QUALITY TOOLBOX

MEETING-xx
DATE : 13-03-16

PROJCECT : CLEAN FUELS COMPLEX PROJECT - RTR DATE : 13-03-16

DISCIPLINE : ELECTRICAL QTBT : Quality
LOCATION : LUP-8 Laydown CONDUCTED BY : VIJAYAN
CLIENT : SAUDI ARAMCO CONTRACT NO : 6600033859 & 6600034000
SUBJECT : HIPOT Testing of cables.

DESCRIPTION
Objective: The purpose of this session is to describe general requirements for HIPOT testing of cables and identify the requirements of
Testing.

Discussion & Explanation of the subject :

Hipot Testing
1. What is “Hipot “testing?

2. Why high voltage test?

3. How do these "Hipot" tests affect quality?

4. Where is the high voltage applied?

5. Where is the current measured?

1) Introduction to Hipot Testing

a. Many people are familiar with a continuity test. A continuity test checks for "good connections."

You do a continuity test by seeing if current will flow from one point to another point. If current

flows easily enough then the points are connected. Many people aren't familiar with a Hipot test.

"Hipot" is short for high potential (high voltage). A Hipot test checks for "good isolation." You do a

Hipot test by making sure no current will flow from one point to another point. In some ways a

Hipot test is the opposite of a continuity test.

b. Continuity Test: "Make sure current flows easily from one point to another point."

c. Hipot Test: "Make sure current won't flow from one point to another point (and turn up the

voltage really high just to make sure no current will flow)."

HIPOT Testing of cables. Page 1 of 5

 d. "Megger" and "hi-pot" tests both determine insulation resistance, the measure of current leakage

in a conductor. A "hi-pot" is used primarily to test the capacity of voltage that insulation can

withstand before failing. In a "dielectric withstand test," voltage is applied to a conductor and

current leakage is measured over time to determine insulation integrity. The leakage is compared

to a limit based on the size of the component being tested. The current that flows is watched

carefully. Ideally not much current will flow. If

too much current flows the points are not well isolated and they should fail the test. The Max value

of leakage current acceptable is 1mA.

2) Why high voltage test?

a. You use a Hipot test to make sure you have good isolation between the parts of a circuit. Having

good isolation helps to guarantee the safety and quality of electrical circuits. Hipot tests are helpful

in finding nicked or crushed insulation, stray wire strands or braided shielding, conductive or

corrosive contaminants around the conductors, terminal spacing problems, and tolerance errors in

IDC cables. All of these conditions might cause a device to fail.

b. What is "dielectric withstand testing" (DW)?

In dielectric withstand testing you are trying to answer the question "Will this cable withstand a

required voltage for a required time?" You apply the voltage for the amount of time and watch the

current that flows. Ideally no current flows and the cable is not harmed.

3) How do these "Hipot" tests affect quality?

a. All of these tests are tools you can use to better understand how a cable will perform and to

monitor any changes in the cable's performance.

b. To minimize your risk of injury from electrical shock make sure your Hipot equipment follows these

guidelines:

 The total charge you can receive in a shock should not exceed 45 µC.

HIPOT Testing of cables. Page 2 of 5

  The total Hipot energy should not exceed 350 mJ.

 The total current should not exceed 5 mA peak (3.5 mA rms)

 The fault current should not stay on longer than 10 mS.

 If the tester doesn't meet these requirements then make sure it has a safety interlock system that

guarantees you cannot contact the cable while it is being Hipot tested.

c. While you are testing cables there are several things you can do to reduce the risk even more:

 Verify the correct operation of the safety circuits in the equipment every time you calibrate it.

 Follow all of the manufacturer's instructions and safety guidelines.

 Don't touch the cable during Hipot testing.

 Allow the Hipot testing to complete before removing the cable.

 Wear insulating gloves.

 If you have any health condition that can be aggravated by being startled then don't use the

equipment.

 If you have any electronic implants then don't use the equipment.

4) Where is the high voltage applied?

a. To understand a how Hipot testing works you'll need to understand where to connect the high

voltage supply. Hipot testers usually connect one side of the supply to safety ground (Earth

ground). The other side of the supply is connected to the conductor being Hipoted.

b. In high potential testing of cable, the D. C. test voltage is applied in a minimum of four steps (each

step approximately equal to the rated rms voltage of the cable) of one (1) minute duration each,

except for the final test voltage which shall be maintained for fifteen (15) minutes

c. For commissioning new cables, the final D. C. test voltage is the 80% test voltage in the tables

below.

HIPOT Testing of cables. Page 3 of 5

 d. For commissioning new cables spliced to old cables, and for testing old cables, the final D. C. test

voltage shall be determined by the proponent of the cables, and should not exceed the 65% test

voltage in the tables below (40% of these values is recommended after 5 years ). A voltage equal to

1.7 X operating voltage is recommended for very old cables with low Megger readings.

TABLE 1: DC HIGH-POTENTIAL FIELD TEST VOLTAGES

Cable Voltage Rating After Installation – before cable is

In Service – first 5 Years
(Insulation Thickness) placed in regular service
5 kV(115 mils)
36 kV (a)(c) 11 kV (a)(c)
Or 6/10 kV(3.4mm)
15 kV(220 mils)
64 kV (a)(c) 20 kV (a)(c)
Or 12/20 kV(5.5mm)
35 kV(345 mils or 9mm) 100 kV (a)(c) 31 kV (a)(c)
69 kV(650 mils or 16.5mm) 192 kV (b)(c) ----
115 kV(800 mils or 20.3mm) 240 kV (b)(c) ----
Notes:
a) Source of test voltage values: ICEA S-94-649 and ICEA S-97-682
b) Source of test voltage values: EPR insulated 69kV cables: AEIC CS6; XLPE Insulated 69 and 115 kV cables:
AEIC CS7, 2nd Edition (1987). See also Paragraph 5.2.4
c) Values apply to both AEIC and IEC type cables.

5) Cables which undergo Hi-Pot Test should be undergone Megger test before and after the Hi-Pot.

6) HI-POT Test Control Equipment and High Voltage Generator.

HIPOT Testing of cables. Page 4 of 5

 6. Connection Diagram for AC VLF HI-POT Test

NAME SIGNATURE DATE

VIJAYAN THEKKEVEEDU

ULYSSES E. GENERALAO

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