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Electrical Research and Testing Laboratory Nuremberg Testing and research at the cutting edge of technology

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Electrical Research and Testing Laboratory Nuremberg Testing and research at the cutting edge of technology

siemens.com/energy/transformers

From general fundamental research using high­voltage tests with various voltage types to dielectric examinations and tests using test setups specially designed for use in electrical components, the Electrical Research and Testing (ERT) Laboratory Nuremberg is capable of conducting a wide range of tests and analyses. In addition to precise replication, modeling, and testing of even the most com­plex setups, the specific material properties of insulation components can also be examined.

Materials technology also plays an important role in the ERT Laboratory. Specially developed devices for oil treat­ment, drying, and impregnation plus other versatile pro­cess materials make it possible to consider quality criteria such as purity, cleanliness, or dryness of the insulants. This ensures that the study results are meaningful and precise.

Various test systems are used for electrical investigations, including a number of independent AC voltage test systems with a maximum test voltage of 400 kV, an auto matically pole­reversible DC voltage test system with

The latest methods, outstanding expertise

up to 400 kV, and a surge generator with a charging voltage of 1,200 kV for lightning and switching impulse voltages. In two separate test halls, highly sensitive measurements can be carried out at an extremely low noise level of <1 pC.

The services offered by the ERT Laboratory Nuremberg, however, go far beyond pure electrical testing. Its collabo­ration with the chemical and physical materials testing laboratory headed by Dr. Atanasova­Höhlein, which is located in the same building, opens up a wealth of possi­bilities for diagnostics and analysis. The materials testing laboratory fully focuses on the laboratory diagnosis of oil­filled electrical equipment. The materials that are elec­trically tested in the ERT Laboratory can then be examined right down to the tiniest detail. The close cooperation between the two laboratories creates synergies that ensure rapid, reliable, and high­quality study results.

The ERT Laboratory Nuremberg offers comprehensive testing and analysis facilities for energy-related material testing, research, and development.

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Extensive equipment and the highly qualified staff of the ERT Laboratory Nuremberg make it possible to fulfill special customer requests and requirements which go far beyond the services available in the usual standard investigations.

Every step can be individually agreed upon and designed with the customer – including trial planning and prepara­tion of the specification, planning and production of the test pieces, test design, as well as conducting the test series with subsequent evaluation and documentation.

The latest CAD and 3­D software is available for the plan­ning phase. This allows test assemblies to be designed using state­of­the­art technology and then simulated with the corresponding electrical and magnetic calculation tools in order to find the ideal test design every time.

Testing tailored to customer require-ments: special contract measurements

From test planning to documentation, the outstanding technical equipment and individual design possibilities make the ERT Laboratory Nuremberg the first choice for meeting special requirements.

In addition, the ERT Laboratory Nuremberg offers testing of electrical components within the framework of its performance class, such as dielectric type and routine testing of capacitors or bushings.

The services provided by the ERT Laboratory Nuremberg are rounded out by a wide range of standard electrical tests for the characterization of insulation materials in accordance with the established regulations and standards.

Range of possible contract measurements

Electrical testing of solid insulants for partial discharge and puncture behavior

Determination of the parameters of electrical solid insulants

Investigation and research into the dielectric properties of liquid insulants

Investigation of alternative liquid insulants and green technologies

Development and testing of innovative insulation designs

Examination and testing of electrical components, type and routine tests

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Process technology and sample preparation

In investigations of insulation materials, the production and preparation of the samples and test items and com­pliance with the process parameters before and during the measurement are of enormous significance. Usable quali­tative results can only be achieved if all the parameters are observed exactly. This is why the ERT Laboratory Nuremberg places such great importance on precision.

All wood and metal treatment processes are carried out in the ERT Laboratory’s own workshop, which is well equipped with everything from lathes to belt grinders and disk sanders.

For preparation work that includes drying and impregnat­ing, vacuum drying cabinets and specially developed impregnating cabinets are available. These are used to precisely regulate and monitor required process parame­ters such as temperature and pressure.

Perfect, from preparation to documentation

Reliable test results ensured by high quality – from test planning to evaluation

Standard material investigations

In the characterization of insulation materials, there are various processes for determining the relevant parame­ters, depending on the material and area of use. These include determination of the electric puncture strength of insulating materials of all types – in the case of AC voltage according to IEC 60243­1 and with DC voltage according to IEC 60243­2.

Another important criterion is the partial discharge behav­ior of solid insulants. This is investigated in the ERT Labo­ratory Nuremberg using a specially developed, standard­ized testing method. The partial discharge behavior of the test pieces provides information about the quality and processing of the material.

To characterize the insulation properties with direct voltage loading, measurements of the specific resistance according to IEC 60093 or the measurement of polariza­tion and depolarization currents (PDC measurement using a step­response measurement) can be carried out. In addi­tion, dielectric properties such as the loss factor tan δ, the

Sample preparation Equipment for oil preparation4

capacities, and the relative dielectric constant of solid and liquid insulants can be determined according to IEC 60247. Determining the electric puncture voltage of liquid insulants according to IEC 60156 and determining the water content of solid and liquid insulants according to IEC 60814 enable all the important parameters to be recorded before, during, and after the measurements.

Research and development projects

The ERT Laboratory Nuremberg provides the best possible conditions for electrotechnical research and development. The excellent equipment in the laboratories and work­shops makes it easy to carry out customer­specific exami­nations. The experts at the ERT Laboratory Nuremberg are also happy to provide assistance in the development of concepts, and they can be helpful in planning the tests or carrying them out on behalf of the customer. When the tests are actually conducted, it is possible to react flexibly and unbureaucratically to technical idiosyncrasies, for example with modifications to the test design or test pieces. Moreover, it is also possible to react spontaneously

to effects during the course of the test series. What is important is the scientific character of the investigations. Because the ERT Laboratory Nuremberg has enough room to maneuver, it can offer a wide range of options to spe­cifically pursue any phenomena that might arise.

All work stages can be swapped on short notice and through direct communication. It goes without saying that the client can be present at every test and investiga­tion and make resulting modifications to the test item. To ensure full reporting, all process stages and measure­ment results are documented and reported with absolute precision.

Air­conditioned measuring and test cell Sample inside the test container 5

Cutting-edge testing technology for precise, reliable results

Technical data for the test areas and material equipment of the ERT Laboratory Nuremberg

Mobile 150 kV AC test system Workshop equipment

Precision high­voltage system device, 60 kV (electrically pole­reversible)

Fully air­conditioned measuring cell, temperature range –40 °C to +180 °C, ambient humidity 10% to 98% rH

Measuring cell to determine dielectric parameters of solid and liquid insulation materials (tan δ, capacity, dielectric constant)

Process technology

Oil preparation unit (300–700 l/h), which can also be used for other liquids

Vacuum drying cabinets

Special vacuum impregnation chambers

Determination of the water content of liquid and solid insulation materials (Karl Fischer titrator)

Determination of oil puncture voltage according to IEC 60156

Workplace for hazardous materials

Workshop for test piece preparation and modification of test designs

High-voltage laboratory

400 kV AC test system with 200 kVA (50 Hz)

150 kV AC test system (50 Hz)

Impulse generator with 1,200 kV charging voltage for lightning (1.2/50 μs) and switching impulse voltages (250/2,500 μs)

Multiple chopping gap for chopped impulse voltages, e.g. for measurements according to IEC 60076­3

400 kV DC test system, automatically pole­reversible (for measurements according to IEC 61378­2)

Screened high­voltage laboratory, background noise level < 1 pC

Crane capability 1 t

Air cushion system up to 7.5 t

Air-conditioned test cell

Screened measuring cell, background noise level ≤ 1 pC

High­voltage module (AC 100 kV/DC 140 kV/LI 140 kV)

PDC measurement system for conductivity investiga­tions of individual materials or components

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New opportunities in diagnosis and analysis

Factors such as humidity and temperature play a crucial role in the electrical characterization of insulants. In the ERT Laboratory Nuremberg, both the characteristic para­meters of the test pieces and the ambient and process parameters can be precisely monitored with the latest measuring and testing equipment. This means that the empirical investigations can be statistically analyzed so that the right conclusions can be drawn for the object under investigation.

The new ERT Laboratory Nuremberg

The laboratory building for the newly established ERT Laboratory Nuremberg is completed in December 2011. After the installation and commissioning of the electrical components, the ERT Laboratory Nuremberg starts work in July 2012. The new facilities set a new quality standard in the testing of insulants. One of the special features of the ERT Laboratory Nuremberg is its close cooperation with the chemical and physical test laboratory housed in the same building, which creates unique synergies for development projects and quality testing.

A long tradition of research and development

In the 1920s, the transformer plant systematically expands its research and development capacities, adding the most modern equipment. The development of transformer tech­nology makes great progress. Oil transformers are moni­tored for the first time with a Buchholz relay, an electrical safety device. In 1923, the first five­limb cores are produced for high­capacity 3­phase AC current transformers. 1927 sees the start of the manufacture of transformers with step switches for uninterruptible voltage adjustment under load. After the war, the research facilities are built up again and systematically expanded. The investigations made possible as a result lay the foundations for the steady growth of the Nuremberg transformer plant.

A comprehensive test portfolio

The ERT Laboratory has a testing hall and an air­ conditioned measurement cell. Both can be operated in parallel or independently of each other. This facilitates flexible workflows and operating sequences and enables unconventional studies to be carried out. In addition to the standard test voltages such as AC, DC, and impulse voltages, polarity reversal tests (DC) can also be carried out and chopped impulse voltages can be generated. In parallel, partial discharge analyses can be conducted and dielectric measurements (e.g. loss factor and capacity measurements) can be carried out in defined climatic conditions.

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Siemens AG Energy Sector Power Transmission Division Transformers Katzwanger Strasse 150 90461 Nuremberg, Germany

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Subject to change without prior notice. The information in this document contains general descriptions of the technical options available, which may not apply in all cases. The required technical options should therefore be specified in the contract.