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This TB replaces Electra article ELT_189_1
Recommendations for Testing of Long AC

Submarine Cables with Extruded Insulation for
System Voltage above 30 (36) to 500 (550) kV
Working Group
B1.27
February 2012
RECOMMENDATIONS FOR TESTING OF LONG
AC SUBMARINE CABLES WITH EXTRUDED
INSULATION FOR SYSTEM VOLTAGE ABOVE
30 (36) TO 500 (550) kV
WG B1.27
MEMBERS
A. GUSTAFSSON, Convenor (SE), J. KARLSTRAND, Secretary (SE),

G. CLASEN (NO), R. DONAGHY (IE), R. GRUNTJES (NL), A. JENSEN (DE), S. KRÜGER OLSEN (DK),
G. MIRAMONTI (IT), T. NAKAJIMA (JP), H. ORTON (CA), J. PRIETO (ES), C. RÉMY (FR)
Copyright © 201
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ISBN :
Recommendations for testing of long AC submarine cables with extruded insulation for system voltage above 30 (36) to
500 (550) kV
Recommendations for testing of long AC

submarine cables with extruded insulation for
system voltage above 30 (36) to 500 (550) kV
Table of Contents
EXECUTIVE SUMMARY .............................................................................. 4

Introduction.............................................................................................. 4
Introduction of new tests .......................................................................... 4
Conclusions .............................................................................................. 5
1. Introduction............................................................................................ 6
1.1 Background ........................................................................................ 6
1.2 Terms of Reference............................................................................. 7
1.3 Scope.................................................................................................. 7
1.4 Experience of extruded AC submarine cables above 170 kV ............... 8
2. Definitions ............................................................................................ 10
3. Current technologies for submarine cable designs ............................... 12
3.1 General aspects on water tightness .................................................. 13
3.2 Conductors ....................................................................................... 14
3.3 Insulation System ............................................................................. 14
3.4 Metal Screen/Sheath ......................................................................... 15
3.5 Armour ............................................................................................. 15
3.6 Outer Protection ............................................................................... 17
4. Current technologies for submarine joint designs ................................ 17
4.1 Factory Joints .................................................................................... 17
4.2 Repair Joints ..................................................................................... 19
4.3 Sea/Land Transition Joint.................................................................. 22
5. General aspects on submarine cable testing ......................................... 23
5.1 Summary of Tests ............................................................................. 23
5.2 Test Conditions ................................................................................ 23
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5.3 Characteristics of Cables .................................................................. 24

5.4 Development Tests ........................................................................... 24
6. Routine Test ......................................................................................... 25
6.1 General ............................................................................................. 25
6.2 Available high voltage test methods ................................................. 25
6.3 Tests on Manufactured Lengths ........................................................ 26
6.4 Tests on Factory Joints...................................................................... 27
6.5 Tests on Complete Delivery Length................................................... 27
6.6 Tests on Repair Joint ......................................................................... 28
6.7 Tests on Terminations ...................................................................... 28
7. Sample Test .......................................................................................... 28
7.1 Sample Tests on Cables .................................................................... 28
7.2 Sample Tests on Factory Joints ......................................................... 30
7.3 Sample Tests on Repair Joints and Terminations............................... 30
8. Type Test on Cable System ................................................................... 31
8.1 General ............................................................................................. 31
8.2 Range of Type Approval .................................................................... 31
8.3 Summary of Tests ............................................................................. 32
8.4 Preparation of Tests.......................................................................... 32
8.5 Check on Insulation Thickness of Cable for Electrical Type Tests...... 32
8.6 Mechanical Tests on Complete Cable System .................................... 32
8.7 Longitudinal/Radial Water Penetration (LWP, RWP) Test .................... 33
8.8 Electrical Tests on Complete Cable System ....................................... 37
8.9 Non-electrical Tests on Cable Components and Complete Cable ...... 38
9. Prequalification Test ............................................................................. 40
9.1 Introduction...................................................................................... 40
9.2 Range of Prequalification Test Approval ........................................... 40
9.3 Prequalification Test on Complete Cable System............................... 41
10. Extension of Qualification Test ........................................................... 42
11. Electrical tests after installation .......................................................... 42
11.1 High Voltage Test ........................................................................... 42
11.2 Time Domain Reflectometry (TDR) .................................................. 42
12. Bibliography/References ..................................................................... 44
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13. Annexes ............................................................................................. 45

Annex A – Routine Test............................................................................. 46
Annex B – Sample Test.............................................................................. 47
Annex C – Type Test ................................................................................. 49
Annex D – Prequalification Test ................................................................ 51
Annex E – Extension of Qualification Test ................................................. 51
Annex F – After Installation Test ............................................................... 52
Annex G - Abbreviations .......................................................................... 53
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EXECUTIVE SUMMARY
Introduction
This technical brochure covers a description of basic designs as well as mechanical and electrical testing of AC
extruded submarine cables intended for use at voltages above 30 (36) kV up to 500 (550) kV.
The aim of the work has been to perform a general view on how extruded AC submarine cable systems should be
verified mechanically and electrically with a special focus on repair joints (rigid or flexible).
The work has mainly been based on the following standards, recommendations and technical brochures:
IEC 60840 Edition 4
IEC 62067 Edition 2
CIGRE Technical Brochure, TB303
Electra 171
Electra 189
Thanks to the recent improvements in partial discharge techniques and AC resonant test techniques, revision of
earlier recommendations (e.g. Electra 189) and introductions and modifications of different tests intended for this
brochure, have been possible.
Introduction of new tests

Extruded AC land cable systems (IEC 62067, IEC 60840 and TB303) differ from submarine cable systems in the
following key aspects:
Water tightness performance of conductors and under metal sheath
Armour
Mechanical treatment during production and installation of cable and joints
Water tightness of rigid repair joints
Delivery lengths and weights
Routine tests (AC and PD) of cable and joints
Taking into account these key aspects as well as the higher electrical stresses of HV and EHV extruded submarine
cables; the following recommendations were introduced and/or modified from Electra 189:
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A more stringent approach to check the quality of factory joints
A possibility to make AC-tests on delivery lengths with a frequency range of 10 – 500 Hz, according to IEC
60060-3
A radial water penetration test of rigid repair joints
A scheme for mechanical tests for different type of repair joints is introduced
A set of tests for visual inspection of submarine cables
A set of tests for checking the volume resistivity of conductive polymeric sheaths
A modified range of approval for type tests, taking into account factory joints, mechanical testing etc
The introduction of PQ- and EQ-tests based on the descriptions in IEC60840 edition 4 and IEC62067
edition 2.
Conclusions
The WG has been in service for almost four years and all items in the Terms of Reference have been taken into
account. The extra year was added due to that the SC B1 decided to also include the voltage interval >36 kV up to
170 kV.
The work started with the existing CIGRE recommendations and the existing and new editions of the relevant IEC
standards. New additions of tests include prequalification testing, range of approval and an improved description of
water penetration testing.
All parts in a submarine cable system are discussed and tests are described including rigid repair joints in this
technical brochure. The chapters follow the scheme starting with routine tests followed by sample tests, type test,
pre-qualification tests and after installation test.
Testing of long high voltage cables is also discussed in this technical brochure but the substantial development in
this area will influence which testing procedures will be possible in the near future. This challenge is as well under
discussion in other working groups and this subject needs to be further treated.
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1. Introduction
1.1 Background
CIGRE Study Committee B1 (formerly 21) have issued different test recommendations in the past, covering both
mechanical testing of AC and DC submarine cable systems (Electra 68 [1] and 171 [2]) and electrical testing of DC
submarine cable systems (Electra 72 and 189). The latest issue for mechanical tests is Electra 171 (Electra 68
REVISION) – “Recommendations for mechanical tests of submarine cables” [2]. The latest issue for electrical
testing of DC cables is Electra 189 – “Recommendations of tests for power transmission DC cables for a rated
voltage up to 800 kV. (Electra 72 – REVISION)”.
In the year of 2000 a recommendation for HV electrical testing of long AC extruded cables was published in Electra
189 – “ Recommendations for testing of long AC submarine cables for extruded insulation for system voltage above
30 (36) to 150 (170) kV” [3].
Tests for AC extruded land cables and accessories have been developed within the framework of IEC. IEC
standards for submarine cable systems have not been elaborated, however.
In 2001, a new test standard for land cable systems, IEC 62067, was issued [4]. This standard covers electrical
and material tests for EHV land cable systems, i.e. for system voltages above 150 (170) and up to 500 (550) kV.
Only a system approach, i.e. cable and accessories which are tested together, is accepted. Within this standard,
not only routine, sample and type tests are included, but also a one-year prequalification (PQ) test of the whole
land cable system. Special attention shall be paid to the thermo-mechanical characteristics of the system. Since
this PQ-test is time-consuming and expensive to perform a new working group (WG B1.06) was launched in 2002
to issue future recommendations for evolutions of IEC 62067 taking into account the expected innovations in cable
technology, the need to reduce the time to market and the overall cost to introduce new evolutions as well as
service experience collected by the cable industry. The outcome of this work was published in a Technical
Brochure (TB 303) in 2006 [5]. The most important outcome of the work was:
Pre-qualification test (PQ) test for HV cable systems for electrical stresses higher than 8.0 kV/mm at inner
conducting shield and/or higher than 4.0 kV/mm for outer conducting shield.
Extension of qualification test (EQ) for both HV and EHV. In general, this test was introduced to more
quickly and less costly re-qualify an already pre-qualified component of the cable system. The EQ test
contains 60 days of heat cycling without voltage followed by a cable system type test. For more detailed
information, see TB 303 [5].
These tests are now under consideration to be introduced by IEC in the new editions of IEC 60840 and IEC 62067.
The purpose of the work by Working Group B1.27 was therefore to investigate how these recommendations and
standards could be accommodated for HV and EHV submarine AC cable systems and which tests could be
introduced, removed or modified.
According to IEC 60840 [6] [7], it is possible to qualify cables and accessories in separate type tests. This is not
possible for EHV cable systems type tested according to IEC 62067, since only a system approach is accepted.
For the purpose of this technical brochure, submarine cables and accessories should be type tested together as a
system in order to be qualified at both HV and EHV levels.
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1.2 Terms of Reference

At the Paris Study Committee meeting in 2006 Task Force (TF B1.27) was launched to decide the terms of
reference for “Recommendations for testing of long AC submarine cables for extruded insulation for system voltage
above 150 (170) to 500 (550) kV”. The terms of reference elaborated by the TF were, as given below.
Examination of relevant IEC standards/CIGRE recommendations and documentation.
The work should adapt a system approach. Particular attention should be paid to repair joints as part of the
submarine cable system and the Working Group should consider tests with external water pressure, heat
cycling and mechanical handling (during installation of repair joint).
The work should propose development and prequalification tests for the EHV submarine cable system and
re-qualification in case of minor changes and define the range of prequalification and type approval for
EHV submarine cable systems.
The work should propose tests for long submarine cable lengths – both in factory and after installation and
explain clearly the basis for the recommended tests and the range of application.
The work should include a review of currently available technologies for submarine cable and joint design
and consider possible implications for testing.
A technical brochure should be prepared for publication.
Introduce updated recommendations for testing of submarine cable systems in the voltage range > 36-170
kV.
Study committee B1 decided to introduce an updated program, taking into consideration the electrical and
mechanical testing at the HV level. This new technical brochure will therefore extend the voltage range to > 36 –
550 kV, thus replacing the existing recommendation in Electra 189 completely.
1.3 Scope
This technical brochure applies to long cable systems intended to be used in AC submarine power transmission
systems with rated voltages above 30 (36) kV up to 500 (550) kV. It is applicable to cables with extruded insulation
1
and fixed installations . The proposed tests are valid for both single-core and three-core AC submarine cables. A
test for a single-core submarine cable may not be applicable to the three-core design and vice versa, however.
In Electra 171 – “Recommendations for mechanical tests on submarine cables” - different mechanical tests are
listed but which test category (routine, sample, type test) they belong to is not clarified. In this new TB reference is
made to Electra 171. Special attention is also given to mechanical tests for repair joints under different installation
conditions.
The tests described in Electra 189 and TB 303 have been taken into account and they have been adapted to be as
consistent as possible with what is needed for qualifying and testing long lengths of AC extruded submarine cable
systems above 36 kV.
1
The WG has only taken installation of submarine cables laid on or buried in the seabed, into account. Special applications, for
example dynamic cables connecting floating platforms are subjected to other types of mechanical stress and are therefore not
considered in the scope of work.
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This technical brochure, compared to the earlier issues of CIGRE recommendations, will further describe and
explain in more detail the rationale behind the tests. Attention has also been paid to the principal design of AC
submarine cables, factory joints and repair joints. Additionally, since the possibility of testing long lengths of cables
with series resonant test sets has been developed during time, a special chapter is dedicated to this subject.
Nowadays, one usually include either fibres in metal tubes (FIMT) or fibre optic cables (FOC) as an integral part of
the cable or bundled to the cable or alternatively laid separately distant from the cable. This brochure will not
propose any test for fibres, even if it is strongly recommended to check the quality and performance during
production and also after installation, taking into account attenuation phenomena etc.
1.4 Experience of extruded AC submarine cables above 170 kV

Table 1 provides a list of installed projects (or decided) at voltages above 170 kV whereas Table 2 lists selected
projects of HV submarine cables below 170 kV starting with the first XLPE submarine cable delivered in 1973
between the Swedish mainland and Åland [13].
Table 1. Installed and planned HVAC submarine extruded cable projects > 170 kV.
Voltage Area Route Depth
Year Country, Project 2 Application
[kV Um] [mm ] [km] [m]
2006 Brazil, Santa Catarina 245 1 x 500 Cu 4.5 10 Interconnection
2006 Norway, Ormen Lange 420 1 x 1200 Cu 2.7 210 Interconnection [9]
2008 Canada, Wolf Island 245 3 x 500 Cu 8.4 30 Wind farm
2008 Norway, Oslo fjord 420 1 x 1200 Cu 3.2 300 Interconnection
2010 Qatar, Doha bay 245 1 x 1600 Cu 7.3 20 Interconnection
2010 Ireland, Cork Harbour 1 245 1 x 1600 Cu 3.3 10 Interconnection
2011 Ireland, Cork Harbour 2 245 1 x 1600 Cu 4.3 30 Interconnection
2011 Sweden, Nacka sjö 245 1 x 1200 Al 6.5 45 City ring
2011 USA, NJ-Brooklyn 362 1 x 1750 kcmil Cu 11 20 Interconnection [10]
2012 Russia, Russky Island 245 3 x 500 Cu 2.2 43 Interconnection [11]
2012 Denmark, Anholt 245 3 x 1600 Al 24.5 20 Wind farm
2012 Norway, Oslo fjord 420 1 x 1200 Cu 13 300 Interconnection [12]
2013 Saudia Arabia 245 3 x 500 Cu 45 60 Oil platform
2013 Malta-Sicily, Italy 245 3 x 630 Cu 100 150 Interconnection
Figure 1. Loading on turntable on cable

laying vessel.
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Table 2. Examples of installed and planned EHV/HV AC submarine extruded cable

projects 170 kV.
Year Country, Project Voltage Area Route Depth Application
[kV Um] [mm2] [km] [m]
1973 Sweden-Åland 84 1 x 185 Cu 55 50 Interconnection [13]
1979 Sweden - Bornholm 72 1 x 240 Cu 43 55 Interconnection
2000 UK (Isle of Man) 90 3 x 300 Cu 104 100 Interconnection
2002 Denmark (Horns Rev 1) 170 3 x 630 Cu 20 20 Wind farm
2003 Denmark (Nysted) 170 3 x 760 Cu 21 10 Wind farm
2005 Japan (Matsushima-Narao) 66 3 x 325 Cu 53 75 Interconnection
2006 UAE (Delma Island) 145 3 x 300 Cu 42 30 Interconnection
2007 Italy (Sardinia-Corsica) 170 3 x 400 Cu 15 75 Interconnection
2008 Belgium (Thornton Banks) 170 3 x 1000 Al 38 24 Wind farm
2009 Denmark (Horns Rev 2) 170 3 x 630 Cu 42 20 Wind farm
2010 Denmark (Rødsand 2) 170 3 x 800 Cu 9 10 Wind farm
2010 Norway (Gjöa) 115 3 x 240 Cu 100 500 Oil/gas rig
2011 Australia (Sydney) 132 1 x 1600 Cu 3.0 21 Bay crossing
2012 Tanzania (Zanzibar 2) 145 3 x 300 Cu 37 55 Interconnection
2012 Norway (Goliat) 115 3 x 240 Cu 106 500 Oil/gas rig
2013 Spain (Mallorca-Ibiza) 145 3 x 300 Cu 117 700 Interconnection
Figure 2. Cable hang-off at platform

showing a three-core cable prepared for
termination works.
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2. Definitions
In this section, definitions of some commonly used terminology in this document are provided. Test definitions are
in full agreement with IEC 62067.
Factory Joint
A factory joint is a joint manufactured in-house between manufactured lengths. They are generally used where the
required delivery length is longer than the manufactured length. The factory joint has normally no armour. The
design principles of factory joints are provided in Section 0.
Field Joint
A field joint is a joint made on board a cable laying vessel or barge, or in the beach area, between cable lengths
which have been armoured. They are generally used to connect two delivery lengths offshore. The design
principles of field joints are generally the same as for repair joints and are treated as such.
Repair Joint
A repair joint is a joint between cable lengths that have been armoured. They are generally used in repairing a
damaged submarine cable or jointing two delivery lengths offshore or in factory. The design principles of repair
joints are provided in Section 0.
Internal Design of Joint

Either the joint is rigid or flexible, single-core or three-core, it has an electrical function based on the design
principles to transfer the current, to control and withstand the electrical stresses, to screen the joint electrically and
to protect the insulation system from moisture ingress. These design principles are attributed to the internal design
of the joint.
External Design of Joint

Either the joint is rigid or flexible, single-core or three-core; it has a mechanical function based on the design
principles to withstand the impact from the surroundings, to withstand (in some designs) the mechanical bending
and to withstand the mechanical tension and torsion during laying and operation. These design principles are
attributed to the external design of the joint.
Sea/Land Transition Joint (SLTJ)

The term ‘transition joint’ is generally understood to involve the connection of two different insulation types. For the
purposes of this document, the term ‘sea/land transition joint’ means the interconnection between the submarine
cable and land cable, both of which are extruded insulated, but with design differences. The transition joint bay is
generally located on, or close to, the shore line.
Manufactured Length
A manufactured length is a complete extrusion run or a part thereof. It normally does not contain any factory joints
but during a failure in routine testing, a factory joint may be part of the manufactured length. A manufactured length
has normally not any armour but may contain armour.
Delivery Length
A delivery length may be one or more manufactured lengths joined with factory joints. A delivery length is typically
the intended shipping length of the submarine cable.
Long Length
The definition of what constitutes a ‘Long’ length is somewhat subjective. In general, underground cables are
supplied on individual delivery lengths of to a thousand metres which are easily transportable. The manufactured or
delivery lengths of submarine cables can be more than one hundred kilometres, which are beyond the capacity of
individual transportable drums; and they are commonly moved from the factory production line directly onto a very
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large turntable outside the factory, or onto a cable laying vessel. The considerably greater manufactured or delivery
lengths of submarine cables imposes a range of practical difficulties on the testing of such submarine cables in
accordance with current IEC standards for HV and EHV underground cables. For the purposes of this document, a
‘long’ length is considered to be:
a cable delivery length which includes one or more factory joints, or

a cable delivery length for which the electrical characteristics make the carrying out of high voltage tests
and partial discharge tests strictly in accordance with IEC 60840/IEC 62067/IEC 60885-3 impractical in
factory test facilities or on site, or
a cable delivery length which cannot be accommodated on an individual transportable drum suitable for
moving around the factory to the appropriate test facilities
Routine tests
Tests made by the manufacturer on all manufactured components (length of cable or accessory) to check that the
component meets the specified requirements.
Sample tests
Tests made by the manufacturer on samples of complete cable or components taken from a complete cable or
accessory, at a specified frequency, so as to verify that the finished product meets the specified requirements.
Type tests
Tests made before supplying on a general commercial basis a type of submarine cable system covered by this
recommendation, in order to demonstrate satisfactory performance characteristics to meet the intended application.
Once successfully completed, these tests need not be repeated, unless changes are made in the cable or
accessory materials, or design or manufacturing process which might change the performance characteristics.
Prequalification test (PQ)

Test made before supplying on a general commercial basis a type of cable system covered by this
recommendation, in order to demonstrate satisfactory long term performance of the complete cable system. The
prequalification test need only be carried out once unless there is a substantial change in the cable system with
respect to material, manufacturing process, design and design levels.
NOTE: A substantial change is defined as that which might adversely affect the performance of the cable system.
The supplier should provide a detailed case, including test evidence, if modifications are introduced, which are
claimed not to constitute a substantial change.
Extension of qualification (EQ)

Tests made before supplying on a general commercial basis a type of cable system covered by this
recommendation, in order to demonstrate satisfactory long term performance of the complete cable system, taking
into account an already pre-qualified cable system.
Factory Acceptance Test (FAT)

Tests made by the manufacturer on the completed cable to check that each length meets the specified
requirements. These tests are often carried out in the presence of the customer.
Electrical tests after installation

Tests made to demonstrate the integrity of the cable system as installed.
Submarine cable system

An AC HV or EHV submarine cable system may consist of submarine cable(s), termination(s) and different type of
joints.
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Development tests
Set of tests designed and performed for new cables or accessories, in order to analyze and validate designs,
materials, components, production processes, installation conditions or long-term behaviour.
The scope and extent is at the discretion of the manufacturer and results usually are confidential.
After these development tests, cable and/or accessories are subject to a regular type and/or pre-qualifying test
program.
3. Curr ent technologies for submari ne cable designs

The application of submarine cables is increasing due to the development of offshore wind farms, offshore oil
platforms, the interconnection of islands and the interconnection of power systems across harbours, rivers, lakes,
gulfs, seas and inlets.
Submarine cables can be either single-core or three-core (Figures 3 and 4). The advantages and disadvantages of
each design are listed below.
Single Core Three Core

Pros Pros
o Lighter weight o Balanced magnetic field
o Smaller diameter o Minimum sheath circulating
o Longer lengths currents and voltages
o Possibly fewer joints-factory and o Lower installation costs
on-site o One trench on seabed
o Higher current rating o Lower protection costs
o Improved security, can add a 4th o Includes optional FOC (Fibre
cable Optic Cable)
o Voltage rating up to 500 kV and
greater
o Reduced repair costs and spares
Cons Cons
o Higher magnetic field o Lower current rating
o Greater installation costs o Heavier
o Individual seabed trenching o Large diameter
increases costs o Security of cable system
o Protection costs increased decreased
o Sheath current must be o All three phases have to be
considered repaired after a fault
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Figure 3. Example of single-core cable design.
Conductor
Profiles
Conductor shield
Metallic sheath
Insulation
Inner plastic sheath
Tapes for assembling

Insulation shield
Armour
Outer sheath (Polypropylene yarn) Optical fiber
Figure 4. Example of three-core cable design.
3.1 General aspects on water tightness

Submarine cables can be of either wet or dry design. A wet design allows water to migrate into the cable insulation
and the conductor. For HV and EHV submarine cables as considered in this document, dry designs are normally
used. Water blocking or water tightness in both the radial and longitudinal directions is crucial.
Water tightness is the ability of a dry cable design to resist water penetration to the maximum submersion depth of
the submarine cable. Water tightness is important for both normal operation and during cable failures, when the
physical integrity of the cable is compromised. Weakness in either conductor or metallic sheath will reduce the
water tightness of the cable.
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If a cable fails during its in-service life then water penetration along the cable, either within the conductor or under
the metal sheath must be limited. This will minimize the length of cable to be replaced during repair. Water
tightness is improved by the conductor design selected, the water blocking used within the conductor and the type
of water blocking utilised under the metal sheath.
Typically water penetration would be less than 30 meters; however depending on different cable designs the
penetration length could be longer and shorter.
3.2 Conductors
Conductor design contributes to the water penetration rates or the degree of water blocking of the conductor.
Conductor designs can be regular, compressed, compact, solid, Milliken or type “M” stranded conductors and key-
stone shaped. A regular stranded conductor is made up of circular strands with interstices or spaces in between
the strands. Compressed conductors have only the outer layer of strands reduced or flattened, but the interstices or
spaces in between the remaining strands remains the same as for a regular conductor. By squeezing each
conductor layer in a die the compact conductor is formed with reduced spacing in between strands. The solid
conductor will not allow any water penetration, but leads to a very stiff cable with higher AC losses. For HV and
EHV cables the Type “M” or Milliken conductor is used widely for conductor sizes greater than 800-1200 mm 2 to
limit the AC losses and to allow for a flexible cable. Semiconducting tapes are normally used in between the
segments, but the interstices still exist unless compaction of the layers is included in the design. To guarantee
water blocking of the conductor, strand blocking and water swellable powders, swellable yarns or tapes are added.
Strand blocking utilizes a compound that is either installed during stranding or laying-up of the conductor or a
pumped compound that is forced into the conductor interstices after the cable has been manufactured. Water
swellable powders and tapes (with different efficiency in pure water and salty water) are installed in the conductor
during manufacture by adding a powder or applying a fabric tape within the conductor.
3.3 Insulation System

HVAC submarine cables with an extruded insulation system consist predominantly of cross-linked polyethylene
(XLPE). The insulation system consists of an inner conducting screen, insulation layer and an outer
semiconducting screen. The semiconducting inner and outer screens contain carbon black as active conducting
filler. The performance of the semiconducting screen compounds and their extrusion is important for HV and EHV
cables. For example the properties are controlled by the percentage of carbon added, the carbon particulate size
with respect to the base polymer, the dispersion of the carbon through the base polymer and the extrusion
properties. In specific cases a volume resistivity stability test may be useful where these properties are crucial for
the final cable performance.
The cross-linking of polyethylene (in particular low density polyethylene, LDPE) is an irreversible process (i. e. no
re-melting is possible) to form a three-dimensional network that makes the insulation more thermally stable. This
process is taking place after the extrusion.
Whilst cable with extruded insulation is in general use for electricity distribution and at the lower transmission
voltages, extruded materials have only recently become the insulation of choice for many utilities for EHV
transmission circuits for underground cables. The first submarine cable using extruded XLPE as insulation system
was introduced in 1973 (84 kV) [13] and the first submarine XLPE cable on 420 kV was installed in 2006 [9].
Another extruded insulation system that may be used is EPR (ethylene-propylene rubber) but is mainly limited to
systems with Um 150 kV [14], [15]. EPR differs from XLPE in that it has fillers for increased mechanical strength
and chemical stability. Although EPR is often considered to have better electrical characteristics in the presence of
water, the disadvantages are lower electrical design stress and a higher dielectric loss of EPR compounds implying
possible use at lower voltages.
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500 (550) kV
3.4 Metal Screen/Sheath

The most commonly used metal screen/sheath consists of an extruded lead alloy sheath covered by an extruded
anticorrosion polymeric sheath or a semiconducting tape. Other emerging metal sheath materials are under
discussion or implementation as alternatives to lead alloy sheaths.
The thickness of the metal sheath is set by mechanical and electrical criteria.
The metal sheath shall exhibit a high level of mechanical performance: consistency, capability of bending during
manufacture and installation as well as resistance to fatigue during operational thermal cycling.
The suitability of lead alloys sheaths against fatigue resistance issues has been demonstrated by decades of long
experience on HV and EHV submarine cables with laminated insulation and more recently on extruded insulation
land cables and on HV extruded insulation submarine cables. The CENELEC standard EN 50307-2002 "Lead and
lead alloys - Lead and lead alloy sheaths and sleeves of electric cables" is a good illustration of this fact and the
mastering gained in the metallurgical successful control of the lead alloys morphology.
Setting practical criteria for maximum permissible strain on the lead sheath by calculation is very difficult because
modelling the behaviour of the cable during load cycling is complex. The complexity is due to the differences in the
coefficients of fatigue resistance [16], [17].
The metal sheath shall also have a minimum cross-section area to allow for the passage of short-circuit currents
without exceeding the maximum permissible temperature at the end of the short circuit (IEC 61443). Additional
wires could be used on single-core cables to increase the short-circuit current capability. When semi-conducting
layers are used over each core of a three-core cable a sharing of the short-circuit currents between the three
parallel paths has to be taken into account.
The continuity of the lead sheath over the factory joints is provided by the application of a lead sleeve of larger
diameter over the joint, followed by drawing the sleeve to the under layer diameter and by wiping it to the lead
sheath of the cable.
The polymeric anticorrosion oversheath is either insulating or semi-conducting and is usually polyolefin based.
When an insulating oversheath is used, an overvoltage will occur between the metal sheath and the surrounding
metal armour during cable system transients. To avoid dielectric breakdown of the insulating oversheath, a
semiconducting oversheath is often used. Alternatively, earthing connections have to be inserted between metal
sheath and armour at regular distances along the cable. Particular attention has to be paid to the water tightness
between metal sheath and armour at the earthing connections. Possible corrosion is to be taken into account. The
cross-sectional area, together with the contact resistances, will allow the flow of capacitive current distribution
towards the armour and the sea. Possible overheating by short-circuit currents going through these connections is
also a sizing parameter.
The radial water tightness of the cable is currently provided by the metal sheath only.
The longitudinal water tightness is therefore provided only under the metal sheath. Semi-conducting water
swellable tapes applied either helically lapped or longitudinally wrapped around the core are use for this purpose.
For providing circularity to the laying-up of the cores of a three-core cable (support on which the armour will be
applied) its outer spaces are filled with non water swellable PP yarns or plastic fillers. A copper tape may be
applied as an equalising counter helix.
3.5 Armour
For submarine cable, metal wire armour is normally applied to provide enough tensile strength during the
installation. When cable is installed in the sea, pulling tension (T) = cable weight in water (W) x depth of water (d) +
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bottom tension (H) occurs on cable. The cable must withstand this tension. Generally the tensile strength is verified
by mechanical tests in accordance with CIGRE Recommendation “Recommendations for mechanical test on sub-
marine cables” published in Electra 171, 1997. The recommendation requires the cable to withstand the test
condition of T = 1.3W x d + H (< 500 m water depth). Therefore, the armour must be designed to meet this
condition.
Copper, steel or stainless steel wires are normally used as armour. The material chosen is project specific
according to various conditions, for example, installation, operation and cost.
In single-phase submarine cables the steel armour creates a large iron loss so non-ferrous materials like copper or
stainless steel are used, or otherwise, a return copper conductor is added in conjunction with steel wires to reduce
the magnetic flux on the steel wire armour. The reason for this choice is that the magnetic field originating from the
conductor current creates eddy currents and thus heat losses in the armour and other metal parts of the cable,
hereunder the screen. If the armour was made of a magnetic material like steel, additional losses, due to
magnetisation, would be significant.
In the case of three core cables, the resulting magnetic field from a symmetrically loaded cable will be significantly
lower. The armour however, is placed close to the cable cores where a resultant magnetic field cannot be
neglected. It is typical that three core submarine cables utilise steel wire armour for cost savings. If the transfer
capacity of the cable system is to be maximised at a certain voltage level, it is possible to replace the steel armour
wires with stainless steel wires. Recent measurements of the steel losses for three-core armoured cables have
shown that formulae from IEC 60287 are providing calculation results higher than actually measured [18], [19].
Methods to calculate magnetic losses in steel armour of three-core cables may need to be reassessed. The
magnetic properties of the materials are important when considering losses.
From a mechanical point-of-view, due to the lower permissible tensile strength, copper cannot be applied in case of
higher pulling tension which is due to a very heavy weight of the cable and/or very deep waters. In such case, steel
or stainless steel is applied. For more severe cases, double layer of armour is applied to obtain higher pulling
strength and anti-torsion properties. Permissible typical tensile strength of each material is shown in Table 3.
Table 3. Typical permissible tensile stress values of armour wires.

Material Copper Steel Stainless steel
Max Tension [MPa] 60-90 90-600 250-450
(a) Single layer armour (b) Double layer armour
Figure 5. Schematic picture of cable cross sections with single

and double layers of armour wires.
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3.6 Outer Protection

A submarine cable, either a single-core or a three-core design, must have an outer protection. The outer protection
for land based cables may, apart from the mechanical function, also have an electrical function. For submarine
cables, however, the outer protection normally has a mechanical function but also keeps the anti-corrosion material
(for example bitumen) in place. The outer protection may either consist of a plastic sheath, or which is more
common, a yarn in one or more layers covering the underlying armour layer(s). One or more threads of yarn may
be applied with a colour different from the others, to visually locate the cable after installation. When using yarn, the
yarn will also stabilise the armour mechanically, so the risk of bird caging is reduced during cable handling.
4. Curr ent technologies for submari ne joint designs
4.1 Factory Joints
4.1.1 General considerations for Factory Joints

The factory joint is manufactured prior to the armouring operation, so that the section of cable containing the joint is
continuously armoured without any discontinuity or appreciable distortion of the armour wires in the vicinity of the
joint. The main feature of a factory joint is that it shall not impose any restrictions on further cable handling or
installation operations, nor imply a variation in the cable mechanical and electrical performance (Figure 6). This
generally implies that the factory joints are fully flexible, with same bending radius, pulling force limit and coiling
performance (if applicable) with respect to the original cable.
If the joint has some limitations with respect to handling this must be declared, so that special precautions can be
taken during handling and installation of the joint.
Figure 6. General drawing of a factory joint having the same

dimensions as the cable (not in scale).
The defined length of a factory joint is the removed length of the metal sheath/outer semi-conducting screen (X1)
plus 1 metre on each side of that length, i.e. the defined length is in total (X1+2) m, see Figure 7. For three-core
cables, the length of the factory joint is defined from the beginning of first core joint to the end of the last core joint,
plus 1 metre in each end of the core joints.
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Figure 7. Definitions of factory joint extensions.
Factory joints are necessary for the following reasons:
limitation in continuous extrusion lengths, due to filter cleaning, scorch formation, etc.
limitation of storage capacity (e.g. process platforms) of the individual lengths
limitation of degassing equipment and process
limitation in the laying-up baskets content (for three-core cables)
power limitation of the AC testing equipment
damage to the cable core during handling
In general, the higher the voltage and higher the cable size the shorter the individual lengths and consequently the
higher the number of joints to be included for a given delivery length.
However, attempts should be made to limit the number of factory joints. Together with improved process
compatibility plus advanced testing protocol, it will ensure that the best cable quality is available for the intended
application.
In any case, the factory joint shall have a robust structure, a highly reliable design and assembly procedure to meet
the same design life of the remaining cable system.
4.1.2 Typical procedure for factory jointing

The same procedure applies for single-core or multi-core cables; for the latter, the joints are performed before
laying-up of the cores.
The two cable ends are suitably prepared.

The conductor is jointed by means of a compression ferrule or by welding. It is better if the conductor joint
has the same diameter as the original cable.
The cable core (inner semi-conducting, insulation and outer semi-conducting) is reconstructed by using
tapes, followed by a curing process. This operation can be performed in separate phases.
Water swellable tapes, metal tapes and/or protective layers are restored.
The lead sheath reconstruction is made with an extruded lead sleeve, to be inserted on one end before
jointing the conductors.
The plastic sheath is re-constructed by means of taping, heat shrinkable tube or by local extrusion or
moulding.
Alternative techniques may be developed in the future for factory jointing.
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4.2 Repair Joints
4.2.1 General considerations f or Repair Joints

A repair joint is made on the complete cable and usually onboard on a repair vessel or barge (or for cable
installation in case of use of the repair joint as a field joint). Therefore, the repair vessel or barge shall be suitably
equipped and shall have sufficient space available to perform the operation onboard. Repair joints can be divided
into three main categories depending upon their handling characteristics:
Type A1: Fully Flexible Joint

Type A2: Flexible Joint with some mechanical restrictions
Type B: Rigid Joint
In any case, the repair joint shall have a robust structure, a highly reliable design and assembly procedure to meet
the same design life of the remaining cable system.
It may not be necessary that the repair joint is required for installation in the maximum water depth. In case the
maximum allowable water depth for the repair joint is less than the maximum allowable water depth of the cable, a
proper repair procedure shall be taken into account to include an appropriate length of spare cable to span the
deepest point of the route.
Similarly, when the maximum tensile force of the repair joint is lower than the allowable tensile force for the cable,
any limitation/restriction that this may represent in terms of repair procedures or environmental conditions (e.g.
max. sea waves, currents or wind speed during repair operation) shall be specified.
It shall also be noted that repair joints are necessary to have in stock for most long submarine cable systems.
Appropriate storage conditions should be provided. The requirements for other spare parts such as cable and shelf
life of joint components should also be taken into account.
4.2.2 Typical procedure for repair jointing

There is a variety of repair jointing procedures, based on different cable constructions and manufacturer’s or
installer’s know-how and experience.
More commonly, fully flexible repair joints have a similar design as factory joints, especially for medium/deep water
applications, while rigid joints often use pre-moulded or preassembled bodies.
Flexible joints with some mechanical restriction apply to both designs (A1 and A2), even if they commonly use pre-
moulded or preassembled bodies.
Particular attention shall be given to the jointing of the armour, so that there is no slack in the armour wires that
could give rise to overstressing of the inner cores during handling.
The defined length of a repair joint is the removed length of the armour (X2) plus 1 metre on each side of that
length, i.e. the defined length is in total (X2+2) m, see Figure 8.
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Figure 8. Definitions of repair joint extensions.
Type A1: Fully Flexible Joint

This joint can be subjected to bending with a minimum bending radius R, [m] and under a tensile force T [N/m], with
same magnitude as the cable (Figure 9).
Flexible Joint
R
Figure 9. Fully flexible joint bent over the sheave.

T: tensile force [N/m] and R: bending radius [m].
Type A2: Flexible Joint with some mechanical restrictions

This type of joint is able to be bent (on same or greater radius with respect to cable) over the sheave but with low
or no tension (minimal tension could mean some tens of metres of cable weight), see Figure 10.
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Flexible Joint with tension

restriction during bending
R
Release of tension
during bending.
T
Figure 10. Flexible joint with some mechanical restrictions pulled over the sheave
by lower tension than in the cable.
After bending, the joint can be pulled with a tensile force T, which is the same as the cable performance (Figure
11).
Figure 11. Flexible joint after pulled over the sheave.
Type B: Rigid Joint

The rigid joint (Figure 13) cannot be bent or passed through the laying equipment. It must be handled and deployed
in a special way, by crane or similar equipment. In this case the mechanical stress on joint/cable depends on joint
design/handling. In any case the bending radius of the cable shall be above the specified minimum value during
joint handling/deployment (Figure 12).
Cable fixation Cable fixation
T T
Figure 12. Rigid joint lowered by a crane and joint laying equipment.
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The cable and joint assembly may also be subjected to partial torsion during laying.
Figure 13. Example of a rigid repair joint with bending stiffeners.
4.3 Sea/Land Transition Joint

The transition joint between the submarine cable and the land cable in a specific project is normally a rigid joint
consisting of prefabricated joint bodies. In that case it is similar to a rigid repair joint for a submarine cable. The
testing of a sea/land transition joint should follow the standard and recommendation for land cables in the
appropriate sections.
The mechanical demands on the Sea/Land Transition Joint may differ from case to case. If the submarine cable is
jetted into a level seabed and the Sea/Land Joint is placed on the shore the armour may just need to be
terminated, while the situation on steep slopes is different and there may be a need to fix the submarine cable by
the armour. This issue needs to be discussed from project to project.
If the armour needs to be fixed to hold the weight of the cable, various designs may come into consideration. One
possibility is to terminate the armour in a steel fixture connected rigidly to an anchoring block made of concrete.
This block or plate may be used as the floor of the joint system.
In any case the conductor joint needs to have the same mechanical properties as the connecting land cables.
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5. General asp ects on s ubmarine cable testing
5.1 Summary of Tests

In general a submarine cable system forms an integral part of the power system. Long submarine cables require
large investments and are costly to repair on the rare occasion that they need to be repaired. Therefore submarine
cables must be of high quality that is checked and tested regularly throughout production to guarantee their high
reliability. In particular, a long manufactured length of submarine cable may be routine tested before armouring,
because an unexpected breakdown in an already armoured cable must be avoided due to cost, complicated
restoration and maybe critical project time frames. A list of relevant tests for AC submarine cable systems is given
below.
Many tests recommended herein have references to IEC 60840 Ed. 4 and IEC 62067 Ed. 2 and other relevant IEC
cable standards. Test levels, test durations and frequency of tests according to IEC should be considered as
necessary but strictly as a minimum requirement.
o Routine tests
- Test on manufactured length
- Test on factory installed joints
- Factory acceptance test
o Sample tests
- Sample tests on cable
- Sample tests on joint
o Type tests
- Mechanical tests on complete cable
- Electrical tests on complete cable
- Non-electrical tests on cable components and on complete cable
o Prequalification tests
o Extension of qualification tests
o Electrical tests after installation
An overview of all the tests are given in Annexes A - F – “Test Charts”
5.2 Test Conditions
5.2.1 Ambient temperature

Unless otherwise specified in the details for the particular test, tests shall be carried out at an ambient temperature
of (20 ± 15) °C as per IEC 60840 and IEC 62067. A deviation from this temperature range should be agreed upon
by the manufacturer and the customer.
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5.2.2 Frequency and wav e f orm of AC test voltages

Unless otherwise indicated in this document, the frequency of the alternating test voltages shall be in the range 49
Hz to 61 Hz. The waveform shall be substantially sinusoidal, as prescribed in IEC 60060-1 and IEEE 519. The
values quoted are r.m.s. values.
However, for routine and electrical tests after installation a wider frequency range of 10-500 Hz may be used (See
6.1 and 11.1).
5.2.3 W ave f orm of impulse test v oltage
Refer to IEC 60840 and IEC 62067.
5.2.4 Relationship of test v oltages and rated voltages
5.3 Characteristics of Cables

For the purpose of carrying out and recording the tests described in this brochure, the following characteristics
must be known or declared in addition to declarations listed in IEC 60840 and IEC 62067:
Material and construction of metal armour, e.g. number and diameter of wires.
Designed laying depth/maximum tensile force in cable during installation
Method for preventing longitudinal water penetration in conductor and under the metal screen/sheath
Maximum design conductor temperature
Ability of the cable to be coiled including coiling test parameters
5.4 Development Tests

Recommendations and standards are generally not sufficient to take all uses of cables into account. Furthermore,
design of new cables and accessories need to be tested for design, materials, components, production processes,
installation conditions and long term behaviour.
Examples of issues that may need to be considered are:
Specific mechanical issues e.g. vibration and strumming of cable in water currents, for example, in the
case of free spans or situations where the J-tube is ending above seabed level at an offshore platform.
The cable system’s ability to withstand deep water pressures, water ingress and deformation
Design of hang-offs for offshore platforms
Efficiency of water blocking tapes/compounds after many years of operation
Handling of optical fibre unit/cable integrated in cable
Thermo-mechanical analysis of cable in HDD (Horizontal Directional Drilling) pipe
The above list may continue depending upon the specific product or project. Development tests or other specific
tests may be a part of the tests within the scope in a project.
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6. Ro utine Test
6.1 General
Routine tests are made to demonstrate the integrity of the manufactured cable and to verify that the product meets
the design and manufacturing specifications within specified tolerances.
The consequences of faults on submarine cable systems are, however, often significantly more problematic than
faults on land cable systems, simply because the outage periods are longer and redundancy is not necessarily built
into the system. Therefore, it is advisable to be extra careful in the production of submarine cables and
accessories. On-line procedures to ensure the quality of the raw materials and dimension monitoring of the
extruded cable during production may help prevent future cable failures. These aspects need to be discussed
between the supplier and the customer.
For AC voltage testing of long cables it is not practicable to test these cables at a frequency of 50/60 Hz as the
charging current will be very high (test transformers and required power will become too large). By decreasing the
test frequency, the test current and power will be reduced considerably, but may in some cases still be a practical
limitation [20][21][22][23].
It has been concluded that a frequency range of 20-300 Hz seems to be reasonable, following the proposal in the
IEC draft for on-site testing of extruded insulation cables and with respect to an optimum design of test systems.
However, based on the results as presented in this paper and research work [17][20], it can also be concluded that
the withstand voltage and electrical breakdown field strength are very close together in the frequency range
between 10 and 300 Hz. Thus, for AC voltage withstand tests, frequencies below 20 Hz down to 10 Hz may be
used.
In 2006, IEC issued a new standard (IEC 60060-3; High-voltage test techniques, on-site testing), describing that for
tests with AC voltages the test voltage shall be a sinusoidal wave-shape having a frequency in the range of 10-500
Hz.
As a result, following this IEC requirement, routine tests may be carried out in a frequency range of 10-500 Hz.
6.2 Available high voltage test methods

There are several test methods which can be used to carry out high voltage tests. The common method is to use
power frequency (50/60 Hz). As already described in the previous clause, using power frequency for testing long
cable lengths (like submarine cables) is not practicable and therefore alternative methods are preferable.
Alternative methods may be high voltage tests using a resonance circuit test system or a VLF (very low frequency)
test set.
Resonance circuit test systems are used for testing of high capacitance objects with AC voltage. Under ideal
conditions the electrical power needed for the test can be reduced to the real power losses in the test circuit and as
a result the required supply power is much lower than the HV test power. For this reason resonance circuit test
systems are often used for on-site AC voltage tests, but of course can also be used for long submarine cables. One
of the additional advantages is that resonance circuit test systems are modular and more systems can be
connected in parallel in order to test even longer lengths (several tens of km).
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In addition to resonance testing, AC voltage tests can also be carried out using VLF test equipment. At the moment
VLF testing (< 1 Hz) is mainly used for on-site diagnostic measurements (PD) and tests on medium voltage cables
having rated voltages up to 36 kV. There is a tendency that new VLF test sets will be developed with test voltages
above 100 kV. However, until now no practical experience is available yet for testing of cable systems above 36
kV. Therefore more research work is required in the area of breakdown mechanisms and which test voltages need
to be applied, that will reveal defects in relation to 50 Hz.
It is recommended that more experience must be obtained from future high voltage tests on EHV and HV cables
using VLF equipment. These experiences together with research work on this field can then be used to propose
VLF test voltages and durations in the future.
Besides the above mentioned test methods using alternating voltages, there also exist some other type of voltages
for on-site testing, such as direct voltage and damped alternating voltage. However, dc tests should be avoided for
AC extruded cables.
Tests with damped AC voltage are generally combined with a PD measurement. This method is considered not to
be suitable as a withstand voltage test, and is more relevant for underground cables as the lengths are relatively
short. Furthermore, PD measurements are perfomed primarily on accessories. Systems for damped AC voltage are
so far not applicable for long submarine cables due to the high cable capacitance.
6.3 Tests on Manufactured Lengths
6.3.1 Partial Discharge Test

The partial discharge test shall be carried out in accordance with IEC 60885-3, except that the sensitivity as
defined in IEC 60885-3 shall be 10 pC or less.
The procedure of PD measurements is as follows:
The test voltage shall be raised gradually to and held at 1.75 U0 for 10 seconds and then slowly reduced to 1,5 U0.
There shall be no detectable discharge exceeding the declared sensitivity level of 10 pC at 1,5 x U0.
Attention must be paid to the attenuation of pulses in order to give the required sensitivity as requested in IEC
60840, IEC 62067 and IEC 60885-3.
Since it is not feasible to move long cable lengths to a screened environment the PD measurements cannot be
performed according to established methods (IEC 60270). In case PD measurements are carried out they will
therefore be for information only.
If the cable length is defined as long (See section 2) the PD-measurement shall be performed on samples
according to 7.1.13.
6.3.2 High Voltage Test
The high voltage test shall be made at ambient temperature using an AC test voltage at a frequency, according to
5.2.2.
The test voltage shall be raised gradually to at least the specified value, which then shall be held for the specified
time, as per IEC 60840 or IEC 62067, between the conductor and screen.
No breakdown of the insulation shall occur during the test.
After agreement between supplier and customer, it should be possible to divide the test time due to for example
overheating of the test equipment.
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6.4 Tests on Factory Joints

There are at least three available methods today for checking the quality of the factory joint insulation system:
PD measurement2
X-ray inspection
AC voltage test
Each joint, manufactured in the factory, is recommended to be PD-tested according to IEC 60270. There shall be
no detectable discharge exceeding the declared sensitivity level of 5 pC at 1,5xU0. The PD-test may be performed
after the restoration of the outer semi-conducting screen.
If it is impossible to perform a PD-measurement according to IEC 60270, for example due to noisy environment,
practical reasons etc, then alternative PD-measurement techniques (acoustic, etc.) or quality procedures may be
agreed between manufacturer and customer.
X-ray inspection gives additional information regarding the quality of interfaces and possible metal inclusions.
All joints in the complete delivery length will be AC voltage tested in the high voltage test described in 6.5.1.
However, an AC voltage test directly after jointing will reduce the time delay in case the joint fails at a later stage in
the production process.
In addition, it is recommended that each conductor joint (welding) is checked by an X-ray inspection.
Even if each factory joint is routine tested, the joint must be installed by experienced personnel. The supplier is
recommended to show qualification records of jointers. Dimension control, check of temperatures and pressures
during joint manufacturing etc. shall be recorded and checked according to instructions.
6.5 Tests on Complete Delivery Length

This test may be considered as a factory acceptance test (FAT) for the delivery length. If permanent mechanical
equipment (e.g. hang-off heads) will be delivered mounted on the cable before shipment, the FAT test should be
performed after the assembly of such permanent mechanical equipment.
6.5.1 High Voltage Test
Every delivery length of cable shall be submitted to a high voltage test as described in 6.3.2. If the complete
delivery length is too long for a routine test, a reduced test voltage but with a longer duration, may be agreed
between supplier and customer.
6.5.2 Partial Discharge Test
In certain cases where the delivery lengths are relatively short (not long) and where factory logistics allow, it may
be possible to carry out a partial discharge on each complete delivery length. Subject to agreement between
supplier and customer it is recommended in such cases that a partial discharge test is carried out on the complete
delivery length in accordance with IEC 60840 or IEC 62067 and not as part of 6.3.1.
2
PD-tests of factory joints are strongly recommended to be performed if the electrical stress at conductor screen is higher than
8 kV/mm or higher than 4 kV/mm at insulation screen [2].
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6.6 Tests on Repair Joint

If the joint consists of pre-fabricated insulation components which are possible to routine test prior to installation,
the procedures described in IEC 60840 or IEC 62067 shall be followed as close as possible and according to
agreement with the customer. If the joint is not built up by any pre-fabricated components, the manufacturer and
customer shall agree on the most practical solution, if any, to check the quality of the repair joint.
6.7 Tests on Terminations

Refer to IEC 60840 or IEC 62067.
7. Sample Test
7.1 Sample Tests on Cables
7.1.1 General
The following tests shall be made on samples to represent the manufacturing of the cable. The tests described in
7.1.4 to 7.1.14 shall be performed on samples from insulation core or completed core. The test in 0 shall be
performed on completed cable.
7.1.2 Frequency of Tests
Tests 7.1.4 to 7.1.12 and 7.1.15 shall be performed on each extrusion run (one sample). Tests 7.1.13 and 7.1.14
are to be performed from the start and stop of each extrusion run (two samples). The test in 7.1.16 shall be
performed from one sample from the delivery length. The number of sample tests may be reduced for short lengths
if the length is possible to be tested for partial discharges. This has however to be agreed between customer and
manufacturer.
7.1.3 Repetition of tests
7.1.4 Conductor examination
7.1.5 Measurem ent of electrical resistance of conductor and, on completed core, of metal
screen/sheath
7.1.6 Measurem ent of thickness of insulation and cable oversheath
7.1.7 Measurement of thickness of metal sheath
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7.1.8 Measurement of thickness of inner non-metallic sheath
Refer to IEC 60840 and IEC 62067 on measurement of cable oversheath.
7.1.9 Measurem ent of diameters of conductor, core and metal sheath
7.1.10 Hot set test f or extruded insulation
7.1.11 Measurement of capacitance
7.1.12 Measurement of density of HDPE insulation
7.1.13 Partial discharge test
To be performed on samples taken from start and end of extrusion lengths on sample at least 10 metres if not
performed as part of Routine Tests (6.3.1).
The test voltage shall be raised to and held at 1.75 U0 for 10 seconds and slowly reduced to 1.5 U0 .
No detectable discharge exceeding the declared sensibility level of 10 pC at 1.5 x U0.
7.1.14 Lightning impulse voltage test
The test is to be performed on same sample as for 7.1.13 if test is performed on a sample.
The test is to be performed with test voltage levels as in IEC 608403 and IEC 62067 and procedure according to
IEC 60230 (only lightning impulse voltage test).
7.1.15 Volume resistivity of conductor screen, insulation screen and semi-conductive polymeric
sheath
The test is performed as per Annex D (Method of measuring resistivity of semi-conducting screens) in IEC 60840
and IEC 62067. The volume resistivity of the semi-conductive polymeric sheath shall not exceed 1000 m.
7.1.16 Examination of completed cable
A sample of completed cable (length: more than one pitch of wire armour) shall be subjected to a visual inspection
to ensure that the manufacturing process has not caused any harmful defects. There shall be no signs of harmful
indentations in the cable cores, no crossing of screen or armour wires, bird cages etc.
The number of wires shall be counted in each armour layer and validated according to the design. The dimensions
of five wires in each layer shall be measured and the average cross-section(s), for the wires (round or flat) shall be
calculated before calculating the total cross-section area. The total cross-section area shall not be less than the
3
The impulse test shall be performed if the electrical stress at conductor screen is higher than 8 kV/mm or higher than 4 kV/mm
at insulation screen.
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declared value. The pitch length(s) of the armour layer(s) shall be measured and validated relative to the declared
value by a tolerance of ± 10%.
7.2 Sample Tests on Factory Joints
7.2.1 General
For AC submarine cable systems it is recommended to test each manufactured length and each factory joint under
the routine tests described in 6.4. Since routine tests check the quality of the whole submarine cable system itself,
the sample tests listed in 7.2.2 to 7.2.5 shall be performed on one factory core joint only, prior to the start of joint
manufacturing. A sample of at least 10 m cable and a factory joint shall be prepared for the tests.
If the factory joint is type tested under the contract, the sample tests may be omitted.
7.2.2 PD measurement and AC voltage test
To be performed after restoring the outer semi-conductive layer and the metal ground conductor or outer sheath.
The PD-measurement and the AC voltage test shall be performed in accordance with 6.3.1 and 6.3.2. The
maximum sensitivity level shall be 5 pC.
7.2.3 Lightning impulse voltage test
According to 7.1.14.
7.2.4 Hot set test for extruded insulation
According to 7.1.10.
7.2.5 Tensile test
Tensile test of the conductor joint shall be performed according to manufacturer specification. The tensile force
applied in the conductor shall not be lower than the declared value given by the cable design. The test may be
performed on a separate conductor sample, only.
7.2.6 Pass criteria
If a factory joint fails in any of the tests listed above, two additional joints shall be tested successfully.
7.3 Sample Tests on Repair Joints and Terminations

Sample tests are not applicable for repair joint and terminations for submarine cable systems. The terminations as
well as the repair joints will be routine tested according to Sections 6.6 and 6.7.
The termination testing will follow the IEC 60840 or IEC 62067 test requirements.
IEC 60840 or IEC 62067 requirements will be used when applicable for repair joints (such as for prefabricated
rubber bodies as electrical insulation). If factory joints are used, the same principle as described in 0 will be
followed.
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500 (550) kV
8. Type Test on Cable Syst em
8.1 General
The tests specified in this clause are intended to demonstrate the satisfactory performance of the submarine cable
system.
In case of interruption/deviations in the test parameters during heating cycle voltage test or impulse withstand test
the cycle/impulse in question should be repeated.
In case of insulation breakdown when testing several objects simultaneously the faulty object may be removed and
the incident shall be treated as an interruption. The faulty object is considered to have failed and needs to be
retested. Any fault within an extension to a test object, as defined in sections 4.1 and 4.2 is considered to be
associated with that test object only.
NOTE: Tests on terminations referring to environmental conditions are covered in [24].
8.2 Range of Type Approval

Apart from a type test for a land cable system according to IEC 60840 or IEC 62067 which includes electrical and
material testing, the submarine AC cable system type test normally includes a more extensive mechanical type test
program prior to electrical and material testing. An AC HV or EHV submarine cable system may consist of
submarine cable(s), termination(s) and different type of joints. The AC submarine cable system (cable(s) and
joint(s)) has to be mechanically tested to the highest expected mechanical loads during cable installation, laying
and repair.
The range of type approval for land AC cable systems is described in IEC 608404 and IEC 62067. When type tests
have been successfully performed on one or more submarine cable system(s) of specific cross-section(s), and of
the same rated voltage and design, the type approval shall be considered as valid for submarine cable systems
with other cross-sections, rated voltages and designs provided that the conditions within IEC 60840 and IEC 62067
and the additional conditions below are met.
the cable system is subjected to less severe mechanical stress (tension, bending etc) than the tested cable
system
the design and method of conductor and/or screen/sheath water tightness is unchanged
NOTE: The whole type test program does not need to be repeated but only the test which is affected of the design
change, i.e. a water penetration test described in 8.7.
the design of conductor connection for joints is unchanged
the calculated nominal electrical stress and the impulse voltage stress calculated using nominal
dimensions at the conductor screen in the flexible joint (factory joint) do not exceed the respective
calculated stresses of the tested cable system(s) by more than 10 %
NOTE: A flexible joint with the same dimensions as the cable, shall be treated and tested as the cable both from an electrical
and mechanical point of view.
4
Even if IEC 60840 includes type testing on cable and accessories, type testing on submarine cables in the range of 36 to 170
kV shall follow the system approach (§12) so that § 14 and § 15 of IEC 60840 do not apply.
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8.3 Summary of Tests

The type tests shall comprise the mechanical and electrical tests on the complete cable and accessories as
specified in sections 8.5 to 8.9.
8.4 Preparation of Tests

For the minimum required complete test length and distance between factory joints for the mechanical tests as
described in 8.6, reference is made to the latest CIGRE Recommendations for Mechanical Tests of Submarine
Cables (currently Electra No. 171).
The tests listed in 8.8 shall be performed on one or more samples of complete cable, depending on the number of
joints involved, at least 10 m cumulative in length excluding the accessories. This cable system is taken from the
sample which has been subjected to the mechanical tests. The minimum cable length between the accessories
shall be 5 m.
One sample of each accessory type shall be tested.
Cable and accessories shall be assembled in the manner specified by the manufacturer's instructions, with the
grade and quantity of materials supplied, including lubricants if any. Earthing connections shall be included.
The external surface of accessories shall be dry and clean, but neither the cables nor the accessories shall be
subjected to any form of conditioning not specified in the manufacturer's instructions which might modify the
electrical, thermal or mechanical performance.
Measurement of resistivity of semi-conducting screens and sheaths described in 8.8 j) shall be made on a separate
sample.
8.5 Check on Insulation Thickness of Cable for Electrical Type Tests

Refer to IEC60840 or IEC 62067.
8.6 Mechanical Tests on Complete Cable System
8.6.1 Cables and Factory Joints
A sample for the tests specified in section 8.8 shall be subjected to a tensile bending test carried out according to
the latest CIGRE Recommendation for Mechanical Tests of submarine cables, currently Electra No. 171 (April ’97)
– Clause 2.2. If applicable a coiling test shall be performed before the bending test (see Electra No. 171 Clause
2.1). However if a rigid repair joint is used, only one flexible factory joint will have to be included for coiling test.
NOTE: If different designs are used on different sections along the cable route then the tensile force shall correspond to the
actual installation conditions.
8.6.2 Repair Joints
With reference to the types of repair joints detailed in paragraph 4.2, in Table 4 below the recommended
mechanical preconditioning tests are given.
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The proposed tests are representative of the actual mechanical stresses to which the joint are subject to during
installation and repair operations.
Table 4. Types of mechanical testing of joints. R=bending radius, T=tension in

joint.
Tensile Bending Tensile Test Sea Trial Test5
Test
Reference Electra 171, § 2.2 Electra 171, § 2.3 Electra 171, § 3
Type A1 Mandatory. For information only (on the Not necessary

Fully flexible same or other cable / joint
Same R and T as for cable. assembly)
joint No limitations for
application
Type A2 Mandatory with R and T as For information only (on the Not necessary
Flexible appropriate for the intended same or other cable / joint
application, i.e. different assembly)
Joint with
from cable.
some
mechanical E.g. repair in shallow water
restrictions depth only6
Type B Bending test only with Mandatory. Advisable

Rigid joint radius R without load, if
applicable. Straight tensile test at T on
the same joint assembly
subjected to bend test at
radius R without load.
8.7 Longitudinal/Radial Water Penetration (LWP, RWP) Test
8.7.1 Background to the LW P, RW P test
The LWP Test was a type test in CIGRE Electra 189, to be applied for submarine cable applications up to 150 kV
and both a type test and a sample test in IEC standards (60840 and 62067) and AEIC CS9-2006 that relates to
land cables.
5
To judge if a Sea Trial Test is necessary or not, the supplier and customer shall take earlier practice, development tests and
experience into account. For types A1 and A2 the tensile bending test is assumed to simulate the mechanical constraint during
installation and operation.
6
Clarification: If the joint is exposed to less mechanical load than the one declared for the cable, the cable must be tested
separately to the higher load. The same criteria apply for the bending radius R, if the cable and joint bending radius differs.
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500 (550) kV
For long submarine cables the water penetration tests are divided into three tests:
LWP a: conductor water penetration test
LWP b: metal sheath water penetration test
RWP: radial water penetration test of joints
The tests have different mechanical and thermal preconditioning as described below.
The mechanical and/or thermal preconditioning is very important for submarine cables and is required to simulate
as close as possible the actual installation conditions. For submarine cables the water pressure is often in the
order of tens of bars, compared to 0.1 bar pressure for land cables.
In addition, for submarine cables the mechanical preconditioning includes a tensile bending test and if applicable a
coiling test before bending.
This mechanical preconditioning may require lengths of cable in the range of 50 – some hundred meters and is
therefore an expensive and time consuming test.
For land cables, the maximum water propagation distance is fixed to 3 m (IEC 60840) or 4 m (IEC 62067).
For submarine cables the maximum water propagation distance in not fixed but is agreed between supplier and
customer, taking into account the minimum spare cable lengths needed for a sea repair operation at any water
depth.
According to the considerations above the LWP and RWP tests should be included under a ‘type test’ scope. They
are performed to qualify the design, the performance of the manufacturing process and materials to meet the
intended application.
It is not necessary to repeat the type test unless changes are made in either swellable materials, water blocking
compounds, conductor and screen-sheath designs or manufacturing process parameters.
The conductor penetration test simulates water ingress in the conductor during a cable fault at the deepest
part of the cable section. The cable sample is preconditioned as close as possible to the actual installation
conditions. This means that the test object shall be submitted to a tensile bending test and a thermal heat
cycling test prior to the water immersion. During the water immersion test no heat cycling is performed
because such a cable fault would cause the link to be out of service.
The metal sheath penetration test simulates a cable damage at the near shore area where the external
water pressure onto the cable does not contribute to increase the ability to stop water from penetrating
under the metal sheath. The cable sample is preconditioned as close as possible to the actual installation
conditions. This means no tensile bending test, but thermal heat cycling to submit the sample to radial
expansion prior to the test. The radial expansion due to heat cycling will be much more severe than
external water pressure the cable is subjected to in shallow waters. Heat cycles must be performed during
the test, because such cable damages do not necessarily imply that the link goes out of service. The
pressure must not compress the metal sheath. Hence a pressure of 3 bars is normally appropriate with
current lead sheath designs. The manufacturer is recommended to provide a justification if other pressure
values will be used.
The external water pressure test for factory and repair joints is designed to check for radial water ingress of
the joints at the maximum water depth. As the designs of HV and EHV cables normally are of water tight
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500 (550) kV
constructions the tightness must be checked for maximum water depth. The cable sample is
preconditioned as close as possible to the actual installation conditions. This means a tensile or a tensile
bending test (depending on construction) and a thermal heat cycling test to submit the sample to adequate
tensile forces and radial expansions prior to the test. During pressure testing the joint shall be subjected to
the same conditions as per Electra 171 clause 2.4.
The water used in the tests shall be either tap water or salt water with a salinity level relevant for the intended
application. The water pressure shall be raised to the test pressure as quickly as practicably possible.
For convenience the following measures are defined:
d1 = maximum declared distance for LWP in conductor
d2 = maximum declared distance for LWP in screen/sheath
8.7.2 Conductor Water Penetration Test
Preparation
The cable sample has to be taken from the cable subjected to the mechanical test, see 8.6.1.
The conductor penetration test may be performed on cable core.
The length of the test object shall be at least the distance d1 + 33% m. The test may be performed on the cable
core (Figure 14).
The test object shall be preconditioned by at least three heating cycles, ensuring that that the cable has
experienced the proper thermal expansion.
Each heating cycle consists of 8 hours of heating followed by 16 hours of cooling. Current heating in the conductor
shall be used to give the declared maximum conductor temperature +(5-10) °C for that specific installation. The
temperature shall be kept at the stated value at least 2 hours in the end of each heating cycle.
After preconditioning, approximately 50 mm of conductor shall be exposed. The ring shall comprise all layers
external to the conductor, thus exposing the conductor to the water. The other end of the test sample shall be
suitably sealed. The test sample is placed inside a pressure vessel.
Figure 14. A typical test setup for a conductor penetration test.
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500 (550) kV
Test
The test object is pressurised while submerged in water with a water pressure corresponding to the specified
maximum laying depth. The pressure shall be raised as fast as is practically possible to simulate a cable fault at the
deepest part of the cable section. The test continues for 10 days with a water temperature of 5 – 35 °C.
When the test time has elapsed, the test object is removed from the water. A cut is made in the conductor at a
distance d1. Water presence can be established by simply visually examine the end(s) or e.g. by emerging the end
sample in silicone oil above 100 °C and observing any crackling noise generated by boiling of water in sample or
by use of blotting paper.
8.7.3 Metal Sheath Water Penetration Test
Preparation
The length of the test object shall be at least the distance d2 + 1 m (Figure 15). The test may be performed on
completed cable.
The test object does not have to be subjected to the mechanical test according to 8.6.1 as the thermal expansion
experienced during heating cycles will be more severe than tensile bending test of cable.
The test object shall be preconditioned by three heating cycles, ensuring that the cable has experienced the
anticipated thermal expansion.
Each heating cycle consists of 8 hours of heating followed by 16 hours of cooling. Current heating in the conductor
shall be used to give the declared maximum conductor temperature +(5-10) °C for that specific installation. The
temperature shall be kept at the stated value at least 2 hours in the end of each heating cycle.
After preconditioning, a ring approximately 50 mm wide shall be removed either from the middle of the test sample
or one metre from the end of the sample. The ring shall comprise all the layers external to the outer semi-
conducting screen, thus exposing the outer semi-conducting layer to the water. The test sample is placed inside a
pressure vessel.
The temperature of the conductor must be measured inside the pressure vessel.
Figure 15. A typical test setup for a sheath penetration test.
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500 (550) kV
Test
The test object is pressurised with a water pressure corresponding to the specified maximum laying depth, but not
as high as contributing to compression of the metal sheath. For lead sheathed cables and similar designs, a
maximum water depth of 30 metres is appropriate. Refer to 8.7.1.
The cable test shall be subjected to 10 heating cycles while pressurised at a water temperature equal to the
ambient temperature of 5 - 35 °C. Each heating cycle consists of 8 hours of heating followed by 16 hours of
cooling. Current heating shall be used to give the declared maximum conductor temperature +(5-10) °C for that
specific installation. The temperature shall be kept at the stated value at least 2 hours in the end of each heating
cycle.
When the test time has elapsed, the test object shall be removed from the water. The underside of the outer sheath
is made visible at a distance d2. Water presence can be established by simply visually examine the end(s).
8.7.4 Radial W ater Penetration Test for j oints
Preparation
The joint sample has to be taken from the joint subjected to mechanical tests, (see 8.6.1 and 8.6.2) and at least 10
heating cycles shall be applied. Each heating cycle consists of 8 hours of heating followed by 16 hours of cooling.
Current heating shall be used to give the declared maximum conductor temperature +5-10 °C for that specific
installation. The temperature shall be kept at the stated value at least 2 hours in the end of each heating cycle.
The test is to be performed on the pressurised part of the joint and not necessary to the whole joint body for rigid
repair joints. For three-core cables at least one core joint has to be tested. The joint sample shall be suitable
sealed at the cable ends by means of caps. The test sample shall be placed inside a pressure vessel.
Test
The test object is submerged in pressurised water corresponding to the specified maximum laying depth. The test
continues for 48 hours with a water temperature of 5 – 35 °C.
When the test time has elapsed, the test object is removed from the water.
a) No water ingress should be present under the water blocking barrier of the joint.
b) No appreciable shape irregularity in the metal sheath.
8.8 Electrical Tests on Complete Cable System

Samples for type test shall be taken from the cable or cable system subjected to previous tensile bending tests
and, if applicable, coiling tests. The sample of repair joint shall be subjected to the tensile test prior to type test.
A cable without armour may give several practical advantages when it comes to the efficiency in electrical testing.
From this viewpoint only one cable core from a three-core cable or a single-core cable without armour may be
subjected to the electrical test, if the following conditions are met:
It can be shown that the thermal distribution for a single-core cable without armour or a cable core from a
three-core cable does not significantly deviate from the thermal distribution in a cable with armour.
Attention shall also be given to the impact the integration of optical fibres may have in this respect
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500 (550) kV
The complete cable and accessories, including armour, joint housings etc. are subjected to the mechanical
tests, prior to the electrical tests
The core(s) not subjected to the electrical test shall be visually checked prior to the electrical test to confirm
the conformity to the requirements and the similarity to the core subjected to the electrical test
The details of test procedure for each specific case shall be declared and approved by customer and manufacturer.
On a sample taken from the cable or cable system subjected to previous tensile bending tests and, if applicable
coiling tests, the following electrical tests shall be performed:
a) partial discharge test at ambient temperature (IEC 60840 and 62067)
b) tan( measurement (IEC 60840 and IEC 62067)
NOTE: This test may be carried out on a different sample with special test terminations from that used for the remainder of the
sequence of tests.
c) heating cycle voltage test (IEC 60840 and IEC 62067)
d) partial discharge tests (IEC 60840 and IEC 62067)
– at ambient temperature, and
– at high temperature
The tests shall be carried out after the final cycle of item c) above or, alternatively, after the lightning impulse
voltage test in item f) below;
e) switching impulse voltage test (required for Um 300 kV, in IEC 62067)
f) lightning impulse voltage test followed by a power frequency voltage test (IEC 60840 and IEC 62067)
g) partial discharge tests, if not previously carried out in item d) above
i) examination of the cable system with cable and accessories on completion of the above tests (IEC 60840 and
IEC 62067)
j) if applicable, the resistivity of the cable semi-conducting screens and polymeric sheaths (IEC 60840 and IEC
62067) shall be measured on a separate sample.
8.9 Non-electrical Tests on Cable Components and Complete Cable
8.9.1 Check of cable construction
Refer to IEC 60840 or IEC 62067 for test details.
8.9.2 Tests f or determining the mechanical properties of insulation before and af ter ageing
Refer to IEC 60840 or IEC 62067 for test procedure and requirements.
8.9.3 Tests f or determining the mechanical properties of oversheaths bef ore and after ageing
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500 (550) kV
8.9.4 Ageing tests on pieces of complete cable to check compatibility of materials
8.9.5 Loss of mass test on PVC oversheaths of type ST2
8.9.6 Pressure test at high temperature on oversheaths
8.9.7 Test on PVC oversheaths (ST1 and ST2) at low temperature
8.9.8 Heat shock test f or PVC oversheaths (ST1 and ST2)
8.9.9 Ozone resistance test for EPR insulation
8.9.10 Hot set test f or EPR, HEPR and XLPE insulations
8.9.11 Measurem ent of density of HDPE insulation
Refer to IEC 60840 or IEC 62067 for test procedure.
8.9.12 Measurem ent of carbon black content of black PE oversheaths
8.9.13 Test under fire conditions
8.9.14 Determination of hardness of HEPR insulation
This paragraph applies to HV cables (Um 170 kV). Refer to IEC 60840 for test procedure and requirements.
8.9.15 Determination of the elastic modulus of HEPR insulation
This paragraph applies to HV cables (Um 170 kV). Refer to IEC 60840 for test procedure and requirements.
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500 (550) kV
9. Prequali fication Test
9.1 Introduction
The prequalification tests for land cable systems described in IEC 60840 and IEC 62067 were introduced to
validate the long term performance of the complete cable system with special focus on the cable and accessory
insulation characteristics, the cable core/accessory interfaces and the thermo-mechanical behaviour over time. The
electrical stress at the insulation screen is considered to be decisive for pre-fabricated accessories and therefore
this stress must not be higher than the electrical stress at the insulation screen for the intended land cable
application. The thermo-mechanical stresses are considered to be severe for large segmental conductors. The
thermo-mechanical stresses in other types of conductors, for example solid, compacted or key-stone shaped are
less severe from a thermo-mechanical point-of-view. The reasons are both the larger cross-section and the twisted
design of segmental conductors.
Extruded AC land cable systems, which undergo such a pre-qualification test, includes normally a land cable with
prefabricated accessories and segmented cable conductors but excludes normally flexible joints and mechanical
supports for repair joints (defined as an external design according to Chapter 2). For cables and flexible joints the
external design is normally implemented by a single- or double armour. The rigid repair joint is normally composed
of a pre-fabricated joint which normally is included in a land cable system PQ test.
For an AC extruded submarine cable system there are mainly four items that make a difference compared to an AC
extruded land cable system:
1. a flexible joint is normally needed
2. the cable has normally an armour
3. the repair joints have normally a mechanical housing (external design)
4. the cable conductor is normally not of a segmented design
The flexible joint (item 1) must be qualified in a PQ-test but the mechanical design (2 and 3) (external design) is
best qualified prior to the electrical type test or as a separate sea trial test. From a mechanical point a view a
segmental conductor (4) is more severe and may therefore be qualified in a land cable PQ-test.
The range of PQ approval for submarine cables systems is therefore more or less related to the pre-qualification of
the flexible or factory joint.
9.2 Range of Prequalification Test Approval

Refer to IEC 60840 and 62067.
If a land (or submarine) cable system already is pre-qualified, another submarine cable system is qualified if the
following conditions and the conditions given in IEC 608407 and IEC 62067 are met:
The electrical stress at insulation screen of a repair joint, using pre-fabricated components, is equal or
lower than the electrical stress at insulation screen in the pre-qualification test
7
A PQ-test may be performed if the electrical stress at conductor screen is higher than 8 kV/mm or higher than 4 kV/mm at
insulation screen. If experience for PQ-tests at these electrical stresses is available for higher voltages, no PQ- test has to be
performed
Page 40
500 (550) kV
If a flexible joint is already PQ-tested on a larger conductor and the proposed flexible joint on the smaller
conductor (for which thermo-mechanical stresses are far less severe) has electrical stress exceeding by
more than 10% the prequalified one, the flexible joint shall be subjected to a mandatory type test with a
stress level larger than that already prequalified.
If the internal design of the flexible joint (materials, vulcanisation process etc.) is substantially changed, then a new
pre-qualification test shall be performed. It may be part of either a land or submarine cable system pre-qualification
test.
Figure 16. Range of approval for factory and pre-moulded joints regarding
electrical stresses at a prequalification test.
9.3 Prequalification Test on Complete Cable System
9.3.1 Check on insulation thickness and test v oltage values f or electrical prequalification test
9.3.2 Test arrangement
For single core cables there will be a circulating current in the armour. To obtain the correct conductor temperature,
both conductor current and armour currents must be the same in both main test loop and dummy loop. The outer
thermal properties must also be the same for both loops.
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500 (550) kV
9.3.3 Heating cycle voltage test
9.3.4 Lightning impulse voltage test on cable samples 8
9.3.5 Examination
10. Extension o f Quali fication T est

Refer to Technical Brochure No. 303, IEC 60840 and IEC 62067.
The extension of qualification test (EQ-test) is mainly related to changes in accessories which already have
undergone a pre-qualification test (PQ-test). In TB 303, the design changes, leading to an EQ-test, are attributed to
the electrical stress or material characteristics of the electrical components, i.e. the internal design of the accessory
(normally the joint).
For the same reasons as for not introducing the PQ-test specifically for submarine cable systems, the rationale for
introducing an EQ-test specifically for submarine cable systems is not adding further value. The EQ-test on land
cable systems is qualifying submarine cable systems as well, as far as the internal electrical designs are the same
or similar. If there are changes in mechanical design, the external design is verified in mechanical tests prior to the
start of electrical type test or a sea trial test.
11 . Electrical tests after installatio n
11.1 High Voltage Test

Test on new installations are made when the installation of the cable and its accessories has been completed.
The cable shall be tested according to IEC 60840 or IEC 62067, Table 4.
If the complete installed length is too long for electrical test after installation, a reduced test voltage with a longer
duration may be agreed between supplier and customer. Alternatively, a voltage of U0 may be applied for 24 h, as a
minimum requirement.
For waveform and frequency, see 5.2.2.
11.2 Time Domain Reflectometry (TDR)

If TDR equipment is to be used with the cable link it is advisable to perform a TDR measurement to obtain a
“fingerprint” of the wave propagation characteristics of the cable.
8
As an alternative the test may be carried out on the whole test assembly or on a shorter sample including accessories.
Page 42
500 (550) kV
The propagation of the pulses used during TDR measurements is dependent upon resistance, capacitance and
inductance of the cable. As all electrical signals tries to consume a minimum of energy, the pulse propagates
where the inductance/resistance is its lowest. Submarine power cables have a metal screen and the pulses do not
propagate outside the screen as the inductance (and impedance) would increase considerably. Hence the pulse is
not affected by the coiling on a turntable or after installation.
Figure 17. Circuit diagram for TDR testing, traditional transmission line diagram,
-model.
For example, the following measurements (Table 5) were performed on different cables, both at factory (on
turntable) and after installation. The measurements are very close to each other but the fingerprint on the cable is
preferred to be made when the cable is installed.
Table 5. Example of TDR pulse speed for different cables.
Cable Factory Installed
extruded Pb sheath v/2 = 81.5 m/ s v/2 = 82.0 m/ s
extruded Cu sheath v/2 = 69.4 m/ s v/2 = 69.1 m/ s
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500 (550) kV
12 . Bibliography/References
[1] ELECTRA 68, 1980, CIGRE Working Group 21.06, “Recommendations for mechanical tests on submarine
cables”
[2] ELECTRA 171, April 1997, CIGRE Working Group 21.02, “Recommendations for mechanical tests on
submarine cables”
[3] ELECTRA 189, April 2000, CIGRE Working Group 21.02, “Recommendations for long AC submarine cables
with extruded insulation for system voltage above 30(36) to 150(170) kV”
[4] IEC 62067 Ed.1, October 2001,” Power Cables with extruded insulation and their accessories for rated
voltages above 150 kV (Um= 170 kV)) up to 500 kV (Um= 550 kV) – Test methods and requirements”
[5] CIGRE TB 303, 2006, Working Group B1.06, “Revision of qualification procedures for HV and EHV AC
extruded underground cable systems”
[6] IEC 60840 Ed.1 1998, “Tests for Power Cables with Extruded Insulation of Rated Voltages above 30 kV
(Um= 36 kV) up to 150 kV (Um= 170 kV)”
[7] IEC 60840 Ed.2, February 1999 and Ed.3, April 2004, “Power Cables with extruded insulation and their
accessories for rated voltages above 30 kV (Um= 36 kV)) up to 150 kV (Um= 170 kV) – Test methods and
requirements”
[8] CIGRE TB 268, 2005, Working Group B1.05, “Transient voltages affecting long cables”
[9] “Qualification, supply and installation of the world’s first 420 kV XLPE submarine cable system in Norway”,
7th Jicable (24-28 June 2007), Paper A9.3 G. Evenset, J-E Larsen, B Knutsen, K. Faugstad.
[10] “Qualification of a long 345 kV submarine XLPE cable system”, 8th Jicable (19-23 June 2011), Paper D4.6 J.
Karlstrand, D. Palmgren, J. Antonischki, J. Johansson, B. Zettervall.
[11] “Application of XLPE submarine power cable for extra high voltage”, 8th Jicable (19-23 June 2011), Paper
A6.4 H. Yanagawa, O. Matsunaga, T. Nakagawa, S. Asai.
th
[12] “The Oslo fjord project – The first project with long length 420 kV XLPE insulated submarine cables”, 8
Jicable (19-23 June 2011), Paper D4.5 T. Skeie, J. Elders, A. E. Rod.
[13] “Teknik i ASEA” ASEA AB Västerås 1983 ISBN 91-7260-765-3.
[14] “Polymer Insulated High Voltage Cables” IEEE Electrical Insulation Magazine, May/June 2006 — Vol. 22,
No. 3. V. Vahedy.
[15] “Submarine Power Cables – Design, Installation, Repair, Environmental Aspects” Springer Verlag 2009
ISBN 978-3-642-01269-3 T. Worzyk.
[16] “Selection of cable sheath lead alloys for fatigue resistance”, IEEE Transactions on Power Apparatus and
Systems, Vol. PAS-96, No. 1, January/February 1977. D.G. Havard.
[17] “The fatigue life of lead alloy E as a sheathing material for submarine power cables”, IEEE/PES (July 20-25,
1986) Summer Meeting Mexico City. P. Donelli, F. Donazzi, W.G. Lawson.
[18] “Power loss and inductance of steel armoured multi-core cables: comparison of IEC values with “2.5D” FEA
results and measurements”, Paper B1-116, CIGRE 2010 J.J. Bremnes, G. Evenset, R. Stolan.
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500 (550) kV
[19] “Armouring loss in three-core submarine XLPE cables”, 8th Jicable (19-23 June 2011), Paper A7.3 D.
Palmgren, J. Karlstrand, G. Henning.
[20] “The Selection of the Frequency Range for High-Voltage Onsite Testing of Extruded Insulation Cable
Systems” IEEE Electrical Insulation Magazine, November /December 2000 — Vol. 16, No. 6. E.
Gockenbach, W. Hauschild.
[21] “Factory testing of long submarine XLPE cables using frequency-tuned resonant systems” CIRED Turin,
June 2005, J. Karlstrand, G. Henning, S. Schierig, P. Coors.
[22] “Sinusoidal 0.1 Hz test voltage for diagnostic PD measurements of high voltage cable systems”, 15th ISH
(27-31 August 2007) K. Rethmeier, P. Mohaupt, S. Seifert, V. Bergmann, W. Kalkner.
[23] “Quality control of extruded HVDC cables: Comparison of AC, VLF and DC voltage stress on flat samples
with contamination”, NORD-IS 2009 F. Mauseth, E. Ildstad, M. Selsjord, R. Hegerberg, M. Jeroense, B.
Sanden, J.- E. Skog.
[24] IEC 60815-1 Ed.1 Part 1-2, October 2008, “Selection and dimensioning of high-voltage insulators intended
for use in polluted conditions”
[25] “Energy transmission on long three core/three foil XLPE power cables”, 6th Jicable (22-24 June 2003), G. E.
Balog, G. Evenset, F. Rudolfsen.
13 . Annexes
A. Test Chart, Routine Test
B. Test Chart, Sample Test
C. Test Chart, Type Test
D. Test Chart, Prequalification Test
E. Test Chart, Extension of Qualification Test
F. Test Chart, After Installation Test
G. Abbreviations
Page 45
500 (550) kV
Annex A – Routine Test
(References to IEC 60840 Ed. 4 and IEC 62067 Ed. 2)
Manufactured Lengths
References
Test
>36-170 kV >170 kV
Partial discharge (PD) test [TB § 6.3.1] IEC60840 § 9.2 IEC62067 § 9.2
High voltage test [TB § 6.3.2] IEC60840 § 9.3 IEC62067 § 9.2
Factory Joints
References
Test
>36-170 kV >170 kV
See TB § 6.4 1 TB § 6.4 TB § 6.4
Repair Joints
References
Test
>36-170 kV >170 kV
See TB § 6.5 TB § 6.5 TB § 6.5
Terminations
References
Test
>36-170 kV >170 kV
See TB § 6.6 IEC60840 § 9.1 IEC62067 § 9.1
Complete Delivery Length (FAT)
References
Test
>36-170 kV >170 kV
High voltage test [TB § 6.7.1] TB § 6.7.1 TB § 6.7.1
Partial discharge (PD) test [TB § 6.7.2] TB § 6.7.2 TB § 6.7.2
(1) If the electric stress is higher than 8 kV/mm at the conductor screen or higher than 4 kV/mm at the insulation
screen (applicable for the PD test).
Page 46
500 (550) kV
Annex B – Sample Test
(References to IEC 60840 Ed. 4 and IEC 62067 Ed. 2) Sample from insulation or completed core
References
Test
>36-170 kV >170 kV
IEC60840 IEC62067
Conductor examination [TB § 7.1.4]
§ 10.4 § 10.4
Measurement of electrical resistance of conductor and IEC60840 IEC62067
metal screen/sheath (1) [TB § 7.1.5] § 10.5 § 10.5
Measurement of thickness of insulation and cable IEC60840 IEC62067
oversheath [TB § 7.1.6] § 10.6 § 10.6
IEC60840 IEC62067
Measurement of thickness of metal sheath [TB § 7.1.7]
§ 10.7 § 10.7
Measurement of thickness of non-metallic inner sheath IEC60840 IEC62067
[TB § 7.1.8] § 10.6 § 10.6
Measurement of diameters of conductor, core and IEC60840 IEC62067
metallic sheath [TB § 7.1.9] § 10.8 § 10.8
IEC60840 IEC62067
Hot set test for extruded insulation [TB § 7.1.10]
§ 10.9 § 10.9
IEC60840 IEC62067
Measurement of capacitance 1 [TB § 7.1.11]
§ 10.10 § 10.10
Measurement of density of HDPE insulation [TB § IEC60840 IEC62067
7.1.12] § 10.11 § 10.11
Partial discharge (PD) test [TB § 7.1.13] TB § 7.1.13 TB § 7.1.13
Lightning impulse voltage test [TB § 7.1.14] TB § 7.1.14 TB § 7.1.14
Volume resistivity of conductor screen, insulation screen Annex D Annex D
and semi-conductive polymeric sheath 2 [TB § 7.1.15] IEC60840 IEC62067
Completed cable
References
Test
>36-170 kV >170 kV
Examination of completed cable TB § 7.1.16 TB § 7.1.16
Factory joints
References
Test
>36-170 kV >170 kV
PD measurement and AC voltage test TB § 7.2.2 TB § 7.2.2
Lightning impulse voltage test TB § 7.1.14 TB § 7.1.14
Tensile test TB § 7.2.5 TB § 7.2.5
Hot set test for extruded insulation IEC60840 § 10.9 IEC62067 § 10.9
Page 47
500 (550) kV
Annex B contd.
(1) Can be performed on the complete cable length.
(2) Can be performed on insulation core.
NOTE 1: Sample tests from insulation or complete core shall be performed on each extrusion run (one sample), except for PD
and lightning impulse that are to be performed from the start and stop of each extrusion run, and examination which shall be
performed from one sample from the delivery length.
NOTE 2: If one sample fails any test, two more samples shall be tested successfully.
NOTE 3: Sample tests for repair joints and terminations are not applicable as they shall be routine tested.
Page 48
500 (550) kV
Annex C – Typ e Test
Main Sample
Cable and Factory Joint
References
Test
>36-170 kV >170 kV
Check of insulation thickness [TB § 8.5] IEC60840 IEC62067 §

§ 12.4.1 12.4.1
Coiling Test (if applicable) [TB § 8.6.1] Electra 171 § 2.1 Electra 171 § 2.1
Tensile Bending Test [TB § 8.6.1] Electra 171 § 2.2 Electra 171 § 2.2
Test voltage values [TB § 8.8] IEC60840 IEC62067
§ 12.4.1 § 12.4.1
Partial discharge test [TB § 8.8] IEC60840 IEC62067
§ 12.4.4 § 12.4.4
Tan( ) measurement1 [TB § 8.8] IEC60840 IEC62067
§ 12.4.5 § 12.4.5
Heating cycle voltage test [TB § 8.8] IEC60840 IEC62067
§ 12.4.6 § 12.4.6
Switching impulse test (U 300 kV) IEC62067
N/A
§ 12.4.7.1
Lightning impulse test [TB § 8.8] IEC60840 IEC62067
§ 12.4.7 § 12.4.7.2
Examination of cable system [TB § 8.8] IEC60840 IEC62067
§ 12.4.8 § 12.4.8
Repair Joints
References
Test
>36-170 kV >170 kV
Mechanical tests prior to electrical type tests [TB
TB § 8.6.2 TB § 8.6.2
§ 8.6.2] Table 4 Table 4
IEC60840 IEC62067
Electrical type test [TB § 8.8] § 12.4.1 to § 12.4.1 to
§ 12.4.9 § 12.4.9
(1) tan( ) – separate sample possible.
Page 49
500 (550) kV
Annex C contd.
Separate Samples
References
Test
>36-170 kV >170 kV
Cable Sample #1
Conductor Water Penetration Test [TB § 8.7.2] TB § 8.7.2 TB § 8.7.2
Cable Sample #2
Metal Sheath Water Penetration Test [TB § 8.7.3] TB § 8.7.3 TB § 8.7.3
Cable Sample #3
Resistivity of polymeric sheath [TB § 8.8] (if IEC60840 IEC62067
applicable) § 12.4.9 § 12.4.9
Cable Sample #4
Resistivity of semiconducting screens [TB § 8.8] (if IEC60840 IEC62067
applicable) § 12.4.9 § 12.4.9
Cable Sample #5
Other non-electrical tests on cable components and
IEC60840 § 12.5 IEC62067 § 12.5
on complete cable [TB § 8.9]
Factory Joint Sample #1
Radial Water Pressure Test [TB § 8.7.4] TB § 8.7.4 TB § 8.7.4
Repair Joint Sample #1
Radial Water Pressure Test [TB § 8.7.4] TB § 8.7.4 TB § 8.7.4
NOTE 1: Cable sample #2 is only applicable to designs with an earthing connection between lead sheath and armour.
NOTE 2: Cable sample #3 is only applicable to designs with a conducting polymeric sheath between lead sheath and armour. It
may be the same sample as cable sample #4.
NOTE 3: Repair joint sample #1 may be a separate sample or taken from the type test circuit.
Page 50
500 (550) kV
Annex D – Preq uali fication Test
Cable System
Cable, factory joint and repair joint

References
Test
>36-170 kV >170 kV
Summary of prequalification test 1
IEC60840 §13.2.1 IEC62067 §13.2.1
[TB § 9.1 - § 9.2]
Test voltage values [TB § 9.3.1] IEC60840 §13.2.21 IEC62067 §13.2.2
Test arrangement [TB § 9.3.2] IEC60840 §13.2.31 IEC62067 §13.2.3
1
Heating cycle voltage test [TB § 9.3.3] IEC60840 §13.2.4 IEC62067 §13.2.4
1
Lightning impulse test [TB § 9.3.4] IEC60840 §13.2.5 IEC62067 §13.2.5
Examination of cable system [TB § 9.3.5] IEC60840 §13.2.61 IEC62067 §13.2.6
(1) For projects where thermo-mechanical aspects have to be considered, the prequalification test
arrangement has to be representative of the actual installation conditions.
NOTE: The conditions for prequalification of submarine cable systems are given in TB § 9.1 – § 9.2.
Annex E – Extension of Qualificatio n Test
Cable System
Cable, factory joint and repair joint

References
Test
>36-170 kV >170 kV
Extension of prequalification test [TB § 10] IEC60840 §13.3 IEC62067 §13.3
NOTE: The conditions for extension of prequalification of submarine cable systems are given in TB §10.
Page 51
500 (550) kV
Annex F – After Installatio n Test
Cable System
References
Test
>36-170 kV >170 kV
High voltage test [TB § 11.1] IEC60840 §16.3 IEC62067 §16.3
Time Domain Reflectometry (TDR) 1 [TB §
TB § 11.2 TB § 11.2
11.2]
(1) Recommended.
NOTE: To be performed when the installation of the cable and its accessories has been completed.
Page 52
500 (550) kV
Annex G - Abbreviations
AC Alternating Current
AEIC Association of Edison Illuminating Companies
DC Direct Current
EHV Extra High Voltage
EPR Ethylene Propylene Rubber
EQ Extended Prequalification
FAT Factory Acceptance Test
FIMT Fibres in Metallic Tubes
FOC Fibre Optic Cable
HDD Horizontal Directional Drill
HDPE High Density Polyethylene
HEPR Hard Grade Ethylene Propylene Rubber
HV High Voltage
HVAC High Voltage Alternating Current
ICEA Insulated Cable Engineers Association
IEC International Electrotechnical Commission
IEEE Institute of Electrical & Electronics Engineers
JEC Japanese Electrotechnical Committee
LDPE Low Density Polyethylene
LWP Longitudinal Water Penetration
PD Partial Discharge
PE Polyethylene
PQ Prequalification
PVC Polyvinylchloride
RWP Radial Water Penetration
SLTJ Sea/Land Transition Joint
TB Technical Brochure
TDR Time Domain Reflectometry
TF Task Force
VLF Very Low Frequency
WG Working Group
XLPE Cross-linked Polyethylene
Page 53

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This TB replaces Electra article ELT_189_1

Recommendations for Testing of Long AC

A. GUSTAFSSON, Convenor (SE), J. KARLSTRAND, Secretary (SE),

Recommendations for testing of long AC

EXECUTIVE SUMMARY .............................................................................. 4

5.3 Characteristics of Cables .................................................................. 24

13. Annexes ............................................................................................. 45

IEC 60840 Edition 4

IEC 62067 Edition 2

CIGRE Technical Brochure, TB303

Introduction of new tests

Water tightness performance of conductors and under metal sheath

Mechanical treatment during production and installation of cable and joints

Water tightness of rigid repair joints

Delivery lengths and weights

Routine tests (AC and PD) of cable and joints

A more stringent approach to check the quality of factory joints

A radial water penetration test of rigid repair joints

A set of tests for visual inspection of submarine cables

1.2 Terms of Reference

Examination of relevant IEC standards/CIGRE recommendations and documentation.

A technical brochure should be prepared for publication.

1.4 Experience of extruded AC submarine cables above 170 kV

Figure 1. Loading on turntable on cable

Table 2. Examples of installed and planned EHV/HV AC submarine extruded cable

Figure 2. Cable hang-off at platform

Internal Design of Joint

External Design of Joint

Sea/Land Transition Joint (SLTJ)

a cable delivery length which includes one or more factory joints, or

Prequalification test (PQ)

Extension of qualification (EQ)

Factory Acceptance Test (FAT)

Electrical tests after installation

Submarine cable system

3. Curr ent technologies for submari ne cable designs

Single Core Three Core

Figure 3. Example of single-core cable design.

Tapes for assembling

Outer sheath (Polypropylene yarn) Optical fiber

Figure 4. Example of three-core cable design.

3.1 General aspects on water tightness

3.3 Insulation System

3.4 Metal Screen/Sheath

Table 3. Typical permissible tensile stress values of armour wires.

Max Tension [MPa] 60-90 90-600 250-450

(a) Single layer armour (b) Double layer armour

Figure 5. Schematic picture of cable cross sections with single

3.6 Outer Protection

4. Curr ent technologies for submari ne joint designs

4.1 Factory Joints

4.1.1 General considerations for Factory Joints

Figure 6. General drawing of a factory joint having the same

Figure 7. Definitions of factory joint extensions.

Factory joints are necessary for the following reasons:

4.1.2 Typical procedure for factory jointing

The two cable ends are suitably prepared.

4.2 Repair Joints

4.2.1 General considerations f or Repair Joints

Type A1: Fully Flexible Joint

4.2.2 Typical procedure for repair jointing

Figure 8. Definitions of repair joint extensions.