Design of Electrical Testing Laboratories

CESI,

Milan,

Italy

CESI Synthetic Facility upgrading on Transformer Limited Fault test with fast transient recovery voltage

2019

A basic design has been carried out to improve Synthetic Facility in order to perform Transformer Limited Fault test having fast transient recovery voltage on HV circuit-breakers with rated voltage up to 420 kV, in full compliance with clause 5 of IEEE Standard C37.06.1.

Tasks performed

• assessment of the requirements relevant the test-duties to be performed according to the reference Standard,
• simulation of the oscillating circuits for current and voltage injections test circuits in order to obtain the required transient recovery voltage,
• validation of simulation results trough the comparison with measurements performed in the Synthetic Facility at low voltage,
• definition of the main ratings of the reactors, capacitors and resistors banks of the oscillating circuit,
• identification of the test circuit configuration for the different test duties to be performed,
• definition of the needed additional equipment(a resistors bank, some reactors and capacitors),
• drafting of the multiline diagram of the oscillating circuit,
• CAD drawings of two mobile platforms housing the additional equipment to be used in performing the test.

CESI,

Milan,

Italy

CESI Synthetic Facility upgrading on Terminal Fault and Out-of-Phase tests on

HV Circuit-breakers and Earth Fault tests on HV Fast Earthing Switches

2019

A basic design has been carried out in order to improve CESI Synthetic Facility to perform making operation in:

• 1-phase and 3-phases Terminal Fault tests and Out-of-Phase tests on HV circuit-breakers with rated voltage up to 420 kV in compliance with the envisaged review of IEC Standard 62271-100 Edition 2.1 2012-09 & Corrigendum 1 2012-12 and relevant STL Guide,
• Earth Fault tests on HV Fast Earthing Switches with rated voltage up to 420 kV in full compliance with clauses 7.101 and D.2.1 of Annex D of IEC Standard 62271-102.

Tasks performed

• assessment of the synthetic basic test circuits able to face the Standard and STL Guide requirements,
• evaluation of the obtainable test voltage trough simulation on six different test circuits and for the different test duties,
• configuration of the test circuits taking into account the results of the simulations and the already existing testing equipment,
• drafting of the multiline diagram of the involved test circuits,
• definition of the main parameters of the required additional testing equipment.

GCC ETL,

Dammam,

Saudi Arabia

Basic and detailed design of a new Testing Laboratory

2018 - 2019

*

Testing Facilities and maximum ratings of equipment to be tested

The Laboratory, supplied by one 3200 MVA generator with provision to add second generator in the future, includes the following testing facility:

• Low Voltage Laboratory able to perform short-circuit tests on circuit-breakers with rated voltage up to 690 V, up to 200 kA,
• Medium Voltage High Power Laboratory able to perform short-circuit tests on MV circuit-breakers with rated voltage up to 52 kV, up to 80 kA,
• Synthetic Test Facility able to perform tests on circuit-breakers up to 245 kV, 80 kA, 3-phase and 550 kV, 80 kA, 1-phase,
• Power Transformer Test Bay able to perform short-circuit withstand tests on Power Transformers up 200 MVA, 230 kV, 3- phase and short-time current on HV disconnectors up to 80 kA,
• Environmental Laboratory able to perform environmental tests in harsh condition,
• Temperature rise Laboratory able to perform tests on switching equipment with rated current up to 6,3 kA and on power transformer up to 200 MVA rated power,
• High Voltage Laboratory on switching equipment with rated voltage up to 550 kV and on power transformers up to 230 kV class,
• Pollution Laboratory able to perform tests on ceramic, glass and polymeric insulators up to 550 kV,
• Mechanical Laboratory able to perform tests on switching equipment up to 550 kV,
• Cables Laboratories able to perform heating cycle tests, dielectric tests and prequalification tests on cables up to 550 kV.

Tasks performed

High Power and Power Transformer Test Bay

• Assessment of Testing Laboratory requirements,
• Basic and Detailed design of Short-circuit Generators,

• Basic and Detailed design of Short-circuit Laboratory Transformers,
• Evaluation of testing capabilities and main ratings of testing equipment.

High Voltage, Pollution and Cables Laboratories

• Assessment of Testing Laboratory requirements,
• Preliminary design of the different test facilities,
• Evaluation of testing capabilities and main ratings of testing equipment,
• Technical specification of:

• Impulse voltage generators,
• Power frequency sources,
• Pollution tests Facilities,
• Heating cycle tests and prequalification tests on cables,
• PD and RIV measurement systems,
• Tan δ and capacitance measurement system.

Temperature Rise and Mechanical Laboratories

• Assessment of Testing Laboratory requirements,
• Evaluation of testing capabilities and main ratings of testing equipment,
• Technical specification of:

• Static Frequency Converter,
• Step-up and Step-down Transformers,
• Capacitor and Resistor Banks,
• Heating Transformers and relevant testing circuits,
• Regulator Transformers for MV cables heating system,
• Automatic compensation for MV cables heating system,
• Measurement system for tests on transformers,
• Test systems for Mechanical and Endurance tests.

Synthetic Test Facility

• Analysis of the proposed testing schemes,
• Calculation of the stresses for the selected testing equipment,
• Technical Specification of:

• the circuits for the TRV control in the current circuit,
• neutral reactors bank,
• Surge Arresters for Current and Oscillating Circuits,

• Oscillating circuits (main spark gaps, Capacitor banks, HVDC charging voltage system, capacitors for the control of the TRV time delay, Reactor banks, Resistor banks, Discharge resistors, Protection resistance and Potential resistor),
• Reignition circuits,
• Auxiliary circuit-breakers and fast making device,
• Short-Line fault circuits.

CPRI,

Bangalore ,

India

Augmentation of High Power Test Facilities in Bangalore High Power Laboratory

2017

in progress

*

Testing Facilities and maximum ratings of equipment to be tested

• The Synthetic Test Facility has been upgraded to perform short-circuit tests on circuit-breakers up to 362 kV, 80 kA 3-phase and 1200 kV, 80 kA 1-phase.
• The Transformer Short-circuit Test Facility has been upgraded to perform short-circuit withstand tests on Power Transformers up to 315 MVA rated power, 420 kV class, 3-phase and up to 105 MVA rated power, 765 kV class, 1-phase.
• The new Temperature rise Laboratory has been upgraded to perform tests on equipment with rated current up to 40 kA.

Tasks performed

Synthetic Test Facility

• Analysis of the proposed testing schemes,
• Proposed solutions to upgrade the existing oscillating circuit,
• Preliminary Evaluation of the Involved Investment,
• Calculation of the stresses for the selected testing equipment,
• Technical Specification of:

• the circuits for the TRV control in the current circuit,
• New oscillating circuit (main spark gaps, Capacitor banks, HVDC charging voltage system, capacitors for the control of the TRV time delay, Reactor banks, Resistor banks, Discharge resistors, Protection resistance and Potential resistor),
• Upgrading of the existing oscillating circuit (Capacitor, Reactor and Resistor banks),
• Neutral reactor bank,
• Reignition circuits,
• Auxiliary circuit-breakers and fast making device,
• Short-Line fault circuits.

Transformer Short-circuit Test Facility

• Basic design criteria,
• Analysis of alternative solutions for short-circuit testing on Power Transformers,
• Preliminary Evaluation of the Involved Investment.
• Technical specification of:

• Short Circuit Generators,
• Short-circuit Laboratory Transformers,
• Current Limiting Reactors Banks and Peak Current Control Resistors,
• Parallel Reactors.

Temperature Rise Laboratory

• Basic design of the test facilities and main ratings of testing equipment,
• Technical specification of:

• Static Frequency Converter,
• Step-up and Step-down Transformers,
• Capacitor and Resistor Banks,
• Heating Transformers and relevant testing circuits.

CPRI,

Hyderabad,

India

Establishment of a new On line Testing Laboratory at Hyderabad

2017

in progress

*

Testing Facilities and maximum ratings of equipment to be tested

• The Medium Voltage Power Laboratory able to test:

• LV circuit-breakers and LV assemblies with rated voltage up to 726 V and rated short-circuit current up to 250 kA;
• MV Metal enclosed switchgear and controlgear with rated voltage up to 33 kV and rated short-circuit current up to 40 kA;
• Disconectors and Current Transformers with rated voltage up to 420 kV and rated short-circuit current up to 63 kA;
• Power Transformers up to 16 MVA rated power, 33 kV class;

• Test Facility for Power Transformers for dielectric tests on Power Transformers 33 kV class;
• Temperature rise Facility able to test equipment with rated current up to 10 kA;
• Supplementary Facility for mechanical tests on LV and MV circuit-breakers, accuracy test on current transformers, dielectric tests on auxiliary of circuit-breakers.

Tasks performed: for each of the testing facility the following tasks have been performed:

• Assessment of testing requirements,
• Basic design,
• Detailed design including the Technical Specifications below listed,

• Assessment of testing requirements,
• Basic design,
• Detailed design including the Technical Specifications below listed.

ERDA,

Vadodara,

India

Basic Design of a new High Power Testing Laboratory

2016

*

Testing Facilities and maximum ratings of equipment to be tested

• Medium Voltage Power Laboratory for testing:

• LV circuit-breakers and LV assemblies with rated voltage up to 726 V and rated short-circuit current upHV Disconnectors and earthing switches with rated voltage from 52 kV up to 420 kV and rated short-circuit current up to 63 kA,
• MV Circuit-breakers, MV Metal-enclosed switchgear and MV Switches with rated voltage up to 36 kV and rated short-circuit current up to 63 kA,
• Contactors with rated voltage up to 12 kV and rated current up to 400 A,
• Current-limiting and Expulsion fuses with rated voltage from 3,6 kV up to 36 kV,
• Line traps with inductance from 0,1 mH up to 2 mH and rated short-circuit current up to 80 kA,
• Surge arresters with rated voltage from 9 kV up to 30 kV and rated short-circuit current from 1 kA up to 50 kA.

• Power Transformer Laboratory for short-circuit withstand tests on Power Transformer:

• with primary windings in the range 11 kV-66 kV and maximum power of 50 MVA,
• with primary windings in the range 66 kV-235 kV and maximum power of 250 MVA.

Tasks performed:

• Confirmation of testing requirements,
• Evaluation of the testing capability taking into account three different Short-circuit Generators (1500 MVA, 2300 MVA and 2750 MVA); the 2300 MVA short-circuit power resulted the most convenient solution,
• Basic design of the MV/HV Transformers bank feeding the Power Transformer Laboratory and of the MV/MV Transformers bank feeding the MV Power Laboratory,
• Basic design of the test circuit located in an outdoor areafor testing HV Disconnectors with rated voltage from 52 kV up to 420 kV and rated short-circuit current up to 63 kA,
• Basic ratings of the Laboratory main testing equipment.

Rosseti,

St. Petersburgh,

Russia

Basic Design of a National Testing Center in Russia

2015-2016

*

Testing Facilities and maximum ratings of equipment to be tested

The Power supply of the Laboratory includes 4 Short-circuit Generator each rated 3500 MVA.

• The High Power Synthetic Section is able to perform:

• Synthetic tests on circuit-breakers up to 1200 kV, 80 kA and on generators circuit-breakers up to 360 kA,
• Direct tests on circuit-breakers up to 123 kV, 40 kA,
• Direct tests on HV disconnectors and earthing switches, gas insulated switchgear and controlgear up to 160 kA.

• The MV-LV Section able to perform MV and LV short-circuit direct tests on equipment with rated voltage up to 52 kV with a maximum current of 160 kA.
• HVDC Power Section for power tests of thyristor valves up to 8 kAdc rated current.

• The Transformer Section for short-circuit withstand tests on Power Transformers up to 400 MVA, 500 kV class, 3-phase and 1-phase unit up to 267 MVA, 750/√3.
• High Voltages Sections to perform dielectric tests in UHV testing hall (up to 1200 kV class, includingMVU thyristor valves), EHV testing hall (up to 550 kV class), HV testing hall (up to 145 kV class) and MV testing hall (up to 72,5 kV class) .
• Pollution tests Section for testing insulators up to 1200 kV.
• Temperature rise Laboratory for Power Transformers (up to 667 MVA, 1200 kV class) and Reactors (up to 300 MVar, 1200 kV class).
• Temperature rise Laboratory for Switchgear up to 10 kA for equipment with rated voltage up 1200 kV and 30 kA for generator circuit-breakers.

Tasks performed:

High Power Laboratory

• Assessment of HPL testing requirements,
• HPL General Configuration,
• HPL Power system description,
• Calculation of HPL circuit parameters and testing capabilities,
• Main equipment Technical Specification of:

• MV-LV Laboratories for direct tests up to 52 kV, 160 kA,
• High Power Transformer Laboratory,
• HVDC Power Laboratory for power tests on thyristor valves,
• TRV Control Banks, MV Resistor Banks and MV Load Circuits.

• Technical Specification of:

• 3500 MVA Short circuit Generators,
• 1100 MVA MV/HV and MV/MV Laboratory Transformers,
• 100 MVA MV/LV1 and 200 MVA MV/LV2 Laboratory Transformers.

High Voltage Laboratory

• Assessment of HVL testing requirements
• HVL Testing capabilities and configuration
• Technical Specification of:

• Impulse Voltage Generators,
• Power Frequency Sources and relevant Regulator Transformers,
• Coupling and standard capacitors,
• DC Voltage Generator for MVU testing,
• Static Frequency Converter,
• Heating cycle system for temperature rise test,
• Power Transformers for Temperature Rise and Induced Voltage tests on Reactors,
• Testing equipment for Artificial Pollution tests on Insulators,
• Capacitors Compensative banks.

Synthetic Test Facility

• Selection of equipment and basic ratings for:

• current and voltage circuits,
• synthetic making test circuit,
• control of the TRV of the current circuit,

• Synthetic Laboratory configuration,
• Technical Specification of:

• Reignition Circuit,
• Voltage Circuit: Capacitor, Reactor andResistor banks.

KONČAR Electrical Industries,

Zagreb,

Croatia

Basic Design of a Testing Laboratory

2014-2015

Testing Facilities and maximum ratings of equipment to be tested

KONČAR - ElectricalIndustries requested the basic design of a Laboratory able to perform type tests on its catalogue manufactured products and including:

• High Voltage Synthetic test bay for short-circuit, capacitive and reactor switching tests on HV circuit-breakers and disconnectors with rated voltage up to 550 kV and short-circuit current up to 63 kA,
• MV test bay for short-circuit, capacitive and reactor switching tests, internal arc tests and load tests on MV equipment with rated voltage from 7,2 kV up to 38 kV and short-circuit current up to 63 kA, Instrument Transformers with short-circuit current up to 100 kA,
• HV outdoor test area and MVTR Test Bay for:

• Short-circuit tests on Distribution and Power Transformers up to 40 MVA, 123 kV (3-phase) and 200 MVA, 400 kV (1- phase),
• Short-time current tests on HV Disconnectors rated voltage up to 550 kV, short-circuit current up to 63 kA,

• Temperature Rise test bay for HV-MV Switchgear and Controlgear, LV Bus-Bar with rated current up to 12 kA,
• Environmental and Mechanical test bay for HV-MV Switchgear and Controlgear.

Tasks performed:

• Assessment of testing requirements,
• Laboratory Configuration,
• Single –line diagram, preliminary calculation of circuit parameters, testing capabilities of the different test bays considering two different Power supply: by 420 kV HV Network (1600 MVA available short-circuit power) and by a 2000 MVA Short-circuit Generator,
• Short-circuit Laboratory Transformers bank configuration and ratings,
• Basic ratings of the Laboratory main testing equipment,
• Preliminary Laboratory layout,
• Budgetary evaluation of the involved investment.

Noja Power Switchgear,

Brisbane,

Australia

Detailed Design of a MV Switches Testing Facility based on Synthetic method

2014

Testing Facilities and maximum ratings of equipment to be tested

The Testing Facility is addressed to perform single phase mainly active load current switching tests at 100% of the rated current on MV Switches with rated voltage from 15.5 kV up to 38 kV and rated mainly active switching current from 100 A up to 800 A at 50 Hz and 60 Hz frequency.

The test supply consists of a pre-charged capacitor bank. The discharge of capacitor bank on the reactor bank determines the test current that is broken by the Switch under test: a parallel branch allows to obtain the Transient Recovery Voltage in agreement with test duty TD _load2 of IEC Standard 62271-103 - Table 4.

Tasks performed:

• Test circuit conceptual design and operating principle,
• Testing Facility configuration and Basic Design,
• Multi-line diagram of the synthetic est circuit,
• Circuit parameters calculation,
• Testing Facility Preliminary Layout,
• Control systems Specification including Test sequencer and Data Acquisition system,
• Capital expenditure budget,

• Technical Specification of the following testing equipment:

• Capacitor banks,
• Dc generator for the pre-charging of the Capacitor bank,
• Reactors banks,
• Resistor banks for TRV control,
• Making switch and Discharge disconnectors,
• Busbar system,
• Voltage dividers and Current shunt.

KEMA,

Arnhem,

Netherlands

Consultancy engineering services addressed to the commissioning of two 2500 MVA Short Circuit Generators installed at KEMA Laboratory

2014-2015

Engineering services performed

In the framework of the supply by Alstom Power to KEMA of two Short-circuit Generators (addressed to supply short-circuit tests in parallel of the already existing four generators) the following technical assistance during Commissioning has been carried out:

• Review of the test program and relevant procedures of the FAT on the Generator protection system,
• Definition of the functional tests to be carried out during the different phases of Commissioning (Cold Commissioning, Hot Commissioning and Trial operation) in order to verify:

• the interoperability of the two Generators with the pre-existing ones,
• the performances of the Generators in different operating conditions (different excitation current, output voltage, etc) related to short-circuit tests execution,

• Review of the operating procedure for the different tests,
• Supporting Alstom Power Team:

• during Commissioning execution,
• in evaluation of the tests results,
• in drafting the Final Commissioning Report

Universidad Del Valle,

Calì,

Colombia

Feasibility Study of MV Power TestingLaboratory

2014-2015

Testing Facilities and maximum ratings of equipment to be tested

• MV Test Bay for short-time current withstand tests on MV Switchgear and Controlgear with rated voltage up to 36 kV and short-circuit current up to 20 kA,
• MV Internal Arc Test Bay for internal arc tests on MV Switchgear and Controlgear with rated voltage up to 36 kV and short-circuit current up to 20 kA,
• MV Power Transformer test bay and MV Power Transformer Outdoor test area for short-circuit withstand tests on Distribution Transformers up to 20 MVA rated power, 36 kV (3-phase),
• LV Test Bay for short-time current withstand tests on MV and LV Switchgear and Controlgear Assemblies with rated voltage up to 1000 V and short-circuit current up to 50 kA.

Tasks performed:

• Laboratory Configuration and preliminary calculation of circuit parameters,
• Multi line diagram,
• Laboratory capabilities in connection with the supply by 115 kV HV Network, with an available short-circuit power of 200 MVA,
• Basic ratings of HV/MV and MV/LV Short-circuit Laboratory Transformers banks operating at 60 Hz,
• Testing Facilities description,
• List of the main testing equipment and relevant main ratings,
• Preliminary layout including Test Facilities and ancillary areas and services,
• Capital expenditure budget,
• Preliminary schedule of the Laboratory establishment.

1. HV Power Supply
2. MV Power Feeder
3. MV Power Transformer test bay
4. MV Power Transformer Outdoor test area
5. MV Internal Arc test bay
6. LV Power Feeder
7. LV test bay
8. Warehouse and AD Hall
9. Warehouse and Workshop
10. Utilities station
11. Elevator
12. Control room
13. Entrance, stairwell and lift
14. Client room
15. Meeting rooms
16. Management offices
17. Laboratory Staff offices
18. Canteen
19. Dressing room
20. WC
21. Underground oil tank
22. HV/MV Transformer Bank
23. TRC System

Expert System,

Russia

Feasibility Study for a new Federal Testing Center

2013-2014

A comprehensive feasibility study has been carried out in supporting the decision by the Russian Federal Grid company (now Rosseti) on the establishment of a Federal Testing Center able to test High Voltage electrical equipment.

On the basis of the following developed outputs:

• role of testing laboratories in achieving equipment quality improvementand Grid reliability performance,
• new opportunities for domestic manufacturers in connection with the establishment of the Federal Testing Center,
• High Voltage equipment Russian market evolution in the medium term and corresponding testing market for High Voltage equipment,

the study demonstrated that a powerful Testing Center can really determine the improvement of the domestic electromechanical sector and the overcoming of the technological gap which ultimately increase the electrical tariffs and hampers the country economic growth.

A complete Business Plan has been evaluated taking into accountcapital expenditure, revenues, staff wages, operating costs, profit & loss plan for a Federal Testing Center including the following testing facilities:

• High Power Laboratories including the High Voltage Synthetic, Short Time Current and Power Transformers tests sections,
• High Voltage Laboratory for dielectric tests and tests on Power Transformers,
• Temperature rise Laboratory including Distribution Transformers tests section,
• Environmental Laboratory,
• Seismic Laboratory,
• EMC Laboratory,
• HV cable Pre-qualification test area,
• Chemical and Physical Laboratory.

Finally a Federal Testing project financinghas been proposed.

Alstom,

Lyon,

France

Detailed Design of CERDA High Power Synthetic Laboratory

2013-2014

*

Testing Facilities and maximum ratings of equipment to be tested

Starting from the results of the Basic Design performed at 2011-2013 the detailed design of the testing facility has been developed to perform short-circuit and capacitive switching tests up to the following maximum ratings of the equipment to be tested:

• 245 kV, 63 kA, 50/60 Hz, (3-ph),
• 800 kV, 63 kA, 50/60 Hz, (1-ph), (full pole),
• 1200 kV , 63 kA, 50/60 Hz, (1-ph), (half pole).

Tasks performed:

• Single-line diagram and layout of the two upgraded oscillating circuits,
• Availability of the existing components of the oscillating circuits able to withstand the requested current and voltage stresses,
• Technical specification:

• Additional components of the oscillating circuits (Reactors, Capacitors, Potential Resistor, Linear Disconnectors in the Reactors banks),
• New Reignition Circuits,
• Surge arrester for the protection of the short-circuit components against over-voltages.

Hyundai Heavy Industries,

South Korea

Basic Design of an High Power Laboratory

2013-2014

*

Testing Facilities and maximum ratings of equipment to be tested

• High Voltage Synthetic test bay for:

• short-time, short-circuit, short-line fault, out of phase, capacitive and shunt-reactor switching tests on HV circuit-breakers with rated voltage up to 252 kV, short-circuit current up to 63 kA in 3-phase tests,
• short-time, bus transfer and induced current switching tests on HV GIS Disconnectors and Earthing Switches, short-circuit current up to 63 kA,

• MV test bay for:

• short-time, short-circuit, short-line fault, out of phase, capacitive switching 3-phase tests on MV circuit-breakers rated voltage up to 25,8 kV, short-circuit current up to 31,5 kA,
• internal arc test on MV GIS Cubicles with short-circuit current up to 31,5 kA,
• mainly active load tests on MV Switches with rated voltage up to 25,8 kV, rated current 800 A,
• short-circuit tests on Distribution Transformers with rated voltage of the winding connected to the supply during the test up to 34,5 kV,

• LV test bay for short-time and short-circuit tests on LV circuit-breakers with rated voltage up to 690 V, short-circuit current up to 200 kA.

Tasks performed:

• Assessment of testing requirements,
• Laboratory Configuration and preliminary calculation of circuit parameters,
• Basic ratings of the 1800 MVA Short-circuit Generator,
• MV/HV, MV/MV and MV/LV Short-circuit Laboratory Transformers banks configuration and ratings,
• Basic ratings of the testing equipment used in direct and synthetic tests in order to obtain TRV in agreement with Standard,
• Testing capabilities of the three test bays.

Alstom Power,

Milan,

Italy

Modelling of the parallel operation of Generators in Short-circuit tests

2012

Engineering services performed

In the framework of Alstom Power proposal to KERI (Korea Electrotechnology Research Institute) of two Short-circuit Generators for a total short-circuit power of 4800 MVA addressed to supply short-circuit tests in parallel of the already existing 4800 MVAGenerator, it has been developed a simulation tool of synchronous generators, including driver, used in short circuit tests.

The model, developed in cooperation with the Electrical Engineering Department of the University of Pavia, allows the simulation of the drive-generator system in three-phase and single-phase systems at 50 Hz and 60 Hz, with and without excitation in a temporal transient of 150 ms from the short circuit start, providing the generator status at the beginning and end of the transient and the power flows in the different configurations.

The model also simulates the operation of 2 or 3 generators feeding short-circuit tests, in particular for the paralleling procedure and the configuration of the protections.

On the basis of the results of the simulations carried out, the required operating conditions (maximum excitation current required, minimum current limiting reactances to be connected in series with the Generators, maximum faults currents, etc.) for an effective parallel operating conditions in three or single phase short-circuit tests, at full power, at 60 Hz and 50 Hz, have been defined.

LS Electric,

Busan,

South Korea

Basic and detailed design of High Power Synthetic Testing Laboratory of HVDC Thyristor Valves

2012-2013

Testing Facilities and maximum ratings of equipment to be tested

In the framework of the establishment by LS Electric of a new Testing Facility for operational electrical tests on HVDC Thyristor Valves with max voltage of 30 kV and max current of 2500 A a review of the Basic and Detailed design of the Facility has been carried out. The performed tests are based on Synthetic method replicating the switching stresses on the valves in operation, in full agreement with IEC Standard 60700-1.

Tasks performed:

• Basic design-Review of the test circuit and main relevant parameters to perform:

• Periodic firing and extinction tests,
• Tests with transient forward voltage during recovery period,
• Valve fault current tests.

• Detailed design review through simulations of the following tests:

• Maximum Continuous Firing Voltage,
• Maximum Continuous Recovery Voltage,
• Maximum Temporary operating duty,
• Minimum delay and minimum extinction angles,
• Temporary undervoltage.

Turkish Standard Institute,

Turkey

Feasibility Study of LV/MV/HV Testing Laboratory Complex

2012-2013

*

Testing Facilities and maximum ratings of equipment to be tested

The Turkish Institute of Standard requested a feasibility study concerning the establishment of an independent Testing Laboratory complex in Turkey to support the domestic electromechanical industries and power utilities. The complex includes the following Testing Facilities:

• High Power laboratory including:
• Low Voltage section for testing LV Switchgear assemblies up to 1000 V rated voltage and up to 160 kA short-circuit current;
• Medium Voltage section for testing:
• MV Switchgear and Controlgear, Circuit-breakers up to 41 kV rated voltage and up to 31.5 kA short-circuit current,
• Power and Distribution Transformers with ratings 100 MVA/400 kV;
• Synthetic section for testing HV Circuit-breakers up to 420 kV rated voltage and up to 63 kA short-circuit current;
• High Voltage laboratory for dielectric tests (Lightning impulse voltage up to 2200 kV, Switching Impulse voltage up to 1600 kV, Power frequency voltage up to 800 kV, DC voltage up to 25 kV for tests on dc railway circuit-breakers, PD measurement, loss measurements, tan d measurements) on Distribution and Power Transformers, Circuit Brakers, Switching Equipment, Switchgears and Controlgears, Cables;
• Temperature rise testing laboratory on:
• Switchgear and Controlgear, Circuit-breakers and Disconnectors up to 6 kA,
• Power Transformer with ratings 100 MVA/400 kV;
• Environmentaltesting laboratory: Dielectric tests under wet conditions and contamination, Low and High temperature mechanical tests, Temperature rise tests at increased ambient temperature;
• Cable laboratory for ageing and prequalification tests up to 550 kV rated voltage;
• Seismic laboratory;
• Chemical laboratory;
• Mechanical endurance tests and protection class testing laboratory.

Tasks performed:

• Assessment of testing requirement and relevant reference Standard,
• Turkish Testing Market survey assessment based also on the inquiry on the key manufacturers,
• Workload and turnover evaluation for different Testing Laboratory Complex options,
• Capital and operating costs estimation for different Testing Laboratory Complex options,
• Profit&Loss Statement for the best option.

KERI,

Changwon,

South Korea

Consultancy engineering services on detailed design of 4000 MVA High Power Laboratory

2012-2013

Testing Facilities and maximum ratings of equipment to be tested

KERI extended its High Power Testing Laboratory with a new section in order to increase testing capabilities up to 4000 MVA short-circuit power through installation of a second Short-circuit Generator, new Short-circuit Transformers and the rearrangement of the power circuits supplying the different test bays.KERI requested a review of some detailed design Technical Specification.

Tasks performed:

• Definition of appropriate guide lines to exploit the total available short-circuit power of the SCG parallel operated,
• Review of the Technical Specifications concerning:

• New three Short-circuit Transformers bank: 1100 MVA, 60 MVA and 45 MVA,
• Single line diagram of the extended Laboratory configuration,
• Layout of High Power Test Facilities,
• Control, monitoring and data acquisition systems,
• Grounding system.

NHPTL,

Bina,

India

Engineering services relating to the construction of Power Transformer Testing Laboratory

2012-2013

*

Testing Facilities and maximum ratings of equipment to be tested

On the basis of the design developped in 2010 year the National High Power Testing Laboratory erected the Power Transformer Testing Laboratory supplied by three incoming lines at 765 kV, 400 kV and 220 kV and including two test sections:

• MV Laboratory to test Transformer with rated power up to 125 MVA, up to 132 kV, 3-phase,
• HV Laboratory to test Transformer:

• 220 kV, up to 315 MVA, (3-phase),
• 400 kV, up to 630 MVA (3-phase),
• 400 kV, up to 260 MVA,(1-phase),
• 765 kV, up to 500 MVA, (1-phase).

NHPTL require engineering services supporting the different phases of the Laboratory construction.

Tasks performed:

• Technical Specifications concerning:

• 800 MVA HV/MV Short-circuit Transformers bank,
• 800 kV and 100 kV HV Reactors banks,
• 800 kV Making Switch.

• Technical assistance to tendering and procurement phases,
• Review of drawings and specifications made by the main contractor,
• Assistance during commissioning.

Alstom,

Lyon,

France

Technical Assistance to the Revamping of CERDA High Power Laboratory

2011-2013

*

Testing Facilities and maximum ratings of equipment to be tested

The Feasibility Study and Basic Design concerning the renovation and upgrade of the Synthetic facilities was addressed to achieve the following performances:

• Full pole 245 kV, 63 kA, 50/60 Hz for three phase short-circuit and capacitive switching tests,
• Full pole 550 kV, 63/80 kA, 50/60 Hz for single phase short-circuit and capacitive switching tests,
• Full pole 800 kV, 63/80 kA, 50/60 Hz for single phase short-circuit tests,
• Half-a-pole 1200 kV, 63/80 kA, 50/60 Hz for single phase short-circuit and capacitive switching tests.

Tasks performed:

• Study of the more appropriate test circuit scheme for the different test duties in order to meet the higher testing capability (63 kA and 80 kA), both for short-circuit and capacitive tests,
• Calculation of the requested circuit parameters and evaluation of component stresses of the main equipment taking into account the whole range of the voltage and short-circuit current,
• Evaluation of the most appropriate connection of the existing Short-circuit Generators and a new 2500 MVA SCG with the existing Short-circuit Transformers to obtain the requested short-circuit currents,
• Preliminary layout of the New Synthetic Test Bay,
• Sizing of the generator building for the housing of the additional 2500 MVA Short-circuit Generator.

State Grid Electrical Power Research Institute,

China

Basic design of a new High Power Testing Laboratory

2011-2012

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Testing Facilities and maximum ratings of equipment to be tested

The High Power Testing Laboratory, is a new section of the State Grid Inspection & Testing Center in Changzou which already includes a AC/DC High Voltage Test Hall and an Environment and Mechanical Test Hall.

The High Power Testing Laboratory, supplied by a multi-generator group (two 3200 MVA generators with provisions to add a third generator in future) and a HV substation fed from the 220 kV network, includes the following testing facilities:

• Synthetic Laboratory, to perform on Circuit-breakers:

• Synthetic Tests with the following max capabilities:
• 100 kA (1-phase) short circuit current (1-phase),
• 363 kV rated voltage and 80 kA (3-phase),
• Direct Tests up to 252 kV, 80 kA (3- phase),

• Medium Voltage Laboratory for Direct Tests on MV Switchgear and Controlgearwith rated voltageup to 40.5kV and short-circuit current up to 63kA,
• Short Time Current Laboratory for tests on HV Disconnectors, HV GIS, MV & HV GIS, MV & HV surge arresterswith short time current up to 150 kA,
• High Power Transformers Laboratory, for short-circuit withstand tests on transformers (either three-phase or single-phase units) up to 160 MVA, 220 kV.

Tasks performed:

Basic Specification for HV Direct and Synthetic tests:

• Three phase synthetic circuits conceptual design,
• Oscillating Circuits,
• Current Circuit for synthetic and direct testing,
• Review of making and breaking in three phase synthetic circuits,
• Testing capabilities evaluation for synthetic and direct testing,
• Testing circuit schemes for synthetic and direct testing,
• Calculation of circuit parameters for synthetic and direct testing,
• List of the main testing equipment and relevant main ratings.

Basic Specification of Medium Voltage Laboratory:

• Laboratory feeder from Short-circuit Generators group and from HV Network,
• Testing capabilities evaluation,
• List of the main testing equipment and relevant main ratings,
• Basic specification of:

• Short-Circuit Generators,
• MV/MV Short-Circuit Transformers bank,
• MV/HV Short-Circuit Transformers bank,
• HV/MV Short-Circuit Transformers bank.

TECNALIA,

Bilbao,

Spain

Engineering services for the contruction of a new High Power Laboratory

2011-2012

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Testing Facilities and maximum ratings of equipment to be tested

The Laboratory, located in the Parque Tecnologiquo Bizcaia, includes the following Testing Facilities:

• High Power Medium Voltage & Internal Arc laboratory whose short-circuit power is supplied by a 235 kV substation through a 300 MVA 3-phase HV/MV Transformer with test voltages from 3 kV up to 40,5 kV and max short-circuit test current 40 kArms, 1 s, frequency 50 Hz,
• Low Voltage High Current laboratory supplied by the 300 MVA HV/MV Short-circuit Transformer and a 100 MVA 3-phase MV/LV Transformer with test voltages from 200 V up to 1000 V and max short-circuit test current 130 kArms, 1 s, frequency 50 Hz.

Tasks performed:

• Assessment of Laboratory requirement,
• Single line diagram,
• List of main testing equipment and relevant main ratings, including ratio changer connected to the secondary side of the HV/MV Short-circuit Transformer,
• Earthing system,
• Technical Specification of:

• Disconnectors and Earthing Switches,
• MV Circuit-breakers and Making Switch,
• MV reactors banks,
• Bus-bar system (component and location) and Cables,
• Control, monitoring and protection systems,
• Measuring system,
• Requirement for the civil works.

State Grid Electrical Power Research,

India

Feasibility study and Basic design for a new On-Line Short-circuit Testing Laboratory

2010

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Testing Facilities and maximum ratings of equipment to be tested

The Laboratory will be supplied by the High Voltage Network at 765 kV and 400 kV and includes the following Testing Facility:

• Facility for short-circuit withstand tests on High Power Transformers up to 765 kV class,
• Facility for short-circuit tests through Synthetic methods on Circuit-breakers with rated voltage up to 550 kV and short-circuit current up to 63 kA,
• Facility for short-time current tests on Switching equipment up to 400 kArms with 1100 kApeak.

Tasks performed:

• Assessment of the Laboratory requirements,
• Laboratory configuration,
• Testing capabilities evaluation for the three Facilities,
• Basic specification of the HV/MV Short-circuit Transformers bank for short-circuit withstand tests on Power Transformer,
• List of the main testing equipment and relevant main ratings of the Facility for short-circuit withstand tests on Power Transformer,
• Budgetary evaluation of the investments related to Facility for short-circuit withstand tests on Power Transformer,
• Synthetic test circuits,
• Three phase synthetic circuits conceptual design and simulations of the most powerful synthetic tests,
• List of the main testing equipment and relevant main ratings of the Facility for short-circuit tests on Circuit-breakers,
• List of the main testing equipment and relevant main ratings of the Facility for short-time current tests on Switching equipment.