Adoption of Best Practices for Cable Testing and Condition Monitoring in the Offshore Renewables Market
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1 Adoption of Best Practices for Cable Testing and Condition Monitoring in the Offshore Renewables Market Presented by: Dr Lee Renforth Managing Director, HVPD Ltd
2 CONTENTS Why do we need improved commissioning testing and condition monitoring for subsea cables? Exploring the options for diagnostic testing as part of the field acceptance/commissioning tests for subsea cables. What options are available for the condition monitoring (CM) of in-service subsea cables? Diagnostic testing and condition monitoring Case Studies from the Oil and Gas industry. How can condition monitoring technology support condition based management (CBM) of these assets.
3 Introduction to HVPD Ltd Introduction to HVPD Ltd HVPD are experts in the field of on-line partial discharge (OLPD) condition monitoring technology with specific expertise in MV and HV cable monitoring. We have over 20 years of experience in testing of in-service MV and HV cables, switchgear, transformers and motors/generators. We supply portable and permanent OLPD diagnostic test and continuous monitoring solutions, and a complimentary range of on-site test services and training. Five main market sectors: Oil & Gas, Renewables, Transmission & Distribution, Shipping and Generation.
4 HVPD s Subsea Cable Clients HVDC & HVAC Interconnector Owners Manx 90kV 108km HVAC Interconnector Google
5 HVPD s Subsea Cable Clients Oil and Gas Operators 33kV Cables from Deepwater Offshore Wind Turbines
6 HVPD s Subsea Cable Clients Offshore Wind Farm (OWF) HVAC Export Cables & 33kV Inter-array Cables
7 Subsea MV and HV Cable Faults Common Causes Incorrect workmanship of the cable accessories leading to partial discharge, electrical tracking and finally complete insulation failure. Mechanical damage caused by poor installation practices including damage to the cable (from jack-up vessels, anchors, etc.) and/or poor quality cable mechanical protection of cable joints leading to scour and mechanical stressing. Thermal damage caused by poor bonding of cable earthing system and/or water ingress that leads to localised heating and thermal breakdown.
8 TEAM Stresses for Subsea Power Cables THERMAL ELECTRICAL AMBIENT MECHANICAL Thermal runaway problems can occur in cables where there are high circulating currents and local high resistance points. This is the No.1 cause of cable faults occurring within the first 3 years of service, typically due to incorrect installation of the cable accessories. The effects of mechanical wear and tear including scour caused by movement of the subsea cables with tidal and current changes. Many subsea cable failures are caused by mechanical damage caused by poor practice when installing and pulling-in the cables.
9 Introduction to Partial Discharge What is partial discharge? Why test for partial discharge? A localised electrical discharge that only partially bridges the insulation between conductors and which can or can not occur adjacent to a conductor PD activity is an indication of an incipient fault in HV insulation and is widely regarded as the best early warning indicator of insulation deterioration. IEC60270 Definition The detection of PD at an early stage enables preventative maintenance action to avoid unplanned outages.
10 Most Likely Sites of PD Activity in Subsea Cables
11 132 kv Onshore Cable Termination Failed and Exploded Outdoor Porcelain Cable Sealing End
12 33 kv OWF Export Cable Joint this joint had been exhibiting high levels of PD and was replaced and removed from service
13 110kV Transformer Cable Terminations Left photo showing PD scorching, Right photo of a failed termination Tracking and scorching on a 110 kv Termination (PD detected before failure) A Failed 110 kv Termination (Same type as opposite)
14 Reliability Centred Maintenance (RCM) Bathtub Curve Infant Mortality Steady State Failure End of Life Wear-out Failure Rate Steady State Failure Infant Mortality Phase Time 3 Years Years
15 Why and When to Perform PD Testing New Equipment At Manufacture Quality Assurance Type/routine tests, e.g. IEEE/IEC standards test to less than 5pC on the cables At Commissioning To check for transport damage To ensure the installation of the cable accessories have made to a good standard (these are the weak points in the cable system)
16 VLF and Soak Test Commissioning Tests for 33 kv Cables To detect any poor workmanship and/or installation damage with a particular focus on the cable accessories. Partial Discharge (PD) and Tan Delta (TD) diagnostic acceptance tests should be made in combination with the VLF voltage withstand test (from 2.0 to 3.0 U 0 i.e kv rms for 33 kv cables). This test is combined with an off-line, electrical Time Domain Reflectometry (TDR) testing to support both future PD Mapping (PD site localisation) and/or rapid fault location in the event of a cable fault.
17 Factory Testing of Cable Systems Cable components tested individually. Cable cores should be tested both before and then after their assembly into the 3-core subsea cable. High sensitivity measurements in a low-noise environment are required, typically to accuracies of <5pC. This requires a Faraday Cage, electromagnetically screened test room to achieve this sensitivity. The Faraday Cage HV test facility shown opposite can measure PD activity down to 1pC.
18 Cable HV Withstand Voltage Field Acceptance Test Options VLF (Very Low Frequency) ( Hz) example supplier: Baur - Austria, b2hv - Austria Variable Frequency Resonant Test Systems (RTS) (20-300Hz) example supplier: High-Volt Germany Damped AC / Oscillating Wave (OWTS) example suppliers: Seitz, SEBAkmt - Germany 24 Hour Soak Test (at U 0 ) No external power supply is required although extended, continuous 24-hour OLPD monitoring is necessary during the duration of the soak test.
19 Acceptance Testing Continuous Monitoring Damage Mistake Aging Repair Manufacturing Transportation Installation Factory Testing Power frequency 50/60 Hz From Cradle to Grave PD Testing and Monitoring Philosophy Operation Power frequency 50/60 Hz
20 Partial Discharge Cable Mapping PD Site Location along the cable The locations of any defects that exhibit PD activity will be detected along the length of the cable using the technique of time domain reflectometery (TDR). The PD Map of the cable below shows three (3) main sites of PD activity along the cable. PD Map of Circuit Meols Drive - Graham Road All Phases PD 7,000 6,500 6,000 5,500 5,000 4,500 4,000 3,500 3,000 2,500 2,000 1,500 1, Location (% along cable) All
21 On-line PD Testing & Monitoring to Support Planned Maintenance Interventions Repeat testing before the cable supplier/jointer warranty runs out! It is highly recommended that an on-line PD test is carried out before the warranty period expires (typically only 12 months). Continuous On-line PD (OLPD) monitoring throughout the service life To detect whether PD activity has initiated during the service life of the cable/plant To support maintenance and operation decisions, by detecting and localising any PD activity in in-service cables To direct preventative maintenance interventions.
22 CONDITION MONITORING OF IN-SERVICE SUBSEA MV AND HV CABLES
23 On-line Condition Monitoring Options for Subsea Power Cables THERMAL Distributed Temperature Sensing (DTS) using fibre optic detection technology. ELECTRICAL On-line Partial Discharge (OLPD), plus sheath current and power quality monitoring. AMBIENT Vibration monitoring using fibre optic detection technology. MECHANICAL Mechanical strain monitoring using fibre optic detection technology.
24 Fibre-Optic Strain, Vibration and Temperature Sensing Solution Optoelectronic devices which measure temperature and strain by means of optical fibres functioning as linear sensors DTS/Strain Monitoring unit Provides real-time, dynamic temperature and strain information along the complete length of power cable for health monitoring. Can identify small hot spot locations and localised mechanical damage without prior installation knowledge. Provides accurate temperature data input for dynamic cable rating based on actual installed conditions to monitor higher power flows through the cable. Local splice box Field splice box Fibre optic monitoring cable
25 Subsea 3-core Cable with Built-in Fibre-Optics Subsea cables can include up to 4 fibre-optic cables that can be utilised for distributed temperature, strain and vibration sensing. The example below shows a fibre along the cable centreline, and 3 fibres laid up and located in the interstices between the phases.
26 Offshore High Voltage Network Monitoring System OHVMS holistic HV/MV network condition monitoring (CM) system for offshore cable networks and connected plant (switchgear and transformers). The Condition Monitoring (CM) data is used to provide predictive, early warnings against incipient insulation faults. The system helps to avoid unplanned outages, supports preventative maintenance and reduces the high O&M costs of the OWF electrical networks.
27 Offshore High Voltage Network Monitoring System
28 OHVMS Cable Condition Monitoring Features and Benefits Earth Faults Loading Partial Discharge Sheath Currents Power Quality OHVMS HOLISTIC MONITORING SYSTEM Ambient Conditions Intelligent Diagnosis System Health Alarms System Stability Alarms Condition- Based Maintenance SMART Grid Integration Dynamic De-Rating
29 OHVMS Holistic MV/HV Cable Condition Monitoring System Example 80 x 3.6MW Turbine Array An OHVMS monitoring hub (MH1) is located at the offshore substation platform (OSP) to monitor: 33 kv switchgear 33/132 kv transformers 33 kv incoming cable strings from the turbine arrays Turbine Monitor Nodes (TMN01 TMN21) are positioned at strategic locations (every 3 rd turbine) across the turbine array, to provide complete network coverage.
30 OHVMS SMART-Quadplex Sensor Location In the Turbine Base
31 OHVMS SMART-Quadplex Sensor Location In the Turbine Nacelle A combined electrical state and condition assessment of the health of the network is provided using SMART-Quadplex sensors. The sensors and OHVMS monitor can be installed either at the base of the turbine or in the nacelle, depending on the turbine design.
32 CASE STUDY 1: ON-LINE PARTIAL DISCHARGE (OLPD) TESTING, LOCATION, MONITORING WITH PREVENTATIVE MAINTENANCE ON A 33 KV OFFSHORE WIND FARM EXPORT CABLE
33 Case Study 1: Export Cable Circuit Details 1.7 km single core XLPE land cable 9.6/11.5 km 3-core XLPE subsea cable
34 OLPD Test and Mapping Data L1 L2 L3 PD Magnitude (pc) Cable PD Phase of Pow er Cycle (deg) PD Magnitude (pc) Cable PD Phase of Pow er Cycle (deg) PD Magnitude (pc) Cable PD 10,000 5, ,000-10, Phase of Pow er Cycle (deg) High levels of PD (of up to 10,000 pc / 10 nc) were measured from the onshore substation on Circuit B, Phase L3.
35 PDMap Graph Showing PD Location Switching Substation Joint Pit 7 Land-sea Transition Joint ,000 Location (meters) 1,200 1,400 1,600
36 PD Signals Before and After Joint Replacement BEFORE High PD detected on L3 PD Located ,000 1,200 Location (meters) 1,400 1,600 Joint 7 with PD removed and replacement cable section installed Lower-level sporadic PD signals from different site after joint replacement AFTER
37 Circuit B Evidence of Surface Tracking and Degradation due to Poorly-Fitted Heatshrink Stress Control
38 CASE STUDY 2: INSTALLATION OF AN OLPD CONDITION MONITORING SYSTEM FOR A 400 KV ONSHORE GRID CONNECTION CABLE
39 Condition Monitoring throughout the service life of the cable. Continuous OLPD Insulation Condition Monitoring In-service Equipment Continuous OLPD monitoring of the insulation condition of the cable network throughout it s service life. Data from the technology supports Condition-Based Management (CBM) of critical cable networks. Provides increased security and reliability of electricity supply from offshore renewables generation. Helps to reduce O&M costs through the avoidance of faults and unplanned outages.
40 Sensor Locations at 400 kv Transformer Terminations
41 HV Cable OLPD Monitor System Drawing
42 CASE STUDY 3: OLPD TESTING AND LOCATION ON A DEEPWATER OFFSHORE WIND TURBINE CONNECTED TO AN OIL & GAS PLATFORM
43 Case Study 2: OLPD Testing and Location on a Deepwater Offshore Wind Turbine connected to an Oil & Gas Platform
44 Background Two deep-water wind turbines supply power exclusively to an oil production platform situated around 2km away. Two on-line PD tests were performed to assess the condition of the 33kV cables from two turbines to the oil & gas platform.
45 Test 1 OLPD Test at 33 kv Switchgear on Platform
46 Results from Test 1 at 33 kv Switchgear on the Platform High PD activity (in excess of 6,000pC+) was detected on the Turbine A Feeder. Analysis of the PD pulse data suggested that the source of the PD activity was at the far end of the Turbine A feeder cable. OLPD Cable Mapping was recommended.
47 Test 2 PD Test at the Wind Turbine s 33 kv Switchgear
48 PD Location at Wind Turbine A Test identified the PD source to the cable joint at the top of the tower close to the 33 kv transformer. Measurement of PD pulses showed the source of the PD being at 52m from the switchgear at Test Point 2. The cause of the discharge was meachanical stress due to insufficient support of the cable joint from the weight of the freehanging cable.
49 CASE STUDY 4: A COMPLETE 33 KV CABLE NETWORK OLPD SURVEY AND ANALYSIS TO SUPPORT CONDITION BASED MAINTENANCE (CBM) DUBAI METRO, DUBAI, UAE
50 Background On-line Partial Discharge (OLPD) test and cable mapping survey of the customer s 33 kv cable network was carried out by HVPD engineers using the HVPD Longshot diagnostic test system. This testing was carried out in response to a number catastrophic failures of 33 kv cable joints within their network which had led to disruption of the power supply to the Metropolitan rail system. The purpose of the testing was to measure and locate any PD activity within the cables with particular focus on the cable joints. It can be noted that this was a recently installed cable system that had been inservice for just over 12 months before the faults started to occur. After four 33kV cable joint faults in 2 months, the client requested a complete OLPD survey of the network to detect any incipient faults on the network.
51 OLPD Testing to Support CBM of a 33kV Cable Network On-line Cable PD Mapping using the HVPD Longshot test unit and Portable Transponder technology was used to carry out an on-line condition assessment of complete 33kV cable network. Tests started with calibration testing with pulse injection HFCTs, followed by OLPD measurements and then cable mapping tests.
52 33kV Cable Network Test Results I Cable PD signals of 6,000pC+ were detected on the Blue Phase with some cross-talk (lower magnitude) on the Red and Yellow phases. The source of PD was located to Joint Number 2 (Jt2) using the cable mapping test technique. The faulty joint on this cable was replaced and re-tested using the HVPD Longshot test unit to verify the repair was good.
53 33kV Cable Network Test Results II Examples of PD located on two 33kV circuits Left PD Located on Red Phase Joint No.1, Right PD located on Red Phase, Joint No.2
54 Top 20 Worst Performing 33kV Circuits The network consisted of 104x 33kV that were circuits tested High Levels of PD were detected in cable joints on the six of the circuits (6%) as shown in RED in the Table below, Condition Category, Major concern, locate PD and then repair. A further five circuits (5%) were in the Orange/Yellow Categor, these were also repaired. Criticality Number Circuit Comments Peak Cable PD Level (pc) Local PD Level (db) Cumulative Cable PD Level (nc/cycle) OLPD Criticality (%) Maintenance Action 1. DUB to MPS1 C2 B Phase < ABS to AH C2 B / Y Phase 9729 < Major concern, 3. BUR to HCC C2 B / Y Phase 3781 < locate PD and 4. BUR to HCC C1 B / Y Phase 3245 < then repair or 5. ABS to AH C1 B / Y Phase 2920 < replace. 6. NHD to QYD C2 R Phase 2849 < ALQ to AHS C2 B Phase 1733 < Some concern, 8. MPS3 to BNS C2 R / B Phase 1337 < repeat test and 9. NHD to QYD C1 R Phase 887 < regular 10. HCC to CRK C1 Y / B Phase 759 < monitoring 11. AHS to SLD Y / R Phase 705 < recommended. 12. STD to ABH Y Phase 238 < ALR to BNS C1 B Phase 184 < ALR to BRJ No PD detected 0 < ALG to PMD No PD detected 0 < ALG to KBW No PD detected 0 < AQD to AQ2 No PD detected 0 < JDD to CRK No PD detected 0 < ODM to JDF C1 No PD detected 0 < ODM to JDF C2 No PD detected 0 < Re-test in 12 months.
55 CONCLUSIONS
56 Conclusions The increasing installation rate of installation of offshore wind farms (OWFs) in Europe, combined with the high MV and HV cable fault rates reported to date, has led to a market need for better MV/HV cable condition monitoring (CM) technology. Offshore wind farm subsea cable owners need to also consider the use of diagnostic testing during cable HV withstand/commissioning tests. It is proposed that any CM system employed should combine thermal, electrical, ambient and mechanical monitoring to cover all four of the TEAM stresses that effect the reliable operation of the cables. The purpose of any CM system is to provide an early warning of incipient cable insulation faults to enable preventative maintenance interventions to avoid unplanned outages. A move towards Condition Based Management (CBM) of the cable networks (using data from holistic CM technologies) is seen as the key to reducing the presently high O&M costs to achieve DECC s target of a 25% reduction in Levelised Cost of Electricity (LCOE) by 2020.
57 End of Presentation Thank you for your time Q&A?
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