Test for Thickness of Insulation of Power Cable

This test covers the technique to confirm the thickness of insulation and sheath of
electric power cables. Adequate thickness of insulation and sheath is provided to
power cable meet up the voltage stresses and mechanical stresses imposed on the
cable during its service life. The measurement of such thickness is necessary to
verify whether it is as per specified limit or not. These dimensions ensure safe and
reliable performance of the cable.
Apparatus required to test for thickness of insulation of Power Cable
This is purely a measurement process, hence the apparatus for the test are to be
chosen very carefully. There should be, a micrometer gauge capable of measuring
at least 0.01 mm variation, a vernier caliper which can clearly read at least 0.01
mm count, a measuring microscope with linear magnification of not less than 7
times and the possibility of reading at least to 0.01 mm, and a graduated
magnifying glass can read clearly at least 0.01 mm.
First different pieces of specimen are to be prepared for different measuring
instruments and methods. The specimen may be of 2 types 1st one is pieces of core
cable and 2nd one is slice pieces.

Procedure for testing of Thickness of Insulation of Power Cable

Approximately not less than 300 mm long pieces of core or cable cut from final
product is used in the case of round conductor and outer sheath. The specimen
must cut from the final product and remove all the covering materials above
insulation or sheath without damaging the insulation and sheath. Slice pieces cut
from the cable are used for optical measurement. In this case the materials outside
and inside of the insulation or sheath which to be measured, can be removed if
required. The slice is cut in sufficiently thin pieces along the plane perpendicular to
the axis of the cable. The measurements are preferably taken at room temperature.
The diameter of core of the cable and the diameter of insulated core and cable with
insulation as well as the sheath is measured with the help of micrometer gauge or a
vernier caliper. The measurement must be taken perpendicular to the axis of the
core or cable.
The measurements should be taken at different 3 points of equal interval along the
length of the specimen. These intervals may be about 75 mm in the case of 300
mm long piece of specimen. Each measurement is taken for the diameter of inside
and outside of the insulation or sheath. At each point two measurements shall be
made for better accuracy. Hence total 6 measurements of the diameter of below as
well as above of insulation/sheath are taken. Taking an average of 6 measured outer
diameters; we get the average measured outer diameter of the insulation / sheath.
Similarly, by taking an average of 6 measured inner diameters, we get the average
measured inner diameter of the insulation / sheath. Difference of average outer and
inner diameter divided by two is nothing but the average radial thickness of the
insulation/sheath.

Wh
ere the visual examination of the specimen reveals eccentricity, the optical method
shall be used by taking slice section the specimen. In the case of sliced section the
specimen is placed under a measuring microscope along the optical axis. For
circular specimen 6 such measurements are taken along the periphery at a regular
interval. For noncircular conductor, such measurement is done radially at each point
where the thickness of insulation appears minimum. The numbers of slices are
taken from a specimen at regular interval along its length in such a manner that the
total of such measurement would be not less than 18. For example, in case of
circular conductor, at least 3 slices are taken from a specimen and 6 measurements
in each slice to be carried out. In case of noncircular conductor, the number of slices
taken from a specimen depends upon the number of points of minimum thickness of
insulation. As in this case measurement is only made at the minimum thickness
points.
Tabulation of Observations
For Core/Cable Piece
Observations

Outer Diameter of

Inner Diameter of

Nos.

Insulation/Sheath (Dout)

Insulation/Sheath (Din)

1.

2.

3.

4.

5.

6.

For Slice Piece -

Observatio
ns Nos.

Minimum Thickness

Minimum Thickness

Minimum Thickness

of Insulation/Sheath of Insulation/Sheath of Insulation/Sheath

for Slice 1

for Slice 2

for Slice 3

1.

2.

3.

4.

5.

6.

Calculation for Thickness of Insulation/Sheath of Cable

For Core/Cable Piece

Where, Dout is the average of six measurements taken for outer diameter of the
insulation/sheath Where, Din is the average of six measurements taken for inner
diameter of the insulation/sheath.

For Slice Piece - The average of 18 optical measurements is taken as the minimum
thickness of insulation/sheath.
Report
Heading - Test for Thickness of Insulation/Sheath Cable Type - Batch No./Lot No. Cable No./Drum No. Results:
Reference Specification ....................................
Thickness of Insulation / Sheath

Observed

Specified

Average

Minimum

Conclusion - Specimen meets/does not meet the requirements of

specification.