HIGHLIGHT | Quarterly Magazine
LOW-VOLTAGE NEEDS HIGH SAFETY
SAFER, SMARTER, GREENER
ENSURING SAFETY IN HIGH-RISE BUILDINGS
No. 68 | February 2017
HVDC TEST FACILITIES AT KEMA LABORATORIES
DNV GL IN ENERGY
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.
Should old acquaintance be forgot? At the time of writing we are in early January, and the text of this old Scottish Hogmanay song from Robert Burns is still in my head, probably because I heard it on New Year’s Eve. It is an appropriate song as in many cultures it is used to mark the passing into something new, whilst remembering the blessings and friendships from the past. For KEMA Laboratories 2017 promises to be such a landmark year; in October we will celebrate our 90 th birthday with the formal inauguration of our extended short- circuit laboratory. Ninety years of successfully assisting our customers with creating and maintaining reliable power networks probably is some evidence that we do not forget our “old acquaintances”. To ensure that we contin ue strengthening the ties with our customers, Muammer Celikel recently joined our Dubai team supporting our ME customers. In this issue you can already get to know him a little bit.
As our world is changing rapidly, we see an influx of new technologies entering global T&D networks. In this issue we say a few words on safety issues around cast resin transformers, and on HVDC testing. Being KEMA Laboratories we take pride in our quality, we are proud to share some of the latest developments in our Prague Laboratory, now focusing on LV power testing. If you have any questions or suggestions how we can help you better, please let me know!
Editorial department DNV GL – Energy KEMA Laboratories P.O. Box 9035 6800 ET Arnhem The Netherlands
T +31 26 356 32 22 E email@example.com I www.dnvgl.com/kemalaboratories
Low-voltage needs high safety
Editorial staff Angela de Geest
Ensuring safety in high-rise buildings
Photography DNV GL Fotostudio Alain Baars
HVDC test facilities at KEMA Laboratories Expansion
Executive Vice-President KEMA Laboratories
of KEMA Laboratories is ready
Muammer Levent Celikel
Testing activities Successful
HV cable system type test for Cabelte, Portugal
Momentary IEC JV
withstand current test for BHEL Rudrapur, India
61439 - successful testing of LV panels manufactured in Turkey
LLC Hayat Power Cable Systems, Uzbekistan, successfully
passed type tests Ulusoy
Electric receives KEMA Type Test Certificate of short-circuit
LOW-VOLTAGE NEEDS HIGH SAFETY
Low-voltage (LV) components are often seen merely as commodities. Price is the main differentiator and manufacturers are under pressure to cut costs – potentially at the risk of quality. But as dramatic failures have shown, verifying safety is as important for LV components as any other. LV components are used in many applications: from feeding wind power into the grid to distributing electricity across large industrial, retail and residential sites. Because of this ubiquity and the belief that the technology is simpler than for higher voltage components, people planning and constructing such projects often assume all LV components are the same. You only need to Google “wind turbine fire” to see the damage such an assumption can cause. The risks of poor quality Many of these disasters are caused by poor-quality LV panels causing fires at the bottom of the tower that travel up the LV cabling and destroy the turbine. All LV applications bring similar risks and it is often people’s lives in danger not just property.
If LV components do cause a problem, the contractor overseeing the project will be held liable. So, despite pressure to keep project costs down, employing LV components without verifying their safety could be a hugely costly mistake. Verification you can rely on Verifying component safety is best done by physical testing according to appropriate international standards. For LV panels, the relevant standard is IEC 61439-1 ed. 2 which covers the ability to withstand the huge electromagnetic stresses that panels experience in operation. This should be complemented with additional tests to establish the panel’s ability to withstand internal arcing – as defined in IEC/TR 61641. LV cables are covered by many different standards, but again additional tests to verify fire safety are advisable.
KEMA Laboratories offers specialized facilities for all these tests at our industry-leading labs around the world. Combined with our extensive testing experience and global reputation for impartiality, this makes physical testing by KEMA Laboratories the most trusted way of verifying safety for LV components. Successful testing at our facilities leads to a KEMA Type Test Certificate. This gives contractors at-a-glance reassurance of a component’s quality.
DNV GL IN ENERGY
ENSURING SAFETY IN HIGH-RISE BUILDINGS
Safety is a critical concern for any power component. But when that component is intended for use in a high-rise building, safety becomes even more pressing. Typically sited in cramped locations at the base of buildings with hundreds of people living or working above, power components in high rises simply cannot add any fire risk. Independent certification is the most reliable way to ensure power components for high rises offer the safety levels required. It is the contractor building a high rise who is ultimately responsible for the safety standards in that building – both in public perception and for any potential legal liability. In this, they are guided by local building codes. While contractors are experts in the construction requirements of these safety regulations, power issues are also increasingly important. This is an area contractors are not familiar with. And the risks here may not be immediately apparent. International standards form the basis of most building codes’ safety requirements for power components. By choosing components that meet those standards, contractors can go a long way to creating a safe building.
But it isn’t enough to just assume a product meets the standard or that meeting the standard alone delivers a sufficiently high safety level. That’s why independent certification and additional testing beyond standards are invaluable tools for component manufacturers looking to do successful business in the highly competitive construction sector. Perhaps the three most relevant component types for high rise designers and builders are distribution transformers, medium-voltage switchgear and power cables. In all cases, the principal area of concern is fire: whether a component starts a fire and how it will behave if a fire breaks out nearby.
Transformer fire resistance Generally, building codes specify the use of dry-type (cast resin) distribution transformers to reduce fire risks. These are less likely to cause or accelerate a fire than oil-based alternatives. However, fire behaviour is still a critical concern. Dry-type transformers are covered by standards such as IEC 60076-11. This standard also defines special (optional) tests for verifying fire behaviour. In a recent analysis of test results from KEMA Laboratories, around 50% of the dry-type transformers we tested initially failed these fire behaviour tests. If these failures had occurred in high-rise buildings rather than the safety of our test facilities, the consequence for the building and its occupants could have been catastrophic. Withstanding arcing For switchgear in high rises, the key characteristic is its ability to withstand internal arcing. This is even more true in high rises than in typical grid applications. Limited space for infrastructure means switchgear is often located in very small rooms in buildings. This brings some unique challenges: technicians carrying out maintenance must work in close proximity to the equipment and any pressure waves caused by internal arcing can travel much faster in confined spaces. Hence there is much greater risk of injury to people and damage to the building. The enclosed switchgear typically used buildings are covered by standards such as IEC 62271-200 and IEEE C37.20.7. These standards look at potential arc exposure to the public and to technicians carrying out maintenance. For high-rise applications, exposure for technicians is typically more relevant and should be a key consideration in the procurement process.
Preventing toxic smoke Electricity cables run throughout the building. The ducts and conduits carrying them link floors creating channels that can spread dangerous smoke very effectively in case of a fire. So, while cables are covered by a number of different standards, when deploying them in a high rise, special attention should be paid to their fire resistance capabilities. In particular, the risk of the cablesâ€™ PVC sheathing catching fire or releasing toxic gases should be verified â€“ both for single cables and bundles. These tests may not be included in a standard type test programme, and contractors are strongly advised to check if they have been performed before procuring cables for a high-rise development. Assuring confidence To be confident in the safety of their building and to protect themselves from any liability if the worst does happen, contractors need to be sure that all these tests have been carried out correctly and impartially. Independent certification by a reputable testing organization such as KEMA Laboratories is the only real way to build that confidence. Our industry-leading testing laboratories have the power and facilities to carry out all the standard and additional tests required to ensure a component is safe enough for use in a high-rise building. And our global reputation for impartiality and reliability means KEMA Type Test Certificates are renowned the world over as a mark of quality and safety. As such, they give contractors greater confidence in the components they are buying and allows manufacturers to compete against the price pressure of lower quality rivals.
DNV GL IN ENERGY
HVDC TEST FACILITIES AT KEMA LABORATORIES
KEMA Laboratories of DNV GL Energy, located in the west part of Arnhem, the Netherlands has almost 90 years of experience in testing, inspection and certification. At this location, test facilities have been tailor-made for allowing HVAC components to be tested with many given setups, using a Plug and Play method. This offers KEMA Laboratories a flexible way of working and the ability to configure to HVAC components. In addition to our HVAC capabilities, investments leading to the extension of our High-Power Laboratory, cleared the way for exploring HVDC opportunities, resulting in the commissioning of a new HVDC test facility. Located in the east part of Arnhem, at the industrial park (IPKW) situated along the river Rhine, it is not far from our KEMA Laboratories headquarters. Here we have once again implemented our uniform philosophy; parallel testing facilities, tailor made for Plug and Play, but now for HVDC components as well. HVDC cable systems and submarine cables up to 320 kV, research and development for switchgear, etc., can all be catered to.
This new location gives access to transportation by road and boat, making it easy to allocate HV components by water from multiple locations. In short, a 600 kV DC-source forms the heart of our HVDC laboratory, followed by a transportable impulse voltage generator for super-imposed lightning and switching impulse tests. In addition, our own design unit for testing buried joints in water is available at our new location, making logistics for a joint less critical after extended testing. Currently most tests are carried out in accordance with CIGRE brochures or customer specifications as there are no international standards available. As part of our commitment to delivering trustworthy worldwide services, we are invested in HVDC research and development in cooperation with the Delft University of Technology, DNV GL Energy Advisory and KEMA Laboratories. We aim to enhance the reproducibility of testing and contribute to the development of a future IEC standard for HVDC cable testing.
Expansion of KEMA Laboratories is ready In 2014 we announced the expansion of our high power short-circuit laboratory. The main goal for the expansion is to test high power transformers for short-circuit performance up to the 800 kV class. The second reason is to add test slots in order to be more flexible towards our customers, resulting from the current dynamic market. The investment for the expansion is EUR 70 million. After years of designing and building we started commissioning in 2016. During the â€™17 winter maintenance stop we completed the commissioning and the integration with the existing laboratory and are proud to announce that all systems are now up and running. We successfully conducted short-circuit tests on a few 800 kV power transformers using the combined power of all 6 short-circuit generators. Our customers are welcome to visit our extended facilities to experience the latest technology in short-circuit laboratory testing and see how we can be of service to you.
Introducing Muammer Levent Celikel The Middle East Region is important to KEMA Laboratories, so being close to our customers and the utility sector is of great value. Therefore, we announce with pleasure that Muammer Levent Celikel has joined KEMA Laboratories as a Sales and Business Development Manager based in Dubai/UAE. As of August 2016, he is responsible for sales and marketing activities in the Middle East region. Muammer has a Degree in Electrical Engineering and a Masters of Business Administration (MBA) and has been professionally active in the Middle East since 2008. Muammer is stationed in our DNV GL â€“ Energy Office in Dubai BurJuman Business Tower and can be contacted at firstname.lastname@example.org and +971 56 520 6450.
INTEGER Cable Conference 7 - 8 March 2017 The Oberoi Dubai, Dubai, United Arab Emirates WIN Automation 16 - 19 March 2017 Tuyap Fair Convention & Congress Center, Istanbul, Turkey CIRED 2017 12 - 15 June 2017 Scottish Exhibition & Conference Centre (SECC), Glasgow, Scotland
DNV GL IN ENERGY
TESTING ACTIVITIES SUCCESSFUL HV CABLE SYSTEM TYPE TEST FOR CABELTE, PORTUGAL
Cabelte has successfully passed type testing on a 220 kV cable system, according to IEC 62067. The tests were performed at KEMA Laboratories in Arnhem. The test loop included two outdoor terminations, two GIS/transformer pluggable terminations and one joint from Pfisterer. According to Cabelte, this success brings them one step closer to meeting today’s high-voltage business area standards.
MOMENTARY WITHSTAND CURRENT TEST FOR BHEL - RUDRAPUR, INDIA
BHEL-Rudrapur (India), has successfully conducted a momentary withstand current test (Peak) on a Delta and a Tap-off bus duct (IPBD) with respectively 850 kA peak and 842 kA peak in our KEMA Laboratories Arnhem. Test procedure and test parameters were based on IEEE Standard C37.23. The IP bus ducts were provided with several connections and joints during tests.
IEC 61439 - SUCCESSFUL TESTING OF LV PANELS MANUFACTURED IN TURKEY EGEPAN, Izmir, Turkey recently decided to test a 400 V, 4000 a low-voltage switchgear and controlgear assembly at KEMA Laboratories in Prague. The low-voltage assembly passed all test duties successfully, resulting in the world recognized KEMA Type Test Certificate of Complete Type Test in accordance with IEC 61439-1:2011 and IEC 61439-2:2011. Safety, durability and reliability are critical factors in LV installations from tertiary to industrial applications. EGEPAN is the first company from Turkey who performed a Complete Type Test in accordance with IEC 61439 at KEMA Laboratories to verify the performance and quality of their products.
JV LLC HAYAT POWER CABLE SYSTEMS, UZBEKISTAN, SUCCESSFULLY PASSED TYPE TESTS With their new cable and wire manufacturing plant in Central Asia, JV LLC Hayat Power Cable Systems (Uzbekistan, Navoi) successfully passed Type Tests on their 33 kV power cable (1 x 300 mm²). The tests were performed in accordance with IEC 60502-2:2014 at the end of 2016 in our KEMA Laboratories. Laboratory test engineers are pictured congratulating the Technology Manager, Mr. Nodir Mamadjanov with obtaining a KEMA Type Test Certificate.
ULUSOY ELECTRIC RECEIVES KEMA TYPE TEST CERTIFICATE OF SHORT-CIRCUIT PERFORMANCE Ulusoy Electric, Ankara, Turkey, increased the scope of MV electrical equipment manufactured by establishing a new factory of distribution transformers in 2015. Two oil immersed three-phase distribution transformers 1500 kVA, 33 kV / 0,415 kV, 50 Hz and 630 kVA, 11 kV / 0,415 kV, 50 Hz have been tested at KEMA Laboratories in Arnhem, in accordance with IEC 60076-5:2006, clause 4.2, with an additional 3 second symmetrical short-circuit test. The successful results entitle Ulusoy Electric to receive the KEMA Type Test Certificate of Short-Circuit Performance for both transformers. Our Sales Manager, Mr. Arman Derviskadic, celebrates a successful out-of-tank inspection after short-circuit tests with Ulusoy Electric’s R&D Manager Mr. Sabri Uzel and the Design Engineer Mr. Samet Balci.