Construction of a High Voltage Test Facility

W. McDermid, J.G. Lambert

Manitoba Hydro
1870 Chevrier Blvd.
Winnipeg, MB R3T 1Y6 Canada

Abstract Manitoba Hydro has constructed a facility for 60 Hz Series Resonant Test Supply
dielectric testing of equipment rated up to 500 kVac and
500 kVdc. A test system for induced, no-load and full load tests The 60 Hz series resonant test supply is rated 800 kV. When
on large power transformers is being added. tuned for the maximum capacitance the current rating is 5 A.
Fig. 2 shows the 60 Hz series resonant test supply under test at
I. INTRODUCTION the manufacturers facility.
The high voltage test facility was constructed to enable
dielectric testing of instrument transformers, bushings and
aerial devices rated up to 500 kVac and 500 kVdc. The facility
also provides for the full electrical testing of power
transformers rated up to 500 kV 310 MVA 3-phase and 400
MVA 1-phase. The applications are new equipment following
transport and service aged equipment that is being evaluated
for re-use. The objective is to minimize forced outages
associated with in-service failures involving lost revenue and
consequential damage as well as to improve safety. Further
details on rationale for the construction will be found in [1].

II. MAJOR COMPONENTS OF THE FACILITY

Impulse Generator

The impulse generator is rated 2400 kV 360 kJ. It is suitable Figure 2. 800 kV series resonant supply under test
for 2200 kV lightning impulse and for +1300 kV and
-1500 kV switching impulse. Fig. 1 shows the impulse
generator under test at the manufacturers facility. Direct-voltage Test Supply

Fig. 3 shows the direct-voltage supply under test at the

manufacturers facility.

Figure 1. 2400 kV 360 kJ impulse generator under test

Figure 3. 1200 kV direct-voltage supply under test

978-1-4673-1935-5/12/$31.00 2012 IEEE

 The 1200 kV direct-voltage test supply is rated 20 mA and is
capable of a polarity reversal at full voltage within 2 minutes.
It meets the requirements for partial discharge measurements
on bushings and converter transformers at 1000 kV.
Test System for Power Transformers
Grade Beams
The construction of the perimeter grade beam of the Test
Hall continued during the winter of 2009/2010. Fig. 5 shows a
section of the perimeter grade beam and adjacent pilaster on
16 February 2010.

A voltage source converter fed from a 3 MVA 60 Hz supply

enables induced, no-load and full load tests on power
transformers up to 310 MVA 3-phase and 400 MVA 1-phase.
During the full load tests compensation is provided by a
capacitor bank that is rated up to 105 MVAr. The voltage
source converter, step-up transformer and capacitor bank are
located in an enclosure that is separate from the Test Hall and
connected by means of 145 kV XLPE cables.

III. CONSTRUCTION OF THE TEST HALL

The Test Hall has the dimensions of 41 m x 38 m with 21 m

from the floor to the bridge crane. There is rail access into the
hall to allow delivery of power transformers of up to 244
tonnes. Following assembly of the largest transformer the
floor must support 375 tonnes. A 10 tonne bridge crane is used
for assembly of radiators and bushings. The transformer \
remains on the rail car or road low bed trailer during test or it Figure 5. Perimeter grade beam and pilaster
is skidded to an immediately adjacent section of the floor.
Fig. 6 shows the reinforced concrete beams that support the
Installation of Piles railway track in the Test Hall as it appeared on 12 June 2010.

The floor of the Test Hall is supported by 165 piles .

including those associated with the perimeter grade beam.
Based on a geotechnical survey in 2007 it was predicted that 2010-06-12

piles having a length of 15 m would be required. Longer piles,

or pile extensions, were required in a number of cases. The
maximum was 29 m. The first precast pile was driven on
22 July 2009. Fig. 4 shows a view on 17 September 2009 by
which time most of the piles had been driven.

2009-09-17

Figure 6. Beams supporting railway track in Test Hall

Core Tower

The core tower contains the stairway to the roof of the Test
Hall as well as the elevator shaft to the elevation of the cat
walk immediately above the bridge crane in the Test Hall. Re-
usable forms were employed for the core tower which was
Figure 4. Completion of driving piles for Test Hall
poured in seven stages. Fig. 7 shows the pouring of the final
stage on 20 May 2010.
 Figure 9. Bonding of wire ropes in pile

Fig. 10 shows bonding of the re-bar laps in the lower course

of the structural floor by welding. The bonding of the
reinforcing steel in the upper course is more extensive.

Figure 7. Pouring final stage of core tower

Test Hall Columns & Roof Trusses

Erection of the columns and roof trusses for the Test Hall
began in October 2010 and was completed in March 2011.
Fig. 8 shows the structure as of 5 November 2010. Note the
12 m x 12 m doorway into the Test Hall for rail access.
Figure 10 Bonding of re-bar laps in lower course of reinforcing steel

2010-11-05
Following the completion of the structural floor the copper
ground mat was put in place. This consists of AWG #6 solid
copper wire spaced 100 mm as is shown in Fig. 11. All piles
are bonded to the ground mat as are 72 equally spaced
grounding points in the super flat topping slab one of which is
shown in Fig. 11. The super flat floor facilitates the use of air
cushions for moving equipment within the Test Hall.

Figure 8. Test Hall structure on 5 November 2010

Electrical Bonding

Each of the precast concrete piles associated with the Test

Hall contains six wire ropes. As shown in Fig. 9 each wire
rope is welded to a re-bar ring which is then bonded to the Figure 11. Copper mesh & grounding point in topping slab
lower course of reinforcing steel in the structural floor.
 The joints between the interior liner panels of the walls were
bonded by welding from the outside at intervals of 600 mm as
is shown in Fig. 12 prior to the application of thermal
insulation and cladding. The copper mesh in the floor is
welded to a steel angle above the perimeter grade beam at
intervals of 200 mm. The steel angle is welded to the liner
panels at intervals <600 mm.
Figure 12. Bonding of interior liner panels from outside every 600 mm
Heating of Test Hall
The structural floor slab contains hydronic water/glycol
heating tubes as can be seen in the view from the cat walk in
Fig. 13 look down over the control room. Also in view are
sub-floor conduits and grounding points. Supplemental
electric forced air make-up units are positioned above the
12 m door.
Figure 13. Hydronic heating tubes in structural floor
External Appearance Nearing Completion
An outdoor photograph take in August 2011 shows in
Fig. 14 the Test Hall nearing completion.
Figure 14. View of Test Hall from west
IV. CONCLUSIONS
The Test Hall will be in use early in 2012 for the dielectric
testing of instrument transformers, bushings and aerial devices
followed later in the year by full electrical testing of power
transformers.
REFERENCES
[1] W. McDermid, Rationale for a High Voltage Test Facility,
International Conference on High Voltage Engineering and
Application, October 2010, New Orleans, USA.