HIGH VOLTAGE TESTING ON

TRANSFORMERS
CEPED 2013, Bali, Indonesia
Dr. Ralf Bergmann
HIGHVOLT Prftechnik Dresden GmbH
Table of contents
Motivation and Standards
Factory Testing Latest Technology
On-Site Testing Same principle
Summary
2013-10-31 2 High Voltage Testing on Trandformers
MOTIVATION AND
STANDARDS
2013-10-31 3 High Voltage Testing on Trandformers
10/31/2013 4 High Voltage Testing on Trandformers
Motivation
Early recognition of:
Design issues
Production failures
Insulation degradation
2013-10-31 5 High Voltage Testing on Trandformers
Motivation
Transformer - Key component in electric energy system
Securing Transformers quality essential for reliability of electric
network
Extensive testing within development and testing of transformers
Routine test
Type test
Increase of old transformers in power grid
Need to verify old transformers condition

10/31/2013 6 High Voltage Testing on Trandformers
STANDARDS FOR FACTORY TESTING
Standards
Standards IEC
IEC 60076-13
Standards IEEE
IEEE C57.12.00 - C57.12.90
IEEE C57.152 (=old IEEE 62)
GOST
GOST 1526, GOST 3484, GOST 52719-2007
On-Site Testing: No separate standards.
use of same testing procedures,
possible test voltage reduction for service aged
transformers





2013-10-31 7 High Voltage Testing on Trandformers
Possible Test`s on power transformers
Measurements of winding resistance
Measurement of no-load loss and current
Dielectric tests
Temperature-rise test
Determination of sound levels
Measurement of the harmonics
of the no-load current
Measurement of insulation resistance
Measurement of turn ratio
Determination of capacitances
Tests on on-load
tap-changers
FACTORY TESTING -
LATEST TECHNOLOGY
2013-10-31 8 High Voltage Testing on Trandformers
IMPULSE VOLTAGE TEST OF
POWER TRANSFORMER
ACCORDING TO
IEC 60076-3, POS. 13-15
IEC 60060-1 2010
2013-10-31 9 High Voltage Testing on Trandformers Modern solutions of power transformer testing
10 High Voltage Testing on Trandformers
Sample of lightning impulses
Tail time
Front time
2013-10-31 Modern solutions of power transformer testing
0,9
0,3
1,0
U
B
A
0,7a
t
T
1
T
C
a
D
C
0,1a
a instant of chopping
Full lightning impulse Chopped lightning impulse
11 High Voltage Testing on Trandformers
Accuracy is important:
Correctness of wave shape

Space is expensive:
Space saving solution

Time is money:
Quick test setup increasing
output of factory

Requirements on impulse
voltage test
2013-10-31 Modern solutions of power transformer testing
Connection Point The all in one solution
Test system consists of only two
individual components:
1) Impulse generator
2) Connection Point
HV divider
Chopping gap and
Overshoot compensation
Benefits of Connection Point:
Space saving solution
Integrated overshoot compensation
Only one connection to the test object
Only one test setup is used

High Voltage Testing on Trandformers 12 2013-10-31 Modern solutions of power transformer testing
Space reduction using Connection Point


2013-10-31 High Voltage Testing on Trandformers 13
Arrangement with Connection Point Arrangement with divider, overshoot
compensation and chopping gap

MOST COMMON LAYOUT
LAYOUT USING CONNECTION POINT
Example: Test system U
LI
=1800 kV U
SI
=1150kV

Space required = 400 m Space Required = 300 m
25% space reduction
Test object
Di vi der
Chopping
gap
Overshoot
Compensat
ion
Impulse
generator
Test object
Connecti on
poi nt
Impulse
generator
FACTORY TESTING -
APPLIED VOLTAGE TESTING
2013-10-31 14 High Voltage Testing on Trandformers
Applied Voltage Test IEC 60076-3, pos. 11
15
Transformer based AC test system
- continuously duty cycle, high feeding power
- high test system costs
Resonant test system with variable inductance
- perfect sine wave, proven/robust technology
- less feeding power, less costs
Resonant test system with variable frequency
- perfect sine wave, proven/robust technology
- small components, lowest feeding power, best price
2013-10-31 High Voltage Testing on Trandformers
Applied voltage test or separate source AC withstand voltage
test can be performed with 3 different type of test systems
16 High Voltage Testing on Trandformers
Example of Applied Voltage Test for 1200 kV
2013-10-31 Modern solutions of power transformer testing
Test of transformer for 800 kV HVDC transmission
at Siemens Nuremberg, Germany
2013-10-31 17 High Voltage Testing on Trandformers
ADVANTAGES
Compact
Easy extendable
Low power consumption
Operates according to
IEC >80% of rated voltage

Lower Investment cost

Applied Voltage Test
Variable Frequency Test System
Test system at Siemens Dresden, Germany
System Concept for Applied
Voltage Test
2013-10-31 18 High Voltage Testing on Trandformers
1 Control and feeding unit
2 Exciter transformer
3 HV reactor
4 Blocking impedance
5 Voltage divider
3
5
4
400V
50 kVA
50/60Hz

LV HV
Transformer
to be tested
FACTORY TESTING -
INDUCED AC VOLTAGE TESTING
2013-10-31 19 High Voltage Testing on Trandformers
2013-10-31 20 High Voltage Testing on Trandformers
Generation of test frequency
Solutions for Induced Voltage test
Since the test voltage Up for the induced voltage test is often higher than twice the rated
voltage, the test frequency must be at least doubled to avoid over-excitation of the iron
core.
Motor / Generator Set Static Frequency Converter
10/31/2013 21 High Voltage Testing on Trandformers
Induced AC Testing
based on Static Frequency Converter
Different frequencies for loss measurement and induced voltage
testing provided by static frequency converter
replacing several different motor-generator-sets
Fulfill all demands of standards
Efficient
Allows testing of transformers >1000 MVA
Expandable
Space-Saving
Easy to operate, intrinsically safe
ADVANTAGES
2013-10-31 22 High Voltage Testing on Trandformers
Induced AC Testing
based on Static Frequency Converter
Block diagram of transformer test system
Induced AC Testing
based on Static Frequency Converter
2013-10-31 High Voltage Testing on Trandformers 23
Transformer test system for induced voltage tests, based on static frequency converter, type WV 2000-4000/170
Static frequency
converter build in
container Cooling system Step-up transformer High voltage filter
Induced AC Testing
based on Static Frequency Converter
2013-10-31 High Voltage Testing on Trandformers Page 24
Static Frequency Converter
built in Container
2013-10-31 25 High Voltage Testing on Trandformers
THD Value < 5%
Test voltage and current waveform no-load loss measurement with THDu <3.5% and THDi =52% (150 MVA transformer)
26
Sensitive PD Measurement
High Voltage Testing on Trandformers 2013-10-31
PD Level <10 pC according to IEC 60270
ON-SITE TESTING
SAME PRINCIPLE
2013-10-31 27 High Voltage Testing on Trandformers
2013-10-31 28 High Voltage Testing on Trandformers
NO STANDARDS FOR ON-SITE TESTING
HIGHVOLT on-site test systems allow tests appropriate to standards
of factory testing

On-Site Tests:

Applied Voltage Test
Induced AC Voltage Tests
Optional: Impulse Testing
HV On-Site Testing
ON-SITE TESTING
APPLIED VOLTAGE TEST
2013-10-31 29 High Voltage Testing on Trandformers
Wide load range of power transformers 5 to 40 nF
Variable test frequency 40 to 200 Hz
Voltage 360 kV Expandable to 720 kV
Electric current 5 A










2013-10-31 30 High Voltage Testing on Trandformers
Test System for Applied Voltage Test
Resonant system with variable frequency



Standard 40 foot trailer
High Voltage Testing on Trandformers 31
Applied Voltage
Procedure and Test sequence
2013-10-31
Transportation to site
Test arrangement and connection of test object (approx. 50 min)
Start system and enter test parameters (approx. 10 min)
Start automatic test sequence
Automatic search of test frequency at 10% of U
test
(frequency shall be not less than 80% of rated frequency per IEC)
Increase the voltage up to U
test

Withstand voltage test
Decrease the voltage up to 0 V
Finish test and print test report (HIGHVOLT Suite

)

32
Summary Applied Voltage Test
Dielectric test of the main insulation
(between winding and iron core/ tank; between the winding systems)

Test voltage up to 360 kV
with additional reactor up to 720 kV

Required power supply:
400 Volt (3~), 40 kVA

Only one HV lead to connect
the transformer under test

High Voltage Testing on Trandformers 2013-10-31
ON-SITE TESTING
INDUCED AC VOLTAGE TEST
2013-10-31 33 High Voltage Testing on Trandformers
Setup for Induced Voltage Test
2013-10-31 34 High Voltage Testing on Trandformers
PD
1234
PLC
3 ~ 400V
/ 50~60 Hz
PD measuring
system
HV capaci ti ve compensati on uni t (Opti on)
Transformer
to be tested
1234
1. Frequency converter
2. Step-up transformer
3. HV filter 1
4. HV compensation (Option)
5. HV filter 2 (Option)
6. Loss measuring system


1 2 3
4
5
6
Space for
accessoiries
Design of Mobile Test System
Static
frequency
converter
Step-up transformer
Control room
HV filter 1
Power supply cable,
HV connection cable
2013-10-31 35 High Voltage Testing on Trandformers
CTs and VTs
Space for
accessories, HV
electrodes, etc.
HV test lead
High Voltage Testing on Trandformers 36
Induced voltage Procedure and Test
Sequence (IEC/ IEEE/customer specification)
2013-10-31
1. Transportation to site
2. Test arrangement and connection of test object (approx. 50 min)
3. Start system and enter test parameters U
test
and f
test
(approx. 10 min)

Typically: U
test
= 80% of U
test at factory

f
test
approx. 2 x f
rated
(between f
rated
and 200 Hz)

Choose frequency of test

= f
test
:

a) Factory test frequency i.e. 120 Hz,180 Hz, etc.

b) Or to minimize the power demand choose frequency to take
advantage of variable frequency to reach self compensation
4. Start automatic test sequence
5. Measure PD at test voltage levels specified
6. Finish test and print test report (HIGHVOLT Suite)

APPLICATION
Required for reactive power compensation during short-circuit tests,
load-loss tests and on-load tap-changer tests
SOLUTION
Capacitor bank on one trailer or in one 40-foot container
for single phase and small three phase types
Capacitor bank on 2 trailers in four 20-foot containers for larger
three phase types (3 containers for capacitors, 1 for measuring
transducers)
Standard types:
- up to 250 MVA test objects: 36 kV / 24 MVA, HVCC 24000/36
- up to 500 MVA test objects: 36 kV / 54 MVA, HVCC 54000/36
Capacitor Banks for Mobile Transformer Test
Systems
Principle sketch of mobile capacitor bank
HVCC 24000/36
power measurement:
current transformer / voltage transformer
CT1CT3: phase current measurement
CT4: protection against unsymmetrical currents
Compensation units can be connected to form a 3-phase
or a powerful single phase capacitor bank
HV capacitive
compensation units
40 ft trailer
cable drums
All transformers
up to highest
ratings can be
tested on site


Higher power by
mobile capacitive
compensation
banks is
available
Mobile capacitor bank HVCC 24000/36
inside a 40ft container
40
Output voltage: Up to 80 kV

Output power: 1000 kVA / 620 kW

Power supply: 400 V (3~)
- 750 kVA mains supply or
- 1200 kVA diesel generator

Only 3 HV cables to connect
the transformer under test

Easy set up:
Within 1 hour ready to test
Summary Induced Voltage Test
High Voltage Testing on Trandformers 2013-10-31
EXAMPLES OF TESTED
TRANSFORMERS
2013-10-31 41 High Voltage Testing on Trandformers
42
Test of a 500 MVA Single Phase Trans-
former in a Nuclear Power Station

High Voltage Testing on Trandformers 2013-10-31
Test of 1phase main transformer with WV 620-1000/80
Power supply by mobile diesel generator
43

Parallel connection of up to 3 test systems (total: 1.9 MW/3 MVA)



Parallel Operation for Testing
up to 1200 MVA Transformers
High Voltage Testing on Trandformers 2013-10-31
Summary
Testing power transformers up to 1200 MVA
According to IEC and IEEE standards
Waveform distortion THD <5%
Partial discharge (PD) noise level <10 pC (with 2
nd
HV filter)
Free adjustable frequency 40 to 200 Hz (self compensation)
Modular design allows for future expansion
Easy and fast test set up

2013-10-31 High Voltage Testing on Trandformers 45
YOU DELIVER QUALITY

OUR EQUPIMENT PROVES IT
High Voltage Testing on Trandformers 47 2013-10-31