of metal HAEFELY Kurt Feser [ On-site high-voltage testing nclosed gas-insulated substations Several possibilities of on-site testing of SF, installations are investigated to determine their physical feasibility and technological sound= ness. The special characteristics of SF insulated systems and several on-site failure modes lead to texting method proposal which s technical {y justifiable and can be implemented at relatively low cost. SF installations are conditioned with an AC voltage at an amplitude approximately thar ofthe phase voltage. The subsequent voltage test I carried ou with an oscillating impulse voltage wth a front time of more than 100 Then, this paper describes atest system which was custom-designed for testing of SB. installations on-site. 1. Introduetion Today, substation and power bus engineering would be inconceivable without SF, insulatior technology. Thanks to SF,, it has been possible to reduce the space requirements of substations {0 approx. 10% as opposed to conventional technologies [1]. Due to the increased operational reliability achieved by metal encapsulation and the practically perfect Protection of the substation against environmental pollu- tion and other external factors, the SF, insulation technolo- ay is not only effective in urban and suburban substations but also for higher voltage installations; developments have approached the 1200 kV voltage range. In the context of on- site substation testing, itis important to mention that thi technology allows the construction of distribution facilities in dams, caverns or other critical locations, This is attibuta- ble to new approaches and low-cost techniques in the deve- opment of substation sites. Because only transportable items are type or routine- tested in the factory, a high voltage on-site test of the com- plete substation is necessary. All on-site tests performed during the past 15-year history of SF, technology were dic- tated by the capabilities of the available test equipment rather than by physical and technological necessities However, the increased use of SF, installations prompted more and more research in the field of on-site testing, espe- cially for high voltage applications [2: 3; 4}. Itis the intention of this paper to present an on-site test- ing method and the test equipment required for all voltages up to 1200kV under consideration of the possible on-site faults. 2, Prosent on-site testing methods To some extent, the techniques used in on-site testing have improved on the basis of experience gained in the field. While many early installations were put into opera- tion without preliminary on-site voltage testing, it was soon realized that such tests were necessary. Obviously, all test voltages used in Factory tests were also employed for on-site testing whenever possible, ‘The following voltages are commonly used for on-site testing: DC, AC 50 or 60 Hz, lightning impulse 1.2/50, and oscillating switching impulse voltages. As a rule, the ampli tude of the test voltage used in on-site testing is 80% of the corresponding voltage used in factory tests. Many different ‘methods are used in these on-site tests; they are based on ex- perience and involve variations in the number of impulse voltages, the polarity of the impulse voltages, the gradual increase of voltage, variations in the duration of the AC of DC voltage tests, etc. faults on the. 3. Influence of possible on-sit behavior of typical configu ‘The faults that might occur on-site can be classified into two categories according to their physical characteristics Category A: free-moving conductive or non-conductive particles. Category B: locally fixed field disturbances due to dis placement of components during assembly: this can be an accumulation of tolerances; due to damage to electrodes or conductors during assembly or transportation; or due to mislaid tools ‘The decisive issue for on-site testing is the reaction of the insulating system most commonly used in SF; installations = pure gas insulation with a relatively homogenous field and the combination of gas and solids - to such defects [3; 5 0 10) Fig. | shows the breakdown voltage in a coaxial cylinder layout for different voltage stresses versus pressure {10}. In a certain pressure range, the breakdown voltage with AC vol- tages may considerably exceed the breakdown level ob- tained with positive lightning impulse or positive switching impulse voltages. Fig. I also shows that under such condi tions, positive impulse voltages are more critical than nega. tive impulse voltages. This phenomenon is explained by the predischarge behavior at defect locations; AC voltages will result in corona stabilization. The conclusion for on-site testing isto use positive impulse voltages in addition to the Bull. ASE/UCS (1981) No. 1 E1-53aaroose ioe Penrose © particle attached tothe internal eylinder af pressarel Parameter: vohage type negative impulse voltages employed to dimension “clean” configurations. Results of further measurements (10) indi cate similar conclusions for isolated particles. [9] gives a report on measurements which indicate that for damaged electrodes (approx. 1mm dents), the break: down threshold in a cylindrical field is not influenced by AC voltages while the negative lightning impulse voltage is considerably reduced and practically corresponds to the Peak value of the AC breakdown voltage. Therefore, when planning on-site test methods, voltage tests with negative ‘impulse voltages are to be incorporated to identify defects of this type. This is especially true because the amplitudes of the test voltages vary significantly with the voltage shapes, For an on-site test voltage of 8% of the test voltage used in Factory tests, this observation means that the amplitude of bd inky Co Ja {item the on-site test voltage employed in the voltage testis to be 80% of the amplitude of the lightning impulse voltage used in the factory ie. 80% of the BIL, regardless the voltage (AC, lightning impulse, or switching impulse) used. Fig.2 shows the results of tests with breakdown voltages with post insulators in the cylinder field and oscillating switching voltages (60/4000 us) [8}. The breakdown level is lowered by the conductive particles. This effect partly de- pends on the location of the particles on the insulator and partly on the pressure (Fig. 3). If AC or DC voltages are used, contaminating particles can move about within the system and may be deposited on the surface of the insula- tors. No flashover occurs because the voltage level is too low. After an AC voltage is applied to the installation, the breakdown behavior of the system should be tested with im- pulse voltages in order to exclude this effect. This test should be performed at rated pressure When evaluating the papers available on this subject (3; 5; 6; 7] and applying the results to a 420 KV system, we ob- tain the diagram shown in Fig. 4. The flashover values for the individual fault possibilities were plotted in per cent and compared to the test voltages of a 420 kV installation. It was assumed that dimensioning was performed in accordance with the lightning impulse voltage level i. the flashover value with a lightning impulse voltage was defined as 100%, For clean layouts, the 1.2/S0 negative lightning impulse and the 250/2500 negative switching impulse voltages are equal- ly critical although the peak value of the switching impulse is approx. 24% lower than the test voltage. This is attributa. ble to the fact that a reduction of the flashover voltage as ‘opposed to the theoretical value also depends on the voltage type. In addition, Fig. 4 shows that category A faults strongly influence the AC voltage strength with the result that an AC voltage represents the most critical type of stress, Neverthe. less, it is interesting to note that only in one on-site testing cease would a flashover occur at 80% of the value used in fac: tory testing. This means that in all other cases, the impulse voltage strength tested only with AC would not be suffi- cient, * eg 4 : oo fr cleansetup 1 With Atpaticl, engih6 mm, diameter prox. 0.45 mm leansetup ' withprticleOe st oped are 51 hesownso6pu x ee tow0si staf gygfe et | dd *. gts Us for practical layouts compared with text votages Uy fora system voltage of 20 KY © Lighting inpuse voltage X_ Switchingiempulsevoliags A ACwohuge crest ave) A Group fate B Group Biaul BIL Basietnsulation Level SI_ Switching mpole voltage se AC ollage Ps, Reference a cent value of nominal phase voltage 1 Clean layouts clinical ed with and without supports, 5) Parte atached to inernal eslinder Shar 3) © Parle ltched to internal singe. 3.5 8 Screw 3) ‘Support with sharp edged parce staches to electrode 3] ‘Support with aluminum partciettached to surface Movable partici cylindrical el, a5 Category B faults result in the lowest flashover values with negative impulse voltages when the amplitude of the test voltages is taken into consideration, The following results on which reports are available ‘must still be considered for on-site tests ~ The typical lifting voltages for free-moving particles are ap- Prox. 25% ofthe fashover values that apply to AC voltage stresses [5]. The lifting voltage values under switehing impulse conditions fare approx. 40% of the Mashover values. Thus, the installation can be conditioned performed with relatively low AC voltages or ‘switching impulse voltages; if partial discharges are measured si ‘multaneously, category A defeets can also be identified, if any. = Other results [11] indicate that category A defects can also be cleared with oscillating switching impulse voltages, even with Na shovers ~{8] proves that in typical SFy systems, the same lashover val tues are obtained with oscillating switching impulse voltages es with exponential switching impulse Voltages. Ths result must be taken into account when looking a the cost/benefit ratio ofa test device 4. Test procedure In view of the measurement results, we should discuss ~ for technical and economical reasons - the following on- site test procedure for SF, installations: 44) Conditioning test with AC voltages 50/60 Hz. Amplitude: 1.1 + Us: duration of test: 30min, the voltage is to be increased in ‘eps of 10% to 20%. Fault detection: partial discharge measure- ‘ment +) Voltage test with oscillating switching impulse voltages. Ampli- tude: 100% of the relevant switching impulse test voltage used in Factory tests (or 80% of the BIL voltage). Front duration: > 100 is; tail duration: > 1000 us. Polarity: negative and positive. Number of shots: 10; the impulse voltage should be increased in steps of $10 10% beginning with 50% of the test voltage and building up to 100% of the test voltage value. For each step, 5 negative shots are tobe ap: plied, Fault detection: fashovers (voltage oscillograms) Flashovers which remain atthe same amplitude during several shots indicate category B faults, Flashovers which do not reoceur aftr one or more shots have been applied even with higher amplitudes indicate category A. Faults (“eleaning™ Nashovers) It appears as if the proposed test procedure considers the characteristics of the SF, insulated systems and the types of failures which can be encountered on site. Nevertheless, itis worthwhile to discuss the following aspects: 2 variation ofthe suggested amplitude ofthe conditioning test Voltage, such as the use of 1.0 0r 2+ Une instead of I.1 = Un ~ a Variation of the suggested duration of the conditioning test. {Instead of 30 min, testing i to proceed until no further partial ds. charges (<20 pC) are measured he conditioning phase could be performed with a switching. impulse volage instead of with AC if no AC testing unit is avail bie. In such eases, further test results are necessary, primarily to de termine the number and the amplitude of the switching impulse voltages. ~ a variation of the amplitude of the on-site test voltage, The amplitude of the oscillating switching impulse voltage could be 80% ‘or 100% of the relevant voltage level used in factory tests. The fact, that SFe insulated systems are not permanently damaged even by Several Mashovers unless an insulator is defective would support 100% of the factory tes voltage. Further, a switching impulse vol tage test at 100% of factory test voltage represents a Tull-sele lightning impulse withstand test at approx. 80% ofthe test voltage, = proceduresto be used in voltage tests « is an additional DC voltage test necessary for SF, installa tions? What amplitudes and test durations are to be used” When cettain substation components are discannected and contain no ‘magnetic voltage transformers of are not grounded, long-duration DC voltage components may arse. SF, insulating systems are ptt. ‘ularly sensitive to DC voltage stresses, 5. Tost equipment for on-site testing of SF. installations At the highest voltages, the test unit impedances to be ex- pected in SF; installations are capacitances between 1 to 20nF in distribution facilities and capacitances up to SO nF with SF. buses. SF, systems often have cable feeders. In these cases, the cable connections and certain parts of the SF, system must be tested with DC voltages. The use of so- Phisticated electronic components in protection systems and control circuits as well as the application of on-line ‘computers for the control of high voltage networks requires 4 close look at interference problems and at the possibility Of flashover-related destruction of low-voltage compo- ‘nents. Itis too early to say whether oF not high- voltage tests will be necessary in the future. Nevertheless, this aspect ‘merits consideration in the development of new on-site test equipment. Table I gives the required voltages for on-site testing of ‘SF; installations versus various transmission voltages. Up-to-date on-site test equipment should feature: Low weight, especially that of the heaviest item ifthe equipment comprises several modules ~ Space-saving design, especially that of the most volumenous in dividual module ~ Suitability for transportation (in trucks in airplanes) = Availability of test power~ Simple assembly = Conditional compatibility for outdoor use ~ Small amount of energy stored in the test equipment itself to lim itdamage inthe case of fashover Basically, there are two design alternatives for SF test equip: ment: entirely metal-clad test equipment preferably with SF. insulation which is direetly flange-mounted on the in- stallation to be tested; or a test equipment which is as- sembled on-site out of several small modules and introdu- ces the test voltage into the SF, installation via bushings. ‘The first solution results in compact test systems which in the upper voltage range (above approx, 420 kV) imply large and expensive, rather cumbersome units [12}. Due to its versatility and considerably lower total cost ‘including transportation costs for each test), the second so- lution seemed preferable. The disadvantage that voltages ‘are generated in air and therefore require considerable safe ty clearances was deemed acceptable, ‘The test system described below is especially suitable for testing high-voltage SF.-installations on-site (series voltages higher than 245 kV), 5.1 AC voltage test set for conditioning tests Since the AC voltage during the conditioning testis only 1+ Uno the magnetic voltage transformer can remain connected during the entire test procedure. For lower vol- tage ranges (up to 245 kV) and relatively small test capaci- tances, itis recommendable to use a magnetic voltage trans- former or a standard test transformer. In the case of higher system voltages, a series-resonant test set is most suitable, because the object to be tested represents a pure capacitive load. Out of the two possibilities for a series-resonant test set ~ variable inductance and fixed frequency (50/60 Hz) or vari- able frequency with fixed inductance [13] - the first solution was chosen despite the weight saving offered by the first so- lution with a given inductance. Thus, conditioning is per- Formed at mains frequency which is better understood at the present time, Fig. 5 shows the necessary output of the test equipment versus the series voltage (conditioning voltage) for various capacitive test objects. Standardization has led to the fol: lowing two modules: Module: 3S0KV, SO0KVA, 30min height 3m; diameter [7 m: weight 6 tons. (Fig. 6 shows a photograph of module |, suta. bile for system voltages of 420KV and capacitances up to 20 nF oF system voltages of up to 525 kV and capacitances up (0 15 nF Module 2: SOOKV, 1SOOkVA, 30min; height 45 m: diameter 2.5 m, weight 15 tons, Fig.S Necessary outpat Po atest equipment inthe function of vallages to achieve conditioning voltage supply. In this case, itis recommended prior to the applica tion of the AC voltage to perform a conditioning test with switching impulse voltages up to approx. 70% of the switch- ing impulse test voltage level. 5.2 Test set for oscillating switching impulses ‘The standard Marx generator is especially suitable as a test system for tests with oscillating switching impulse vol: tages; the series resistors are replaced by inductances [14 Fig. 7a shows the n-stage schematic diagram of an oscilla. ing switching impulse generator and Fig. 7b illustrates the Fig.6 350bV Series If no AC test set is available, the AC voltage condition- ree ing operation can also be performed directly via the power ivi) Tablet Synenvolasiniv as sa] v5 | Condon votge 1 rr AC volage 80/60 He inkV Galli 8 156 220 268 34 ase Test voltage: | Oscillating switching impulse voltage in 440 760 | 950 1050. | 1095 1580 | wv | u i al)i. 7 Schemati diagram of an esi multistage sins stage single-stage circuit. Fig. 8 gives the definitions of the time to ‘rest T,, and the time to half value T,. From the basic dia- _gram, the following correlations can be derived: Stienzeit Ruckenhalbwertszeit Ty Wirkungsgrad far Fip.8 Definitions in selling switching impulses Th timeto aif value cilating ‘switching impulse generator versus loud capacitance Cy C= 1000 Parameter: inductance L In testing SF, installations, a time to crest of more than 100 1 is envisaged 2} Since efficiency will decrease as the time to crest increases, several inductances will be selected for the load range of | to 50 nF used in SF, systems. In the design and dimensioning of these inductances, the engineer ‘must make sure that the DC resistance of the induetance is, sufficiently small since this will also influence the efficiency ratio. In addition, it must be considered that flashovers which occur when testing SF, installations are very steep (a few ns) resulting in a non-linear voltage distribution across the inductance. This distribution must therefore be linear- ized by means of design or circuit engineering measures When we look at the formula for the efficiency ratio it be- comes obvious that apart from inductance L which determ- ines the time to crest T,, and resistance R, we also have the impulse capacitance C.to consider. An impulse capacitance of 600 nF/100kV was selected: it comprises two 35 kg ca pacitors, representing the heaviest single components ‘weight of the entre installation, Fig.9 shows time to crest T., and efficiency ratio n (and the maximum test voltage) versus load capacity C, for a 6-stage test system. The efficiency of this system results in a ‘maximum output voltage which is sufficiently high for a ser- ies voltage of 420 kV and load capacitances up to 15 nF. For load capacitances exceeding this figure, increase either the number of generator stages or the energy of the generator, Table II shows the required charging voltage of an im: pulse generator for oscillating switching impulses based on aan assumed impulse capacitance of 600 nF/100 KV. This charging voltage is sufficient to generate an oscillating switching voltage in the load range from I nF to 50 nF with atime to crest T, oF 100 sat the corresponding system vol: tage. Fig. 10 shows two typical oscillograms of oscillating switching impulse voltages under varying loads for a 7-stage generator with an inductance of 900 mH. ‘Two different types of switching spark gaps have been ‘completely redesigned. A multiple spark gap with eight par- tial spark gaps provides the advantage of a trigger range of (60% [14 its minor disadvantage isthe open design For this reason, a completely encapsulated single spark ‘Rap was developed for use as a switching spark gap. This ‘unit is provided with a manual distance adjustment device and with compressed air connection (at constant distance), ‘The impulse system is triggered in the first stage via cross- ‘wise triggering with a trigger impulse of approx. 25 kV; the rest of the stages are triggered by the natural overvoltages. An auxiliary spark is also triggered in each encapsulated spark gap to keep ignition scatter as small as possible. Due to the fact that weights and volumes of the test equipment are very important in on-site testing and that transportation costs are major testing expense items, the test set had to be designed in such manner that the generator can, be easily disassembled into 100 kV stages while the voltage divider and the inductance can be taken apart into 300kV sections. Thus, only the parts actually needed for the appli- cable test voltage must be transported. Test equipment space requirements are just as important. Due to its exter- nal-inductance design no switching impulse voltage ap: pears at the top of the impulse voltage generator; thus, the impulse generator can be located quite close to grounded ‘components (for instance at 1000 kV up to 1.5m). In addi-Table 11 Sem votageiniV @ [6 [8 [ms] Test voltage in kV. 440 [760 950 1050 ws | 1550 Charge votageat Sa xo | «| aw | ao | aw] om Toor mw | | om | ae ion ar ee inev snr ee ehh LL tion, the electrodes ofthe voltage divider have been optim- 5.3 Further onsite ests ized with respect tothe discharge onset level for postive The development of the test sytem for on-site testing of switching impulse voltages 15}. SF; installations described in this paper also considers other To increase the flexibility of the impulse system, the on-site test methods so that the equipment can be configur- ‘charge resistors and the parallel resistors have been selected ated with several optional components to run such alternate in such manner that the standard switching impulse voltage ace ‘of 250/2500 can be generated by replacing the inductances With series resistors. By including a further parallel resi tance and replacing the series inductances, the generator can be converted 0a lightning impulse voltage generator as well Naturally the design ofthe voltage divider also allows its a usein conditioning tess with AC voltage Fig. 11 shows a complete 6-stage test set Fig. 12s ade tailed photograph of the pneumatic spark gap. For the en tire system, shipping crates have been designed in such manner that each stage can be shipped in its own container. ‘Thus, the entire system can be loaded on standard trucks or shipped by air freight without difficulty. b Fig. 13 presents the test layout used for testing a 362 kV installation with two vertical buses in South Altica, The lightweight construction and space-saving design ofthe est equipment made it possible to haul the tes installation and lower it into the cavern where the on-site tests were per formed. In many cases, its not possible to tet all compo nents of an SF. installation from the outside. Ths is espe- cially the ease in underground hydroelecte installations. which are connected withthe outdoor substation via Sein. Online ncn ina ye ih Sulated buses bGrstar Ter meg ba asyshea aspstes stops capacitances 1 6-stage oscillating impale generator test set, Couey B Inthecenters compressed air spark pasFig. 13 Testing 2 362-KV unit with vertical bus undergrn CCouresy Siemens Inthe foreground: vokage vider Inthebacksround: Stage osilstng switching impulse beneraae DC rests One configuration which is often required implies an ex- tension of the charging rectifier so that the equipment can be used for DC voltage tests. The present basic charging rec- tifier system can be configurated to a DC test set if addition: al stages are connected according to Greinacher's multiply ing principle. This DC set will have a nominal rating of 530KV and will deliver a nominal current of 8 mA. Fig.14 shows the configuration of the charging rectifier which re sults in a DC test set. With this equipment, cable terminals ‘or SF; installations ean be DC-tested. Electromagnetic compatibility tests On-site testing of low-voltage wiring in substations with advanced electronics in the protective and control circuits is becoming mandatory, not at least because of their low sig nal levels and signal-to-noise ratios. For testing a complex interactive system, only a high-voltage test can satisfy all re- quirements. The very fast voltage changes which occur ‘when switching @ power circuit breaker or in the event of a flashover in the substation must be simulated, ‘The oscillating switching impulse generator is also an on-site test generator which can be equipped with a second- ary peaking circuit and an antenna to perform the necessary electromagnetic compatibility tests. Fig. 1S shows a mobile 500 kV EMP system. With this system, itis possible to reach Field strengths of $0 t0 100 kV/m with rise times of less than 10ns, Depending on the circuit and the terminating resistor of the antenna, times to half values between 200 ns and 20s can be obtained [16]. The electromagnetic pulse is re- flected off the object to be tested (for instance an electronic protection system) via an antenna (vertical or horizontal an- tena). In addition to the direct electromagnetic interference, the magnitude of the interference factors reaching the elee- tronic device via the cable jacket must also be considered. In ‘order to check whether or not the electronic device is sensi- tive to interference present in the cable jacket, it is recom- mendable to perform tests in which the simulated interfer- cence is transmitted directly to the cable jacket. At present discussions are in progress in various committees to determ- ine the shape and amplitude of these interferences types um, Fig, 15 Oscillating switching impulse generator onfigurated {0 SOOKV EMP generat Inthe forearound: SF insulate secondary circuit of he EMP genertorLteratare: 1d iiger Die Anwendung von SF Alger: wed Sener, Bul. 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