by Thermo 5. October 2011 15:34
 Water Trees – Too Big to Fail?
Dear Ample Amphibian,
  
We had three cable samples (tagged A, B, and C) sent out for testing from different areas. These areas are not those we are injecting this year. Each area has suffered multiple failures. I am attaching a confidential lab report (summarized within the table below) on the condition of the cables (presence of vented trees, voids and bow tie trees). We would like to have your opinion as to whether the injection process will be able to revive cables that have deterioration to this extent. Please send us any literature that you have, which can illustrate the extent of damaged cables and their successful rejuvenation.
 
Max dimension
Sample A
Sample B
Sample C
Bow-tie trees
25%
36%
46%
Vented trees
18%
4%
0%
Voids
no void geometry reported
Note: Values in percent are relative to insulation thickness. 
  
Not wishing to go to the dark side,
 
Bright Light in Ontario
 

"Chancellor Palpatine, Sith Lords are our specialty."

                                                  ―Obi-Wan Kenobi
 
Dear Ontario-
 
In Star Wars Episode III, Revenge of the Sith, Obi-Wan was not discouraged by the presumed strength of a Sith Lord.  It was easy for Obi-Wan to profess bravado, as he had slain a Sith Lord in a previous episode.  Likewise, the Jedi Masters of Reliability at Novinium are not frightened of water trees – not even those that span 100% of the insulation thickness! Virtually all of the millions of meters of cable treated by Novinium Masters include very large water trees. Even previous generations of technology developed by Novinium founders have successfully rejuvenated cables with monstrous, Sith-like water trees.
Consider the graph nearby, which compiles before-and-after AC breakdown values as a function of water tree length from several sources. To provide context, a construct of KEMA’s Fred Steennis is included. Fred is the world’s foremost authority on water treeing and a friend of this frog. The curve labeled, “Steennis Model,” shows the relationship between the largest water tree length identified in a cable and the AC breakdown (ACBD) strength in kV per millimeter of insulation thickness. With a great deal of field data, Dr. Steennis was also able to determine that a “Good” box is delineated at its bottom at 16 kV/mm. Of the dozens of cables removed from service in the Netherlands utilized to create this curve, none with over 16 kV/mm of ACBD had ever failed in service.  Below 16 kV/mm there were service reliability issues. Six before-treatment and after-treatment examples with trees ranging from 25% to 100% of the insulation thickness are provided from circuit owners in North America and Europe. In all cases treatment is able to raise the AC breakdown values above 16kV/mm, generally approaching the anticipated AC breakdown values expected of a new polyethylene cable, about 40 kV/mm.  The newest Novinium technology can accomplish this feat in as little as a week. Here are sources for the data in that figure. If you need any help accessing these papers, write to the Novinium librarian and tell them you are a friend of mine. Click here for the librarian’s home page and email address.

Reference
Citation
Steennis work
Steennis et al, “Water Treeing in Service Aged Cables, Experience and Evaluation Procedure,” IEEE Transactions on Power Delivery, Vol. 5, No.1, January 1990.
CPS Energy (San Antonio, TX)
Mokry, Chatterton, Carter, Sibbald, Clemmer, Bertini & George, “Cable Fault Prevention Using Dielectric Enhancement Technology,” Jicable, June 1995.  Republished in REE Spécial Câbles.
Essent (EGD/Edon, Netherlands)
OG&E (Oklahoma Gas & Electric)
Virginia Power (VEPCO)
Florida Power & Light (FPL)
Cable Tech. Labs (CTL, New Jersey)
Bertini, “New Developments in Solid Dielectric Life Extension Technology”, IEEE International Symposium on Electrical Insulation (ISEI), September 2004.  Click here to view.
 
No matter the size of your vented or bow-tie water trees, Novinium’s Jedi Masters of Reliability will take them on and defeat them. Preserve your capital and avoid the seductive dark side – expensive cable replacement.
  
May the force be with you,
Froggy-Wan Kenobi

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Operational Considerations

by Thermo 3. October 2011 18:36

 Bursting a Bubble

Frankest of Frogs,

 

I need a written response to my inquiry.  I will use your response as a basis to NOT inject #2 copper cable that was installed prior to 1970.  My stance is that there has been an instance where this older cable has burst during injection due to loading and geometry changes and should be replaced. Your comments would help substantiate this claim.

 

Sincerely,

 

Albert A.

 

 

Figure 9.  Enlarged cross section of a cable, which burst at its tailored injection pressure (TIP). The cable was eccentric along a significant length. This photograph was taken 72 cm from the burst point. The minimum insulation thickness is less than the 4.19 mm minimum insulation thickness required by Table 4-7 of ICEA S-97-682-2004. Note that the strand-shield remains in intimate contact with the strands. 

 

 Dear Albert-

I’m not sure you will be able to use my comments to substantiate your claim. While you are exactly right that “… there has been an instance where this older cable burst during injection,” it is also true that about 9,999 cable segments of similar vintage have not burst during injection.  Put another way, bursting cable has historically occurred in just 0.01% of injection cases – success is realized 99.99% of the time! There aren’t many things with that level of performance.  And even for that single case, the burst occurred, because the cable was eccentric and did not meet the minimum insulation thickness requirements of Table 4-7 of ICEA S-97-682-2004 of 4.19 mm. This lonely case was described in some detail on Page 5 of ...

 

Silicone Injection: Better with Pressure

 

... presented in Subcommittee A of the Insulated Conductors Committee (ICC) on May 19, 2009. I have reproduced Figure 9 from that paper above.

 

Reliably yours (at least with four nines),

 

T. B. Frog

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Operational Considerations

by Thermo 1. October 2011 12:47

Reflections on a TDR

Dear Thermo,

The blog entitled "Neutral Corrosion - How much is too much?" includes a waveform from a TDR (time domain reflectometer, often called a radar) that is used to pinpoint bad sections of cable neutral. The TDR is also used to pinpoint splice locations on the cable. Please provide the details of how the TDR determines the neutral corrosion and splices on the cable and how the wave form is read to tell them apart and to pinpoint their locations.

Reflective in MD 

Dear Reflective-

Step-by-step instructions for how to identify and pinpoint neutral corrosion and splices on concentric medium voltage power cables are provided in Novinium Rejuvenation Instruction 12 entitled, “Electronic Cable Diagnosis and Pinpointing.” Click NRI-12 to view the document as a PDF. The TDR sends a low voltage (10-20 volts), short wave length (1-20 nanoseconds) pulse down the cable. A portion of the wave is reflected when it encounters a change in impedance. There are four main types of impedance changes encountered along the length of a test cable.  Remember – impedance includes three elements, resistance, capacitance, and inductance. 

(1)       Instrument-Cable Interface

The first impedance change that is encountered results from the mating of the test instrument lead, an RG59 coaxial cable, which has a characteristic impedance of 75 ohms, with the power cable, which has a characteristic impedance of 8 to 38 ohms depending upon its geometry and polymer system. To minimize the reflection from this unavoidable impedance change, the masters of reliability at Novinium use a proprietary impedance streamliner. This is akin to an aerodynamic sports car versus a squarish pick-up truck. The impedance streamliner is like the smooth curves of the sports car, reflecting less of the input pulse, minimizing signal attenuation and dispersion. Attenuation is the reduction of signal amplitude and dispersion is the smearing of narrow pulse into a broader, less discrete pulse. Both are undesirable. Some reflection is unavoidable. The signature of Novinium’s impedance streamliner shown in red is superimposed upon the green signature of an older impedance technology device (ITD) in the image nearby. Untoward noise and reflections avoided improve the usability and hence the sensitivity and accuracy of the TDR.

(2)       Splice 

In the image nearby I am standing next to a very typical splice during a recent coffee break. The neutrals are all dirty as they are prone to be in a pit, but if you look carefully along the orange annotation, you can see how the neutrals are close to the conductor on the cable, then are pig-tailed together and lay farther from the conductor as they jump across the molded splice body. On the far end of the splice the neutrals again come back to intimate proximity. This change in the separation of the two signal conductors – the conductor and the neutral – changes the circuit impedance. The resistance is not significantly changed, the already low capacitance decreases with increasing distance, but that capacitance change is trivial compared to the change in inductance. The inductance and hence the impedance skyrockets as the neutrals leave the insulation shield and then plummets when the neutrals return to the cable. I have superimposed the actual TDR image of a splice, a characteristic sine wave, in the lower-right-hand corner.

(3)       Neutral Corrosion

The physics are even simpler for neutral corrosion. The capacitance and inductance components are insignificant. A good old-fashioned resistance increase is displayed as an impedance increase. Check out the nearby image.

 

(4)       End-of-cable

Simpler still, the end of the cable is characterized by either an infinite impedance increase if the circuit is open or an infinite impedance decrease if the conductor is grounded to the neutral. When used, grounding devices add some more color to the wave shape, but the basic idea remains the same.

The TDR signal is reflected by each of the above impedance changes and the time the signal takes to travel to and then from the impedance change can be used to estimate the distance to that change. Note that the TDR is not a pinpointing technology, it provides a location estimate. To pinpoint splices and corrosion a second technology, radio-frequency (RF) locating, is utilized. If you desire, I will be happy to explain how that works too. NRI-12, described earlier, provides step-by-step instructions to accomplish RF pinpointing.

Your adroit amphibian,

T. B. Frog

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