entry
 Process 2- Nitrogen Purging for Residual Moisture Removal

Thermal Image report

Core conductor Temp Core Conductor Temp (After

Cable Core
(Before Purging) Purging)
Core1 7.5 deg C 13.3 deg C
Core 2 10.8 deg C 13.2 deg C
Core 3 11.1 deg C 13.6 deg C

❑ Nitrogen purging is done at a pressure: 1.30

bar

❑ It is mainly to prevent oxidation & to ensure the

removal of residual moisture

❑ Thermal image captured “before-after” to

ensure effectiveness of the process Before After
 Test Parameters: Before & After
HVDC Test Result TDR/Signature
Leakage Current Recommended
Core Test Voltage LC (After RLE)
(before RLE) Value Before
Core1 to 6.6kV DC for 3
4.22mA 0.26mA
Earth min
Core 2 to 6.6kV DC for 3 < 1 mA as per IS
2.03mA 0.11mA
Earth min 1255
Core 3 to 6.6kV DC for 3
1.86mA 0.15mA
Earth min

PI Result
Recommended
Core Method PI (Before RLE) PI (After RLE) Value After
Core1 to
5 KV megger 0.78 1.92 Poor => less than
Earth
1.0
Core 2 to
5 KV megger 0.98 1.98 Fair => 1.0 – 1.25
Earth Good => 1.25 – 2.0
Core 3 to Excellent => > 2.0
5 KV megger 1.21 2.02
Earth
Economic Evaluation-RLE vs. Replacement

Life Extension cost is

5% of Replacement Cost

RLE Replacement
➢ Cost of Replacement (Approx.) : Rs 70 Lakhs/Km
➢ Cost of Life Extension through On-site Curing- Rs 1-2 Lakhs/Km.
➢ Sick Section will be treated In-house during Cable Repair Job
➢ This will Save RR Cost, Excavation Charges.
➢ In-House availability of Testing Equipment ( TDR/Route
115 Tracer/VLF)
 Impact & benefit
Cable Fault Fault in Run Joint Failure

1400
1352 Asset Life
1156 1186 enhancement
1118 1076
1200
1000
712
800
600
400
355 326 358 304 Financial Year Feeder Identified Executed
196
200 352 313 336 287 315 280
208
0
FY 20-21
Customer40 26
Fy 17-18 18-19 19-20 20-21 21-22 22-23
Reduction in Reliability
failure satisfaction Enhancement
FY 21-22 90 82
YOY contibution of Joint Failure

355 358
400 326 315 304 FY 22-23 72 63
300 196
200
CAPEX/OPEX
100
optimization
0
Fy 17-18 18-19 19-20 20-21 21-22 22-23
 RLE/Cable Maintenance technique
Uniqueness

Scalability
First power Replicable across
distribution all Power
utility to develop Distribution
inhouse cable Utilities.
healing system