22 Application
Efficient on-site testing
High-voltage tests on power transformers
For power supply companies and industrial enterprises, power
transformers are critical to operations and also highly capital-
intensive investments. Transformer testing and diagnostics are
therefore extremely important. Alongside the various laboratory-
based processes for testing the insulating liquid, a whole range
of electrical diagnostics processes is available. Several of these
methods can be performed on-site at relatively low costs, while
others require high voltages, which then have to be generated
with transportable test sources.
On-site high-voltage tests
When performing on-site high-voltage tests, mobile test ap-
paratus is used (generally installed in containers or trailers). This
equipment is transported directly to where it is needed by road,
rail or ship at relatively low costs. In the past, motor-generator
sets were predominantly used for mobile AC voltage test bays.
OMICRON  Magazine | Volume 1 Issue 1 2010
To simplify on-site tests of power transformers,
ABB developed a 'travel-friendly' high-voltage
test bay. This mobile system, which is based on
a 3-phase, static frequency converter and is the
only one of its kind in the world, was specially
designed to perform routine and special tests in
line with the standards IEC 60060-3, IEC 60076-1
and IEEE Std. C57.12.00.
In combination with the multifunctional
testing devices from OMICRON, this allows ABB
to offer a broad range of diagnostics options for
all types and brands of transformers, from small
distribution transformers, right up to the largest
power plant transformers.
Yet their physical weight makes transportation both complex
and costly. Test bays with three-phase converter technology are
therefore increasingly being used. These systems employ a static,
IGBT-based (Insulated Gate Bipolar Transistor) frequency converter
to generate the variable-frequency output voltage. This converts
a three-phase input voltage into a DC voltage and then (using the
module mentioned above) to a three-phase AC voltage, whose
frequency can be adjusted within a range, for example from
15 to 200 Hz.
High outputs required of the test bay / apparatus
Particularly important AC voltage tests on transformers include
determining the no-load losses, the short-circuit losses and the
warm-ups. While determining the no-load losses only requires
comparably modest outputs of the mobile test bay, determin-
ing the short-circuit losses is often only possible at a reduced

transformer rated current due to the
test bay power required. Warm-ups, on
the other hand, can generally only be
performed with additional compensation
capacitors. And even then, there are limits
for large transformers.
The most powerful mobile AC voltage
test bay in the world
The mobile AC voltage test bay developed
by ABB is currently the most powerful
in the world. It works with converters
and is installed in a 40 foot container.
Its converter output is 1.35 MW. With
additional reactive power compensation, a
test output of around 2 MVA is achieved
for voltage tests of up to 90 kV. "Applied
voltage tests of up to 500 kV are possible
with this system", explains Matthias Steiger,
from the mobile test bay department at
ABB in Halle, adding: "This allows even the
largest generator transformers to be tested
on-site." With the MPD 600 partial dis-
charge analysis system, the accompanying
partial discharge measurements can then
be made with a system interference level
with sensitivity of less than 5 pC. The sinu-
soidal voltage produced by the generator
generally displays THD of less than 3 %.
Safe measurement of power systems
with the OMICRON CPC 100
With modern power electronics, it is
possible to measure the short-circuit and
no-load impedances, the transformation
ratio, the no-load current, the capacitance
and the dissipation factor over a wide
frequency range independently of the
Application  23
"The modern analytic technology of the
CPC 100 enables efficient testing of
power transformers."
Dr.-Ing. Peter Werle
Head of Engineering Solutions,
ABB Transformer Service Center in Halle / Saale
mains frequency. Since there is often a to be detected. When extended with the
lot of electromagnetic interference when CP TD1 option, the CPC 100 is currently
testing systems on site, it is always a good the most flexible system available in the
idea to take sensitive measurements not sector for insulation diagnostics. Measure-
at exactly the mains frequency, but rather ments of the dielectric response using the
at frequencies slightly off this frequency. 'DIelectric Response ANAlyzer' (DIRANA)
This allows mains frequency interference allow statements to be made about the
to be filtered out. The OMICRON CPC 100 water content in the fixed insulation
testing device also allows analysis of the
leakage flux losses by measuring the
ohmic components of the short-circuit
impedance in a broad frequency range.
This measurement, often referred to as
the 'frequency response of stray losses',
also allows short-circuits between parallel
conductors to be detected. The CPC 100 is
perfectly suited to this.
Flexible diagnostics system
Further examples of OMICRON's
innovative measurement and test engi-
neering include the frequency response
analysis (FRA) integrated into the CPC 100,
which enables a detailed analysis of wind-
ing deformations, yet also allows shorted
coils, core errors, defective shield con-
nections and defective core groundings
Enables testing of 750 kV transformers with
lightning surge and switching surge voltages:
Mobile pulse test system from ABB with a total
charging voltage of 2 MV and energy of 300 kJ.
24 Application
On-site: Partial discharge measurements based on the
example of a 400 kV/433 MVA generator transformer.
(cellulose) of a transformer using two measuring procedures. The
first of these is 'Frequency Domain Spectroscopy' (FDS), which
enables dissipation-factor measurements to be made over a wide
frequency range from 0.1 mHz to several kHz. The second involves
'Polarization Depolarization Current' (PDC) measurement, which
measures the charge and discharge current when applying and
shutting off the DC voltage. By taking measurements on models
with defined water contents and with equivalent circuit diagrams
which portray the geometry of the transformer insulation with oil
gaps, barriers and centering rods, the water content in the cel-
lulose can be determined. The DIRANA testing device combines
both approaches in one and also reduces the amount of time
needed to perform the tests.
Mobile voltage pulse test bay
With voltage pulse testing systems, lightning surge and switching
surge voltage tests are performed to simulate transient voltage
stressing. Marx generators are used here to generate a high
voltage pulse using a special arrangement of capacitors, which
are charged in parallel and then discharged in series across the
test object to generate the high test voltage. A large number
of stages on top of one another are required to generate high
voltages. Generators for testing large transformers can therefore
easily reach a height of 15 meters and more.
Hydraulically erectable pulse generator
In the past, generators of this kind were often made up of indi-
vidual modules stacked on top of each other using a crane when
performing on-site tests. However, this approach is time-consum-
ing and expensive. "Our newly developed mobile surge voltage
test concept excels above all through the simple and fast erection
of the pulse generator required to perform the pulse test", com-
ments Dr.-Ing. Peter Werle, Head of Engineering Solutions at
ABB Transformer Service Center in Halle / Saale, explaining the
OMICRON  Magazine | Volume 1 Issue 1 2010
Compact design: The new three-phase,
mobile test bay from ABB.
key benefits of the new system. The pulse generator is housed
horizontally in a 40 foot container and then erected quickly using
a hydraulic system, meaning that no other auxiliary equipment is
required on-site.
Successful partnership
In cases where transporting a transformer to the manufacturer or
to the designated repair facility is too expensive, too complex or
too risky, as well as in cases where transformer downtime needs
to be kept to a minimum, on-site repairs represent a sensible
alternative. Following maintenance / repair work of this nature,
however, it is necessary to perform standard measurements
and high voltage tests to ensure the quality of the repairs and
the reliability of the transformer. "OMICRON's modern analytical
technology and ABB's mobile high-voltage testing systems make
it possible to meet the increasing requirements of on-site testing
and also to perform this testing in a similar way in the factory",
explains Dr.-Ing. Werle, summarizing the advantages for custom-
ers and thereby the result of a successful partnership between the
two companies.
ABB Engineering Solutions
ABB has more than 50 transformer plants and more than
30 service sites worldwide. The company is the global market
leader for on-site transformer testing and repair work. Its latest
development, a mobile high-voltage test bay for on-site test-
ing of power transformers, offers unparalleled opportunities
for testing, maintaining and repairing transformers on-site.
OMICRON supplies the measurement and test engineering
required for this.
Further info: www.ABB.com