ON-SITE TESTING OF MEDIUM AND HIGH VOLTAGE

ELECTRICAL POWER EQUIPMENT - OVERVIEW OF STATE-

OF-THE-ART TECHNOLOGIES

Kay Leiteritz, Dr. Mario Jochim, Dr. Alexander Kraetge HIGHVOLT Prueftechnik
Dresden GmbH, Germany
Bruno Fainaru Consultant, Israel

ABSTRACT

Our modern life strongly depends on the availability of electrical power at any time.
Therefore the reliability of electrical power systems is of outmost importance. Even if
the overall performance of well-maintained transmission and distribution systems can
be described as good, the breakdown of key network components is dangerous,
costly, sometimes long-lasting and may harm the environment. Common reasons for
system outages caused by equipment breakdowns are problems in the electrical in-
sulation of network components like transformers, cables or switchgear. While com-
missioning tests of newly installed equipment are common practice, field testing of
aged assets becomes increasingly popular, too. Examples are induced or applied
voltage tests on transformers showing suspicious and increasing rates of fault gases
during routine tests or after having been repaired on site. On cable systems, high
voltage may be needed to be applied after a joint repair while such tests are per-
formed on GIS when e.g. a partial discharge (PD) source has to be located for an
efficient repair process.
The experience since the mid-90s shows that the use of power electronic test
equipment has advantages over the application of motor-generator sets for the men-
tioned purposes.

The author explain the practical application of mobile test systems based on static
frequency converters for testing transformers, cable systems and GIS/GIL on-site.
The frequency of such test arrangement has to be chosen according to the different
assets cables are usually tested with frequencies lower than rated while transform-
ers are tested with higher frequency. Also, the required and allowed PD levels and
methods (electrical, acoustical or UHF) differ for various test objects and purposes.
This has to be taken into account when planning this kind of tests.

Based on practical examples, the paper will give hints on how to plan and perform
such tests in a safe and efficient manner.

INTRODUCTION

Modern life and industry have great need for electrical energy and rising demand on
the requirements for power supply stability and reliability. And this in time of growing
international competition which exerts pressure on cost-saving energy generation,
transmission and distribution. Modern asset management is a fundamental supposi-
tion to meet these contradictory requirements.
An efficient asset management is the concurrence and combination of diverse com-
prehensive measures in order to know amongst others the condition of the elec-
tric equipment such as transformers, cables and GIS/GIL as exact as possible. One
of these measures is the diagnostic investigation of the electrical equipment which
allows having a clear knowledge on the condition of the equipments insulation, for
instance.

Respective electric and also non-electric analyses and measurements on equipment

can be done online as well as offline. For offline measuring, which has a greater in-
formation value due to the possibility of an increased exposure, the appropriate
sources of energy have to be available on site.

The insulating capability of equipment is designed for and basically influenced by the
50/60 Hz transmission voltage. Therefore, the diagnostic offline analyses should rea-
sonably be done with energy sources or test systems which simulate this 50/60 Hz
stress as exactly as possible and for a defined period of time.

Due to reasons such as

supply of enormous electrical test power for large equipment with high nominal
voltages like long cables,
convenient transportability and minimum weight at high electrical test powers,
high reliability under on-site conditions,
simple and fast installation and disassembly of the test system,
resonant test systems, where the resonance is adjusted by adapting the frequency
(ACRF [1]), have become commonly accepted. Hereby the resonant frequency is in
the range of 20 Hz to 300 Hz for example which allows a physically-reasonable
comparison with the behavior of the equipment at an operation frequency of
50/60 Hz. This is considered in international standards and recommendations for on-
site testing [2], [3], [4], [5]. Exemplarily Figure 1 shows a practical application of reso-
nant test systems during an after laying test on 400 kV XLPE cables.

Figure 1: Example for cable on-site testing in London (2006)

TESTING OF HV POWER CABLES

Required test power

The growing length and transmission voltage of extruded XLPE-cables cause an in-
crease in the needed testing power of up to 100 MVA (Figure 2). The requirements of
test voltage and frequency for on-site tests of complete cable test systems are de-
fined in the IEC-Standards IEC 62067 [2] and IEC 60840 [3].
Most of the HV tests performed on plastic cables are combined with non-destructive
diagnostic measurements.

Figure 2: Required AC test power depending on cable capacitance and length respectively

Besides the testing of very long extruded cables for AC voltage supply networks, the
AC voltage testing is also applied successfully for the testing super-long extruded
XLPE-cables for DC voltage. The HV AC testing allows a fast and easy recognition of
failures inside the insulation [6]. These kinds of cables can be manufactured in one
piece with lengths of up to 100 km and are used - for example - to connect off-shore
oil platforms with the mainland.

Selection of suited HV test systems

Important for testing of very long cables, mainly on-site, is the necessary feeding
power from the grid. Especially in cases of construction sites for new cable installa-
tions, the availability of this feeding power is often very limited. Therefore the ACRF
circuitries used, have to be of a high Q-factor, i.e. the test system itself needs a high
Q-factor and the test object as well.

The losses in the cable are the losses in the insulation (reflected in a very low tan
as it is very typical for XLPE-insulated cables) and the ohmic losses in the inner and
outer cable conductor. The resulting Q-factor of the test object is normally high
enough for cable lengths up to some ten kilometers.

Therefore the focus of test system design directs to the high quality of the test sys-
tem itself and especially to the HV reactor. Its losses are caused mainly by the re-
sistance of the reactor winding but also by losses in the iron core. The latter can be
influenced by the design of the core. Because a multi-gap-core is used for a reactor
with a fixed inductivity, the losses in the core are smaller compared to a tunable reac-
tor with adjustable gaps.

The resulting Q-factor goes up to more than 200 in the normally used frequency
range around 50/60 Hz for measurements on site.

The demand for reactive power is linearly dependent on the frequency when the test
voltage is constant. If the test frequency is reduced from 50 Hz to 20 Hz, the demand
for test power decreases to 40%. Therefore the frequency range from 20 Hz to about
40 Hz has turned out to be the ideal frequency range for testing of long power cables.
Design of ACRF test systems

Every ACRF system consists of a resonant reactor with a fixed inductivity, an exciter
transformer, a frequency inverter unit and a capacitive voltage divider. The power
inverter is part of the control and feeding unit, which contains amongst the inverter all
necessary sub-circuits for voltage regulation, test control and safety functions. The
exciter transformer adapts the output voltage of the frequency inverter to the neces-
sary input voltage for the resonant circuit, usually some kV. Since the test voltage
depends on the quality factor of the resonant circuit, the exciter transformer has dif-
ferent output taps. This enables an optimum working range for the frequency inverter
for each test voltage and different quality factors. The exact value of the test voltage
is controlled by the pulse width of the inverter.

Figure 3: Basic principle of resonant test system with variable frequency for HV cables

The testing of very long XLPE cables requires a very powerful test system. The max-
imum size and weight of a resonant reactor is limited with respect to an easy trans-
portation without special permissions. The limit for a single test system [1] is at a 50-
Hz-equivalence-power of about 35 MVA. Because of that, the high need of testing
power requires usually a combination of two or more reactors in series or parallel
connection. The following example (Figure 4) describes a test setup which is used for
testing super-long extruded submarine DC cables up to a length of approx. 80 km [5].

To get the most flexible design, two resonant reactors (110 kV / 194 A each, (see
Figure 4, item 5)) in oil-filled steal tanks are used. They can be connected in series
for higher voltages and lower frequencies or in parallel for lower voltages and very
large capacitances.
5 5

2 4

3
6 7

4
3x 400 V 1
50 Hz
4

Figure 4: Principle design of ACRF system with more reactors and exciters

To compensate the high losses in the special cable with relatively high resistance of
outer screen (7), the power inverter is realized by two control and feeding units, one
(1) for 400 kVA and a second (2) for 200 kVA output power. Both work in a master-
slave mode and are coupled by fiber optic links (3). Each control and feeding unit is
built in a separate control container. The voltage divider (6) is connected to the mas-
ter unit and enables the measurement of the test voltage, automatic search of reso-
nant point and breakdown detection. The output power of the inverter units is coupled
with three identical exciter transformers (4). This flexible design allows a separation
in two independent test systems by adding an additional voltage divider only.
Exemplarily, Table 1 documents two tests which have been carried out with the de-
scribed test system recently.
Table 1: Examples of performed tests on DC cables
Test voltage Length Cable capacitance Frequency
[kV] [km] [F] [Hz]
160 52 8.1 25.9
92 74 18.0 16.6

AC withstand tests combined with PD measurement

The withstand tests on cables are often combined with PD measurements. PD

measurements on cable ends according IEC 60270 and IEC 60840 seem to be inap-
propriate, especially when testing super-long cables.

Although the function principle of HIGHVOLT inverters supports sensitive PD meas-

urements (real-time TTL noise gating), the measuring sensitivity is limited by the PD
background noise level, which is typically very high on-site. Due to the damping of
the PD signals passing the cables from the failure location to the end of the cable,
only a fraction of the signal reaches the measuring sensor at the end of the cable [7].
PD signals are already damped by the factor 25 at a failure distance of only 6 km
from the cable end (Figure 5). For sure this factor depends on the type of cable but
the overall effect appears on all kinds of cables. However, the main goal of after lay-
ing tests is to identify potentially problematic joints and end terminations. Thus these
are under special surveillance during the PD tests.

100

80
reduction factor [p.U.]

60

40

20

0
0 2 4 6 8 10
cable length [km]

Figure 5: Damping of PD pulses depending on the cable length

MV TEST SYSTEMS

The general principle of test technique is that a test voltage shall simulate the stress
under operation conditions of the test object. Traditional AC test systems with
50/60 Hz for MV were too large for on-site application. As a next step test voltages of
very low frequency (VLF, 0.1 Hz) have been introduced which enable partial dis-
charge (PD) and dielectric loss (tan ) measurement. But also VLF tests cannot fulfil
the above general principle: The resistive stress distribution at VLF is much different
from the capacitive at power frequency. Also the number of stress cycles is very
much lower (A 50 Hz test of 15 min has the same numbers of cycle as a VLF test of
125 hours). The way out is the use of AC resonant test systems tuned into resonance
by the frequency of the exciting voltage (equivalent to the ACRF test system for HV
cables). The application of systems covers the full range of MV cable systems with
extruded and oil-paper cables up to 36 kV rated voltage. The test currents of the
standard systems enable the testing of capacitances of more than 4 F. This corre-
sponds to about 15 km of cables and covers also the full range for electric machines,
instrument transformers and similar MV equipment. The measurement of the PD and
tan can be carried out as described in the previous chapter.
In Figure 6 is shown an example for a resonant test system with variable frequency
for MV applications. In this case the entire test system is installed in a common van.

Figure 6: Resonant test system with variable frequency for MV applications in a transporter

TESTING OF GIS/GIL

The on-site testing and diagnosis of GIS is the classical application of ACRF test sys-
tems [8], [9]. Today components for open and shielded circuits are supplied. The
required frequency range is usually 50 ... 300 Hz, which enables the testing including
voltage and current transformers.

To guarantee the mobility of ACRF test systems for GIS testing there are limitations
for dimension and weight and so for the amount of copper and iron used. This results
in a low Q-factor in the range of Q = 10 to 12 and high exciting voltages.

Modular HV reactors (oil-paper insulated in an insulating tank) for open circuits ena-
ble to form cascades up to three modules as well as the parallel connection of sever-
al modules or cascades, and thereby an optimum adaptation to the test voltage and
test object capacitance.
For testing of 400 kV GIS three series-connected modular reactors for 230 kV/3 A
each are necessary. Their combination covers a wide ranges of voltages (20 to
680 kV) and delivers the required set of frequency-load characteristics of Figure 7.

Figure 7: Frequency load characteristics for the combination of three modular reactors
(s=serial, p=parallel)

A second powerful series of reactors with a rating of 300 kV/10 A per unit is especial-
ly designed for on-site testing of future long-distance GIL. With two such modules in
series 400 kV GIL up to 10 km length can be tested at 600 kV (Figure 8).

Figure 8 and 9: Open ACRF circuit (left) and shielded ACRF circuit (right) for GIS/GIL testing in
France (2008)

SF6 insulated reactors (Figure 9) can directly be flanged to the GIS to be tested and
the complete HV circuit is metal-enclosed and therefore electromagnetically shielded.
The conditions for PD measurement are identically with that in shielded HV test la-
boratories. Using the real time TTL noise-gating of the frequency inverter unit a PD
sensitivity of less than 2 pC was achieved on site. The reactors are realised for volt-
ages up to 750 kV, currents up to 3 A (short time operation), with a combined SF6-
foil insulation and a disk bushing inside a metal tank. A capacitive probe for the volt-
age measurement is integrated in the SF6 tank.
TESTING OF POWER TRANSFORMERS

The lifetime of transformers in the grid is typically round about between 25 and 40
years, for sure depending on type, load and maintenance concept. However, a lot of
transformers are even older than their predicted lifetime. Therefore, reliable condition
assessment of these objects is necessary. A wide range of diagnostic methods such
as oil tests, dissolved gas analysis, PD-measurements, winding or insulation re-
sistance and others give an extensive review of the current state of transformers
condition. If one or more of these diagnostic measurements indicate suspicious or
critical condition of a transformer, its owner has to decide about the next steps on
how to proceed with the effected unit. Typically an extended set of diagnostic tech-
niques is performed to confirm the first assumptions. According to the results of the
test, maintenance or repair work has to be done, which is carried out more and more
directly on site.

In the past, main repair work and dielectric tests were usually performed in a factory
or repair shop as there all necessary equipment to overhaul the transformer and to
carry out all dielectric tests is available. But since shipment and transportation of
power transformers is often expensive and sometimes not possible, on-site repair
measures became increasingly popular over last 15 years. After an intensive repair
process in the field, especially if the windings have been repaired or replaced, dielec-
tric tests or usually demanded to verify the success of the repair procedure. These
tests are carried out with high voltage, while it is not recommendable to use the feed-
ing voltage directly from the grid because sensitive measurements, especially PD
tests are more or less impossible with connection to the power network. In these
cases external high voltage test equipment comes into service. For this purpose,
converter-based variable frequency test systems have been developed into the in-
dustry standard.

The mobile transformer test system is a combined test system for induced and ap-
plied voltage testing according to IEC 60076-3 [4] on the basis of a static frequency
converter as the main power source.
C om p ens a toi n 1

T rans fo m
r er
C onv e r te r A d ap toi n T rans fo m
r er HV -F ilte r und e r T e s t B u sh ni g
M e a su r ni g d ev ic es o f
cu rren tand vo ltage

S PS

C om p ens a toi n 2 PD m e asu r n

ig
3 x P ea k - 12345 12345 P ow e r an a lys e r 12345 d ev ic e
vo lm
t e te r
U SP
/ Q
/ PD

E TH ER N E T

PR O F B
I US

O p e ra to r C on tro l
d ev ic e com pu te r

Figure 10: Circuit of a mobile transformer test system, type WV 620-1000/80

The components for testing induced voltage basically contain a three phase static
frequency converter with a capacity of up to 1000 kVA and 620 kW, a three phase
adaptation transformer with an output voltage of up to 80 kV, a high-voltage HF filter
as well as the complete measuring and control system including the PD-measuring
system.
For the induced voltage test the frequency converter, the filter, the adaption trans-
former and the control and measurement tools are installed in a 40 ft container, see
Figure 11.

HV- Filter
HV-test lead Control room

Step-up transformer

Option load , no-

load losses test: Frequency
CTs and VTs Converter
Type CFI
Space for
accessories, HV
electrodes, etc.

Power supply cable,

HV connection cable

Space for accessories:

measuring cables, tools, etc.

Figure 11: Design of the mobile transformer test system (induced voltage)

The described system permits the testing of transformers up to a size of 1000 MVA.
The presented test system provides a practicable possibility to carry out tests on
large power transformers on site and therefore enables a reliable form of testing after
an on-site repair. Furthermore, it is a helpful tool for off-line diagnostics. IEC 60076-3
[4] defines the frequency for induced voltage testing: f 2 fn. The advantage of a free
adjustable frequency enables the selection of the point of self-compensation of the
transformer under test.

Self-compensation appears at the change-over of the test object from inductive char-
acteristic at lower frequencies to capacitive characteristics at higher frequencies. At
the self-compensation point, only active losses have to be fed to the test circuit and
the power of the frequency converter can be kept as low as necessary resulting in
physical dimensions enabling convenient road transportation.

To perform applied voltage tests, the system is split in a second system with control
and feeding unit, a 360 kV resonant reactor, an exciter transformer and the corre-
sponding voltage divider. The system for applied voltages is installed in a 10 ft con-
tainer. By applying the test voltage to the secondary site of the test object, the trans-
former to be tested is a simple capacitive load. Therefore, the applied voltage test is
similar to a test of GIS or cables. As mentioned before, GIS and cables are to be
tested on site using a resonant circuit with variable frequency in the range of 20
300 Hz. Therefore, the same principle can also be used for transformer testing, as
according to IEC 60076 [4], the test frequency should amount of 80 % of the rated
frequency (e.g. 40 Hz for a 50 Hz power transformer).

If the power of one system is not sufficient to test a large power transformer on site,
different extensions can be added as 2nd system in parallel, mobile HV capacitor
bank or mobile HV compensation reactor.

Picture 12 shows the parallel testing with two systems of a large power transformer.
 Figure 12: Power transformer on-site testing in Germany (2010)

CONCLUSION

The ACRF HV test systems are the ideal solution for offline testing of electrical power
equipment on site. They do not only offer real HV withstand tests with physically cor-
rect test voltages, but also the possibility to do diagnostic measurements. They com-
plete the preconditions for modern asset management of the power generation,
transmission and distribution components.
The various designs of the test systems are well adapted to the power equipment to
be tested with different ratings like power and voltage. Modular applications further
extend the performance. Small and light-weight test system components can be con-
nected in series and/or parallel to supply the power demand in an extremely wide
range.
The overall design of the ACRF test system and especially the operation principle of
the feeding source allow the combination of the HV test with sensitive measurements
in order to evaluate the actual condition of electrical insulation systems.

REFERENCES
[1] W. Hauschild; S. Schierig; P. Coors: Resonant Test Systems for High-Voltage
Testing of Super-Long Cables and Gas-Insulated Transmission Lines, ISH 2005,
Bejing
[2] IEC 62067: Power cables with extruded insulation and their accessories for rated
voltages above 150kV (Um = 170kV) up to 500kV (Um = 550kV) Test methods
and requirements (second edition 2011)
[3] IEC 60840: Power cables with extruded insulation and their accessories for rated
voltages above 30 kV (Um = 36 kV) up to 150 kV (Um = 170 kV) Test methods
and requirements (fourth edition 2011)
[4] IEC 60076-3: Power transformers Part 3: Insulation levels, dielectric tests and
external clearances in air. (second edition 2000-03)
[5] IEC 62276-3: High voltage switchgear and control gear Part 203: Gas-insulated
metal-enclosed switchgear for rated voltages above 52kV (first edition 2003)
[6] J. Karlstrand; G.Henning; S. Schierig; P. Coors: Factory testing of long subma-
rine cables using frequency-tuned resonant systems, CIRED 2005, Turin
[7] CIGRE study 379: Update of service experience of HV underground and subma-
rine cable systems CIGRE Working Group B1.10 Study 379
[8] WG 33/23-12-A (A. Sabot et. al.).: Insulation co-ordination of GIS and return of
experience, on-site tests and diagnostic techniques, ELECTRA No. 176 (1998)
[9] A. Thiede; T. Steiner; R. Pietsch: New Approach of Testing Power Transformers
by Means of Static Frequency Converters., CIGRE, Paris (2010), Paper D1-202