Adapting to Evolving Cable Testing Standards in a Demanding Industry

Understanding Electrical Cable Testing Standards

Electrical cable testing standards ensure the safety and reliability of electrical installations by providing a uniform method for assessing the integrity of cables and checking for faults. Standards provide a common language for manufacturers, customers, and technicians to use and limits to ensure consistent expectations locally and globally.

IEEE Standards

The Institute of Electrical and Electronics Engineers (IEEE) is the world’s largest organization of technical professionals. Its goal is to advance the knowledge and development of technology to benefit everyone. Its members are both volunteer and elected, and its operation includes full- and part-time employees from nearly every country.

The following IEEE Electrical Cable Testing Standards apply to most situations:

• IEEE 400 Series. his series includes guidelines for field testing and evaluating the insulation of shielded power cable systems. It also includes DC testing for cable systems, very low frequency (VLF) testing, partial discharge, and damped AC testing.
• IEEE 2412. Establishes procedures for testing the integrity of fire resistive cable systems in passenger rail and road tunnels.

ANSI/NETA Standards

The International Electrical Testing Association (NETA), in collaboration with the American National Standards Institute (ANSI), has developed comprehensive standards to ensure that electrical power systems and equipment are installed correctly, function properly, and meet manufacturer standards and tolerances. They provide two main electrical cable testing standards.

• ANSI/NETA ATS. This standard applies to acceptance testing for electrical power systems and equipment to determine readiness for initial energization. It defines electrical test procedures, including applied potential, test duration, and power factor tests,  and it establishes standards for technician training, certification, and supervision.
• ANSI/NETA MTS. This standard covers maintenance testing specifications for electrical power equipment and systems, including field tests and inspections, to determine the condition and reliability of electrical systems and their suitability for continued service.

IEC Standards

The International Electrochemical Commission (IEC) publishes international standards for electrical, electronic, and related technologies such as power generation, solar energy, and home appliances. Here are their main international electrical cable testing standards:

• IEC 60228. Standards for wire sizes and resistance.
• IEC 60502. Standards for power cables with extruded insulation and guidance on operating at voltages of 1kV to 30 kV.
• IEC 60840. Testing procedures for high-voltage transmission cables and cables rated for 30kV and higher.
• IEC 62067. Testing procedures for very high-voltage (EHV) cables.
• IEC 63026. Specifies standards for offshore wind farm and subsea cable destiny.

OSHA Standards

The Occupational Safety and Health Administration (OSHA) provides safety standards for most workplaces in the United States to protect workers from hazards and create safer working environments. Here are a few specific sections of OSHA Standard 1910 that may apply when performing cable testing on various job sites.

• Subpart I. Covers PPE requirements for working in hazardous conditions, including working with electrical components.
• Subpart R. Includes regulations for special industries, such as textiles, sawmills, and logging operations.
• Subpart S. This section covers specific electrical safety standards for the workplace.

Changes to ANSI/NETA Standards in 2023

There were several changes and updates to ANSI/NETA MTS standards. A new section was added for electric vehicle charging systems, references have been updated, and new workplace safety practices were added, in addition to other changes.

Regarding electrical cable testing standards, the section for testing medium- and high-voltage cables received a major rewrite after years of being unable to reach a consensus throughout the industry. A subcommittee was created in 2020 to make recommendations to revise this section and provide clear information on cable testing.

One major change included dielectric insulation testing for medium- and high-voltage cables to recommend very low frequency (VLF) withstand test. Previous versions of this electrical cable testing standard allowed the tester to determine which testing method to use. Tan-Delta testing and offline/online partial discharge testing are considered accurate methods, but optional at this time, and an appendix has been added to help technicians better understand when to utilize these optional tests.

Now that specific tests to perform are included, the electrical cable testing standard was also amended to add the expected test values, while other test values were reviewed. Offline and online partial discharge test values remain unchanged, and Tan-Delta values were moved to new tables at the end of the section.

Finally, a consensus was reached regarding acceptable insulation resistance values for shielded medium- and high-voltage cables. Because the correct method to verify insulation resistance is a formula with constants that are not easy to attain, the insulation resistance test should not be used in cable testing to find a discrete number for acceptability,

Key Factors Driving Changes in Cable Testing Standards

Testing and safety standards are continually revised to keep pace with technological advancements and changing industry and consumer demands. These changes not only accommodate new technology and applications but also reveal opportunities to improve safety and testing procedures.

Recent changes to IEEE and ANSI/NETA standards are driven in part by growth in renewable power generation and increasing demand in urban areas for buried cables rather than overhead lines. New materials in cable insulation also called for updates, along with evaluation of modern production processes for power cables and accessories. Environmental and sustainability concerns are also driving changes as regulations push for more sustainable practices and safer materials in both the manufacturing process and electrical cable testing standards.

Environmental & Sustainability Challenges in U.S. Cable Testing

The primary challenge in terms of sustainability and environmental challenges in electrical cable testing standards comes from the need to balance rigorous testing with the ecological impact of testing procedures and equipment. For example, PVC and plastics are traditionally used for cable insulation, but these materials are not biodegradable and produce pollution when improperly disposed of. Standards are gradually moving toward the use of more sustainable materials, but testing and maintenance standards must move along the same path.

Energy consumption during testing is another concern. In particular, testing high-voltage cables using AC testing methods uses a particularly high amount of energy. Current electrical cable testing standards are now emphasizing lower-consumption methods such as VLF testing. Still, legacy equipment and outdated procedures can sometimes complicate the shift in this direction.

Some electrical cable testing methods, including those that use chemicals and dielectric fluids, create waste that is harmful to the environment unless strict disposal methods are used. Changes in electrical cable testing standards are now incorporating detailed guidelines for the handling and disposal of testing byproducts to prevent environmental contamination.

Underground and submarine cable testing poses environmental concerns for the natural habitats surrounding these cables. Regular testing and maintenance of these cables can cause harmful disruptions to habitats, and non-invasive testing methods can provide a potential solution for some of the disruptions.

How International Standards Compare to American Cable Testing Standards

The IEC is the primary organization concerned with international electrical cable testing standards. American standards are typically provided by the IEEE and ANSI/NETA. In most cases, the goals of cable testing are aligned across organizations, and differences are found mainly in methods and scope.

For example, IEC standards are primarily focused on high-voltage and extra-high-voltage cables which are present in European systems that rely heavily on underground high-voltage cables. North American distribution systems commonly rely on medium-voltage cables, and the IEEE and ANSI/NETA include detailed sections of electrical cable testing standards for these systems.

In terms of testing methods, American electrical cable testing standards are likely to be more specific in maintenance requirements and include detailed instructions for inspection intervals, testing frequencies, and environmental factors that affect the health of a cable. Both international and American standards prescribe specific testing for new cables and installations.

The scope of American standards tends to cater to US regulations and provide specific guidance for industries such as utilities, construction, and public infrastructure. IEC standards are more broadly applicable across countries and industries and reflect European practices, but not always locally-specific regulations.

The Impact of New Electrical Cable Testing Standards on Industrial Operations

For industrial and manufacturing operations, new standards in cable testing are all good news. Better practices and regular inspections bring significant benefits, including:

• Preventive Maintenance. Rather than requiring emergency action due to an unexpected failure, regularly testing cables can identify potential issues and allow for scheduled maintenance and repair. Proactive testing can also offer insight into the overal working life left in a cable.
• Longer Working Life. Regular cable testing and inspection allow problems to be detected and solved before they become major issues that require the replacement of the cable. Delaying the need for replacement cables results in a more reliable system and reduced expenses.
• Cost Efficiency. Timely maintenance can defer the need for replacement equipment, and a reliable electrical system can also reduce unexpected downtime and the associated losses.
• Increased Safety & Compliance. Providing a safe workplace for employees is required in the United States, and failure to do so can result in serious consequences for industrial and manufacturing operations. One of the main purposes of industry and regulatory standards is to keep people safe. Complying with all electrical cable testing standards is the best way to protect your workers, your equipment, and your entire operation.

Compliance Challenges with Evolving Testing Standards

Complying with national and international electrical cable testing standards, such as those provided by the IEEE and NETA, is often legally required, depending on the industry and location. In the United States, compliance with all applicable OSHA standards is required for nearly all employers who are not regulated by another federal or state agency. Failing to comply with required standards could result in hefty fines, penalties, or even shutdowns.

Complying with electrical cable testing standards also helps reduce your liability for workplace incidents. Power cables can potentially cause serious harm to workers, and companies are far more likely to be held liable for damages if required standards and recommended steps are not followed.

In addition to legal and financial liabilities, other parties may have an interest in ensuring your operations adhere to all standards for cable testing and other industry regulations. For example, insurance policies can stipulate adherance, and insurers may cancel coverage or reject a claim due to non-compliance. Vendors and contractors can specify that cable testing and maintenance adhere to industry standards.

Best Practices for Adapting to New Testing Standards

First, be proactive to stay current with changing electrical cable testing standards. Organizations like the IEEE and ANSI/NETA regularly publish information relating to updates and changes in the industry. Attending industry events and staying connected with informed colleagues can also help keep you informed.

For testing providers, it may be prudent to conduct a gap analysis to compare their current testing processes with new standards and determine where their crew needs additional training. It’s also critical to determine whether tools need to be upgraded and whether processes and procedures need to be reexamined.

It can be helpful to partner with groups that offer training and certification for workers. For example, NETA offers a program for Certified Electrical Testing technicians with guidelines for education, training, experience, and on-the-job supervision that makes it easy to ensure that cable testers are up to date on the latest techniques and protocols.

Emerging Technologies in Electrical Cable Testing

New technology makes it easier to be proactive when it comes to cable management. Innovations in testing are delivering more precise measurements that allow for better predictions, longer cable life, and a reduction in unexpected cable failures.

Smart Technology

Smart technology, or devices that can communicate with each other and with other systems, has impacted nearly every industry. Smart devices allow more data to be captured using sophisticated technology, and this data can be easily compiled, shared, analyzed, and stored for future use.

Some smart devices can remain in place and collect data, allowing for remote monitoring and reducing the need for traveling field technicians. Along with being more cost effective, remote devices can reduce risks associated with hands-on testing of cables, including electric shock and arc flash.

When it’s time to analyze all this collected data, artificial intelligence and machine learning are already helping to detect patterns, trends, and anomalies and providing enhanced insight into the remaining life of a cable or component and when future maintenance should be performed.

Advanced Partial Discharge (PD) Detection

Online PD testing allows for the real-time monitoring of insulation health without requiring cables to be offline. It reduces downtime and provides insights into wear patterns over time for more accurate failure prediction. Ultra-high-frequency PD detection is extremely sensitive and is used to detect insulation faults at earlier stages, and is useful in critical applications and high-voltage systems where precise measurements are essential.

VLF and Damped AC Testing

Very Low Frequency (VLF) testing uses low-frequency alternating current to test the insulation of medium- and high-voltage cables. It provides a safer alternative to DC testing that is non-destructive and effective for long cable runs.

Damped AC (DAC) testing uses a damped AC signal that reduces stress on insulation without impeding diagnostics. Industries such as offshore wind use DAC testing for long-distance high-voltage cables.

Fiber Optic Sensing

Distributed Temperature Sensing (DTS) uses embedded fiber optic sensors along cables to measure temperature variations and identify hotspots that might point to an insulation failure. Distributed Acoustic Sensing (DAS) uses sensors to detect vibrations along the length of a cable to identify faults resulting from mechanical strain or disturbances. DAS technology is especially useful for monitoring buried cables in challenging climates and environments.

The Importance of Choosing the Right Cable Testing Partner

Cable testing is critical to ensure the safety and reliability of your operations. New cables must demonstrate that they are fit for purpose before being energized, and aging cables must be monitored and tested for deterioration and remaining lifespan.

It is imperative to partner with a NETA-certified organization that has a roster of NETA-certified technicians with the knowledge and experience to perform acceptance and maintenance testing of your power cables and electrical systems.

Quad Plus is an all-inclusive power systems service provider for nearly every industry. Our team of NETA-certified technicians is ready to perform acceptance and maintenance testing according to all electrical cable testing standards. To learn more or to get started, contact Quad Plus today.