Test and research facilities

Institute of electrical energy systems High Voltage Laboratories

Darmstadt University of Technology

Test and research facilities of High Voltage Laboratories for Electrical Energy Systems at Darmstadt University of Technology
(Stand: December 2009) Address: Prof. Dr.-Ing. Volker Hinrichsen High Voltage Laboratories Darmstadt University of Technology Landgraf-Georg-Strae 4 64283 Darmstadt Telephone: +49-6151-162529 Telefax: +49-6151-162329 Email: hinrichsen@hst.tu-darmstadt.de http://www.hst.tu-darmstadt.de

How to find us:

High Voltage Laboratories -Offices: building S3/10 -Big high voltage hall: building S3/08 -Workshop and small high voltage hall: building S3/09 (Parking possibilities between S3/08 und S3/09, access from LandgrafGeorg-Strae)

Front page photograph: Sight of the high voltage hall and the office building from the Institutes of Energy Technology at the Darmstadt University of Technology.

Table of Content
1. Testing facilities
1.1 Big high voltage hall (accredited Test laboratory) 1.2 High power facilities 1.2.1 Synthetic test facility 1.2.2 1.35 MJ capacitor bank 1.2.3 1.5-MW-DC current facility 1.3 Aging facilities 1.4 Diagnostic test facilities 1.5 Impulse current laboratory 1.5.1 Exponential impulse current circuit 1.5.2 Long duration impulse circuit 1.5.3 AC current testing system 1.5.4 Impulse generator for testing of low voltage arresters (SPDs)

2. Testing equipments for special research projects

2.1 Test setup for the accelerated aging test of MO resistors as per IEC 60099-4 2.2 Temperature measurement with passive remote surface acoustic wave (SAW) sensors 2.3 Optical monitoring with high speed camera and photo sensing instruments 2.4 Diagnostics of vacuum in medium voltage vacuum arc chambers

3. Other laboratory equipment

3.1 Molding facility for the fabrication of EP-, PURresin and plastic molded materials 3.2 Shielding room 3.3 Heating cabinet/oven 3.4 Equipment for student laboratory work 3.5 Physical instruments

4. Measuring instrument and facilities

4.1 4.2 4.3 4.4 4.5 4.6 4.7 Transient recorder Optical fiber transmission circuits Voltage measurement Current measurement Impedance measurement Temperature measurement Electrostatic Voltmeter

1 Testing facilities 1.1 Big high voltage hall (accredited laboratory)

Dimensions of the hall: 32 m length x 24 m width x 20 m height
Technical specification of the test circuit:
Impulse voltage: AC voltage: DC voltage: 2.8 MV LI/1.8 MV SI; 80 kJ; 16 Taps 1 MV (50 Hz-60 Hz); 16 Hz 60 Hz; 1 MVA; 4 Taps +600 kV 0.01%; 4 mA

Voltage Measurement System approved by IEC 60060-2:

Lightning impulse voltage: Lightning impulse voltage: Switching impulse voltage: AC voltage: DC voltage: 50 kV till 500 kV 200 kV till 2.8 MV 400 kV till 1.8 MV 95 kV till 980 kV 150 kV till 550 kV

Examples of test and research activities:

Type tests (dry and wet) of equipment with a maximum operating voltage of Um = 24 kV till 800 kV at AC, DC, lightning impulse and switching impulse voltage Measurement from steep impulse voltage up to 3 MV Protective zone of MO-arrestors in 220 kV and 380 kV outdoor systems Comparison of methods for review of the linearity of lightning impulse voltage measurement circuits Effectivity of Early Streamer Emission Devices Development tests on a 1200 kV surge arrestor

Thermal study of a 1200 kV surge arrestor with the AC voltage source

Lightning impulse voltage testing on a current transformer

1.2 High power facilities 1.2.1 Synthetic medium voltage test circuit for high power tests
Technical data:
Available test currents .................................................................... up to 35 kA (rms) Transient voltages ...................................................... up to 200 kV Maximum energy ..........................................................................................1.35 MJ Charging voltage High current circuit ...................................................... up to 15 kV High voltage circuit .................................................... up to 120 kV

Construction and functioning:

L-C-oscillating circuit as an energy source, functions according to the principal of current superposition

Applications and research activities:

Short circuit tests with exponentially decaying sinusoidal 50 Hz currents Tests of the switching performance of vacuum circuit breakers when new contact materials are used

1.2.2 1.35-MJ- Capacitor bank

Technical data:
Available 50 Hz test currents ......................................................... up to 35 kA (rms) Maximum energy.............................................................................................1.35 MJ Capacitance .......................................................................................................12 mF Charging voltage ...................................................................................... up to 15 kV Frequency: adjustment with three air coils 50 Hz

Configuration:

Applications and research activities:

Short circuit tests with a exponential decaying sinusoidal 50 Hz currents (feeding of the synthetic test facility) Generation of current strong interference arcs Supply of over currents for tests of the turn off behavior of high voltage fuses

1.2.3 1.5-MW-DC current facility

Technical data:
Current converter circuit: Twelve pulse rectifier with three phase side phase controlled modulator over an ac power controller

Nominal power at continuous operation:1.5 MW Current voltage combinations at nominal power: Current / A Voltage / V 3000 500 1500 1000 1000 1500 750 2000 500 3000 250 6000

The current can in each case be change up to the maximum value for that voltage range. A voltage control is also possible. Short time operation: The current level can be doubled up to a duration of 8 s. Current ripple: 1 % (with reference to the chosen current value) Statistical accuracy Of the current control: + 0.1 %

Configuration:
The picture shows the rectifying and current smoothing of the facility.

Applications and research activities

Arc and plasma tests of different applications Tests of the thermal effects of interference arcs on synthetic materials used at electrical substations, origin of fire through interference arcs Tests on equipment for DC current systems (i.e. tram, underground and commuter trains)

1.3 Aging test facilities

a) Fogging room for conducting aging tests by weathering

Fogging room 1

Execution of long term tests e.g. test as per IEC 61109 or weather aging test as per IEC 60099-4

Test procedure of a 5000 h test

The department has three fogging rooms with the following options: Fogging room I (in the basement):

-Intended for 5000 h test as well as 1000 h test -Two voltage supplies with the same earthing reference - 0...40 kV AC and 0... 8 kV DC -Monitoring of maximally 6 channels - UV light with 2x2 kW gas discharge lamps - Volume 14.8 m Fogging room II (on the Bhne):

-Intended for 5000 h test as well as 1000 h test -Two voltage supplies with the same earthing reference - 0...60 kV AC and 0... 8 kV DC -Monitoring of maximally 6 channels - UV light with 2x2 kW gas discharge lamps - Volume 16.5 m (reducible by a partition wall) Fogging room III (on the Bhne):

-Intended for 1000 h test - 0...130 kV AC -Monitoring of maximally 6 channels - Volume 58 m

b)

Modified wheel test

For execution of accelerated surface aging of insulation materials e.g. as per IEEE Std C62.11. Adjustable parameters: - Voltage: U = 0...100 kV - Conductivity: = 5...10000 S/cm

1.4 Diagnostic Test Facilities

a) Inclined Plane Test
Fixed and step voltage for the creepage distance formation according to IEC 587, VDE 0303 T.10 and ASTM 2303-97 A second inclined plane test facility (see image) is in use since March 2007. Now, the parallel operation of 5 test samples is possible.

b) Partial Discharge measuring room

Available measuring instruments: - Computerized PD-measuring system ICMSystem (Power Diagnostics) up to 150 kV rating Data of the shielded room: - Room 1: ................................................................................Cabin (Siemens make) Dimensions (B x T x H): ..............................................approx. 2 m x 4 m x 2 m Max. voltage: .....................................................................U = 50 kV (PD-free) Basic interference level: .......................................................................... < 1 pC - Room 2: ................................................................................. Built in-house-cabin Dimensions (B x T x H): ..............................................approx. 8 m x 5 m x 5 m Dimensions of the door: ......................................................approx. 3 m x 2,5 m Max. voltage: ....................................................................U = 250 kV (PD-free) Basic interference level: .......................................................................... < 1 pC

c) Edge angle measuring system

For the determination of the surface tension of a solid surface, two edge angle measuring systems (of the company Krss, Hamburg) are used. The measuring and evaluation software record the edge angles of drops on the solid surface with different test liquids and hence, calculate the surface tension of the solid. The measuring system 1 is used for samples with small geometrical dimensions. With measuring system 2, observation of drops is possible in the electrical field in specified time intervals.

Edge angle measuring system DAS 10L (System 2)

Measuring system 1: Data: - Measuring range: ........................................................................................ 0-180 - max. sample size LxBxH: ........................................................ 150 x 150 x 50 mm - Measurement accuracy: ................................................................................... 0,5 Measuring system 2: Data: - Measuring range: ........................................................................................ 0-180 - max. sample size LxBxH: ...........................................................510 x x 50 mm

d) AC voltage test system

The equipment offers the possibility of investigations, e.g. as per IEC 60243-1, on insulation materials. The following quantities can be determined: Discharge voltage, Ud Dielectric strength, Ed

Measurements of AC voltage are possible, with constant rate of increase of voltage (2 V/s, 5 V/s, 10 V/s, 20 V/s, 50 V/s, 5 kV/s). The measurement of the electrical quantities is made by means of high precision instrument or by an oscilloscope (values may be stored). Technical data of the equipment: AC voltage: 0 200 kV (50 mA) Rate of increase of voltage: (2 V/s, 5 V/s, 10 V/s, 20 V/s, 50 V/s, 100 V/s, 200 V/s, 500 V/s, 1 kV, 2 kV/s, 5 kV/s) Various electrode arrangements depending on the type of insulating material.

Test specimen setup with ball-ball electrode arrangement for testing disc shaped insulating materials

e) Equipment for characterizing dielectric properties of insulating materials

The equipment offers the possibility of dielectric investigations, e.g. as per IEC 60093, on disc shaped insulating materials. The following quantities can be determined: relative Permittivity r dielectric loss factor tan specific electric resistance discharge voltage Ud Partial discharge initiation voltage Ue

Measurement of DC and AC voltages is possible. The measurement of the electrical quantities is made by means of a high precision pointer instrument or by an oscilloscope (values may be stored). Technical data: DC voltage: 0 15 kV (max. 100 mA) AC voltage: 0 20 kV (max. 20 mA) Frequency domain: 10 Hz 100 Hz (distortion free curve shapes) Current measurement: 10 nA 100 mA

Test specimen setup with protection ring electrode as per IEC 60093 for testing disc shaped insulating materials.

1.5

Impulse current laboratory

1.5.1 Exponential impulse current circuit

Technical data Description Lightning impulse Switching impulse Lightning impulse High impulse Steep impulse Current shape 8/20 8/20 30/60 80/200 4/10 1/<20 Max. charging voltage 100 kV 500 kV 100 kV 50 kV 100 kV 100 kV Current 40 kA 10 kA 2 kA 35 kA 100 kA 20 kA Residual voltage 40 kV 300 kV 1 35 kV 60 kV 30 kV

Exponential impulse current circuit (Highvolt) (Lightning impulse, switching impulse, high impulse, steep impulse)
FS L R PO

UL

1.5.2 Long duration impulse circuit

Technical data Description Long wave Current shape 0,5 ms 1 ms 2 ms 2,4 ms 2,8 ms 3,2 ms 4 ms 5 ms Max. charging voltage 40 (50 kV) 40 (50 kV) 40 (50 kV) 40 (50 kV) 40 (50 kV) 40 (50 kV) 40 (50 kV) 40 (50 kV) current (12 kA) (6 kA) 3 kA 25 kV Residual voltage

1,2 kA

Long duration impulse circuit (Built in house)

Ln UL Cn L1 C1 FS PO

CGesamt = 20 10 F = 200 F

1.5.3 AC current testing system

To load MO resistances with AC current: U = 0-10 kV, S = 450 kVA, S(2s) = 750 kVA, = 400 A, duration 1-2 s, time gap 10 min.

1.5.4 Impulse generator for testing of low voltage arresters (SPDs)

The department has several impulse generators (from Hilo-test): Impulse current generator CSG 5-105 Peak value of the open circuit voltage 10/350 s: Peak value of the short circuit current 8/20 s: 0 ... 5 kV 0,2 ... 5 kA

Hybrid generator CWG 4-404 (current and voltage impulse by system voltage) Peak value of the open circuit voltage 1,2/50 s: 0,1 ... 4 kV Peak value of the short circuit current 8/20 s: 0,05 ... 2 kA Impulse in positive / negative half wave or alternating Impulse generator HVPG 6-363 Charging voltage: 0 ... 6,3 kV Curve type: 1,2/50 s, 10/700 s High voltage impulse generator HVPG 4-640 Charging voltage: 0 ... 4 kV Curve type: 10/700 s

2. Testing equipments for special research projects 2.1 Test setup for the accelerated aging test of MO resistance as per IEC 60099-4

Temperature range fort he thermal stability in the arrester

For a surge arrester, input electrical power must always remain smaller than the thermal power which it can dissipate to the surroundings in the form of heat. Only then, thermally stable operation can be ensured.

Possible trends of energy dissipation over time

As per definition of IEC 60099-4, accelerated aging test determines whether an arrester remains thermally stable for a time of over 100 years during load with its continuous operation voltage. A resistance is heated in a furnace at 115 C (heating serves as accelerated aging) and stressed for a duration of 1000 h with 105% of its continuous operation voltage. Thereby, the measured energy dissipation should become constantly smaller or at least not rise significantly.

Furnace with varistor at T = 115 C

Ohmic voltage divider

Transformer Ueff = 0...8 kV Imax = 40 mA UTr

UN

UShunt Shunt for current measurement

PVerlust =

U I dt

Mesystemsystem zur Auswertung Measuring for evaluation

Schematic representation of the aging test stand

2.2 Temperature measurement with passive remote surface acoustic wave (SAW) sensors
Temperature range -20 - +150C Measuring accuracy of the SAW-sensor chips -+0.5C Dimensions of the SAW-sensor chips ca. 1x1.5 cm Wireless high frequency measuring signal transmission over distances up to approximately 15 meters, also through (non-metallic bodies) SAW Technique Receiver unit (power system 12 24 V DC) 2,45 GHz receiver antenna passive SAW-Temperature sensor (SAW-Sensor chip, Sensor antenna, housing)

Picture 1: Components of a SAW system

Picture 2: Operation of a SAW system (DSP Signal processor, NCO Oscillator)

2.3 Optical monitoring with high speed camera and photo sensing instruments
High speed camera

High speed camera Redlake Imaging Motion Scope PCI 2000 SC Model: 1108-0012 2000 fps Maximum recording time: 2 sec

Photomultiplier A photomultiplier is a special vacuum tube, in order to strengthen and convert weak light signals into individual photons and hence into an electrical signal. A photomultiplier consists of an entrance window, a photocathode and a secondary downstream multiplier. The output signal of the photomultiplier can be used electrically, like a constant current source.

Type: H 8249 Series Spectral response: 185 680 nm Frequency bandwidth: DC till 200 kHz

POWER SUPPLY

SAMPLE

PMT
O SCILOSCO PE

Schematic representation, PMT-photomultiplier

2.4 Diagnostics of vacuum in medium voltage vacuum arc chambers

For the investigation of various factors, e.g. contact material, contact stress, gas composition and gas pressure, regarding the decreasing function of the field emission as a diagnostic procedure of vacuum diagnostics, a test vacuum arc chamber was developed.

Test vacuum arc chamer:

The test vacuum arc chamber consists of a fixed and movable contact support rod. The fixed contact is fastened to a 100CF blanking flange cap. The movable support rod is welded with another 100CF blanking flange comer on a metal bellow. 100CF flanges are welded on the ceramic insulators. Optical monitoring of pre-discharge currents is made possible by a distance piece with a 35CF flange. The chamber base has a commercial 100CFT-fitting with two 35CF flanges. These are for the connection of the pump and for analysis and measuring instruments.

Vacuum pump stand:

Commercial vacuum arc quenching chambers exhibit an internal chamber pressure of p<10-7 mbar. In order to achieve the same pressure conditions in a test vacuum chamber, a vacuum pump stand was developed.

Turbo molecular pump:

PFEIFFER-TURBO TPU 510 Pumping rate for nitrogen N2 Booster pump Compression for nitrogen N2 Final pressure Revolution speed Weight 500 l/s two stage rotary pump 8 108 10-11 mbar 60.000 U/min 30 kg

Booster pump:
Two stage rotary pump: DUO 030 A Pumping rate for nitrogen N2 Final pressure Nominal connection diameter 500 m3/h 10-3 mbar DN 40 ISO KF

3 Other Laboratory Equipment 3.1 Molding facility for the fabrication of EP-, PUR-resin and plastic molded materials Fabrication of insulating components from epoxy resin or polyurethane resin molded materials with a vacuum molding system (Hbers make, type Epsilon).
Technical data - Volume of vacuum mixer: .....................................................................................3 l - Internal volume of the vacuum tank: .......................................500 x 700 x 850 mm - Vacuum pump volume: ................................................................................ 27 m3/h - Mixer heating temperature:....................................................................max. 130 C

3.2 Shielding room

Non-portable shielding rooms ............................. fabricated by Siemens and In-house, ....................................................................... max 200 m3 .............................................. high shielding effectiveness

3.3 Heating cabinet/oven

Various heating cabinets of different dimensions...................................... up to 1100 C

3.4 Equipment for student laboratory work

MWB-modular system..........................................................impulse voltage till 280 kV ........................................................................... AC voltage till 200 kV ......................................................................... DC voltages till 280 kV Test transformers in the high voltage range ...............................................up to 200 kV ......................................up to 100 kVA ..........Cascade usage partially possible Resistances, capacitors ............................................... dielectric strength till 140 kV DC

3.5 Physical instruments

Various thermostats, working range: -30 ...+150 C Instruments for the measurement of: .......................... - Volume conductivity of liquids - Humidity Various electronic scales (1/100 g measuring accuracy) Precision scale, Sartorius make (Type 2842), measuring accuracy +/- 0.1 mg; max. 160g SF6 handling equipment (DILO) for pure SF6

4 Measuring instrument and facilities

4. 1 Transient recorder
Several transient recorders and digital memory oscilloscopes with scanning rates up to 2 GS/s and memory up to 1 MB/channel.

4.2 Optical fiber transmission circuits

Several fiber optic cable transmission circuits for galvanic isolated measurement with system bandwidths of 5 MHz, 15 MHz and 100 MHz.

4.3 Voltage measurements

Broadband voltage measurements in medium voltage range. Voltage measurements up to 3 MV.

4.4 Current measurements

Broadband current measurements with shunts and special current transformers up to 120 kV (continuous).

4.5 Impedance measurement

Impedance measurement from 10 m till 100 M within the range of 5 Hz till 13 MHz. Recording of magnitude and phase.

4.6 Temperature recording

Recording system for SAW wireless sensors with an operating frequency of 2.45 GHz and a range of 10 m, various wireless sensors for temperature measurement.

4.7 Electrostatic Voltmeter

-Measurement up to +/- 20 kV DC or peak AC -Rise time of approx. 5 kV/ms .