Power cables with extruded insulation and their accessories for rated voltages above 30 kV (U<sub>m</sub>= 36 kV) up to 150 kV (U<sub>m</sub> = 170 kV) - Test methods and requirements

IEC 60840:2020 is available as IEC 60840:2020 RLV which contains the International Standard and its Redline version, showing all changes of the technical content compared to the previous edition.
IEC 60840:2020 specifies test methods and requirements for power cable systems, cables alone and accessories alone, for fixed installations and for rated voltages above 30 kV (Um = 36 kV) up to and including 150 kV (Um = 170 kV). The requirements apply to single-core cables and to individually screened three-core cables and to their accessories for usual conditions of installation and operation, but not to special cables, such as submarine cables and their accessories, for which modifications to the standard tests or the setup of special test conditions can be necessary. This document does not cover transition joints between cables with extruded insulation and paper insulated cables. This fifth edition cancels and replaces the fourth edition, published in 2011. This edition constitutes a technical revision. This edition includes the following significant technical changes with respect to the previous edition:
- Gas immersed cable terminations for use at rated voltages above 52 kV are required to be designed, type and routine tested in accordance with IEC 62271-209 in addition to the routine and type tests specified in this document.
- Requirements are introduced for composite outdoor termination insulators.
- The test cylinder diameters specified for the bending test (type and prequalification tests) have been modified in line with IEC TR 61901:2016.
- A low smoke halogen free oversheath material, designated ST12 is introduced.
- Additional tests under fire conditions are introduced: vertical flame spread, smoke density, acidity and conductivity, which shall be applied according to the fire performance declared for the cable.
- A test for water penetration in the conductor is added.
- In addition to tests on the outer protection of joints, type tests on the screen sectionalizing insulation of all accessories have been introduced.
The contents of the corrigendum of February 2021 have been included in this copy.

Câbles d'énergie à isolation extrudée et leurs accessoires pour des tensions assignées supérieures à 30 kV (U<sub>m</sub> = 36 kV) et jusqu'à 150 kV (U<sub>m</sub> = 170 kV) - Méthodes et exigences d'essai

IEC 60840:2020 est disponible sous forme de IEC 60840:2020 RLV qui contient la Norme internationale et sa version Redline, illustrant les modifications du contenu technique depuis l'édition précédente.
L'IEC 60840:2020 spécifie les méthodes et les exigences d'essai applicables aux systèmes de câbles d'énergie, câbles seuls et accessoires seuls, pour installations fixes, pour des tensions assignées supérieures à 30 kV (Um = 36 kV) et jusqu'à 150 kV (Um = 170 kV) inclus. Les exigences s'appliquent aux câbles unipolaires, aux câbles tripolaires à écran individuel et à leurs accessoires, pour des conditions habituelles d'installation et de fonctionnement, mais pas aux câbles spéciaux, tels que les câbles sous-marins et leurs accessoires, pour lesquels il peut être nécessaire d'apporter des modifications aux essais normaux ou d'élaborer des conditions d'essai particulières. Les jonctions assurant le raccordement des câbles à isolant extrudé aux câbles isolés au papier ne sont pas couvertes par le présent document. Cette cinquième édition annule et remplace la quatrième édition parue en 2011. Cette édition constitue une révision technique.
Cette édition inclut les modifications techniques majeures suivantes par rapport à l'édition précédente:
- il est exigé que les extrémités de câble immergées dans du gaz pour une utilisation à des tensions assignées supérieures à 52 kV soient soumises à des essais de type et des essais individuels de série conformément à l'IEC 62271-209 en plus des essais individuels de série et des essais de type spécifiés dans le présent document;
- les exigences relatives aux isolateurs composites pour extrémités de câble extérieures ont été introduites;
- les diamètres des cylindres d'essai spécifiés pour l'essai d'enroulement (essais de type et de préqualification) ont été modifiés conformément à l'IEC TR 61901:2016;
- un matériau de gaine extérieure sans halogène à faible dégagement de fumée, appelé ST12 a été introduit;
- les essais supplémentaires des câbles soumis au feu (propagation verticale de flammes, densité de fumées, acidité et conductivité) qui doivent être appliqués conformément aux performances de résistance au feu déclarées pour le câble ont été introduits;
- un essai de pénétration d'eau dans l'âme a été ajouté;
- en plus des essais des protections externes des jonctions, les essais de type de l'arrêt d'écran ont été étendus à tous les accessoires.
Le contenu du corrigendum de février 2021 a été pris en considération dans cet exemplaire.

General Information

Status
Published
Publication Date
18-May-2020
Technical Committee
Current Stage
PPUB - Publication issued
Completion Date
19-May-2020
Ref Project

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IEC 60840:2020 - Power cables with extruded insulation and their accessories for rated voltages above 30 kV (U<sub>m</sub>= 36 kV) up to 150 kV (U<sub>m</sub> = 170 kV) - Test methods and requirements
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IEC 60840
Edition 5.0 2020-05
INTERNATIONAL
STANDARD
NORME
INTERNATIONALE
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
Câbles d'énergie à isolation extrudée et leurs accessoires pour des tensions
assignées supérieures à 30 kV (Um = 36 kV) et jusqu'à 150 kV (Um = 170 kV) –
Méthodes et exigences d'essai
IEC 60840:2020-05(en-fr)
---------------------- Page: 1 ----------------------
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---------------------- Page: 2 ----------------------
IEC 60840
Edition 5.0 2020-05
INTERNATIONAL
STANDARD
NORME
INTERNATIONALE
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
Câbles d'énergie à isolation extrudée et leurs accessoires pour des tensions
assignées supérieures à 30 kV (Um = 36 kV) et jusqu'à 150 kV (Um = 170 kV) –
Méthodes et exigences d'essai
INTERNATIONAL
ELECTROTECHNICAL
COMMISSION
COMMISSION
ELECTROTECHNIQUE
INTERNATIONALE
ICS 29.060.20 ISBN 978-2-8322-8302-8

Warning! Make sure that you obtained this publication from an authorized distributor.

Attention! Veuillez vous assurer que vous avez obtenu cette publication via un distributeur agréé.

® Registered trademark of the International Electrotechnical Commission
Marque déposée de la Commission Electrotechnique Internationale
---------------------- Page: 3 ----------------------
– 2 – IEC 60840:2020 © IEC 2020
CONTENTS

FOREWORD ........................................................................................................................... 8

INTRODUCTION ................................................................................................................... 10

1 Scope ............................................................................................................................ 11

2 Normative references .................................................................................................... 11

3 Terms and definitions .................................................................................................... 13

3.1 Definitions of dimensional values (thicknesses, cross-sections, etc.) .................... 13

3.2 Definitions concerning tests .................................................................................. 13

3.3 Other definitions ................................................................................................... 14

4 Voltage designations, materials and rounding of numbers ............................................. 15

4.1 Rated voltages ...................................................................................................... 15

4.2 Cable insulating compounds ................................................................................. 15

4.3 Cable metal screens/sheaths ................................................................................ 15

4.4 Cable oversheathing compounds .......................................................................... 16

4.5 Rounding of numbers ............................................................................................ 16

5 Precautions against water penetration in cables ............................................................ 16

6 Cable characteristics ..................................................................................................... 17

7 Accessories characteristics ........................................................................................... 18

7.1 Gas immersed cable terminations ......................................................................... 18

7.2 Composite insulators for outdoor cable terminations ............................................. 18

7.3 Accessory characteristics to be declared .............................................................. 18

8 Test conditions .............................................................................................................. 19

8.1 Ambient temperature............................................................................................. 19

8.2 High voltage tests ................................................................................................. 19

8.3 Waveform of lightning impulse test voltages .......................................................... 19

8.4 Relationship of test voltages to rated voltages ...................................................... 19

8.5 Determination of the cable conductor temperature ................................................ 19

9 Routine tests on cables and accessories ....................................................................... 19

9.1 General ................................................................................................................. 19

9.2 Partial discharge test ............................................................................................ 20

9.3 Voltage test .......................................................................................................... 20

9.4 Electrical test on oversheath of the cable .............................................................. 21

10 Sample tests on cables .................................................................................................. 21

10.1 General ................................................................................................................. 21

10.2 Frequency of tests ................................................................................................ 21

10.3 Repetition of tests ................................................................................................. 21

10.4 Conductor examination ......................................................................................... 21

10.5 Measurement of electrical resistance of conductor and metal screen .................... 22

10.6 Measurement of thickness of cable insulation and oversheath .............................. 22

10.6.1 General ......................................................................................................... 22

10.6.2 Requirements for the insulation ..................................................................... 22

10.6.3 Requirements for the cable oversheath .......................................................... 23

10.7 Measurement of thickness of metal sheath ............................................................ 23

10.7.1 General ......................................................................................................... 23

10.7.2 Lead or lead alloy sheath ............................................................................... 23

10.7.3 Copper or aluminium sheath .......................................................................... 24

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IEC 60840:2020 © IEC 2020 – 3 –

10.7.4 Metal tape for CD design ............................................................................... 24

10.8 Measurement of diameters .................................................................................... 24

10.9 Hot set test for XLPE, EPR and HEPR insulations................................................. 24

10.9.1 Procedure ...................................................................................................... 24

10.9.2 Requirements ................................................................................................ 24

10.10 Measurement of capacitance ................................................................................ 25

10.11 Measurement of density of HDPE insulation .......................................................... 25

10.11.1 Procedure ...................................................................................................... 25

10.11.2 Requirements ................................................................................................ 25

10.12 Lightning impulse voltage test ............................................................................... 25

10.13 Water penetration test ........................................................................................... 25

10.14 Additional tests on components of cables with a longitudinally applied metal

tape or foil, bonded to the oversheath ................................................................... 25

11 Sample tests on accessories ......................................................................................... 26

11.1 Tests on components of accessory ....................................................................... 26

11.2 Tests on complete accessory ................................................................................ 26

12 Type tests on cable systems .......................................................................................... 26

12.1 General ................................................................................................................. 26

12.2 Range of type approval ......................................................................................... 27

12.3 Summary of type tests .......................................................................................... 28

12.4 Electrical type tests on cable systems ................................................................... 28

12.4.1 Test voltage values ........................................................................................ 28

12.4.2 Tests and sequence of tests .......................................................................... 29

12.4.3 Bending test .................................................................................................. 29

12.4.4 Partial discharge tests ................................................................................... 30

12.4.5 Tan δ measurement ....................................................................................... 30

12.4.6 Heating cycle voltage test .............................................................................. 30

12.4.7 Lightning impulse voltage test followed by a power frequency voltage

test ................................................................................................................ 31

12.4.8 Examination ................................................................................................... 31

12.4.9 Resistivity of semi-conducting screens .......................................................... 32

12.5 Non-electrical type tests on cable components and on complete cable .................. 32

12.5.1 General ......................................................................................................... 32

12.5.2 Check of cable construction ........................................................................... 33

12.5.3 Tests for determining the mechanical properties of insulation before and

after ageing ................................................................................................... 33

12.5.4 Tests for determining the mechanical properties of oversheaths before

and after ageing ............................................................................................ 33

12.5.5 Ageing tests on pieces of complete cable to check compatibility of

materials ....................................................................................................... 34

12.5.6 Loss of mass test on PVC oversheaths of type ST ....................................... 34

12.5.7 Pressure test at high temperature on oversheaths ......................................... 34

12.5.8 Test on PVC oversheaths (ST , ST ) and LSHF oversheaths (ST ) at
1 2 12

low temperature ............................................................................................. 35

12.5.9 Heat shock test for PVC oversheaths (ST and ST ) ..................................... 35

1 2

12.5.10 Ozone resistance test for EPR and HEPR insulations .................................... 35

12.5.11 Hot set test for EPR, HEPR and XLPE insulations ......................................... 35

12.5.12 Measurement of density of HDPE insulation .................................................. 35

---------------------- Page: 5 ----------------------
– 4 – IEC 60840:2020 © IEC 2020
12.5.13 Measurement of carbon black content of black PE oversheaths (ST

and ST ) ....................................................................................................... 36

12.5.14 Test under fire conditions .............................................................................. 36

12.5.15 Water penetration test ................................................................................... 37

12.5.16 Tests on components of cables with a longitudinally applied metal tape

or foil, bonded to the oversheath ................................................................... 37

12.5.17 Shrinkage test for PE, HDPE and XLPE insulations ....................................... 37

12.5.18 Shrinkage test for PE oversheaths (ST , ST ) and LSHF oversheaths
3 7

(ST ) ........................................................................................................... 37

12.5.19 Determination of hardness of HEPR insulation ............................................... 38

12.5.20 Determination of the elastic modulus of HEPR insulation ............................... 38

13 Prequalification test of the cable system ........................................................................ 38

13.1 General and range of prequalification test approval .............................................. 38

13.2 Prequalification test on complete system .............................................................. 39

13.2.1 Summary of prequalification tests .................................................................. 39

13.2.2 Test voltage values ........................................................................................ 39

13.2.3 Test arrangement .......................................................................................... 39

13.2.4 Heating cycle voltage test .............................................................................. 40

13.2.5 Lightning impulse voltage test ........................................................................ 41

13.2.6 Examination ................................................................................................... 41

13.3 Tests for the extension of the prequalification of a cable system ........................... 41

13.3.1 Summary of the extension of prequalification test .......................................... 41

13.3.2 Electrical part of the extension of prequalification tests on complete

cable system ................................................................................................. 41

14 Type tests on cables ...................................................................................................... 43

14.1 General ................................................................................................................. 43

14.2 Range of type approval ......................................................................................... 44

14.3 Summary of type tests .......................................................................................... 44

14.4 Electrical type tests on completed cables .............................................................. 45

15 Type tests on accessories ............................................................................................. 45

15.1 General ................................................................................................................. 45

15.2 Range of type approval ......................................................................................... 45

15.3 Summary of type tests .......................................................................................... 46

15.4 Electrical type tests on accessories ...................................................................... 47

15.4.1 Test voltage values ........................................................................................ 47

15.4.2 Tests and sequence of tests .......................................................................... 47

16 Electrical tests after installation ..................................................................................... 47

16.1 General ................................................................................................................. 47

16.2 DC voltage test of the oversheath ......................................................................... 47

16.3 AC voltage test of the insulation ............................................................................ 47

Annex A (informative) Determination of the cable conductor temperature ............................. 55

A.1 Purpose ................................................................................................................ 55

A.2 Calibration of the temperature of the main test loop .............................................. 55

A.2.1 General ......................................................................................................... 55

A.2.2 Installation of cable and temperature sensors ................................................ 55

A.2.3 Calibration method ........................................................................................ 57

A.3 Heating for the test ............................................................................................... 57

A.3.1 Method 1 – Test using a reference cable ....................................................... 57

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IEC 60840:2020 © IEC 2020 – 5 –
A.3.2 Method 2 – Test using conductor temperature calculations and

measurement of the surface temperature ....................................................... 58

Annex B (normative) Rounding of numbers .......................................................................... 59

Annex C (informative) List of type, prequalification and extension of prequalification

tests for cable systems, cables and accessories ................................................................... 60

Annex D (normative) Method of measuring resistivity of semi-conducting screens ............... 62

Annex E (normative) Water penetration test ......................................................................... 65

E.1 Test piece ............................................................................................................. 65

E.2 Test ...................................................................................................................... 65

E.3 Requirements ....................................................................................................... 66

Annex F (normative) Test for water penetration in the conductor .......................................... 67

F.1 Test piece ............................................................................................................. 67

F.2 Test ...................................................................................................................... 67

F.3 Requirements ....................................................................................................... 67

Annex G (normative) Tests on components of cables with a longitudinally applied

metal tape or foil, bonded to the oversheath ......................................................................... 69

G.1 Visual examination ................................................................................................ 69

G.2 Adhesion and peel strength................................................................................... 69

G.2.1 General ......................................................................................................... 69

G.2.2 Test: Adhesion strength ................................................................................. 69

G.2.3 Test: Peel strength of overlapped metal foil ................................................... 70

G.2.4 Requirements ................................................................................................ 71

Annex H (normative) Additional tests for accessories ........................................................... 73

H.1 General ................................................................................................................. 73

H.2 Range of approval................................................................................................. 74

H.2.1 Range of approval for joints without screen or metal sheath interruption ........ 74

H.2.2 Range of approval for joints with screen or metal sheath interruption ............. 74

H.2.3 Range of approval for accessories for cable screen interruption and/or

earth connection ............................................................................................ 74

H.2.4 Range of approval for terminations with sectionalizing insulation ................... 75

H.3 Tests of joints with or without screen or metal sheath interruption and

accessories for cable screen interruption and/or earth connection ........................ 75

H.3.1 Water immersion ........................................................................................... 75

H.3.2 Electrical tests ............................................................................................... 75

H.4 Tests of terminations with sheath sectionalizing insulation .................................... 77

H.4.1 DC voltage withstand test between screen and earth ..................................... 77

H.4.2 Lightning impulse voltage withstand test between screen and earth ............... 77

H.5 Examination .......................................................................................................... 77

H.6 Tests for composite insulators for outdoor terminations ......................................... 78

H.6.1 General ......................................................................................................... 78

H.6.2 Internal pressure test ..................................................................................... 78

H.6.3 Cantilever load test ........................................................................................ 78

Annex I (normative) Determination of hardness of HEPR insulations .................................... 79

I.1 Test piece ............................................................................................................. 79

I.2 Test procedure ...................................................................................................... 79

I.2.1 General ......................................................................................................... 79

I.2.2 Surfaces of large radius of curvature ............................................................. 79

I.2.3 Surfaces of small radius of curvature ............................................................. 79

I.2.4 Conditioning and test temperature ................................................................. 79

---------------------- Page: 7 ----------------------
– 6 – IEC 60840:2020 © IEC 2020

I.2.5 Number of measurements .............................................................................. 80

Annex J (informative) Guidance on examination of cable and accessories ........................... 81

Annex K (normative) Methods of determining the weighted value of the cable for

measurement of halogen content .......................................................................................... 82

K.1 Calculating the weighted value of the cable when the halogen content of

individual materials is tested ................................................................................. 82

K.2 Preparation of the test sample for measurement of halogen content on a

sample representative of the cable construction .................................................... 82

Bibliography .......................................................................................................................... 83

Figure 1 – Example of the test arrangement for the prequalification test ............................... 40

Figure 2 – Example of extension of prequalification test arrangement for the

prequalification of a system with another joint, designed for rigid as well as flexible

installation ............................................................................................................................ 42

Figure A.1 – Typical test set-up for the reference loop and the main test loop ....................... 56

...

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