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 Telephone: +49-6151-162529
Darmstadt University of Technology Telefax: +49-6151-162329
Landgraf-Georg-Strae 4 Email: hinrichsen@hst.tu-darmstadt.de
64283 Darmstadt http://www.hst.tu-darmstadt.de



How to find us:










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.


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 Landgraf-
Georg-Strae)


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 Transient recorder
4.2 Optical fiber transmission circuits
4.3 Voltage measurement
4.4 Current measurement
4.5 Impedance measurement
4.6 Temperature measurement
4.7 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: 2.8 MV LI/1.8 MV SI; 80 kJ; 16 Taps
AC voltage: 1 MV (50 Hz-60 Hz); 16 Hz 60 Hz; 1 MVA; 4 Taps
DC voltage: +600 kV 0.01%; 4 mA

Voltage Measurement System approved by IEC 60060-2:

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

Examples of test and research activities:

Type tests (dry and wet) of equipment with a maximum operating voltage of
U
m
= 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

3000

1500

1000

750

500

250

Voltage / V

500

1000

1500

2000

3000

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, U
d

- Dielectric strength, E
d


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 U
d

Partial discharge initiation voltage U
e


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 Current shape
Max. charging
voltage
Current Residual voltage
8/20
100 kV 40 kA 40 kV Lightning impulse
8/20
500 kV 10 kA 300 kV
1

Switching impulse 30/60 100 kV 2 kA
Lightning impulse 80/200 50 kV 35 kA 35 kV
High impulse
4/10
100 kV 100 kA 60 kV
Steep impulse 1/<20 100 kV 20 kA 30 kV

Exponential impulse current circuit (Highvolt)

(Lightning impulse, switching impulse,
high impulse, steep impulse)

C
FS L R
PO
U
L
C
FS L R
PO
U
L


1.5.2 Long duration impulse circuit

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








Long duration impulse circuit (Built in house)



Gesamt
20 10 F 200 F C = =




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.



C
n
FS L
1
PO U
L
C
1
L
n
C
n
FS L
1
PO U
L
C
1
L
n





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: 0 ... 5 kV
Peak value of the short circuit current 8/20 s: 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





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
Temperature range fort he thermal stability in the arrester



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.




U
N
U
Tr
U
Shunt
Transformer
U
eff
= 0...8 kV
I
max
= 40 mA
Furnace with varistor at
T = 115 C
Ohmic voltage
divider
Shunt for current
measurement
Verlust
1
dt
T
o
P U I
T
=

Mesystem zur Auswertung
Schematic representation of the aging test stand
Measuring system for evaluation



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












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.





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



Type: H 8249 Series

Spectral response: 185 680 nm

Frequency bandwidth: DC till 200 kHz









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.



OSCILOSC
SAMPLE
PMT
POWER
SUPPLY
OPE



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 N
2
500 l/s
Booster pump two stage rotary pump
Compression for
nitrogen N
2
8 10
8

Final pressure 10
-11
mbar
Revolution speed 60.000 U/min
Weight 30 kg



Booster pump:
Two stage rotary pump: DUO 030 A

Pumping rate for
nitrogen N
2
500 m
3
/h
Final pressure 10
-3
mbar
Nominal connection diameter 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 m
3
/h
- Mixer heating temperature:....................................................................max. 130 C


3.2 Shielding room

Non-portable shielding rooms ............................. fabricated by Siemens and In-house,
....................................................................... max 200 m
3

.............................................. 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
SF
6
handling equipment (DILO) for pure SF
6




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
.