Published by Megger October 2010 The industry’s recognised information tool ELECTRICAL TESTER The SMRT way to test relays protective relay test sets also need generous short time ratings. The benchmark of performance for an amplifier with a 30 A continuous rating is a short-time rating of 60 A, plus the ability to supply up to 180 A at high power for instantaneous overcurrent test applications. So much for the brawn, but what about the brain? After all, as every protection engineer knows, power is nothing without control. Let’s start with the user interface, as this is what makes the difference between a test set that’s a pleasure to use, and one that’s viewed with dread and foreboding. The gold standard in this area is set by the latest touch-screen interfaces that provide a simple way of testing even the most complex relays. They allow users to perform manual, steady-state and dynamic tests quickly and easily, and they have built-in preset test routines for popular relays. Naturally, the new generation test sets also make provision for automatic testing, using powerful yet intuitive software running on a PC. It’s clear that the new generation relay test sets will handle all of today’s demands with ease and convenience, but what of the future? Relay test sets are no trivial investment, and users rightly expect them to retain their value and usefulness for many years. The secret of testing the SMART GRID revealed! Stan Thompson Product Manager With the challenges of testing the smart grid just around the corner, and IEC 61850 networking starting to transform the way substations operate, is now really a good time to be thinking about buying a protective relay test set? Surprisingly perhaps, the answer is yes – provided that it’s a smart test set that has been designed with future developments in mind. The reasons for investing now rather than waiting are simple: there’s a new generation of test sets that makes testing easier, faster and more convenient. And, in today’s highpressure world where time – and downtime – are everything, which protection engineer doesn’t need these benefits now rather than later? Let’s take a look at what makes these revolutionary new test sets so attractive. First of all, they’re light and small. To put this in perspective, it’s not so very long Moisture in current transformers Exploding CTs are a real issue in Europe and North America. Failure of a substation-type oilimmersed CT can lead to a high-energy release and thermal runaway, very possibly resulting in an explosion. At a number of recent failures, the cause has been linked back to moisture ingress. In the first of a two part series, we examine how to identify these possible catastrophes before they happen with a combination of simple procedures and a clever test tool. See how it’s done on page 4. www.megger.com ago that a complete three-phase test set with modest output power weighed in at around 150 kg, and even today, most of the instruments on sale tip the scale at around 25 kg. The new test sets halve this to 12 kg and they are also smaller than their predecessors, making them much easier and more convenient to transport and handle. Size isn’t everything, however, although it’s undeniably important! Protection engineers also need versatility. For testing threephase schemes, three current outputs plus three voltage outputs are the minimum requirement, but if numerical current differential relays are to be tested, six current channels are needed. The most convenient and economical way to provide these is to arrange for the three “voltage” channels to be convertible, so that they can be used either for current or voltage, as required. With their requirements for size and versatility addressed, protection engineers will undoubtedly turn their thoughts to power. For convenient testing, current Erratic readings! Now to avoid errors when tesing in electrically noisy environments, see page 2. amplifiers with a constant power output are highly desirable, and it needs to be a high constant power to allow the testing of protection schemes that use electromechanical relays – we may be looking to the future, but legacy equipment is still going to be with us for a very long time. Fortunately, despite their small size and weight, the new generation test sets have no problems in the power department. They can offer a full 200 VA up to 30 A, with a compliance voltage of 50 V at up to 4 A. They even make provision for current outputs to be series connected to double the compliance voltage to 100 V and provide a constant 400 VA output power. Of course, power is also important for the voltage outputs and the designers of the new generation test sets have taken this into account. From 30 V to 150 V, the voltage amplifiers can deliver a constant 150 VA, thereby providing high current at “difficult” low test voltages. The best of the new test sets fully address this requirement. Their logic systems feature high-power processors to take care of future requirements, and their functionality can be readily enhanced to meet changing requirements by means of firmware upgrades. But what of IEC 61850? As might be expected, new generation test sets are IEC 61850 ready. That is, they can be supplied now without integrated IEC 61850 functionality, to eliminate the need for users to pay for features they don’t currently require, but they can be upgraded easily and economically to provide full IEC 61850 support as soon as the user has a need for it. Hopefully, by now these new protection relay test sets are starting to sound like a very attractive investment, but how can you get hold of one? The answer is simple – contact Megger. All of the characteristics and benefits discussed in this article are embodied in the new SMRT 36 test sets and, if you would like one, they’re ready for delivery right now! Continuous power rating is one thing, but Safety first Calling planet earth There have been too many avoidable accidents caused by ignorance of basic safety procedures. It may seem obvious to seasoned electrical engineering professionals, but insulation testers can store a lethal static charge in its capacitance and polarisation of the molecules in the insulation material. If the instrument is discharged, the user will not want to be part of the discharge circuit. If you want to be safe around your test instrumentation, then reading our article on page 6 could be a life-saver. ‘So just how do you get your clamp-on earth tester down a pit when the jaws are the wrong shape? And what happens when the serrated jaws get dirty or misaligned? It must seem sometimes like your test tools conspire against you to make life difficult. The obvious solutions – are an oval jaw that has the capacity for a normal cable, and the ability to reach into awkward places; and flat jaws with some behind-thescenes- complex circuitry to eliminate alignment issues. Read more on page 3. Megger ELECTRICAL TESTER October 2010 1 Contents The SMRT way to test relays.............. 1 Stan Thompson, Product Manager Keep the noise down! Paul Swinerd Product Manager Electrical noise is the enemy of accurate measurement, and it is often a particularly acute problem in high-voltage insulation testing. But what exactly is electrical noise, what are its effects and what can be done about it? Paul Swinerd supplies the answers. Keep the noise down!......................... 2 Paul Swinerd, Product Manager What is electrical noise? The term electrical noise is used to describe a whole range of phenomena, but the most general definition is spurious electrical or electromagnetic energy that produces an unwanted effect. In a hi-fi system, the unwanted effect might, for example, be background hiss, but in measurement systems it most usually manifests itself as inaccurate or unstable readings. Ground test auto................................. 3 Paul Swinerd, Product Manager The next step in insulation diagnostics.......................................... 3 Matz Ohlen, Director - Transformer Test Systems Moisture contect detection................. 4 Diego Robalino, PhD, Applications Engineer Norwegian Blues................................ 5 Per Vågsether, Applications Engineer In measurement applications, noise takes the form of voltages and currents induced from adjacent equipment. This is very common in substations, and particularly in high voltage substations where induced noise at power frequencies predominates. Ask Jowett - Warning - Safety first...... 6 Jeff Jowett, Applications Engineer The EGIL has landed.......................... 6 Romain Douib, Product Marketing Manager Magnetic losses, finances and environment....................................... 7 Dr Stan Zurek, Magnetics Technical Specialist Q&A.................................................... 8 The story of Multi-Amp...................... 8 Bruce Buxkemper, VP, Megger Dallas Megger makes beautiful music........... 8 What is the effect of noise? In insulation testing, electrical noise superimposes an AC signal on the DC test current. This can cause readings to vary erratically, and can even prevent a reading of any kind being obtained if the level of noise exceeds the capabilities of the instrument. Many operators see this as something they have to live with – a form of occupational hazard – but, as we shall see, this doesn’t have to be the case. These instruments have a noise immunity of 4 mA at power frequency, and have been successfully used in some of the world’s noisiest switchyards. Nevertheless, the question remains – can noise levels exceed 4 mA and if they do, what can be done about it? The answer is that noise levels of more than 4 mA are very rare, but they are not unknown. They may be encountered for example, where making connections to the bushings on the top of a transformer involves the use of very long test leads, since these act as effective aerials for picking up noise. In these circumstances, the best course of action is to take steps to minimise noise pick up in the first place. How can the effects of noise be reduced? One of the most effective ways of minimising noise pick up is to take care with the test lead layout. In particular, keep the leads as short as possible and route them near to grounded objects, such as the casing of a transformer. One solution of course, is to implement a complete shutdown of adjacent plant to eliminate the noise source, but this is in many cases both costly and inconvenient. More often, noise leads to tests being omitted, which is very undesirable since the objective of diagnostic insulation testing is to prevent expensive and dangerous failures. How can insulation testers deal with noise? Noise immunity can be designed into insulation testers and indeed, instruments that are sold in the EU must meet the EMC requirements of the latest edition of IEC 61326-1, which came into force in February 2009. Megger has its own EMC laboratory at its Dover site, which it has used to ensure that all of its latest MIT and S1 5 kV and 10 kV not only meet this standard, but also conform to the requirements for heavy industrial use. However, even that is not always enough. Experience has shown that in extreme environments such as HV substations, instruments can be subjected to levels of noise far in excess of those laid down in IEC 61326. That’s why it’s essential not only to look for standards compliance, but also to take into account the noise immunity specification of an instrument. What do noise immunity specifications mean? It’s very easy for an instrument manufacturer to say that its HV insulation testers have high noise immunity, but unless the level of immunity is specified, such claims are worthless. But exactly how is noise immunity specified? A typical specification might say that the instrument has an immunity of 2 mA at 50/60 Hz. This means that if the noise current induced in the test circuit at power frequency is 2 mA or less, the instrument will give accurate and reliable results. Adjacent live cables inducing noise current A printed newsletter is not as interactive as its email equivalent so to help you find items quickly on www.megger.com, we have underlined key search words in blue. Adjacent equipment radiating noise Test piece <2 mA Max. Note from the Editor Time for your say. We have introduced a ‘Questions and Answers’ section and would like your input. If you have any questions or stories that you think we could use, then please email electricaltester@megger.com The word ‘Megger’ is a registered trademark Megger Limited Archcliffe Road Dover Kent CT17 9EN T +44 (0)1304 502100 E electricaltester@megger.com www.megger.com 2 When screened test leads are used, the screen is connected to the guard terminal on the insulation tester. This ensures that noise currents are diverted away from the measuring circuits and are, therefore, ignored. The guard terminal is also used in the normal way to eliminate the effects of leakage currents. It is important to note that shielding is only effective in reducing noise pick up on the test leads. If noise is picked up on the test piece itself, as might well be the case with long overhead power cables, for example, there is no substitute for using an instrument with high noise immunity. ‘Views expressed in Electrical Tester are not necessarily the views of Megger.’ Editor Nick Hilditch. T +44 (0)1304 502232 E nick.hilditch@megger.com www.megger.com Another effective option is to use screened test leads. The short test lead between the insulation tester and ground will not pick up enough noise to cause problems, but it is often beneficial to use a screened lead for the longer connection to the equipment under test. Megger offers suitable leads in lengths of 3 m, 10 m and 15 m. Specifying the maximum permissible noise current at power frequency is actually considering the worst case, as instruments usually incorporate capacitive filtering that increases in effectiveness as frequency rises. As a result, the noise immunity of the instrument also increases with frequency. This can be very useful, for example, with corona discharge on bushings, which typically generates electrical noise with frequencies in the kilohertz range. While noise immunity of 2 mA is adequate for the majority of applications, there are extreme environments such as substations operating at 300 kV and above, where even this isn’t enough. For applications of this type, Megger has produced HV insulation testers that not only incorporate specially developed input filtration to minimise the effects of high frequency noise, but also employ firmware filtering to remove low frequency effects. Megger ELECTRICAL TESTER October 2010 Electrical noise is undoubtedly a troublesome issue in HV insulation testing, especially in substation environments. By choosing instruments with high noise immunity however, and using shielded test leads where appropriate, it should be possible to make accurate and dependable measurements in even the most challenging of circumstances. www.megger.com Ground test auto Paul Swinerd Product Manager For many years, stakeless or clamp-on testing has been accepted as an established method of testing earth system resistance, and is now included in the German standard VDE 0100-600:2008 (appendix B3). This method has a number of real user benefits, in particular not having to disconnect the electrode under test, increased user safety and huge savings in time and aggravation. However, many users are failing to enjoy the benefits of stakeless testing, and that’s mainly down to two main issues. Firstly many potential users do not fully understand the testing technique, and avoid it; secondly many people have found some problems when testing, resulting in a number of concerns. The first issue is easy to solve when you know where to go. You can find forums and micro-sites such as the one at www.megger.com/det to help with many of these problems, or you could phone one of Megger’s regional technical support offices. Easy, if you have time to stop your work and do the research! The second issue is not so easily fixed. Problems experienced in actual testing are often caused by the abilities – or inadequacies - of the test equipment. Let’s take a look at these concerns and see how we can eliminate or maybe get round them. For obvious reasons, most users have safety as their primary concern. In substation environments, the stakeless testing method may be the only method available to you. But what happens if you are holding the instrument when a massive fault produces a huge transient on the cable that you happen to be clamped around? This could also be a concern to users testing lightning protection; there can be a sudden lightning bolt that could kill you. The other and maybe less obvious hazard will present itself if, for whatever reason, the user has to disconnect one of the electrodes that is being tested. If there is too much current flowing down the electrode when it is disconnected, it will quickly turn into a hazardous voltage. What’s the answer? Firstly, choose an instrument with the highest IEC safety category; it will have the best isolation between your hand and what ever you are clamped around. Secondly choose one that has a current measuring range, then you can measure whether there is a hazardous level of current flowing before you disconnect. If you work in a sub-station environment you may also have another concern which many users have no doubt experienced. Noise interference in the form of leakage currents flowing through the electrode under test can result in varying readings or in some cases actually prevent testing completely. In this case the solution is to select an instrument with the highest noise current immunity you can find. Many electrodes are in difficult to access locations; in boxes, pits or are just difficult to reach. What can you do in these situations? Your choice of instrument will directly influence your success in such situations. Choosing a clamp with a large jaw capacity is not just about the size of cable it can clamp around, it will also provide a better angle of approach. Also, look at the instrument’s body length. The longer it is, the more instrument there is to accommodate down an electrode pit. Another feature that will help with access is to have a jaw head that is slimmer in profile, and a backlit display will surely help too, especially in substation basements. Lets recap and talk about clamp capacity. The challenge isn’t always to clamp around the large size of cables, as there may also be a requirement to clamp around flat earth tapes. In many cases these flat tapes have to be pried from walls, so a smaller section clamp will help. However these tapes are getting bigger, and in some locations such as on earth systems used on ~400 kV supplies they can be 50 mm x 10 mm. That really limits your choice of how to test. The other burning issue is reliability. Earth testing clamps get used in tough environments and are often used in remote locations such as on utility pole electrodes. Many instruments have interlocking laminations (or interlocking teeth as they are often referred to). These ‘teeth’ are easily damaged and collect dirt which can either produce errors in measurement, or render the instrument useless and awaiting a trip to the repair shop. The answer is to use an instrument with smooth mating jaw surfaces. That sounds obvious but it is often overlooked. Also carefully check the instrument’s battery life and check that there are readily available batteries in the location where you will be working. In a remote area, this could be a real concern to the user. Stakeless testing has real advantages and specifying the right instrument will really help get the best out of the method. Megger has just launched a new range stakeless testers specifically designed to overcome the problems outlined in this article. The new DET14C and DET24C have these new features: n n n n n n n CATIV 600 V safety, with 8 kV of transient isolation Auto hazardous current warning even on the resistance range, giving you peace of mind, and no need to worry about remembering to measure it Auto noise filter to provide the best of immunity to noise current Unique elliptical shape head with a 37 mm x 55 mm capacity and slim profile which provides excellent access and can clamp around a 50 mm x 10 mm earth tape Smooth mating jaw surfaces which are easy to clean and have no teeth to bend Huge battery life from readily available AA batteries, which last 24 hours with a 25 Ω load Pre-hold function which automatically initiates a test when clamped around an electrode, then The next step in insulation diagnostics Matz Ohlen A new generation of instruments is now available which addresses these shortcomings. To see what these versatile products have to offer, let’s take a look at one of the latest 12 kV insulation diagnostic systems. The first thing users are likely to notice is that it is much more portable than its older www.megger.com holds the reading for reviewing when removed from the electrode. n Backlit display With all these ground test auto functions, you could find your worst problems just go away! The ability of the test set to generate its own test voltage, which can be varied in frequency over the range 1 to 500 Hz not only increases its versatility, but also ensures that dependable and repeatable results are obtained even when the instrument is fed from a poor quality supply. Director - Transformer Test Systems High-voltage insulation testing is an essential tool for condition assessment of almost all major items of electrical power plant, including transformers, bushings, circuit breakers, cables and rotating machines. Many of the insulation test sets currently in use, however, have significant shortcomings, which means not only that they are less convenient to use than they should be, but also that the results obtained are less comprehensive and less reliable. counterparts – its two-piece design weighs a total of 36 kg, making it probably the industry’s lightest power factor test set. Another useful benefit is provision for fully automatic tan delta/ power factor and tip-up testing, which is a big time saver. Facilities are also available for manual testing – including the option to increase the test voltage during the test – to allow special testing requirements to be accommodated. Another benefit is automatic voltage dependence detection. If the instrument detects, for example, that the dissipation factor of the test object varies with the applied voltage, which suggests there is a problem that requires further investigation, it instantly provides a user alarm. The inability to correct accurately for temperature differences when calculating results is a weakness of many insulation test sets currently in use. The new generation instrument overcomes this by using a novel method to apply individual and accurate temperature compensation for the actual test object. This is based on carrying out an additional DFR measurement and mathematically converting data at different frequencies to data at different temperatures. Results analysis is a key aspect of insulation testing and, in the new instrument, analysis is facilitated by allowing immediate comparisons to be made between the current results and stored data sets. Comparisons of results of obtained at different voltages and frequencies can also easily be made. The instrument is supplied complete with powerful industry-standard acceptance and maintenance test data software, which not only offers extended test automation options, but also provides comprehensive facilities for archiving, analysing and reporting results. The instrument described in this short item is Megger’s recently launched DELTA4000 series 12 kV insulation diagnosis system, which is supplied with the powerful yet easy to use PowerDB software package. Developed after careful analysis of user requirements in relation to high voltage insulation testing, this innovative new test set is a significant step forward in highvoltage insulation testing technology. Megger ELECTRICAL TESTER October 2010 3 MOISTURE CONTENT DETECTION IN OIL IMMERSED CURRENT TRANSFORMERS Diego Robalino, PhD Applications Engineer Part I. Measurement Set Up As discussed in the last issue of Electrical Tester, frequency domain spectroscopy (FDS) is an invaluable tool for determining the moisture content of the solid insulation in combined oil-paper insulation systems. In particular, work carried out in North America and Europe has verified the effectiveness of FDS as way of determining the moisture content in instrument transformers and, more specifically, in high voltage current transformers (CTs). This article describes FDS testing of CTs. It includes configuration data and a step-by-step test procedure using the Megger IDAX 300 test set. Part 2, which will appear in the January 2011 edition of Electrical Tester, discusses analysis of results using MODS software and gives recommended values for new and aged units. The dynamic properties of dielectric materials can be measured in the time and/or frequency domain. The fundamentals of dielectric response functions and the theory of dynamic properties of dielectrics are well described in several publications and, in particular, in a very detailed way in two articles by W S Zeangl, which appeared in the IEEE Electrical Insulation Magazine Vol. 19, 2003. The traditional dissipation factor testing technique allows identification of the deterioration process of the insulation by measuring the changes in the dielectric properties of the tested unit. This approach involves measurements of capacitance and dielectric loss quantified by the loss or dissipation factor . This type of testing is part of many manufacturing quality control procedures but it is normally carried out at power frequency only. With FDS, however, a wide frequency range from 0.001 to 1000 Hz is used, and this allows the determination of the moisture content in the solid insulation. Water significantly accelerates the ageing of cellulose. Oil analyses by means of Karl Fischer titration (KFT) have traditionally been used for the evaluation of moisture content, assuming existence of equilibrium in distribution of moisture between oil and paper/ pressboard. In reality, the analysis only reflects the moisture percentage in the liquid insulation and equilibrium curves are required to estimate water content in the cellulose insulation. The equilibrium curves are a useful reference but their reliability is still a topic of discussion. Moreover, continual sampling for DGA and water content analysis is not recommended for CTs due to the small volume of dielectric oil they contain. “A chain is no stronger than its weakest link”………. [1868 L. Stephen in Cornhill Mag. XVII. 295] Failure of a substation-type oil-immersed CT can lead to a high-energy release and thermal runaway, very possibly ending in an explosion (see Figure 1). Because of the difference in thermal expansion ratio between the metallic housing of the CT and the relatively fragile porcelain insulator, mechanical stress builds up, resulting in a blast where fragments from the porcelain insulator may reach up to 50 m from the location of the unit. Loss of this important device results in phase to ground fault that will trip the substation, shut down operation and possibly affect other electrical components in the vicinity. Figure 2 - Cross Section: CT windings, core & insulation In some applications, the core housing can accommodate up to six independent multiratio cores feeding protection relays, or cores feeding a combination of relays and meters, requiring up to 30 secondary leads. More details of the construction of oil-immersed CTs can be found on manufacturers’ web sites and literature. A very real concern The issue of exploding CTs is currently a very real concern as, in Europe and North America, there have recently been several catastrophic failures of hermetically sealed units in sub-station applications. Initial investigations carried out on CTs similar to those that have failed, using dissolved gas analysis (DGA), have revealed that the failures are due to moisture ingress, and that many CTs still in service are at risk of similar failures. Regular CT testing is, therefore, increasingly seen as essential but, as has already been noted, tests that involve oil sampling, which includes DGA testing, cannot be used regularly on CTs because of the small volume of oil they contain. FDS testing, which eliminates entirely the need for oil sampling, is therefore establishing itself as the preferred approach. Performing FDS tests on an oil-immersed current transformers First make a visual inspection of the unit and its surroundings. Ensure that local safety procedures (tag-out/lock-out) have been observed and that the test area is properly identified and is free of obstacles on emergency evacuation paths. The procedure for testing a HV CT uses the same configuration as that used to perform power factor/dissipation factor tests. Thus, the unit must be isolated from the power system (primary as well as secondary winding) and discharged. If the test is to be performed after a through fault, it must also be demagnetized. As a general rule, when a series of tests is to be carried out on an HV CT, DC tests should be performed last. With a clear area of operation established, confirm that good connections have been made to the unit under test (UUT), to the substation’s ground system, and from the test instrument to the same grounding point. Typically, the ground terminal of the test equipment is connected to the same ground terminal on the secondary box of the CT. The CT is tested using the standard method. This implies energizing the primary winding and measuring the secondary connected to ground. The recommended test setup is grounded specimen test (GST) as shown in Figure 3. Core Liquid insulation Solid insulation Low voltage winding High voltage conductor Figure 3 - GST measuring setup for HV CT Figure 1 - Failure of a CT in a substation The internal construction of typical oil-immersed CT is shown in Figure 2. The high voltage/high current primary winding is a conductor, a bar or a set of conductors passing through the window of the toroidal core. Engineers or technicians testing the unit should verify with the manufacturer the construction of the primary conductor, as there are applications where a single conductor is wound inside the CT to provide multiple turns. The core is surrounded by the low voltage winding, which is evenly distributed all along the toroidal core. This is completely covered by solid insulation, which wraps the secondary winding and the core in multiple layers of paper insulation. The core, the primary and secondary windings and the solid insulation are fully immersed in liquid insulation (mineral dielectric oil). 4 Megger ELECTRICAL TESTER October 2010 Normally, there is no need to short circuit the primary winding but if, as mentioned earlier, there are several units built in with multiple turn arrangement of primary conductors, these need to be shorted. Bar-type and single-conductor primary windings do not require short-circuiting of the P1-P2 terminals. The UUT should preferably be at thermal equilibrium. The average temperature of the insulation should be measured or estimated and recorded. One option is to measure on several positions on the outside of the CT core housing with a pistol grip laser target temperature gauge or, if the CT has not been in recent operation, the insulation temperature can be assumed to be the same as ambient temperature. www.megger.com Per Vågsether Sales Engineer, Tormatic AS Norwegian Blues Per Vågsether, Sales Engineer at Tormatic AS, a leading supplier of equipment and consultancy services to Norway’s power industry, provides an overview of the Norwegian energy supply sector, and explains how global warming is creating problems that are giving electrical utilities a definite attack of the blues. Hydro electric power As might be expected in such a mountainous country, most of Norway’s electricity is generated by hydroelectric plant. In fact, Statkraft, a power utility which is wholly owned by the Norwegian government and which supplies much of the country’s power, is Europe’s largest renewable energy company. In recent times Statkraft has diversified its operations, partly for reasons that will become clear later in this article, and now, in addition to hydroelectric power, it is also involved with wind power, gas power, solar power and biopower. In 2008, the latest year for which figures are currently available, Norway had a total of 737 power stations, of which 691 were hydroelectric, 29 thermal and 17 wind power. The total installed generating capacity was almost 31 GW. During the year, Norway produced 142 TWh of electricity, almost all of which was consumed domestically, one of the largest users being the aluminium industry that developed in the country principally because of the availability of cheap electricity. Norway power stations in 2008 Norway has an open electricity market and it routinely imports and exports energy over direct power links with countries that include Sweden, Denmark, Germany and the Netherlands. Since Norway, with its large hydroelectric power base can, for most of the time, generate electricity at lower cost than its neighbours, energy exports predominate over imports. In 2008, for example, it exported 17.3 TWh and imported only 3.4 TWh. Deregulation Norway’s power distribution companies were deregulated and privatised a few years ago. Consumers are, however, still tied to their local distribution companies in an arrangement the Norwegian Ministry of Petroleum and Energy describes as “monopoly regulation”, which includes an income cap for each network company. Monopoly regulation is intended to safeguard consumer rights while ensuring a wellfunctioning power market and that the grid is developed and managed efficiently. The regulatory system has recently been fine-tuned to provide enhanced incentives for investment and to make it more certain that the benefits of efficiency improvements will be passed to the customer. In spite of this arrangement, the privatisation of the power companies and the recent acquisition of some of them by foreign organisations have brought mixed benefits. These developments are certainly working well for the owners of the companies, but not necessarily quite as well for energy users, who are seeing higher prices with no perceptible improvement in performance. These criticisms may, however, be a little unfair as Norway’s energy prices are still among the lowest in Europe, and the country’s transmission network already has one of Europe’s highest uptimes. The effect of global warming There is, however, a much bigger cloud on the horizon, one that is certainly significant enough to create a distinct feeling of “the blues” among energy producers and consumers alike. This problem is that the amount of energy available from hydro-electric power plants, on which the country is highly dependent, is falling. And it is by no means certain when, or even if this decline will end. It’s not hard to find the reasons for this. Hydroelectric generation depends on water flow and, in Norway’s case, most of the water comes from melting snow. Because of global warming, however, much less snow is now falling, so there is much less melt water, which means significantly reduced generating capacity. With these facts in mind, it’s not hard to see why ecology and environmental protection are currently such hot topics in Norway. Of course, the utility companies are responding to this issue, typically by putting research efforts into alternative green energy sources, such as wind power and wavepower, the latter being a particularly attractive option given the country’s very long coastline. There’s a very long way to go before these sources make a significant contribution, but it is worth noting that Norway was the first country to generate electricity commercially with seabed tidal power, when a prototype 300 kW plant was brought into service near Hammerfest late in 2003. Wind power The utilisation of wind power in the country is considerably more advanced, with some 913 GWh of electricity obtained from this source in 2008. Nevertheless, there are concerns about building more on-shore wind farms, not least because, in spite of their excellent carbon footprint, they are thought to adversely affect the environment in other ways, such as disrupting the breeding of eagles. Offshore wind farms are seen as a more attractive proposition, in spite of the higher costs and the technical difficulties involved. Another option under consideration is the building of new gas-fired thermal stations, which initially seems logical as Norway has access to large reserves of natural gas in the North Sea. There are very great environmental concerns with this course of action, however, because of the CO2 emissions that are almost unavoidably associated with hydrocarbon fuels like natural gas. For this reason, there are many who suggest that the natural gas should be seen as an export opportunity and sold to other countries like the UK, where gas-fired power stations are already www.megger.com Norway has an ambitious plan to cut greenhouse gases in widespread use. Unfortunately, this does seem rather like transferring the problem to a neighbour, rather than genuinely solving it. Ambitious plan to cut greenhouse gases However challenging they may be, these issues will have to be addressed promptly as, in January 2008, the Norwegian government set itself what it describes as “the world’s most ambitious target for cutting greenhouse gas emissions” – this is to make the country as a whole carbon neutral by 2030. The full details of how this is going to be achieved remain a little sketchy, but the plan is not only to reduce CO2 emissions at home, but also to invest up to 3 billion Norwegian Kroner (about US$ 0.5 billion) per year to combat deforestation in developing countries and thereby gain carbon credits. For decades, Norway has enjoyed cheap “green” electric power, and the country is still well blessed with renewable and non-renewable energy resources. Nevertheless, as we’ve seen, there are major issues to be addressed over the next few years and as a result, this will undoubtedly be a very interesting and challenging period for all of those involved in the country’s energy sector. Megger ELECTRICAL TESTER October 2010 5 Warning! Safety first Jeff Jowett Applications Engineer Safety should be the first concern when preparing to carry out electrical testing, but all too often it’s taken for granted. Lack of attention to safety requirements and lack of sufficient expertise can, however, have life threatening consequences. This two-part article, the second part of which will appear in the next issue of Electrical Tester, explains how safety requirements should be systematically and thoroughly assessed before testing commences. The first essential for safe testing is to keep in mind that safety involves equipment, procedure, and the test item. Each should be considered in turn. Beware of focusing entirely on one aspect and letting the others take care of themselves. Equipment, for instance, may have adequate or even superior safeguards while the item being tested presents an overlooked danger. Of paramount importance is the degree of protection against arc flash/arc blast. This combines elements of all three: the test instrument, the test item, and procedure. Arc flash protection is covered by the standard EN61010-1:2001, issued under the aegis of the International Electrotechnical Commission (IEC). The rating defines the level of spike or surge transient the instrument has been designed to withstand. Remember, the rating pertains to transient voltage, not line voltage. Spikes can be many multiples of line voltage and can cause test instruments that happen to be connected at the time to arc internally. The arc can produce tremendous heat, violent expansion of air in a small space, exploding the instrument and exposing the operator to burns, shock waves and flying particles. The key to safety is to design the instrument so as to minimize the risk of internal arcing, but that isn’t enough. The operator must understand the rating system and use the instrument accordingly. The standard defines clearance and creepage distances between critical parts within the instrument. The degree of protection is interpreted as a Category (“CAT”) rating, plus a voltage limitation. CAT ratings are assigned from I to IV, although CAT I is nowadays of little practical use. Instruments with higher category ratings have better capacity to withstand transients. The ratings indicate the position of the circuit under test “downstream” from the transformer serving the premises. Energy dissipates with attenuation and therefore so does risk. CAT IV is assigned to the utility feed from the transformer to the service entrance, CAT III is from the fuse panel to an outlet, and CAT II is downstream of the outlet. The rating doesn’t stop here, though, but also must include a voltage limit for the rated voltage of any system being tested, because CAT rating is based on multiples of system voltage. Some instruments list a CAT rating but do not specify the voltage. These should be avoided, as it is an indication of shortcutting for economy in design. To ensure safety, the operator must use an instrument with a CAT rating matching or exceeding that of the system being worked on. A recent study by a utility company has indicated that using an instrument rated one category lower than the application requires increases the chances of an accident by a factor of 30. Looked at another way, this means that if 100 operators used instruments of the wrong rating connected to live systems for one hour per day over a 200-day year, a dangerous situation is likely to occur every 18 months. These are not good odds for anyone intending to spend a career in the industry! After CAT rating, it’s time to consider the many other safety features that are designed into quality equipment. A worthy illustration relates to the common practice of insulation testing. Years ago, poorly designed test equipment would leave the operator unprotected, and extra diligence was required to avoid being shocked, or worse. Remember, while many in the industry take non-lethal “shocks” for granted, they can produce unexpected consequences like falling from a ladder or catwalk or jostling a nearby person who is working close to dangerous machinery. Better to eliminate the issue altogether than to try to live with it. Testers now come with additional safeguards that didn’t exist years ago. A special safety hazard exists with insulation testing because the tester will charge up the capacitance and absorption inherent in the item being tested. This is a prime example of how the test item can be an unrecognized source of danger. Insulation tests are always performed on de-energized equipment. Therefore, given the safety features of the tester itself, it’s easy for the operator to become complacent and think that he or she is working in a completely safe environment. Not necessarily so! The test item can store a lethal static charge in its capacitance and polarization of molecules in the insulating material. At termination of the test, with the field gradient provided by the tester now removed, the charged item will generate a relaxation or reabsorption current. The operator does not want to become part of this discharge circuit! Older testers at best had a discharge switch, if any protection at all. Operator involvement was paramount, as it was easy to forget to engage this switch. Modern testers virtually eliminate the chance of operator error by providing automatic safe discharge. When such a tester senses extraneous voltage (not provided by the tester itself), visual and audible warnings are engaged, and the actual voltage may be automatically displayed, with flashing symbols to ensure the operator’s attention. A discharge circuit will then safely dissipate the stored charge and monitor it on the display, so that the operator will not get across the terminals until the voltage falls to less than 50 V. This warning circuit will of course, operate at any time during the course of a test, so that if the operator accidentally connects to a live circuit, or someone closes a breaker or flips a switch while the test is in progress, the operator will be immediately warned. But beware of fuse protection; make sure it’s properly integrated with other functions. In some units, a blown fuse disables the protection circuits; in others, it doesn’t. If a blown fuse has disabled the alarms, the operator may not realize what has happened and not be warned if the tested equipment becomes live. One might also want to consider job protection along with personal protection. Before instruments were provided with modern safeguards, it was common for operators to cook not themselves but the tester. Manufacturers of test equipment were flooded with “warranty” returns that had burn tracks across the terminal boards. And their answer was invariably, “Sorry, the warranty does not cover connection to a live high voltage circuit.” Operators were disregarding voltage indications, if they existed at all, and proceeding to engage the test button. As soon as they did, the tester was ruined. Well-designed modern testers remove this source of anxiety and embarrassment by disabling the test circuit in the presence of extraneous voltage. The operator presses the test button and nothing happens. Phew! De-energize the circuit and proceed with the test! One factor to be aware of, however, is the possibility of low voltage background noise, such as crosstalk on communications circuits. Testing may have to proceed in the presence of this, so the tester must have an appropriate threshold that will not disable it in such situations. This article is continued in the next issue of Electrical Tester. The second part will cover further issues relating to the safe use of test equipment and will include information about test leads, multifunction testers and ground testers. The EGIL has landed! Romain Douib Product Marketing Manager Featuring compact construction and straightforward operation, Megger’s latest EGIL circuit breaker analyser is suitable for testing timing and travel on all breakers that have a single interrupter per phase. In addition, when used in conjunction with the SDRM option and the new SDRM201 accessory, the instrument can also be used to carry out static and dynamic resistance measurements. Although the EGIL is available at a very attractive price, no compromises have been made on its versatility or performance. It is, therefore, an ideal choice for operators of small power plants and for the maintenance of simple circuit breakers by power distribution utilities. To aid ease and speed of use, the EGIL has a built-in sequencer that automatically runs the selected breaker operating sequence while making the appropriate measurements and recording the results. In addition, menu-driven procedures invoke sensible default settings, thereby eliminating the 6 need for time-consuming pre-setting. Megger’s EGIL test set offers three timing channels for the circuit breaker main contacts. Main contacts and pre-insertion resistor contacts can be timed on the same channel, with the results recorded graphically and numerically on the integral printed. Results are also shown numerically on the instrument’s large easy-to-read display. Two additional galvanically isolated timing channels are provided for auxiliary contacts. In addition, an analogue channel is available as an option. While primarily intended for monitoring contact motion, this channel also finds many other applications. For EGIL test sets that have the SDRM option installed, the SDRM201 module extends the facilities to allow accurate resistance measurements to be made on circuit breaker contacts and other lowresistance devices. When used with the test leads provided, the SDRM201 is capable of supplying an instantaneous current of 200 A DC, falling to 140 A after one second. Multiple tests can be run with only a short waiting time between them. Megger ELECTRICAL TESTER October 2010 Used in conjunction with the SDRM201, the EGIL test set supports dynamic resistance measurement from 0 to 32 mΩ, and static resistance measurement from 0 to 2 mΩ. The inaccuracy of static resistance measurements is 2% ±2 µΩ or better. To complement the latest models of its EGIL circuit breaker analyser, Megger has introduced a new version – R03A – of its CABA Win computer-aided breaker analysis software. Designed to run under Microsoft Windows on a standard PC, this adds full support for static and dynamic resistancemeasurements, new test plans for applications where the EGIL is used with the SDRM201, and 19 new timing parameters for multiple operations. www.megger.com Photography by Damon Mount Dr Stan Zurek Magnetics Technical Specialist All electric energy in the national grid is transformed several times before it is delivered from the power plant to the final user. The high-voltage power transformers used are devices of considerable weight, size and cost. However, the cost of a transformer relates not only to materials and manufacturing, but also to the energy lost over its lifetime. Read on to find how magnetic losses affect economy and the environment. All transformers dissipate some energy in the process of transformation. Operating principles dictate that the magnetic core is always magnetised to the same level, regardless the load. This means that even when transformer works with no load, the magnetic losses are almost the same as when it is operating at full load. At full load, the efficiency of large power transformers can be very high – above 99% in some cases. However, because the magnetic loss is practically fixed, efficiency reduces with the load. Inevitably, under no load conditions any transformer operates with 0% efficiency – it consumes some energy to remain energised, but it delivers no energy to any load. The electricity transmission grid and all the transformers in it are exposed to varying load. At night the load is relatively light, so the transformers operate at much less than nominal conditions, but they keep dissipating exactly the same energy in magnetic losses. Remembering that a power transformer can have a life of 20 years or more, let’s now consider the hypothetical case of a 10 MVA (10 MW) transformer that dissipates 1% of the energy in magnetic losses. With a simple calculation, we can conclude that over 20 years 614 MWh of energy is lost and, if the price is 10p per kWh, the cost of the losses is £61 k/€73 k/$90 k. This is just for a single transformer – if we consider the case nationally, not to mention globally, then we can see that the amount of energy lost, the money associated with it and the environmental impact are tremendous. When transformers were first invented, magnetic cores were made from so-called “soft iron”. This material was quite lossy and, ever since, engineers and scientists have been striving to improve efficiency by introducing a number of technological modifications – to chemical structure, mechanical processing, annealing, postprocessing, etc. The diagram shows how these changes have helped to reduce losses over time. Magnetic losses, finances and environment times lower than that of soft steel. This has had a very significant impact on the overall efficiency of power transformers. In some cases, medium voltage power transformers are still in use after 50 years of operation. Because these old transformers were made from inferior magnetic material, their losses are much higher and replacing them with modern units would most likely bring noticeable savings in the energy distribution network – a transformer made 50 years ago could lose 5-10 times more energy (for magnetic loss) than a modern equivalent with the same rating. The production of the grain-oriented electrical steel is a very complex process (perhaps a topic for a future article). Further improvements are on the horizon, but currently are too expensive to implement. However, another approach is possible – different material can be used. 10 core loss at 50 Hz 1.5 T (W/kg) 1 reduced C contentlarger grains high temp. annealing decarburistai addition on stress of Si Goss coating domain structur refinemen e treduced thickness Hi-B amorphous 0.1 1900 1950 2000 In the US many smaller distribution transformers are made from material called “amorphous”. Its operating flux density is slightly lower, but the losses are much lower than in the case of electrical steel. Amorphous transformers are slightly bigger, heavier, and more expensive to make, but the energy savings of their lifetime easily justify the larger capital cost. Yet in Europe such transformers are still not very popular. To ensure correct operation, several properties of transformers must be tested regularly: electric insulation, degradation of oil, turns and voltage ratio, etc. Higher losses in the magnetic core can influence to some degree the voltage ratio or the phase shifts between the test signals. However, this is usually not a problem because correctly designed transformer testers can cope with these effects, even for older transformers. Study and research continue into the problem of losses in magnetic materials. Manufacturers of electrical steel and amorphous ribbon sponsor many of these studies, and there are a number of international “magnetic” conferences where the newest developments are presented and discussed. There is, for example, pressure from industry for making acoustically quieter transformers. Also, rapid development in Asian countries is making electrical steel one of the hottest items on the market, so that the manufacturers have serious problems in keeping up with demand, despite the recent economic crisis. One thing is, however, certain. In future we can expect even better and more efficient magnetic cores. The improvements might not be ground breaking, but every single percentage point counts: for efficiency, for running costs and for the environment. Nowadays, the most commonly used material for magnetic cores of power transformers is electrical steel, which is a descendant of soft steel. However, the power loss of the best grade of electrical steel now in use is around 50 www.megger.com Megger ELECTRICAL TESTER October 2010 7 Q&A In this issue, experts from the Megger Technical Support Group supply answers to the questions they most frequently receive about earth testing. Q: Most of the time I find that clamp-type testers provide a quick and convenient way of measuring earth resistance. Where space is tight, however, I sometimes have trouble getting the clamp round the cable or earth strap. Is there a solution? A: The root of this problem is two fold most earth resistance testers have clamps with a round aperture and a long body length. While round clamps make life easier for the instrument manufacturer, they’re not really ideal for getting into inaccessible places, or for clamping round earth straps, which usually have a rectangular cross section. However, Megger’s new DET14C and DET24C models, have elliptical clamps and a short body length making them much more versatile. In addition, the Megger instruments have a pre-hold key, which makes them easier to use in restricted locations as the meter can be simply clamped around the cable or electrode and then withdrawn before reading the display. Q: After I’ve been using my earth clamp meter for a while, especially in harsh environments, I find that it starts to give inconsistent and inaccurate results. Why is this and what can I do about it? A: This kind of problem is usually an indication that the jaws of the clamp are not closing properly. In many earth clamp meters, the mating faces of the jaws take the form of laminations that interlock when the clamp is closed. This arrangement is particularly susceptible to contamination – it only takes a small particle of grit or dirt to prevent the laminations from interlocking and, when this happens, the meter will not give accurate or reliable results. The short-term solution is to carefully clean the mating faces of the jaws. There is, however, another problem associated with instruments of this type – the laminations in the jaw faces are thin and so are easy to damage. When this happens, the only certain remedy is to return the instrument to the manufacturer for repair and recalibration. Attempts to straighten the bent laminations without the proper equipment are likely to make things worse and, after an ad-hoc “repair” of this type, there’s no way of knowing whether the instrument is giving accurate readings. A better and longer lasting solution is to choose an earth clamp tester that has flat jaw faces, as these are much easier to keep clean and far less susceptible to damage. Q: What is the point of the ground leakage current measurement feature that is offered by some earth resistance clamp meters? The story of Multi-Amp In the late 1970s, the pioneering SR range was complemented by the company’s first solid state relay test set, the SSR-78. This evolved into the EPOCH series of protective relay test sets in the 1980s, laying the foundations for the development of Megger’s latest MPRT and SMRT testers. At every stage, the development process was customer led. Multi-Amp was then – as Megger is today – committed to talking to its customers, discovering their needs, and then applying its technical expertise to meet those needs efficiently and costeffectively. Bruce Buxkemper VP, Megger Dallas While Megger today is a single organization that supplies one of the world’s widest and most innovative ranges of portable electrical test equipment and measuring instruments, it continues to benefit greatly from the unrivalled expertise it has acquired from the many businesses that have, over the years, joined the Megger family. One of these is Multi-Amp, and here we provide a brief insight into the fascinating history of this company. Multi-Amp was founded in 1951 by a group of utility engineers who realised that there was a need for reliable portable instruments for testing at high currents. This guided the choice of company name – its products would test at multiple amps! Among its early offerings was a very popular, and for the time very compact, high current test set designated the MS-1, which was widely used by heavy industrial companies for testing motor overload relays and small circuit breakers. Multi-Amp also introduced primary injection test sets with current ratings as high as 100,000 A. These units were used principally for testing large low voltage circuit breakers. Arguably an even more significant factor in the success of Multi-Amp was its A: Measuring earth currents, preferably with an instrument that gives true RMS readings, is a good way of pre-empting potential problems with earth resistance tests, as large standing earth currents can affect the accuracy of the results obtained. The current measurements also provide a very useful indication of the overall dynamics of the earth system. In addition, should it become necessary to disconnect an electrode, it’s a very good idea to measure the leakage current flowing. A high leakage current will become a dangerous live voltage when the cable is disconnected. Again, Megger’s DET14C and DET24C has been designed with this in mind. The instrument has a very high resistance to ‘noise’ current, and includes an automatic firmware filter to smooth out varying readings. Another additional user benefit is the automatic current warning which operates even when in resistance range – just in case the user forgets to measure it. The Multi-Amp® PULSAR® Universal Protective Relay Test System represented the next generation in protective relay testing. pioneering work in the field of protective relay testing. Until the middle of the 1960s, few utilities recognised the importance of such testing but then things changed literally overnight. On November 5, 1965 a huge power blackout left 30 million consumers in parts of the North-eastern United States and Canada without electricity. The initial cause of the problem was a protective relay that failed to trip. Suddenly protective relay testing moved to centre stage. At that time, Multi-Amp was under the guidance of Ed Redlhammer, who was an evangelist for better relay testing and maintenance. Most relay testing in those days was done using a variety of variable autotransformers, resistive loads, ammeters, voltmeters and other sundry equipment. As a result, it often took longer to set up the equipment than to carry out the test itself. Ed’s insight was to produce a dedicated relay test set that would eliminate the need to use many separate items of equipment, so that the test technician or engineer could spend more time testing, calibrating and servicing the relays, and a lot less time in setting up and taking down the test equipment. This approach meant that Multi-Amp was well placed to respond to the sudden increase in demand for protective relay testing after the blackout with its SR-51 protective relay test set. Taking advantage of successive advances in technology, this evolved in several stages into the SR-76, and subsequently, the SR-90, which was introduced in 1990 and finally discontinued only this year. Technology moves on, and even the best of instrument designs eventually reach the end of their life! After Ed Redlhammer retired as president of Multi-Amp in the late 1980s, his role was taken over by Ruben Esquivel, who had fled Cuba when the Castro regime came to power. He joined the company as an assembler wiring high-current test sets, and went to night school to earn his electrical engineering degree. He then continued his education to earn an MBA, and ultimately became one of the co-owners of Multi-Amp. He retained his share of the ownership until the company joined, among others, AVO and Biddle to become part of the present-day Megger organisation. This gave the members of the Multi-Amp team access to the resources they needed to drive their ambitious development programme forward, so that the company could continue to produce equipment that would meet the ever-increasing expectations of end users. Megger continues to uphold the proud traditions established by Multi-Amp, and to this day retains its position as a leading innovator and manufacturer of high current test equipment and versatile protective relay test sets. Megger makes beautiful music Megger is certainly well known for instruments, but it’s instruments of a rather different kind that come to the fore when MELON is in town! That’s because MELON is the Megger Electric Light Orchestra – OK, the N doesn’t actually stand for anything, but it does provide the group with a catchy name and a convenient logo! Based at the Megger site in Taby, Sweden, MELON is a group of Megger employees with a shared interest in music, and is in great demand to perform at sales conferences and other special events. Specialising mostly in popular rock music, though occasionally writing and performing its own songs, MELON has now been in the vanguard of the test gear music scene for over 20 years. “There is a lot of interest in music at the 8 Taby site,” said MELON lead vocalist Stefan Bornholm, “and, in fact, there are several professional musicians working there. It’s only natural that some of us should get together to form our own group to entertain our colleagues and customers. We toil on test equipment by day, but by night we make beautiful music together!” The present day line up is Matz Öhlen, Magnus Thieldgard, Stefan Bornholm, Peter Fagerström, Klas Petterson and Conny Edholm. Of these, Peter Fagerström and Conny Edholm are founder members who still retain their original enthusiasm for Megger music making. Megger may not yet be quite as well known for its musical output as it is for its test equipment but, given the enthusiasm of the members of MELON, it is perhaps, worth remembering that the world is still waiting for Sweden to produce a worthy successor to ABBA … Megger ELECTRICAL TESTER October 2010 www.megger.com