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ENERGY

HIGHLIGHT DNV GL’s Quarterly Magazine of Power Testing, Inspections & Certification

New test cell expands capacity

SAFER, SMARTER, GREENER

The importance of certification by a 3rd party

No. 58 | 2014

New measuring and reporting system for KEMA Laboratory, Chalfont, USA


DNV GL IN ENERGY

Safeguarding Life, Property and the Environment Highlight is the quarterly newsletter of DNV GL – Energy Power TIC services. Since recently, KEMA is part of DNV GL’s Energy division. Our expertise spans onshore and offshore wind power, solar, conventional generation, transmission and distribution, smart grids, and sustainable energy use, as well as energy markets and regulations. Our 3,000 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 the world over 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. The laboratories are located in the Netherlands, USA, and the Czech Republic. Editorial department DNV GL – Energy Power Testing, Inspections & Certification P.O. Box 9035 6800 ET Arnhem The Netherlands

This sentence is at the core of our business, and since we were acquired by DNV, increasingly also in the hearts of our employees. In this issue you can read more about our new company DNV GL. With some 17000 colleagues we offer Testing, Inspections and Certification services, in the Maritime, Oil and Gas sectors and off course, across the globe, though KEMA laboratories in the Power Transmission and Distribution business. You will also find an update on some of our activities in the USA, for example on new investments in our Chalfont Laboratory facilities to provide an improved service on our existing testing activities. With energy storage increasingly a hot topic in our industry, e.g. as an essential element in microgrids, or as the power source in electric vehicles, we are also proud to share with you the latest

developments that we are undertaking together with the state of New York, on our new Battery Test Center (NYBEST). Our aim is to develop an independent test center for storage devices, where – in due course once appropriate standards are available – we will certify batteries. This further leads us to what we also see as our mission in High-Power and HighVoltage testing, namely Certification, for which the significance is described in a center article in this Highlight issue.

CONTENT 02

Safeguarding Life, Property and the Environment

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New test cell expands capacity

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The importance of certification by a 3rd party

Editorial staff Angela de Geest

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New measuring and reporting system for KEMA Laboratory, Chalfont, USA

Photography DNV GL Fotostudio Alain Baars Alex Feilbach, TU Darmstadt, Germany

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The BEST Test & Commercialization Center

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Power Transformer Testing

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Explanation of the photo on the front

T +31 26 356 32 22 E highlight@dnvgl.com I www.dnvgl.com/energy

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Testing activities Electrical Systems, Inc.

n Powell n

Medium voltage capacitor bank 5 kV – 38 kV

n Tollgrade

Events

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Communications, Inc.

If after reading you wish to learn more – please let us know! Best regards, Jacob Fontijne, Executive VicePresident Power TIC


KEMA LABORATORIES

New test cell expands capacity

As part of DNV GL’s policy of continued investment in updating facilities to meet evolving market needs, we are adding a new, bigger test cell to our KEMA Laboratory in Chalfont, USA. Test Cell 9 increases capacity, efficiency and safety, especially for internal arc testing. It combines a state-of-the-art data acquisition and measurement system with today’s most advanced testing technology. In developing Test Cell 9 we focused on three key factors: the ability to handle larger components, increased capacity with higher efficiency, and greater attention to safety. Test Cell 9 also incorporates the state-of-the-art MARS measurement and reporting system, already in operation at our laboratory in Arnhem, the Netherlands. This enables recorders to capture data at higher resolution thereby helping customers to identify where and how to optimise their designs more easily. Customers can view these data online, have them immediately available and match them directly with their own models, making the testing part of their design process. The new test cell includes a number of features to allow testing of larger components – from improved access to higher crane capacity. In addition, a retention basin and fire suppression system

allow the cell to be used for testing of oil-filled transformers. The entire site and structure have been designed to minimise the risk of accidents, especially in the event of explosive failures. As a result video recordings of the test will be much clearer. It will also allow earlier access to the test cell for inspection. The addition of Test Cell 9 will relieve the test load in other test cells, helping to make the entire testing process faster. Four cells can now operate in parallel, and to ensure the process is as quick as possible we will implement a second work shift. As a result, there will be two shifts per day, one conducting tests while the other prepares equipment for the next test shift. These improvements will increase capacity by some 20%.

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DNV GL IN ENERGY

The importance of certification by a 3rd party Independent certification of power system components helps ensure that utilities provide the most reliable service possible. It guarantees that equipment operates to the highest international standards, and performs correctly in all network conditions. DNV GL’s globally recognised KEMA Type Test Certificates verify that performance and safety criteria were met – a critical proof in liability cases. Furthermore, certificates help simplify and optimise the equipment purchasing process. Blackouts The modern world depends on electricity, and blackouts are unacceptable. Power outages cause several major issues. One is the loss of the utility’s reputation, both among the general public and local authorities, accompanied by financial penalties with claims from customers and fines from regulators and other authorities. Health hazards can also result during and after blackouts. In addition, there is interruption to the electricity trade, and damage to local or national economies. But the increasing scale and complexity of power grids make outages more common and more costly. For example, in the US the number of blackouts affecting 50,000 or more people increased from 42 in 2009 to 109 in 2011, and of those companies that experienced a blackout, 20% lost between $500,000 and $2 million. Liability lessons When it comes to liability, the responsibility often lies with the service provider. Therefore, utilities and industry need to guarantee that they have done everything possible to ensure quality and to minimize their liability. Quality assurance best practices can reduce the chance of a failure in one piece of equipment turning into a large-scale outage, thereby reducing the liabilities the utility might otherwise face.

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Liability issues also arise if failed components cause accidents or injury. Recognised, independent equipment certification such as provided by DNV GL is the utility’s first line of defence in liability cases. Certification shows all reasonable measures have been taken to ensure the quality of components used in the power grid. Level playing field Certification also simplifies the equipment procurement process. By telling companies responding to a request to bid that all components must be certified according to applicable international standards by an independent certification body, a level playing field is created. This guarantees that all bidders have to attain certain quality level and performance standard, enabling the buyer to compare competitive bids more easily and focus on other key factors such as getting the most economic solution. Fault limitation Reliable certification is built on three things: well-defined international standards, a laboratory with the capacity and facilities to test devices in accordance with such standards, and people with the competences to apply all this. DNV GL performs accredited testing and certification of medium- and high-voltage equipment, and continually invests in facilities and training of personnel to ensure that we stay at the forefront of testing capabilities. Our laboratories can attain


KEMA LABORATORIES

Air-photo of the KEMA Laboratory in Chalfont, USA.

the highest power and voltage levels required to test equipment to the most demanding standards. We are also active in the relevant standardisation committees of IEEE and IEC, and can anticipate key requirements in new or updated standards. DNV GL has extensive know-how of T&D networks. Because the majority of blackouts are caused by equipment failures, we aim at helping utilities to minimise the possibility of faults. We also aim at limiting the impact when faults do occur, by ensuring equipment can withstand the stresses such faults cause and reducing the time taken to restore the system. While many other certification agencies rely on testing services provided by others, DNV GL uses its own laboratories to provide a complete one-stop testing and certification service. This means a more complete, seamless evaluation of the component under test and ensures strict compliance with the standards. As a result, the component is expected to perform more reliably and safely when placed in service.

Global experience DNV GL is a new company whose heritage and expertise stretches back 150 years. It is the result of a merger last year that brought together such wellknown and respected brands as KEMA, Garrad Hassan, DNV and GL. Drawing KEMA’s more than 80 years’ experience in medium- and high-voltage testing, inspections and certification, DNV GL is trusted by utility and industry leaders throughout the world for their certification needs. KEMA Type Test Certificates are accepted throughout the entire world, which enable manufacturers to do business globally. Moreover, because of our unparalleled HV expertise and internationally recognised KEMA Type Test Certificates, other certification bodies not having laboratory facilities at their disposal rely on our experience, knowledge and competence for HV testing. We are also regularly approached by the legal community to assess failed components after outages and equipment failures to help deciding liability. Because, when it comes to something as important as keeping the electricity on, people turn to a partner they can trust.

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DNV GL IN ENERGY

IN BRIEF

New measuring and reporting system for the KEMA Laboratory, Chalfont, USA The KEMA Laboratory in Chalfont, USA (KPT), has taken steps towards aligning the measuring and reporting structure of the KEMA laboratories, in order to come to one global reporting format.The measuring system contains new equipment installations, signal transportation schemes, and grounding methods, as well as data acquisition system hardware and software. KPT will soon be using MARS, the same software the KEMA High-Power Laboratory (HPL) in Arnhem uses. This will improve efficiency and increase productivity at KPT, ultimately provide the client with his own monitor and ultimately with our final product, the test report or certificate, equal to that from any of the KEMA laboratories. Some of the new equipment includes: Rogowski Coils Shunt Boxes Voltage Dividers Isolation Amplifiers Recorder Other miscellaneous data lines and equipment in new EMC cabinets A test technician connects the measurement signals.

The BEST Test & Commercialization Center

Soon to be opened: the BEST Test & Commercialization Center, a cooperation between NY BEST and DNV GL for testing of cells and batteries for energy storage systems and in electrical vehicles. hundred channels will be there for CENTER NY Three BEST COMMERCIALIZATION performance testing against (upcoming) standards like the IEC 61427. From 5 V and 50 A telescoping in size to 2 MW cycling against the grid and beyond, using the 200 channels data acquisition and control system. As soon as the laboratory got its ISO 17025 accreditation and there are international recognized standards, KEMA laboratories will certify.

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KEMA LABORATORIES

IN BRIEF

Power Transformer Testing

Power transformers are essential elements in the power network. In our laboratory we test power transformers for short-circuit behavior. Long term experience shows that approximately 25% of the transformers tested do not meet the requirements and need modifications and retesting before allowed in the network. Power transformers are tested while sitting in a river barge thus no need for special onsite heavy lifting.

The High-Power Laboratory in Arnhem is being expanded to increase the power rating required for testing power transformers used in 500 kV and 800 kV super grids. Under the expansion program, we will increase the number of short-circuit generators at the HighPower Laboratory from four to six, extending the available testing power to 15 GVA. When the expansion finishes towards the end of 2015, the High-Power Laboratory will be the only facility in the world capable of extreme highpower short-circuit testing at 800 kV levels and above. This will give DNV GL - Energy a solid platform to grow in an unpopulated market where the entrance barriers are very high.

Photography: Alex Feilbach, TU Darmstadt

The growth of high-voltage power networks around the world will drive proliferation of new high-voltage T&D components, such as circuit-breakers and power transformers, and new component manufacturers. Before installing these new components in the power network, utilities must be confident they are reliable and function correctly to minimize the risk of economically, socially and technically disastrous outages.

Explanation

Explanation of the photo on the front: you see the firing of one of the three trigger gaps. The trigger gap on the photo makes a small auxiliary discharge that releases a plasma in the gap between the hemispheres (see detail in the photo attached). This blueish plasma weakens the voltage withstand capability so that the gap breaks down causing a massive discharge. At the same moment, a similar process occurs in the other two gaps in series with the one shown, so that a conducting path is created that discharges the impulse capacitors. The current of this discharge is sent through the test-breaker just before 60 Hz current zero in order to force the breaker to reignite.

Transformer tested in the boat at KEMA High-Power Laboratory, Arnhem, the Netherlands.

In this way, the breaker gets an� offer it cannot refuse�, and gives way to the steep pulse; no choice than to go on with another long long loop of arcing.

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DNV GL IN ENERGY

Testing Activities

Transformer Rectifier Powell Electrical Systems, Inc.

A rectifier transformer and diode rectifier unit (3000 kW, 590 VDC), complete with bus duct, was tested at the KEMA Laboratory in Chalfont, USA per detailed Powell and end user requirements. Typical tests for a rectifier-transformer unit were performed but this test program also included multiple temperature-rise tests at various loads as well as a short-circuit test at the very end of the test program. It was a rigorous test program for both the rectifier transformer and the diode rectifier but one that was necessary to prove the equipment suitable for the end user’s transit system. All equipment functioned as expected and the test was successfully completed.

MEDIUM VOLTAGE CAPACITOR BANK 5 kV – 38 kV

KEMA Laboratory, Chalfont, USA (KPT) is proud to announce their capabilities to perform capacitor switching tests. KPT can currently test 38 kV, 1000 amps and 15 kV, 1600 amps. The plan in the near future is to increase the capabilities to 38 kV, 1600 amps and 15 kV, 2000 amps. The increased capacity will enable KPT to cover the entire range of capacitor switching ratings, which is required by industry standards. The increased capabilities include part of the capacitors being placed in special made mobile trailers and part in the existing building. All banks will have switches, which make circuit changes more efficient.

TOLLGRADE COMMUNICATIONS, Inc.

Tollgrade Communications, Inc. worked closely with our KEMA Laboratory in Chalfont, USA (KPT) to successfully demonstrate the accuracy of its LightHouse MV sensor in the electric utility operating environment. The LightHouse sensor is powered inductively from overhead MV lines, communicates via the public wireless infrastructure and provides convenient, real-time visibility into the operation of MV feeders and laterals without touching ground or neutral. Specifically KPT constructed a representative overhead MV line segment, provided continuous 3-phase MV excitation and reported the reference values of line current and power factor as these values were varied with resistive, capacitive and inductive load banks.

EVENTS African Utility Week May 13–14, 2014 Booth #C6 Cape Town International Convention Centre Cape Town – South Africa

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Metering China May 28–30, 2014 Booth #B101 Shanghai Everbright Convention & Exhibition Center International Hotel Shanghai – China

Three-day training course on “Switching in T&D networks” by KEMA Laboratories September 9–11, 2014 Las Vegas, Nevada – USA More information: academy.energy@dnvgl.com

CIGRE 2014 August 25–29, 2014 Booth #355 Palais des Congrès Paris – France

HighLight 58  

HighLight is the quarterly newsletter of KEMA Laboratories

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