Cable testing solutions for renewable photovoltaic power projects

The U.S. plans to add 54.5 gigawatts of new utility-scale electric-generating capacity to the power grid in 2023. More than half (54%) will be solar power and about 17% battery storage. 2023 will have the highest utility-scale solar capacity added in a single year, more than doubling the current record! This is an exciting development for the renewable energy world.

Access to high voltage distribution and transmission lines is key for the development of utility-scale solar power projects, as these are what move the power from where the electricity is generated to where it is consumed. These lines are critical from an energy delivery and reliability perspective.

Faults in cables can occur due to many reasons, such as regular service aging, over voltages, thermal overload, corrosion, and poor workmanship during transport and installation, among others. It is imperative that the high voltage cables are tested properly at the cable manufacturer to ensure no manufacturer defects are present and also on-site while the cable is laid to ensure no transportation damage has occurred. Furthermore, if a fault does occur while in service, obtaining efficient equipment to locate and resolve faults quickly is imperative so that the transmission of power can continue and potentially huge operating losses are kept to a minimum.

BAUR offers a number of custom cable fault location solutions even for new extra-long HVDC cables. The most time-saving measure a solar field operator can conduct to reduce the downtime created by a fault is to have a stationary cable fault location measurement system, ideally installing one at both ends to allow for the ability to measure from both ends significantly improving measuring and fault position accuracy. Another time-saving measure would be for utilities or solar field operators to have all necessary equipment installed in the Titron Cable Test Van.

The powerful IRG 4000 could be used to conduct a “fingerprint” analysis of the cable over the course of its lifetime. Systems can be built on trolleys that are stored in converter substations and used when required. If space is a factor, container solutions are also available so that the equipment could remain outside of the converter substations, regardless of weather conditions.

The Shirla, a revolutionary and unique device from BAUR, can be used to pre-locate cable faults and cable sheath faults. In combination with the BAUR Protrac Pinpointing System cable sheath faults and faults due to earth contact can be accurately pinpointed.

Shirla Features

• Fully automatic cable and cable sheath testing with DC voltage up to 10 kV
• Insulation resistance measurement
• Pre-location of cable sheath faults and faults due to earth contact (i.e. bad neutrals)
• Step-voltage method for cable sheath fault pinpointing with Protrac
• Automatic evaluation
• Portable and lightweight
• Mains and battery operated
• Data export via USB interface

Protrac Features

• Different sets available for:
• Acoustic and electromagnetic pinpointing of cable faults
• Pinpointing of cable sheath faults and faults due to earth contact using the step voltage method
• Tracing, cable fault location, and joint location with audio frequency
• Unique operating convenience thanks to wireless Bluetooth connections
• All system components except for step voltage probes are connected with Bluetooth
• Precise 3D user guidance to the fault
• Real-time fault calculation and display of the fault distance
• Excellent acoustic quality and range
• Adaptive two-stage ambient noise suppression
• Can also be used without headphones with the integrated loudspeaker in the control unit

A portable fault location system used for pre-location and pinpointing faults in power cables is the BAUR Syscompact 400 Portable. The simple menu, which can be controlled via a tablet or laptop, and integrated location methods, allow for fast and precise fault location. Remote operation via Wi-Fi is also available.

Syscompact 400 Features

• Fully integrated proven cable fault pre-location methods
• TDR
• SIM/MIM Secondary/Multiple Impulse Method
• DC-SIM/MIM
• ICM Impulse Current Method
• Control of measurement via tablet with BAUR BUI-F app or via laptop with BAUR Software 4
• TDR measurement can be controlled via WiFi
• Fast and reliable
• Precise, dependable cable fault location
• High-performance surge voltage generator
• Three voltage ranges: 8, 16, and 32 kV
• Surge energy up to 1100 J (Optionally up to 1540 J or 2050 J)
• Acoustic pin-pointing with Protrac

BAUR VLF test equipment can also be used to conduct tests on cables, cable sheaths, and electrical equipment according to the latest IEEE and IEC standards. There are several models available for different applications.

Frida Features

• VLF voltages up to 26.1 kV_rms (34 kV_peak) and DC voltages up to 34 kV
• Portable, compact, and lightweight
• Precise and non-destructive determination of the cable condition
• Easy and quick test setup with integrated high voltage cable
• Automatic testing sequences
• USB data transfer and display of measurement data with BAUR Diagnostic Reporter
• Ideal for cable testing on 20 kV cable systems according to IEEE 400.2
• Expandable to include integrated tan delta measuring function (Frida TD)
• Expandable to a VLF PD diagnostic system (with PD-TaD 62)
• Remote control of the generator and advanced data analysis capabilities with BAUR Software 4

Viola Features

• VLF voltages up to 44 kV_rms (62 kV_peak) and DC voltages up to 60 kV
• High performance and compact
• Precise and non-destructive determination of cable condition
• Easy and quick test setup with integrated high voltage cable
• Automatic testing sequences
• USB data transfer and display of measurement data with BAUR Diagnostic Reporter
• Ideal for cable testing on 35 kV cable systems according to IEEE 400.2
• Expandable to include integrated tan delta measuring function (Viola TD)
• Expandable to a VLF PD diagnostic system with PD-TaD 62
• Remote control of the generator and advanced data analysis capabilities with BAUR Software 4

PHG 80 Portable Features

• VLF voltages up to 57 kV_rms (80 kV_peak) and DC voltages up to 80 kV
• Fully automatic programmable test sequences via laptop with BAUR Software 4
• Very powerful 3 kVA generator capable of testing very long cable lengths with cable capacitance up to 20 µF
• Ideal for cable testing on 46 kV cable systems according to IEEE 400.2
• Compact 19″ housing
• Can be used as a stand-alone unit or installed in a test vehicle
• Expandable to a VLF tan delta diagnostic system with PD-TaD 80
• Expandable to a VLF PD diagnostic system with PD-TaD 80

OHV offers damped AC test systems for very long lengths of medium voltage cables: DAC M30 / M40 / M60 and for high voltage cables: DAC H200 / DAC H300, used as an asset management tool to help assess the cable insulation condition of newly installed, repaired, or service-aged cables. The systems allow for voltage withstand tests, partial discharge (PD) measurement with source localization along the length of cable, as well as the estimation of loss factor (or tan delta).

For testing high voltage transmission class cables up to 500 kV, the HAEFELY RSKF Variable Frequency Resonant Test System is based on the latest frequency converters to facilitate testing of long cable lengths in the field with fixed core, variable frequency reactors. The RSKF is mobile and easy to use and the low noise level is optimized to allow partial discharge measurements with the DDX 9121b, including PD site location along the length of the power cable.

RSKF Features

• RSKF model available with 260 kV, 83 A
• Frequency range 20 – 300 Hz
• Pure sinusoidal waveform at the system output
• Universally proven frequency converters
• Standard 3 phase generator can feed the system
• Front end components and control room are air-conditioned
• System noise level ≤ 10 PC for on-site PD measurements
• Models to match industry-standard voltages and currents
• Integrated solution on one trailer
• Multiple trailers can be used in series or in parallel configurations
• Easy integration with existing fixed-gap reactors (even non-HAEFELY reactors)

The transformers used in solar fields to step up the voltage converted from DC voltage is another important part of the photovoltaic plants that need testing solutions. Read our blog on the top of the line transformer testing solutions that we offer.