kema laboratories

ENERGY

SAFER, SMARTER, GREENER

KEMA LAborAtoriEsTesting, Inspections & Certification: the keys to your energy business

Impartial experts who share your energy future | 4

All for your peace of mind | 6

Certificates and reports | 8

Circuit breaker testing | 10Safeguarding the electricity supply

Power transformer testing | 12Maintaining the grid’s heartbeat

Cable testing | 14Going the distance for reliable transmission

Low-voltage assembly testing | 16Protecting the end user

Battery and energy storage testing | 17Ensuring reliable green energy supplies

Additional testing | 18Covering the whole grid

Witnessing high-voltage tests | 20

Global facilities | 22

CoNtENts

DNV GL – EnergyKEMA LaboratoriesTesting, Inspections & CertificationP.O. Box 90356800 ET ArnhemThe Netherlands

[email protected]

KEMA Laboratories ENERGY 32 ENERGY KEMA Laboratories

iMpArtiAL ExpErts who shArE your ENErgy futurE

Never stand stillThe energy industry never stands still and nor do we. We continually invest in new facilities and innovative technologies to meet ever changing market needs. Manufacturers get the best resources for testing their equipment, and utilities can rely on the most up-to-date certification.

Recent examples include our High-Power Laboratory in Arnhem, the Netherlands, extending its capabilities to 1200 kV. This makes our High-Power Laboratory the first facility in the world to offer extreme high-voltage and ultra high-power testing.

Engineers who make a differenceOur test engineers are ready to help you. With a long heritage of involvement in the world’s energy grids, they understand both the equipment and the standards it must meet. They help you join the dots to see the bigger picture.

Their invaluable insight allows them to fully appreciate testing effects. In this way they can offer impartial advice on how to best interpret test results to help manufacturers improve or enhance their designs.

Comprehensive tests covering every componentBecause we don’t leave anything to chance, our Testing, Inspections & Certification Services cover the entire range of AC and DC transmission and distribution (T&D) components.

KEMA Laboratories is DNV GL’s world-renowned Testing, Inspections & Certification organisation. Located at several sites across the globe, we combine traditional with state-of-the-art gear to ensure every kind of grid equipment, from medium- to ultra high-voltage, can be tested, satisfying todays increasingly demanding criteria for performance and safety.

4 ENERGY KEMA Laboratories KEMA Laboratories ENERGY 5

ALL for your pEACE of MiNd

The high costs of power outagesSociety continues to demand more from electricity systems. The integration of renewables, international energy trading and cross-border networks mean longer transmission distances, which require higher voltages. It also means more complex MV systems and a change in philosophy regarding protection and control. More advanced T&D equipment is needed to deal with the changes. So it’s no wonder that the increasing scale and complexity of power grids is liable to make outages more common, and ultimately more costly.

Guaranteed impartialityUtilities must protect themselves against liability, while component manufacturers need to ensure their equipment lives up to the high quality and reliability demanded. The industry’s best security is through impartial testing, inspection and certification by an independent party. KEMA Laboratories is renowned as the most trusted brand for impartial testing in the T&D industry.

Proven reliabilityOur impartial services help ensure equipment operates to the highest international standards. Certification is based on testing to determine how equipment works in reality, not just in theory. It demonstrates equipment will perform correctly under all network conditions, allowing utilities to provide the most reliable service possible.

First line of defenceOur globally renowned KEMA Type Test Certificates verify that all relevant performance and safety criteria are met. They provide manufacturers with proof of their components’ quality and capabilities. They can also act as a utility’s first line of defence in liability cases.

Furthermore, certificates help streamline the equipment purchasing process. By guaranteeing a certain standard is met, they allow easier comparison of bids when finding the most economic solution. For everyone involved, doing business was never easier.

The modern world’s dependence on electricity means power outages are simply unacceptable. They cause major issues for individuals, companies and society as a whole. Service providers and utilities can lose their reputations, and suffer financial penalties through fines and customers’ costs. Outages can also result in health hazards, have far-reaching effects on the electricity trade, and damage local or national economies.


CErtifiCAtEs ANd rEports

Gold: KEMA Type Test CertificateWith its gold-embossed cover and gold seal, the KEMA Type Test Certificate is the hallmark of a high-quality component. It signifies that the component successfully passed all the tests according to the referred Standard’s Type Test program, its technical drawings have been verified and a visual inspection has been carried out.

For utilities and network operators, a gold KEMA Type Test Certificate says the component meets all requirements of the standard and no further effort is needed to assess it.

Silver: KEMA Report of PerformanceA KEMA Report of Performance is issued when a component successfully passes a subset of a Standard’s Type Test program, its technical drawings have been verified and a visual inspection has been carried out.

Identified by its silver-embossed cover and seal, a KEMA Report of Performance tells the end customer that the component partly meets the requirements of the Standard’s Type Test program. The end customer may use these results and test program to determine if they are applicable and sufficient for their needs.

Grey: KEMA Test ReportIn all other cases where tests are performed at a KEMA Laboratories facility, a KEMA Test Report, with a grey-embossed cover and seal, is issued. This could mean tests were performed according to the customer’s specifications or that the tests did not fulfil the requirements of the Standard. It could also mean drawings were not provided or there was no visual inspection.

When utilities and network operators see a grey KEMA Test Report, they must read it carefully to assess the component’s performance themselves. This requires deep technical knowledge of standards and expertise on how to interpret them.

Whenever a component is tested at a KEMA Laboratories facility, the outcome is documented in a certificate or report. These test documents come in three colour-coded levels – including the globally renowned KEMA Type Test Certificate.

KEMA INSPECTIoN REPoRT

For tests witnessed by our highly experienced inspectors outside our own facilities, we issue a white, softcover KEMA Inspection Report. These reports can cover a wide range of tests, and a one-page summary is available on request.


CirCuit brEAKEr tEstiNg

Endurance testsTo ensure they fulfil their role of safeguarding the grid, circuit breakers need to be tested thoroughly and correctly. They must endure appropriate stresses replicating a variety of real application conditions. The IEC and IEEE standards specify a host of short-circuit and switching tests, in addition to fundamental Type Tests such as dielectric, temperature-rise and mechanical tests.

LV to UHVCorrect short-circuit testing of circuit-breakers requires extensive test facilities. KEMA Laboratories include the most advanced and comprehensive facilities for short-circuit and switching tests of circuit breakers. They cover AC and DC, and everything from low to ultra high-voltages, including 1200 kV, 100 kA circuit breakers. Furthermore, we are capable of short-circuit testing generator circuit breakers up to a breaking current of 300 kA rms.

Unique facilitiesOur world-beating facilities can recreate a wide range of normal and fault conditions. For example, they can accurately reproduce terminal fault conditions in a power network to apply the correct short-circuit stresses for even UHV circuit breakers.

Regardless of how many preventative measures are taken, equipment faults can still occur. When they do it is crucial to limit damage and grid disruption by restricting the affected part of the system. For this reason, circuit breakers are critical to ensuring a functional, reliable and safe network for transmitting and distributing electricity.

Safeguarding the electricity supply


powEr trANsforMEr tEstiNg

Power transformers form the heart of electricity transmission systems. They need to perform with steadfast reliability, while undergoing practically no major overhaul for decades. During their lifetime, transformers may experience extreme stress due to fault conditions which must not affect their normal service capabilities or life expectancy.

No short-cuts to short-circuit testsTesting power transformers for extreme fault conditions is very important in ensuring network reliability. To verify the robustness of a transformer’s design, the best method is full-scale short-circuit testing. This is because a transformer’s performance depends not only on its theoretical design but also, to a large extent, on the production process and workmanship. These latter simply cannot be verified by calculations, and high failure rates during laboratory short-circuit testing confirm this.

KEMA Laboratories are equipped to test large power transformers with an extremely high short-circuit capability. Our facilities include an expansion to fully cover 800 kV class transformers.

Flexible and fast; easy design improvementWith power supplied by specially designed generators, KEMA Laboratories can offer excellent flexibility. They provide a high degree of protection for the tested transformer. A very fast (a few milliseconds) protection system enables early identification of faults for easier design improvement.

objective testingFor even higher-rated systems, short-circuit tests can also be made on mock-up transformers. The mock-up transformers are carefully designed test objects that simulate stresses equivalent to full-scale testing, but only applied to the a portion of the transformer to be tested.

Maintaining the grid’s heartbeat


CAbLE tEstiNg

Today’s T&D networks cover greater distances and carry more power, making cable quality even more essential in meeting the escalating demand for electricity. Power cables are becoming longer and larger in diameter, enabling higher voltages. Cable failures incur enormous costs. Besides the outage, the repair can disrupt roads and other services, and system restoration takes a long time.

Quality mattersCable systems may look simple – just a copper core, insulation and a protective shield with connecting joints and composite or porcelain terminations. But they must function flawlessly for decades and withstand the harshest conditions. Stress on cables can affect longevity, so the insulation must be high quality. Furthermore joints and terminations must be designed to control the high electric fields.

Testing for a lifetimeEnsuring quality means testing the cable system, including joints and terminations. IEC standards define the most important test protocols. KEMA Laboratories can perform them all for you.

Type Tests verify normal operation. Experience shows Type Testing every new combination is essential. Even when using separate certified cable

and certified accessories, there is no guarantee the combination will work in the field. Therefore we offer pre-qualification for cable systems, simulating the complete lifecycle through 180 heat cycles at high-voltage.

Our facilities can handle electrical tests on cable systems rated up to 550 kV, as well as non-electrical and short-circuit withstand tests. We can test and certify high-voltage (DC) cable systems.

Verifying installationOn-site testing of high-voltage and ultra high-voltage cables is crucial when verifying correct installation. We operate two specialised series-resonant test facilities for testing (ultra) high-voltage cables on-site.

Going the distance for reliable transmission


Low-voLtAgE AssEMbLy tEstiNg

bAttEry ANd ENErgy storAgE tEstiNg

For low-voltage (LV) panels and cables, quality means safety. These components are used in large industrial and residential applications and handle very high currents. Poor quality could lead to power outages or even fires. And any failure could be disastrous for the end user. Given their critical nature, verification is essential. However, not all verification processes give a true appraisal of a component’s performance.

The ability to store energy is essential for ensuring future clean energy systems can reliably meet demand in every circumstance. However, battery and energy storage technology (BEST) solutions vary hugely in deliverable power and discharge time, while application requirements can vary even more. Whatever storage you choose for your system, you need to be sure it is efficient, reliable and scalable.

True appraisal by physical verificationKEMA Laboratories offers physical verification of LV panels and cables, based on actual testing under real-world conditions. Compared to simple “paper certification” – which only estimates performance based on documentation – physical verification provides a much more accurate assessment of panel performance and safety. This, combined with our KEMA Type Test Certificate, provides the trustworthy evidence you need to demonstrate you deliver a premium product.

Global coverage in world class facilitiesAssemblies are tested according to the IEC 61439-1 international standard, ensuring complete transparency. The covers mechanical, dielectric, short circuit and temperature rise effects. Tests can be carried out at both 50 and 60 Hz for global coverage. All testing is performed at our own world-class facilities, for example the KEMA Laboratory Prague which features a temperature-rise test bay for LV switchgear and control gear assemblies, plus power LV test capabilities up to 180 kArms.

Protecting the end user Ensuring reliable green energy supplies

Testing, verification and certification Our KEMA Laboratories provide extensive compliance testing, verification and certification services for the full range of battery technologies – from single cells to complete systems with cycle capacities up to 2 MW. This is complemented by expert consulting solutions to help ensure you find the best storage technology for your application.

Furthermore, you can call on our pre-testing services to support you in prototype development. We can ascertain the best tests to apply, and

the best approach for designing tests to ensure technologies meet your application’s needs.

BEST testing by independent expertsAt our high-quality testing facilities at the BEST Test & Commercialization Center (BEST T&CC) in Rochester, USA, you can draw on the in-depth know-how of our expert staff both locally and globally. They deliver independent testing services to assess the suitability and scalability of BEST solutions for your intended application – so you can be sure of making the right choice.


AdditioNAL tEstiNg

Power grids rely on a lot more than just transformers, cables and circuit breakers. Because you can’t leave anything to chance, our Testing, Inspections and Certification Services extend to a wide range of equally essential energy components. Here is just a handful…

GIS componentsGas-insulated switchgear (GIS) components – such as disconnectors, earthing switches and fast-acting earthing switches (FES) – can be tested for short-circuit withstand capability. We also provide several special assessments, including three-phase short-circuit making tests up to 420 kV rated FES, induced current switching and bus-transfer switching tests.

Medium-voltage switchgearOur varied assessments for medium-voltage switchgear components include short-circuit, capacitive current switching, load-break and internal-arc tests. Together with dielectric and temperature-rise tests, all required tests for a complete Type Test Certificate can be performed.

Generator busductsCharacterised by their very high short-time current ratings, generator busducts efficiently distribute power to the system. Any problems with a busduct can lead to catastrophic damage and extensive downtime, so their approved quality is a must. Our facilities can perform short-time withstand current tests on busducts rated up to 1000 kA peak.

Distribution transformersWe perform both routine and type tests for complete certification of both oil-immersed and dry (cast resin) distribution transformers, plus a range of additional tests that go beyond certification requirements.

Surge arrestersSeveral of our facilities can perform pressure-relief tests on both Design A and B type surge arresters. With the expanded facilities, tests can be performed with short-circuit currents up to 100 kA.

FusesLike circuit breakers, fuses have to clear over-current during fault conditions. We perform tests that can lead to full Type Test Certificates on both drop-out and current-limiting fuses, including dielectric tests and current breaking test duties.

Metering, protection and substation automation equipmentWe perform standards-based certification of electronic and electromechanical energy (domestic and industrial) meters, electromechanical and digital protection systems and relays, and substation automation equipment. We also offer compliance testing for protocols, communications interfaces and cyber security measures.

Covering the whole grid


High-quality inspectionsOur experienced inspectors have extensive knowledge in the field of high-voltage testing. Their impartial reporting means manufacturers and utilities can trust the correctness of test performance and the accuracy of test results.

Inspections are accredited according to ISO/IEC 17020 for all HV/MV components used in the T&D field. We offer inspection services for Type Testing and Factory Acceptance Tests (FATs) according to internationally recognised standards, and for tests conducted to your specific requirements.

Type TestType Tests are performed in accordance with a corresponding standard. They are executed in the same way, regardless of the laboratory. While some elements may differ, such as test set-up or measuring devices, the essence of the test must remain the same. This is crucial to ensuring the standard’s requirements are fulfilled. For this

reason, assessment of the calibration system plus a review of the test set-up form part of the inspection.

Factory Acceptance TestFATs are among the most important checkpoints in the quality assurance process. Often based on international standards, they can also include some client-specific requirements. A completely new product may not be governed by existing standards, so test requirements are specified based on available information, completed by client approval.

Globally trusted reportsInspections can be carried out at any manufacturing, university or laboratory facility where international standards testing is possible. Having witnessed your tests, we provide a KEMA Inspection Report, recognised and trusted throughout the global industry.

Given the constant innovation in high-voltage component manufacturing, coupled with the tendency to design with minimal margins, component testing needs to keep pace. Manufacturers have to assure customers that their testing is carried out to the highest standards. Our Inspection Services offer this reassurance by witnessing testing at your facility.

witNEssiNg high-voLtAgE tEsts


gLobAL fACiLitiEs

KEMA High-Power LaboratoryThe world’s first facility for testing extreme high-voltage (1200 kV) power equipment. Has the industry’s highest short-circuit power (8800 MVA) delivered by four generators in parallel. The 2014-15 expansion will raise short-circuit power in the test bed to 13000 MVA.

KEMA High-Voltage LaboratoryMedium-, high- and ultra high-voltage testing using state-of-the-art equipment and computerised control systems within several flexible test bays.

KEMA Metering Protection and Substation Automation LaboratoryComplete range of testing for metering, protection and substation automation (MPSA) equipment. We are a Notified Body for energy meter type testing according to the EU’s Measuring Instruments Directive (MID) and accredited for testing according to many other standards.

KEMA Laboratory USAThe largest of its kind in the US. Features 1000 MVA and 2500 MVA short-circuit generators; a 1500 kV impulse generator; a 600 kV power frequency test set; a 13 kA thermal supply; battery test cells, and a 2 MW grid-connected energy storage test lab.

KEMA Battery and Energy Storage Test LaboratoryHandles testing of the complete range of battery and energy storage technologies (BEST), from single cells to complete systems with cycle capacities up to 240 kW.

KEMA High-Power & High-Voltage Laboratory PragueComprehensive test facilities for medium-voltage and high-voltage components covering short-circuit, arcing, load switching and other power testing. Features two 2500 MVA rated generators.

FACILITIES

All our laboratories are fully equipped with a range of ancillary facilities for customers to streamline their testing.

These include: ■ Workshops ■ Assembly bays ■ SF6 handling ■ Customer guestrooms ■ Transportation ■ Fitters assistance ■ Customs ■ Shipments

All our labs are certified to ISo 17025, 18001 & 14001.

ARNHEM, THE NETHERLANDS CHALFoNT, USA RoCHESTER, USA PRAGUE, CzECH REPUBLIC


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