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| Quarterly Magazine No. 64 | December 2015 ENERGY INTERNET OF THINGS SAFER, SMARTER, GREENER POWER ARC TESTING ON INSULATOR SETS ONE–STOP TESTING IMPROVES SALEABILITY FOR MV SWITCHGEAR HIGHLIGHT

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DNV GL’s Quarterly Newsletter of Testing, Inspections & Certification

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Page 1: HighLight 64

| Quarterly Magazine No. 64 | December 2015

ENERGY

INTERNET OF THINGS

SAFER, SMARTER, GREENER

POWER ARC TESTING ON INSULATOR SETS

ONE–STOP TESTING IMPROVES SALEABILITY FOR MV SWITCHGEAR

HIGHLIGHT

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Highlight is the quarterly newsletter of KEMA Laboratories.

KEMA Laboratories are part of DNV GL – Energy. Our expertise spans from proficiency in onshore and offshore wind power, solar, conventional generation, transmission and distribution, smart grids, and sustainable energy use to innovative involvement in the energy markets and regulations.

Our 2,500 energy experts support clients around the globe in delivering a safe, reliable, efficient, and sustainable energy supply.

We have over 80 years of experience in testing, inspections and certification – and the KEMA brand is renowned globally as the gold standard for quality. Our Testing, Inspections and Certification (TIC) activities are internationally recognised for their quality and integrity.

Our main product is the KEMA Type Test Certificate, which is issued if a component successfully passes an internationally recognised type test program in our laboratories. For our customers, the award of a KEMA Type Test Certificate is a respected indicator of the reliability and safety of their products. KEMA Laboratories are located in the Netherlands, USA, and the Czech Republic.

Editorial departmentDNV GL – EnergyKEMA LaboratoriesP.O. Box 90356800 ET ArnhemThe Netherlands

T +31 26 356 32 22E [email protected] www.dnvgl.com/kemalaboratories

Editorial staffAngela de Geest

PhotographyDNV GL Fotostudio Alain Baars

It is the time of year in the Northern Hemisphere that the days are getting shorter. Fortunately the lights in our labs are shining brightly on new equipment making us proud and helping us serve our customers even better. Our two new large short-circuit generators are securely positioned in the new generator building making a very pleasant humming sound and soon to be connected to their four brothers. In our KEMA Laboratory in Prague we are further expanding our LV panel testing capacities.The Diwali festival in India last week also celebrated light with celebrations in Arnhem as well. The India - Arnhem connection has steadily been growing over the last decade, while India’s power grids took their place among the world leading grids, clearly demonstrated by their plans to construct a 1.200 kVsystem. Our lab is ready to help our customers become successful in operating at these new voltage levels.The success of the Indian grid has the two critical factors for me: a great electrical engineering culture driven by knowledge and innovation, and consistently demanding type

test certificates from independent laboratories during the expansion and replacement of the Indian grid and its components.Even in our industry, some people want to save money by taking shortcuts by not going for full type tests, deviating from test standards, or even worse forgetting about the need for quality or independence in the actual tests and just buying a paper certificate from any test lab. Recent scandals e.g. in the German car industry clearly indicate that independent inspection and certification is required – Let’s hope our industry does not need a wake-up call in ‘man-made’ darkness.In this issue of Highlight you can read more about our services to Indian customers, and an interview with our distinguished colleague in India, Mr. Kishore.

Best regards,

Jacob Fonteijne,

Executive Vice-President KEMA Laboratories

CONTENTInternet of Things

Power arc testing on insulatorsets

One-stop testing improves saleability for MV switchgear

ELECRAMA: delivering rapid growth in AsiaEvents

Testing activitiesn ALSTOM GRID TESTED AN 800 KV SF6 CIRCUIT-BREAKER

n NEXANS FROM HANNOVER

n RIYADH CABLES FROM SAUDI ARABIA

03

04

06

07

08

Festival of Lights

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INTERNET OF THINGS

Internet of Things for control and protection of power systems, a new technology

Within the energy trilemma, digitalization (automation/communication) will play a crucial role. With the implementation of large scale renewable energy sources, conventional control and protection systems will be insufficient. Lots of data will be needed to ensure reliable, sustainable and affordable energy flows. Power generation will be more fluctuating than before. Transmission and distribution of energy will be dual way instead of only downstream and power consumers become prosumers. How to control and protect this complicated system?

One new technology used is ‘’Internet of Things’’ in substation environments. Up to today different communication systems and communication media are used for different services like protection, control, surveillance, office network, etc. With new communication technologies like package based IP/MPLS all of these services become integrated using the same hardware. Protection and control rely on real time information. What does this mean in terms of reliability and availability? Is the equipment used hardened for the medium- and high-voltage environment under normal and faulty conditions? Another important issue is data integrity

and data security. Is cyber security assured? The way to prove this is by testing components and systems. KEMA Laboratories of DNV GL can assist with testing and certification based on international recognized standards like IEC 61850-3 and IEEE 1613. These standards enclose requirements for comprehensive testing of functional performance, electromagnetic compatibility, climatic and mechanical environmental conditions and electrical safety compliance. Is our KEMA Type Test Certificate your global passport to the future of internet of things based power systems?

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KEMA LABORATORIES

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POWER ARC TESTING ON INSULATOR SETS

Insulator sets are among the most common components in electricity transmission networks. Their quality and performance play a vital role in ensuring a reliable electricity supply, and a key part of that is their behaviour when exposed to a power arc. Poor design with respect to power arc behaviour can significantly reduce the lifetime of the insulator set and increase the likelihood of interruptions to the supply.

There is a wide variety of insulating material options and environments in which insulator sets are used. So insulator set designs can vary considerably and may need to be individually tailored for specific applications. Even the smallest differences in design can affect the power arc behaviour of a string. Hence, physical testing is the most reliable way to assess a string’s power arc behaviour.

Over the last five years, KEMA Laboratories, Prague has carried out over 160 such power arc tests on insulator sets of various types. These tests were performed according to the IEC 61467:2008 standard. This standard applies to insulator strings or sets comprised of ceramic, glass or composite materials, and that will be mounted on metallic poles or towers and used in AC overhead lines with a nominal voltage above 1000 V.

The standard defines methods, parameters, circuits etc. for power arc tests on both insulator sets and short strings. Different test arrangements are allowed within the standard, and the choice of test arrangement depends entirely on the final application of the insulator sets according to customer requirements. As such, the test circuit and series should be chosen based on factors such as the geometry and type of insulator, its position in the line and the type of tower it is to be used with. Figure 1 shows a typical test arrangement for a V-string set with composite insulator units. This test arrangement comprises balanced supply and return circuits.

The main verification test performed is the mechanical failing load test (MFLT). This is performed on the insulator units to ensure they can withstand mechanical forces after a power arc is applied. Insulator sets may also be required to undergo a dry power frequency flashover (DPFF) test to ensure the insulator does not suffer punctures at voltages below the flashover voltage. Additional electrical tests may be performed on the fittings and conductors within the insulator set to verify their withstand capabilities.

Figure 1: Typical arrangement for testing an insulator set in the laboratory

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As shown in figure 2, 66% of components tested successfully completed a full test sequence. Just one set suffered a separation failure during the arc test. DPFF tests were not performed on an additional 35 sets and no MFLT was performed on an additional 10 sets. These 45 sets are not included among those sets that successfully completed testing even if no failure occurred during those tests carried out.

The configuration of the insulator, tower and current return paths are subject to an agreement between the utility and the manufacturer. The results from the test are valid for that configuration only. For other applications and configurations the test needs to be repeated.

Critical componentsLong-rod insulator setsFor long-rod sets, three particular potential issues were identified. The metallic parts of the insulator unit can be prone to melt if not well designed. Furthermore, poor design can lead to the sheds near these metallic parts breaking. Finally, the arc can cause metal to evaporate from the set’s protective fitting, causing puddling.

Composite insulator setsThe silicone rubber used in composite insulator exhibits a very high resistance to power arc testing. However, for these sets, the critical point is the where the fibre-glass core connects with the metal end fittings.

Figure 2: Summary of test results for 162 insulator sets tested at KEMA Laboratories, Prague over a five-year period

Cap-and-pin insulator sets (glass or porcelain)Cap-and-pin insulators exhibit very high mechanical resistance after power arc tests. The main areas of concern for these sets are the possibility of sheds breaking and, for glass sets, the cooling of the cap-and-pin units.

Protective fittings: load-bearing fitting protection and arc direction fittingsPower arc tests put much greater mechanical and thermal strain on these fittings than short-circuit tests, and this must be taken into account when designing the protective fittings of insulator sets of all kinds. There is also a danger of material from these fittings melting onto the insulator units. Care should also be taken to ensure that protective fittings do not move during arcing, which can lead to arc root sitting on the load-bearing fittings.

Protective fittings: corona rings, grading rings, etc.These fittings are not primarily designated for arc currents, but they influence the position of the arc root and how it moves. As with other protective fittings, risk factors here include material melting onto the insulator units and movement of the fittings causing the arc root to move away from its intended position. In addition, changes to the contours of these fittings can lead to excessive corona discharge and radio noise.

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KEMA LABORATORIES

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Gaining market success for your medium-voltage switchgear can be difficult. Prospective customers want evidence your product will work as expected. Certification based on laboratory testing is the most reliable way to provide that evidence. KEMA Laboratories offer a one-stop shop for all your MV switchgear testing needs. It can lead to a globally renowned KEMA Type Test Certificate, and increases transparency in the testing process – making your product more attractive to customers.

A complete testing packageOur industry-leading facilities are fully equipped to perform all the tests required by international standards such as IEC 62271-200 and IEEE C37.20.7.

One-stop testing improves saleability for MV switchgear

IN BRIEF

This includes the established tests that make up today’s standards such as:• Short-circuit tests• Dielectric tests• Temperature rise tests• Mechanical tests• Internal arc tests• Tightness tests

However additional tests are becoming more important as the demands on MV switchgear evolve. For example, more control electronics in switchgear makes electromagnetic compatibility (EMC) testing more prevalent. And X-ray testing is becoming standard for certain types of vacuum interrupters. At KEMA Laboratories, we already offer these tests.

What’s more, we are proactively helping to extend the working life of MV switchgear by participating in technical committees for standardisation.

Through our involvement in standardisation bodies and commitment to invest in new technologies, we will ensure that any new tests are available in good time. So that we continue to be a one-stop shop for MV switchgear testing.

All tests are performed by our highly skilled and experienced test engineers, ensuring great efficiency and cost-effectiveness in testing while maintaining the highest levels of rigour.

Maximum customer confidenceOur all-in-one testing package is the only way your MV switchgear can attain a KEMA Type Test Certificate. These certificates are recognised the world over as a mark of quality. They add real value for you and your customers, opening doors for you to do business around the world.

In addition, having all testing done at a single lab brings greater transparency. It shows that all tests were performed on the same design. There can be no suggestion that components were (unintentionally) optimised for specific tests. Hence potential customers can have greater confidence in your products, making them a more attractive proposition.

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ELECRAMA: delivering rapid growth in Asia

From 13 to 17 February, the Bangalore International Exhibition Centre (BIEC) in India is playing host to the biennial ELECRAMA exhibition. The Asian market is about to undergo huge changes and therefore ELECRAMA is a key event in the energy industry’s calendar. BN Kishore, KEMA Laboratories’ representative in India, tells us more.

IN BRIEF

As an expert in the Asian market, why do you think it is important to be at ELECRAMA?Everyone in the energy industry in ASEAN (Association of Southeast Asian Nations), India and China will be there. So it is the perfect forum to discuss the big changes ahead in this region, which is fast becoming a powerhouse of the global energy market. The event has over 1000 exhibitors and is organised by IEEMA and supported by several organisations of the government of India.

So what are these changes, and which challenges do they bring?India is poised for economic growth of more than 8%. Achieving this will require 80,000 MW of additional generating capacity every five years. To cope with this increased capacity, India has already upgraded its transmission voltage to 765 kV AC, which means installing a large number of 765 kV transformers. It has also commissioned an experimental 1200 kV AC line (the world’s highest transmission voltage).

What is KEMA Laboratories doing to support these developments?A lot. But perhaps the biggest thing is the upgrade of the High-Power Lab in Arnhem, the Netherlands.Our €70 million investment there will create the world’s first facility for testing the extreme high-voltage (EHV) components required for supergrids. Due to open in 2016, it will be capable of short-circuit testing the 765 kV transformers India needs to install. This is a crucial step in ensuring the safety and reliability of India’s upgraded transmission system. Our experts will be at ELECRAMA to discuss the changes facing the Asian market and how we can help local players prepare for them. You can find us in Hall 3B, Stand H3 M 46

2nd Advanced Cable Middle East 20162-3 February 2016The Oberoi, Dubai, United Arab Emirates

Elecrama-201613–17 February 2016BIEC, Bengaluru, India

Middle East Electricity 20161–3 March 2016Dubai International Convention & Exhibition - Dubai, UAE

NY Best – Capture The Energy9–10 March 2016Marriott - Albany, NY, United States

Dutch national event on substation equipmentMarch 18 2016Tennet HQ, Arnhem, the Netherlands

EVENTS

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KEMA LABORATORIES

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NEXANS FROM HANNOVER

RIYADH CABLES FROM SAUDI ARABIA

Nexans from Hannover, Germany, tested a three-pole superconducting resistive fault current limiter device in a prefabricated concrete substation. The device, rated 12 kV-1600 A, successfully limited the post-set short-circuit currents.

Riyadh Cables in Saudi Arabia has recently successfully tested a 132 kV cable system in accordance with IEC 60840:2011 at KEMA Laboratories, Arnhem.The power cable system included one power cable at 132 kV (1x630 sqmm, CU/XLPE/LEAD/HDPE), two outdoor terminations, two GIS terminations and one cross-bonding joint with screen interruption.The cable also passed the additional tests according to DEWA specification (FTIR, DSC, TGA, water penetration for lead sheath, additional procedure for phase conductor, measurement of moisture content, resistance test of semi-conducting tape etc.).

ALSTOM GRID TESTED AN 800 KV SF6 CIRCUIT-BREAKER

In this summer Alstom Grid tested an 800 kV SF6 circuit-breaker at KEMA Laboratories, Arnhem. The test duties T100s and L90 included the voltage test as a condition check, were successfully performed in a full pole test circuit.Inspection of the interrupter contacts were performed in the ALSTOM depollution facility with the presence of a KEMA Laboratories test engineer.For these results they received a Silver KEMA Report of Performance.

TESTING ACTIVITIES

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