Professional Documents
Culture Documents
ABB
HV Components
Surge Arresters
Ludvika, Sweden
2009 Edition
ABB
TABLE OF CONTENTS
Page
1.
Introduction
2.
Definitions
3.
Overvoltages
11
4.
Historical Background
17
5.
22
6.
36
7.
49
8.
50
9.
Arrester Selection
81
10.
Installation Guidelines
98
11.
101
12.
Special Applications
106
13.
References
115
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1.
INTRODUCTION
All electrical systems and equipment are subjected to electrical stresses caused by higher than
normal voltages many times during their lifetime. Such overvoltages are caused by atmospheric
disturbances (lightning), switching phenomena as well as system disturbances, and these
cannot be avoided.
It is vital that the electrical equipment operates fault-free during such abnormal conditions.
However, for economic reasons, it is not possible to insulate the electrical equipment with a
sufficiently high withstand level to survive all these overvoltages, particularly those resulting
from lightning or switching surges. Consequently, these pose a very real danger for causing
failure of the electrical equipment. An economical and safe on-line network therefore requires
extensive protection against unacceptable overvoltage loads.
Overvoltage protection is not new, and has been used in one form or another for well over
100 years. Today, overvoltage protection can basically be achieved in two ways (sometimes in
combination):
Avoid or limit the overvoltages at the point of origin. For example, through the use of
overhead shield earth wires and lower tower footing resistance as countermeasures
against atmospheric overvoltages and pre-insertion resistors and/or controlled switching
against switching overvoltages.
Limit overvoltages near the electrical equipment with surge arresters
In isolation, shield earth wires and pre-insertion resistors offer a degree of protection. However,
by their nature, surge arresters provide the primary protection against different types of
overvoltages (atmospheric and switching). They are generally connected between each phase
and ground, in parallel with the equipment to be protected and function to divert the surge
current safely to earth; thereby limiting the overvoltage seen by the protected object.
Insulation co-ordination is the art and science of choosing the right insulation strength of
electrical equipment taking into account normal and abnormal service conditions as well as the
characteristics and location of suitable surge arresters.
Despite being a well-established technology, there remains a degree of mysticism about the
design, selection and application of surge arresters in electrical networks. This is not made
easier through the continual improvement and development of the active elements by leading
manufacturers as well as the designs and housing material, ultimately leading to new
applications for surge arresters.
This guide is intended to clear away some of this mystification, and guide the reader to a better
understanding of how to select and use modern day surge arresters. It is principally limited to
the common application of the protection of transformer insulation between phase and ground in
outdoor air-insulated substations. Other applications are briefly discussed, but are, for the most
part, considered beyond the scope of this Guide. Instead, the reader is referred on to additional
technical literature which covers the topic in more detail. In addition, International Standard
IEC 60099-5 Surge arresters - Selection and application recommendations is recommended
reading.
Finally, the reader is referred to the ABB surge arresters Arresters Online web page
(www.abb.com/arrestersonline) for continually updated information on surge arresters.
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2.
DEFINITIONS
To permit the reader to understand the basis for the selection and application of surge arresters,
it is important to make a brief review of some of the common terminology used throughout this
Guide.
The surge arrester standards referred to herein are the prevailing editions of:
Backflashover
Occurs when lightning strikes the transmission line tower structure or overhead shield wire. The
lightning discharge current, flowing through the tower and tower footing impedance, produces
potential differences across the line insulation. If the line insulation strength is exceeded,
flashover occurs, i.e. a backflashover. Backflashover is most prevalent when tower footing
impedance is high.
Continuous current (Ic)
The current that flows through the arrester at continuous operating voltage (Uc or MCOV).
This current is predominantly capacitive (in the range of mA) and is generally expressed as a
peak value.
Continuous operating voltage
It is the maximum permissible r.m.s. power frequency voltage that may be applied continuously
between the arrester terminals. This voltage is defined in different ways (verified by different test
procedures)in IEC and IEEE.
IEC (Uc)
IEC gives the manufacturer the freedom to decide Uc. The value is
verified in the operating duty test. Any uneven voltage distribution in the
arrester shall be accounted for.
IEEE (MCOV)
IEEE lists the maximum continuous operating voltage (MCOV) for
arrester ratings used in a table. The value is used in all tests specified by IEEE.
Note! MCOV is less stringent as regards uneven voltage distribution in an arrester.
all
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Earthing
Solidly earthed system
A system whose neutral points are earthed directly.
Impedance earthed system
A system whose neutral points are earthed through impedances to limit earth
fault currents.
Resonant earthed system
A system in which one or more neutral points are connected to earth through
reactances which approximately compensate the capacitive component of a singlephase-to-earth fault current
Isolated neutral system
A system where the neutral point is not intentionally connected to earth, except for high
impedance connections for protection or measurement purposes.
Earth-fault factor (ke)
The ratio of the voltages in the healthy phases during and prior to earth-fault conditions.
Energy capability
The energy that a surge arrester can absorb in one or more impulses, without damage and
without loss of thermal stability. The capability is different for different types and duration of
impulses.
Standards do not explicitly define the energy capability of an arrester. The only measure
specified is the Line Discharge Class in IEC. Often, this is not enough information to compare
different manufacturers. Therefore ABB presents energy capability also in kJ/kV (Ur). This is
done in 3 different ways:
Two impulses as per IEC switching surge operating duty test
This is the energy that the arrester is subjected to in the switching surge
operating duty test while remaining thermally stable thereafter against the specified TOV
and Uc.
Routine test energy
This is the total energy that each individual block is subjected to in production tests.
Single-impulse energy
This is the maximum permissible energy, which an arrester may be
subjected to in one single impulse of 4 ms duration or longer and remain
thermally stable against specified TOV and Uc.
Follow current
The current from the connected power source which flows through an arrester with series gaps
following the passage of discharge current.
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Hydrophobicity Classification
The superior electrical performance of composite
insulators and coated insulators stems from the
hydrophobicity (water-repellency) of their surfaces. The
hydrophobicity will change with time due to exposure to
the outdoor environment and partial discharges
(corona).
Seven wettability (hydrophobicity) classes (WC) have
been defined with a value between 1 and 7
(IEC TS 62073). WC 1 corresponds to a completely
hydrophobic (water-repellent) surface and WC 7 to a
completely hydrophilic (totally wetted filmed) surface.
These classes provide a coarse value of the wetting
status and are particularly suitable for a fast and easy
check of insulators in the field.
Fig. 1
Wettability class
(source IEC TS 62073)
Waveshape (T1/T2)
T1 = 1 s
T2 < 20 s
T2 = 20 s
T1 = 8 s
30s < T1 < 100 s
T2 ~ 2T1
(usually designated 30/60 s)
T2 = 10 s
T1 = 4 s
(LIWL)
(SIWL)
(PFW)
Voltage waveshape
1.2/50 s
250/2500 s
50 Hz or 60 Hz sinusoidal
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Maintainability prediction
Mean-time-between-failure (MTBF) is the average time between failures, typically measured in
hours. MTBF is a statistical value and is meant to be the mean over a long period of time and
large number of units. In practice, MTBF is only relevant with reference to repairable items,
since calculations of MTBF assume that a system is "renewed", i.e. fixed, after each failure and
then returned to service immediately after failure. Mean-time-to-failure (MTTF) is the average
time expected to the first failure of a piece of equipment and should be used instead of MTBF in
cases where a non-repairable item is replaced after a failure. However, MTBF is commonly
used for both repairable and non-repairable items. Mean Time to Repair (MTTR) is the total
amount of time spent performing all corrective maintenance repairs divided by the total number
of those repairs.
A common misconception about MTBF is that it specifies the time (on average) when the
likelihood of failure equals the likelihood of not having a failure. This is only true for certain
symmetric distributions. For typical distributions with some variance and uncertainty, MTBF only
represents a statistical value and hence is not suitable for predicting detailed time of failure.
Maximum system voltage (Um)
The maximum voltage between phases during normal service expressed in kV r.m.s.
Mean breaking load, MBL
The average breaking load for porcelain-housed arresters.
Nominal discharge current (In according to IEC)
The peak value of the lightning current impulse which is used to classify the arrester.
Normal service conditions
The service conditions which the surge arresters should normally be suitable to operate under
without any special consideration in design, manufacture or application.
Ambient temperature
Solar radiation
Altitude above sea level
Power system frequency
Wind velocity
Erection
-40 C to +40 C
< 1.1 kW/m2
< 1000 m (< 1800 m according to IEEE)
48 62 Hz
< 34 m/s
vertical
This should be seen as the minimum requirement for compliance with the Standards, and
individual designs may operate in wider extremes, even without the need for special
consideration.
Overvoltage
A voltage level exceeding the maximum allowable continuous operating voltage for an electrical
system.
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Protective characteristic
The combination of the arresters residual voltages for different current impulses. For good
protection, the arrester characteristic should lie well below the equipment insulation withstand
characteristic at all points.
Lightning impulse withstand level (LIWL or BIL) is the equipments insulation
withstand level against lightning impulses
Switching impulse withstand level (SIWL or BSL) is the equipments insulation
withstand level against switching impulses
Lightning impulse protection level (LIPL
residual voltage for the nominal discharge current
or
Upl)
of
the
arrester
is
the
Switching impulse protection level (SIPL or Ups) of the arrester is the residual voltage
for a specified switching impulse current
Note! IEEE standards refer to LIWL as BIL and SIWL as BSL
Parameters
of the
system
Voltage
Parameters
of the
surge
arrester
BIL / BSL
LIWL / SIWL
Protective margin
Protection level
LIPL / SIPL
Upl / Ups
TOV
TOV capability
COV
Fig. 2
Protective margin
The protective ratio minus 1 and expressed as a percentage. As an absolute minimum, the
margin should cover the voltage increase due to the connections between the arrester and the
protected equipment as well as the increase in the residual voltage due to the discharge
amplitude and front-time being different from the nominal discharge current of the arrester.
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Protective ratio
The ratio of the equipment insulation withstand level to the corresponding protection level of its
arrester.
Rated voltage (Ur)
For other apparatus, the voltage that may be applied continuously is usually called its rated
voltage. However, this is not the case for surge arresters. An arrester fulfilling the IEC standard
must withstand its rated voltage (Ur) for 10 s after being preheated to 60 C and subjected to
two long duration current impulses, corresponding to its line discharge class as defined in the
standard. Thus, Ur shall equal at least the 10 second TOV capability of an arrester. Additionally,
rated voltage is used as a reference parameter.
Reference current (Iref)
The peak value of the power frequency resistive current at which the reference voltage is
measured.
Reference voltage (Uref)
The peak value divided by 2 of the voltage measured across the arrester at reference current.
Residual voltage/ Discharge voltage
This is the peak value of the voltage that appears between the terminals of an arrester during
the passage of discharge current through it. Residual voltage depends on both the magnitude
and the waveform of the discharge current.
Shielding
Protection of phase conductors from direct lightning strokes; generally by means of additional
conductor(s) running on the top of the towers and grounded through the tower structures to
earth. Stations can also be shielded by earth wires or lightning masts.
Shielding failure
Occurs when lightning strikes a phase conductor of a line protected by overhead shield wires.
Short circuit (pressure relief) capability
The ability of the arrester, in the event of its overloading due to any reason, to conduct the
resulting system short-circuit current through it without a violent explosion which may damage
nearby equipment or injure personnel. After this operation, the arrester must be replaced.
Specified long-term load, SLL
A bending moment allowed to be continuously applied during service without causing any
mechanical damage to the arrester. Often referred to simply as continuous load.
Specified short-term load, SSL
The maximum bending moment allowed to be applied during service without causing any
mechanical damage to the arrester. Often referred to simply as short-term load.
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Surge Impedance
Studies of transient disturbances can be a complicated process involving many calculations and
iterations through travelling wave analysis. A transmission line can be modelled as a distributed
parameter network consisting of series inductance and resistance and shunt capacitance and
resistance. Partial differential equations are then written and solved for the voltage and current.
Computer programs specifically designed for solving these equations are available.
A simplified method is to approximate the transient phenomenon by considering that a lightning
strike to a conductor or the closing of a breaker will produce a travelling wave of voltage e and
current i that are related by a surge impedance Z equal to e/i that travels along the conductor at
the speed of light c. The surge impedance Z is purely resistive and therefore e and i have the
same shape. Only system components such as a transmission lines and towers, cables or a
GIS bus present a surge impedance. The surge impedance and velocity v of propagation can
be obtained from their inductance and capacitance, i.e. Z = (L / C) and v = 1 / (LC).
From which the equations can be derived: L = Z / v and C = 1 / (Zv)
where L is the inductance and C is the capacitance per unit length.
For an overhead line, v = 300 m/s and the surge impedance of a single conductor varies in a
narrow band between about 400 and 500 ohms. The surge impedance of an oil-paper cable
varies from about 30 to 60 ohms and the velocity of propagation is taken to be around 150 m/s.
In many cases, an equivalent surge impedance or a combined surge impedance of two or more
conductors is desired, leading to the need for more complicated calculations. Furthermore, the
simplified analysis does not take into consideration line geometry, coupling factor (whereby a
travelling wave voltage and current are impressed on only one conductor, leading to a voltage
being induced or coupled to the other conductor) points of discontinuity nor corona effects. More
detailed guidance is given in Cigr 63 and IEC 60071-2.
Temporary overvoltages (TOV)
Temporary overvoltages, as differentiated from surge overvoltages, are oscillatory power
frequency overvoltages of relatively long duration (from a few cycles to hours or longer). The
most common form of TOV occurs on the healthy phases of a system during an earth-fault
involving one or more phases. Other sources of TOV are load-rejection, energization of
unloaded lines, etc.
Temporary overvoltage withstand strength factor (Tr or Tc)
This is the TOV capability of the arrester expressed in multiples of Ur or Uc respectively.
Tower footing impedance
The impedance seen by a lightning surge flowing from the tower base to true ground (earth).
The risk for backflashover increases with increasing footing impedance.
Travelling wave
Occurs when lightning strikes a transmission line span and a high current surge is injected onto
the struck conductor. The impulse voltage and current waves divide and propagate in both
directions from the stroke terminal at a velocity of approximately 300 m/s with magnitudes
determined by the stroke current and line surge impedance.
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3.
OVERVOLTAGES
3.1
External Overvoltages
Atmospheric overvoltages are normally divided into two different groups: those arriving from
direct lightning strokes to the lines or equipment and those induced from nearby strokes to
ground or between clouds.
3.1.1 Direct lightning strokes
A direct lightning stoke to a transmission line will result in two identical travelling
waves propagating in either direction along the line. Arrester currents of extreme amplitude and
steepness can occur in arresters located on an unshielded transmission line. For lower system
voltages, the current in these cases will be approximately a third of the stroke current since
flashover to all three phases is likely to occur.
When lightning strikes a transmission line, the line itself is usually not damaged but the
overvoltage generated may result in flashovers of the line insulators and can also cause
insulation breakdowns in apparatus in sub-stations connected to the line. A lightning impulse
has a very short front time, microseconds (s), and the voltage on the transmission line can
rapidly increase to several thousands of kilovolts when lightning strikes the line. If the earthing
impedances of the towers are not sufficiently low, a lightning stroke to the tower or to the
overhead shield wires (if any) might cause a so called backflashover across the insulator
strings to the phase conductors. Travelling waves are generated at the location where the
lightning hits the line and these waves propagate along the line. The insulation is stressed
further if the travelling waves reach an open end of the line where they are reflected; causing a
doubling of the voltage.
It has been acknowledged that many lightning strikes are not a single stroke, but instead consist
of a series of consecutive strokes of varying magnitude and intervals. The incidence of multistroke flashes naturally varies considerably by region and season. In some cases, about
70 - 80 percent of lightning strikes may consist of multiple strokes; 3 - 4 pulses on average, with
an interval between each pulse of less than 50 milliseconds. Distribution lines are generally
unshielded, and hence bear the full force of direct strikes. Consequently, multipulse
performance is a decisive measure of survival ability and reliability of distribution arresters near
direct strikes.
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Temporary overvoltages (TOVs) can be defined as overvoltages which are sustained for a
number of cycles. The frequency can either be the network fundamental or a higher frequency
determined by system resonances superimposed on the power frequency.
Temporary overvoltages typically arise from events such as:
Earth faults
Sudden change of load
Resonance phenomena
These overvoltages can normally be kept to acceptable levels with the help of a high shortcircuit power in the supply network, line compensation with shunt reactors, suitable generator
control, automatic fault clearing, etc. Hence, this type of overvoltage is normally not of concern
for the system equipment itself (although at system voltages of 550 kV and above it may
become significant).
1 p.u =
p.u
6
Um x 2
Lightning over-voltages
5
Switching over-voltages
Fig. 3
Classification of
overvoltages showing
duration and amplitudes of
stress on insulation in
HV networks
Temporary over-voltages
System voltage
2
1
t
10-6
10 -4
10-2
10 0
102
104
3.3
Protection measures
Atmospheric overvoltages are particularly dangerous for low voltage, distribution and even subtransmission systems. Transmission lines for 300 kV and above are usually equipped with
overhead shield wires as a protection against direct lightning strokes. These overhead shield
wires are installed along the entire transmission line and are earthed at each tower and
connected to the common earthing system in the substations at the ends of the line. Lines for
lower systems voltages usually lack overhead shield wires along the entire line length. Instead,
they are only used in close vicinity (1 2 km) out from the substations in order to prevent direct
strokes to the phase conductors close to the stations. The amplitudes of incoming lightning
surges to the stations will thus be limited.
In some cases, earthed crossarms or spark gaps have been used close to substations in an
attempt to limit the amplitude of incoming lightning overvoltages. However, such measures tend
to increase the likelihood of flashovers near the station with the consequent generation of fastfront surges. Special attention should be given to tower earthing near the station to lower the
probability of back flashovers at this location.
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Fig. 4
Station protected by
surge arresters
Surge arresters are not normally required to protect against temporary overvoltages (although
special cases exist), but they must survive them. TOVs can thus be decisive in selection of the
rated voltage for the arresters.
3.3.1 Cable connected to a lighting endangered line
If a travelling wave coming from an overhead line enters a cable that is connected to a
transformer, reflections will take place at the point where the surge impedance changes.
Typically, about 80% of the wave in question will be reflected at the point of changed impedance,
which means that the voltage passed into the cable will be about 20% due to the lower surgeimpedance of the cable.
U
Ucable = 20% of U
Ureflect = 80% of U
Fig. 5
For the purpose of analysis of cables connected to a transformer, the surge impedance of the
transformer is considered as infinite, so that total reflection occurs at the transformer terminals.
To further simplify the matter, the incoming wave is assumed to be rectangular. The result is a
step-wise increase in the voltage, up to potentially double the initial incident voltage, U. In
contrast, for a cable connected between two overhead lines, the voltage reflected in both ends
of the cable will increase to the value of the incoming voltage U.
In practice, the wave front is not rectangular, but has a rate of rise. This rate of rise will change
the way the cable is charged, but not the value. Generally a cable can be considered as a
concentrated capacitance, which will be able to bring down the steepness of the incoming wave,
but if the wave energy is sufficiently high, the cable does not limit the voltage rise.
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The flashover to earth of a busbar or line conductor will cause a brief power outage, but
subsequent serious damage is rare. In contrast, flashovers (puncture) in cables or at cable
terminations can cause severe damage to insulation and require extensive and expensive repairs.
The resultant outage times can be very long and costly. Cables should therefore be treated as
station equipment and be protected against lightning by well-specified surge arresters.
Fig. 6
For transformers which are manufactured with internally connected cable boxes, the cable is
connected directly to the transformer terminal, without any possibility of connecting arresters at
this point. Therefore arresters can only be installed at the far end of the cable. A certain higher
degree of associated risk for insulation failure may therefore have to be accepted.
In order to achieve the greatest possible protection zone and ensure a sufficient protective
margin between the cable/transformer LIWL and the voltage that may occur, special attention
should be paid to the following for cables operating at 72.5kV and above:
The incoming overhead line connected to the cable should have a zone of about 2km
out from the substation equipped with shield wires for cables lengths of up to 1000m.
For longer cables, the length of line with shield wires should be equivalent to at
least double the length of the cable. The shield wires and tower configuration must
effectively shield the line against direct strikes to the phase conductors as well as back
flashovers.
Inside this zone out from the substation, the footing resistance of the towers must be
kept sufficiently low, i.e. a few ohms.
The incoming lines should be fitted with surge arresters, to further limit the overvoltages
actually transferred into the substation.
The location of the arresters for cable protection must be as close as possible to the
cable terminal in order to achieve the maximum degree of protection.
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3.3.2
Protection of Line-side station equipment
High voltage equipment in line bays of a substation are dielectrically designed and tested in
accordance with applicable Standards. Sometimes, however, breakdown of insulation on
equipment may still occur due to lightning overvoltages with higher amplitude and rate of rise
than prescribed by the Standards.
Specifically, flashovers are known to occur in cases when the line circuit breaker is open. This
risk is most likely to arise during normal operation as a result of subsequent strokes of the
lightning flash during the open-close cycle; presuming that prolonged opened breaker condition
normally dictates that the breaker disconnecting switches are also opened and grounded. Due
to the open breaker the incoming voltage surge will be doubled. As a result, there may be a
flashover across the open breaker or an insulation breakdown of other line-side equipment;
notably instrument transformers.
A backflashover on the transmission line towers adjacent to the substation can also lead to a
steep voltage wave propagating on the phase conductor towards the substation. The risk of
insulation failures in the substation is proportional to the rate of back flashovers on the lines.
Other important parameters are the steepness and the amplitude of the voltage wave entering
the substation. When selecting the MTBF for the substation insulation, it is important to
consider the consequences of a fault in terms of outage and repair times and costs.
Regardless of the cause, some form of protection should be used to prevent surges impinging
on the line-side equipment. Arresters should always be located adjacent to the power
transformers in the substation. With the line breaker closed, these arresters are often (subject
to their effective protective distance) all that is needed to protect apparatus connected to the
same line within the substation; presuming a low backflashover rate. However, with the breaker
opened, no protection exists for the line side of the breaker, making it and other equipment
vulnerable. Occurrence of overvoltages that may lead to flashovers is related to the key design
and protection of the incoming overhead line.
A Cigr survey made in 1990 showed that almost 60% of all reported violent failures of
instrument transformers were due to lightning. The survey concluded that the number of failures
due either to an inadequate lightning protection or to an inadequate transient withstand voltage
is significant and that this field has to be investigated to reduce the number of failures of
Instrument transformers
A similar Cigr survey conducted in 1997 regarding circuit breakers concluded:
Line insulation and spark gaps cannot be dimensioned to protect the breaker
Appropriate shielding and sufficiently low tower resistance gives low risk of flashovers
For existing lines, surge arresters placed at the incoming line end gives efficient
protection
There are a number of advantages with additional arresters located on the line side of the
station; i.e. in front of line breaker
Reduces the overvoltage seen at the station transformer
Reduces overvoltages seen at the closed breaker; especially with long distance to the
station arresters
Protects the open breaker by limiting the effects of multiple lightning strokes
Protects all equipment at the line entrance e.g. instrument transformers
Removes the risk for backflashover; especially when fitted on transmission line towers
with high footing resistance
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4.
HISTORICAL BACKGROUND
Surge arresters constitute the primary protection for all equipment in a network against
overvoltages which may occur as the result of lightning or switching operations in the network.
The earliest overvoltage protection devices were introduced during the last decade of the
19th Century and consisted of a simple air gap for which the sparkover voltage changed with
weather conditions, i.e. temperature, air pressure and humidity. One major disadvantage with this
device was that its operation led to a power arc and consequent interruption of power supply on
systems having earthed neutral points.
The next significant step in the development was the so called conventional arrester, or gapped
arrester, developed during the 1930s. The arrester comprised of voltage dependent silicon
carbide (SiC) resistor blocks in series with spark gaps, mounted together in a porcelain housing.
The gapped arrester was improved through several generations
during the subsequent decades. The voltage across the series
connected spark gaps was controlled with grading components
comprising non-linear resistors and capacitors and the protection
characteristics were improved by introduction of current limiting
(active) gaps around 1960. Better protection was achieved through
the active gaps permitting the use of SiC resistors with a lower
residual voltage.
The conventional spark-gap assembly consisted of stacked brass
electrodes with steatite spacers and grading resistors (if present)
between them. Between each electrode was a device for preionization of the ignition point. This ensured that the ignition was
distinct and as free as possible from variations resulting from
different surge steepnesses.
Active gaps were formed between electrodes riveted to discs of arcresistant material, with several assembled to form a stack. The
stack also comprised a blow-out coil with a parallel-connected
voltage-dependent resistor.
Active gap arresters had better
extinguishing capacity, a lower discharge level and a greater
discharging capacity for switching surges than conventional gapped
arresters.
Fig. 7
Conventional
spark-gap
assembly
The most advanced gapped SiC arresters in the middle of the 1970s gave good protection
against overvoltages, but the technique had reached its limits. It was difficult, for example, to
design arresters with several parallel columns to cope with the very high energy requirements
needed for HVDC transmissions. The statistical scatter of the sparkover voltage was also a
limiting factor with respect to the accuracy of the protection levels.
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The metal-oxide (also called MO, zinc-oxide or ZnO) surge arrester was introduced in the mid to
late 1970s and proved to be a solution to the problems which could not be solved with the old
technology. The protection level of a surge arrester was no longer a statistical parameter, but
could be accurately given. The protective function was no longer dependant on the installation or
vicinity to other apparatus - as compared to SiC arresters, whose sparkover voltage could be
affected by surrounding electrical fields. The ZnO arrester could be designed to meet virtually any
energy requirements by connecting ZnO varistors in parallel (even though the technique to ensure
a sufficiently good current sharing, and thus energy sharing, between the columns is
sophisticated). The possibility to design protective equipment which could handle extremely high
energy stresses also opened up new application areas; protection of series capacitors, for
example.
Some of the first arresters with ZnO blocks utilised spark gaps in series with the ZnO blocks or in
parallel with sections of the block column (shunt gaps). These designs reflected, to some extent,
a concern for the long-term stability of the ZnO material. Using spark gaps in series or parallel
consequently decreased the voltage stress on the blocks. These designs are not found on the
market any longer for HV applications. With experience, the elimination of gaps permitted the
building of very compact, reliable, low profile arresters compared to what was possible with the old
technology.
Ures
Ur
E (kJ/kV)
3.0
15
2.0
10
1.0
ZnO
Active spark-gaps
Passive spark-gaps
1930
40
50
60
70
80
90
2000
Vintage
Polymer housings
Many of the early polymeric designs utilized EPDM rubber as an insulator material, but during the
1990s more and more manufacturers changed to silicone, which is less affected by
environmental conditions, including UV radiation and pollution.
4.1
Operation of gapped and gapless surge arresters
A non-linear resistor type gapped arrester, commonly known as a silicon carbide (SiC) arrester,
comprises SiC valve resistor blocks in series with either passive or active (current limiting) spark
gaps. The purpose of the gaps is to protect the valve elements, give an exact sparkover voltage,
carry the arc during the discharge without being damaged and to deionize the arc sufficiently at
the short time at zero passage to avoid a reignition of the gap. The active gap has the additional
function to create an arc voltage drop resulting in a counter voltage, and thus a current limitation,
during the follow current and extinction interval. In series with the active gaps, a coil is connected
electrically in parallel with a non-linear resistor valve block. See Figure 9.
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The operating principle for SiC arresters with passive (non current limiting) gaps and active
(current limiting) gaps differs. For the passive gaps, the overvoltage wave creates an increasing
voltage across the gaps until sparkover occurs and, during a short period of time, an impulse
current rushes through the arrester. Thereafter, the normal power frequency voltage will force a
follow current through the arrester of several hundreds of amperes. Due to the non-linearity of the
resistor blocks, the current is reduced much faster than the voltage, and when the voltage
approaches zero, the current is choked and the arc extinguishes.
Practically the entire voltage is across the blocks, with only some small percentage being across
the gaps as an arc voltage drop. When the current has been reduced to below about 1 ampere,
occurring some electrical degrees before zero, the arc voltage drop is suddenly increased since
the low current cannot support any plasma. The arc is transformed to a corona discharge and is
extinguished some hundred microseconds before the zero crossing.
The function of an arrester with active gaps is somewhat different. A lightning overvoltage, which
has a high steepness, causes a sparkover of the gaps and the impulse current passes through
the non-linear resistor blocks in parallel with the coils, since the impedance of the coil for the steep
wave is much higher than that for the non-linear resistor. The follow current is, however, much
lower, both in steepness and magnitude, and the current is forced into the coil and a magnetic
field is built up.
A.
B.
C.
D.
E.
Fig. 9
Stack of spark-gaps
Coil
Shunt resistor
Valve resistor
Grading resistor
The magnetic field results in an electromagnetic force acting on the arc, which is forced from the
initial ignition point out into a narrow chamber where the arc is lengthened 50 - 100 times. The arc
is cooled against the walls and starts to take up voltage. The resulting voltage reduces the follow
current and, as soon as the momentary value of the power frequency voltage falls below the arc
voltage, the follow current ceases. This is in contrast to a passive gap, which must wait until the
voltage is almost zero before it can interrupt the current.
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Voltage distribution for steeper waves is determined by the capacitance of the arrester. The
function of the grading resistors in gapped arresters is to distribute the voltage evenly across the
gaps in the event of relatively slow voltage variations. The sparkover voltage at power frequency
and for switching surges is then determined by these grading resistors. There are two kinds of
grading resistors, those with linear resistance and those with non-linear resistance. Generally,
the sparkover voltages for this frequency range needs to be fairly high to prevent false
operations for normal service voltage variations.
Service under polluted conditions has always been a problem for gapped arresters. The
formation of so called dry bands on the porcelain surface under such conditions leads to a
disturbed voltage gradient, which affects the internal gaps by means of coupling capacitance
between gaps and porcelains. As a result, some arresters may then even sparkover at service
voltage during periods of heavy pollution. Repeated sparkover may result in overheating when
the gaps fail to reseal, leading to complete failure of the arrester. Improved reliability under
conditions of high contamination requires a strong grading, which can be achieved with highly
non-linear grading resistors.
Should a SiC resistor be placed on high service voltage without series gaps, it would draw a
continuous current of some hundreds of amperes and thus quickly destroy itself. A gapless SiC
arrester is therefore not a possibility.
Zinc-oxide (ZnO) varistors, in contrast, represent a high impedance at normal service voltage and
draw only a small leakage current (predominantly capacitive), with the resistive component of the
current in the order of only 50 to 250Apeak (depending on the varistor diameter). Such a low
leakage is neither dangerous to the varistor nor uneconomic for the system. Therefore ZnO
varistors can be placed directly on voltage, and it is possible to remove the series gaps entirely
from the arrester.
ZnO varistors have an extremely non-linear, but well defined, volt-amp operating characteristic.
The working principle of a gapless ZnO arrester is therefore very simple: When an impulse
occurs, the arresters impedance reduces via its operating characteristic and subsequently
changes over from conducting a small, predominantly capacitive current to a large resistive
current. Due to the passage of the impulse current, a voltage is consequently built up across the
arrester (residual voltage), the magnitude of which is determined by the volt-amp operating
characteristic of the arrester for the applied impulse current and waveshape. Once the impulse
has been dissipated, the arrester thereafter immediately returns back along its operating
characteristic to its non-conducting state.
Even though a lightning overvoltage causes an impulse current through a gapless ZnO arrester
as for the gapped arrester, the normal power frequency voltage after the discharge is not high
enough to force a follow current through the arrester. Hence, a ZnO arrester is only subjected to
the energy from the lightning, in contrast to the SiC arrester, where a large energy contribution is
obtained from the follow current. See Figure 10.
Protection levels for gapless ZnO arresters depend only on the residual voltages determined by
the operating characteristic for the respective waveshapes and currents and thus are better
defined and more stable compared with gapped types. In general, the protection levels are lower
(i.e. better) than for gapped SiC arresters of equal rated voltage. This improvement is particularly
marked when steep-fronted impulses and switching surges are considered.
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arrester
with
passive
gaps
The following Table 1 gives a summary of the major differences between gapless ZnO and
gapped SiC arresters.
Metal-oxide type (gapless)
No sparkover, current flows as per U-I
characteristic
Small scatter band for residual voltages,
typically 3%
Excellent steep-front wave characteristics
(only approx. 10%)
Temporary power frequency load above
Uc possible
Energy absorption capability can be
increased (arresters in parallel)
Simple active part with few components
Practically no ageing effect
Gapped type
Sparkover, afterwards power frequency follow
current
Usual scatter band for spark-gaps (up to 15%
scatter; even higher for poorly graded arresters)
Strong rise (>25%) in sparkover voltage due to
steep-front overvoltages
Continuous voltage at power frequency, always
lower than rated voltage
Restricted energy absorption capacity, parallel
connection has no effect
Complex structure for active part
Ageing of spark-gaps due to arc erosion
Table 1 Summary of the major differences between gapless ZnO and gapped SiC arresters
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5.
A zinc-oxide (ZnO) surge arrester for high voltage applications comprises the following main
components:
ZnO varistors (blocks)
Internal parts
Housing of porcelain or polymeric material with end fittings of metal (e.g. flanges)
A grading ring arrangement where necessary
The internal parts can differ considerably between a porcelain housed arrester and a polymerhoused arrester. The only certain commonality between these two designs is that both include a
stack of series connected zinc oxide varistors, together with components to keep the stack
together.
Fig. 11
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5.1
ZnO varistor
The most important component in the arrester is the zinc-oxide (ZnO) varistor itself, which gives
the arrester its protective characteristics. All other components are simply used to protect or keep
the ZnO varistors in place.
The ZnO varistor is a densely sintered block, pressed to a cylindrical body. The block consists of
approximately 90% zinc oxide and 10% of other rare earth oxides (additives). During the
manufacturing process a powder is prepared, which is then pressed to a cylindrical body under
high pressure. The pressed bodies are sintered in a kiln for several hours at a temperature in the
order of 1200 C. During the sintering, the oxide powder transforms to a dense ceramic body with
varistor properties, whereby the additives form an intergranular layer surrounding the zinc oxide
grains.
ZnO Grains
1015 m
Fig. 12
These layers, or barriers, give the varistor its non-linear characteristics. Metal is applied on the
end surfaces of the finished varistor to improve the current carrying capability and to secure a
good contact between series-connected varistors. An insulating layer is also applied to the
cylindrical surface to give protection against external flashover and chemical influence.
Before the blocks are assembled in an arrester, they must be subjected to a variety of tests to
verify their protection performance, energy and current capability as well as long term electrical
stability.
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In the breakdown region (Region 2), when the voltage stress has increased due, for example,
to temporary overvoltages or switching overvoltages, the intergranular layers switch from
insulating barriers to conducting layers and the current carrying capability of the varistor
increases many-fold. For example, if the voltage stress increases from 200V/mm to 300V/mm,
the current increases 10 000 times. This acts as a voltage limitation, and gives the arrester its
protective characteristics.
At even larger current densities, the arrester is working in the high current region (Region 3)
and the curve turns upwards, which determines the impulse behaviour of the surge arrester.
The barriers between the ZnO grains are electrically broken down and the current increase is
solely limited by the resistivity of the ZnO grains.
When the voltage across the arrester is reduced to a normal level, the working point returns again
to Region 1, without delay.
Voltage (p.u.)
Min protection levels in kV (peak)
according IEC60099-4
Region 1
Region 3
Region 2
1.0 x 2
0.8 x 2
Ires
Effect of increased
block temperature
on Ires
Icap
Icap, capacitive
current (no influence
from temperature)
10-5
10-3
102
103
104
Log scale
Current (Ampere)
Fig. 13
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5.2
Housing of a surge arrester
The main purpose of the insulator housing is to :
Keep the internal parts together
Protect against external flashovers
Secure that the function of the arrester is independent of external influences
An arrester must also be equipped with fastening devices to ease the erection. This is achieved
by assembling flanges (or similar) at one or both ends of the insulator. If the arrester consists of
several series connected units, the flanges are also used to mechanically and electrically secure
arrester units to each other.
Insulators can be manufactured with different mechanical fracture values. The required fracture
value for a specific insulator is determined by the design and intended use of the arrester.
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Fig. 14
Insulators made from silicone
retain their hydrophobic
properties over their
in-service lifetime
Polymeric materials can potentially be more affected by ageing due to partial discharges and
leakage currents on the surface, UV radiation, chemicals, etc, compared to porcelain, which is a
non-organic material. For this reason, the raw material is often blended with a variety of additives
and fillers to achieve the desired material features: UV stability, anti-tracking, flame-retardancy,
etc. Silicone, as a material, has a natural resistance against these effects, and thus such
additives simply aid in further improving the materials inherent properties.
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If steps are not taken, there is a likelihood that arresters which contain an enclosed gas volume
might explode due to the internal pressure increase caused by the heat generated from the
short circuit arc. This leads to the need for these arresters to be fitted with some type of
pressure relief system which will open quickly to release the enclosed gas volume to the
outside. Such arresters are normally supplied with devices at the top and bottom of each unit,
which operate as soon as the internal pressure reaches a certain value. The ionized gas will
subsequently be evacuated to the outside of the arrester, and when the two gas streams meet
the internal arc will commute to the outside, thus preventing a continual internal pressure
increase.
Fig. 15
Operating principle of the pressure
relief device of an ABB type EXLIM
porcelain housed arrester.
(1) Arrester in its healthy state
(2) Arrester has failed short-circuit,
pressure relief plates open and gas
begins to be expelled through the
venting ducts
(3) The two gas streams meet and the
internal arc is commuted safely to
the outside
(1)
(2)
(3)
The sealing cover in ABBs high voltage EXLIM porcelain-housed arresters also acts as an
overpressure relief device. Other manufacturers may have other solutions; a blast plate for
example.
During normal service, the sealing
cover tightens against the porcelain.
At an internal short-circuit of the
arrester, an open arc occurs across
the block column. Due to the heat
from the arc, the internal pressure
increases and would soon reach a
value that could cause an explosion of
the insulator if no pressure relief
device was present. The sealing
cover is designed such that it will
open, both at the top and bottom, as
soon as the internal pressure reaches
a certain value (significantly below the
bursting pressure of the porcelain)
and the enclosed gas volume can be
evacuated to the outside of the
arrester. The internal pressure is thus
relieved, and a violent shattering of
the porcelain is avoided.
Pressure relief
and Sealing plate
Flange cover
Venting duct
O-ring
Indicating cover
Flange
Cementing
Fig. 16
The position of the overpressure relief device on an ABB
type EXLIM T porcelain housed arrester. The figure shows the key
parts of an arrester with the pressure relief and sealing plate,
block column, spring device and the cemented metallic flange.
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Safer short-circuit performance is not, however, automatically achieved simply by replacing the
porcelain housing with one made of polymer. In the past, there has been the incorrect belief that
all polymer-housed arresters, irrespective of design, were capable of carrying enormous
short-circuit currents. Standardised short circuit test procedures within IEC (for both porcelain and
polymer-housed arresters) now take into consideration what might happen at failure of the ZnO
blocks for individual designs.
Fig. 17
Operating principle of pressure relief for an ABB type PEXLIM
moulded open-cage design.
(1) Arrester has failed short-circuit and gas begins to be expelled
through the soft silicone housing
(2) The gas streams trigger an external flashover and the internal
arc is commutated safely to the outside
The short circuit capability for surge arresters (porcelain and polymer) is verified by tests to
minimize the risk for damage to surrounding equipment and personnel. However, the risks
related to an open arc in service can also be influenced by the physical positioning of the
equipment as well as by the circuit connections.
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Corona
ring
Grading
rings
Fig. 18
Example of grading ring
and corona ring arrangement
on an ABB type EXLIM surge
arrester for 550KV system
voltage
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Both IEC and IEEE standards require the maximum voltage stress to be taken into
consideration in accelerated ageing tests on ZnO blocks. However, it is not possible to
determine the correct voltage stress to be used in these tests without proper calculations of the
maximum voltage stress occurring in practical three-phase installations. If no such calculations
have been performed, the tests should therefore be carried out with a voltage stress
corresponding to the knee-point of the voltage-current characteristics, i.e. at the reference
voltage.
Type tests in accordance with Standards to verify the long-term stability of the ZnO blocks are
hence not valid if the actual voltage stress on the arrester during service is allowed to exceed the
applied voltage stress proven in the type tests.
When grading arrangements for surge arresters are based on complete electrical field
calculations for each arrester design at the maximum continuous operating voltage and with the
maximum possible three-phase influence taken into account, this guarantees that the voltage
stress remains below the critical level at all points along the block column. This maximum
voltage stress level is then used in accelerated ageing tests on the ZnO blocks. In this way, the
long-term stability of the ZnO blocks is verified at the highest possible voltage stress found in
any installation under normal service conditions.
A guide for the determination of the voltage distribution along surge arresters using simplified
representations of arrester geometries and boundary conditions (applied voltage, proximity and
voltage applied to other objects in the vicinity) is given in IEC 60099-4.
5.3
Polymer arrester designs
The potential weight reduction for polymer arresters can be considerable compared to porcelain
housed arresters. As an example, one of the standard ABB type EXLIM arresters with porcelain
insulator for a 362 kV system voltage has a mass of approximately 430 kg. A PEXLIM siliconehoused arrester for conventional up-right erection, with the same rated voltage, has a mass of
only approximately 125 kg.
This leads to the obvious benefit of lighter structures with subsequent reduced costs, and even
the possible complete elimination of the need for a structure at all if alternative mounting
arrangements are acceptable; e.g. suspended mounting.
Fig. 19
Two examples of possible mounting arrangements for ABB type
PEXLIM silicone housed surge arresters
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Since the soft outer polymeric insulator does not have the necessary mechanical strength to keep
the ZnO column together, other insulator materials must be used in the design. The most common
material used for this purpose is glass-fibre reinforced plastic.
There are then several types of mechanical designs in common use: loops or rods, cross-winding
and tubes. These designs can be grouped generally into three basic categories:
Open or cage design
Closed or wrap design
Tubular design
5.3.1 Open or cage design
This design may consist of loops of glass-fibre, glass-fibre rods or a cage of glass-fibre weave
around the block column. It is worth noting that there are solutions which can be considered
open or cage or a combination open-cage. What defines this type of design is that the active
components are not fully enclosed by hard materials. Instead, a body of soft polymer material
directly surrounds the internal components.
An outer insulator with sheds is required over the inner body, with two common methods for
achieving this being:
A pre-moulded polymer insulator is made in a separate process, and then slipped over the
internal component assembly (which itself may be enclosed in soft polymer). The
boundary between the internal assembly and the outer polymer insulator is usually filled
with grease or gel, generally of silicone.
The outer housing is moulded directly onto the internal components to form a void-free,
sealed housing along the entire length of the insulator.
Such designs lack enclosed gas volume. Should the arrester be stressed in excess of its design
capability, an internal arc will be established. Due to the design principle, the arc will easily tear or
burn its way through the polymer material, permitting the arc, along with any resultant gases, to
escape quickly and directly. Hence, special pressure relief vents or diaphragms are not required
for this type of design. However, it is important that the design is not too open, otherwise the
internal active elements may be violently cast out.
It is of great importance that these designs are totally void-free and no air pockets are present,
otherwise partial discharges might occur, which would lead to the destruction of the insulator over
time.
Penetration of water and moisture must also be prevented, which places strict requirements on
the sealing of the insulator at the metallic flanges (in the case of a pre-moulded housing) and
adherence or bonding of the rubber to all internal parts (in the case where the polymer is directly
moulded onto the inner body).
ABB employs a unique, patented design for the PEXLIM arrester to enclose the ZnO blocks of
each module under pre-compression in a cage formed of glass-fibre reinforced loops fixed
between two yokes which form the electrodes. A special mineral-fibre is wound as belts around
the loops resulting in an open-cage design for the module. This achieves high mechanical
strength and excellent short circuit performance, through the belt-windings preventing explosive
expulsion of the internal components.
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Each module is then passed through a computer-controlled cleaning and priming process.
Thereafter, the module is loaded in a highly automated vulcanising press, where silicone is
injected at high pressure and temperature to completely bond to the active parts, leaving no
internal voids or air spaces.
5.3.2 Closed or wrap design
Surge arresters in this category incorporate a void-free (partial or total) polymer housing around
the internal assembly, while surrounding the active components themselves with hard material. In
contrast to the open design, they have been mechanically designed to not include a direct path for
externalising the arc during internal short circuit.
Typical designs include a glass-fibre weave wound directly on the block column or a separate
tube in which the ZnO blocks are mounted.
A soft polymer insulator is then fitted (either
pre-moulded or directly moulded) over this internal component assembly; often together with
grease or gel to fill the interfaces.
In order to obtain a good mechanical strength, the weave/tube must be made sufficiently strong,
which, in turn, might lead to a too strong/closed design with respect to short-circuit strength. The
internal overpressure could rise in the tube design to a high value before cracking the tube, which
may lead to an explosive failure with parts being thrown over a wide area. To prevent a violent
shattering of the housing, a variety of work-around solutions have been utilised, e.g. slots in the
tube. When glass-fibre weave is used, an alternative has been to arrange the windings in a
special manner to obtain weaknesses that may crack. These weaknesses are intended to ensure
a pressure relief and commutation of the internal arc to the outside; thus preventing an explosion.
Note that such alterations do not inherently then make these an open/cage design, as the arc
path is not considered to be direct and the internal components are still, in practical terms,
completely surrounded by hard material.
Sealing and partial discharge issues also require consideration in a similar manner as for the open
or cage design.
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5.4
Silicone for use as an insulator
There is a worldwide trend towards the use of polymer housings for surge arresters because of
their light weight, flexibility and non-shattering performance. Silicone is recognised and proven
world wide as the technically superior polymer for all high voltage outdoor applications. It's
exclusive use is prevented only by it's comparatively high raw material cost. Nevertheless, an
increasing number of utilities are specifying the more expensive silicone composite insulators;
especially for more demanding or polluted environments; recognising silicone's long-term cost
benefits over porcelain and other polymer materials.
The unique properties of silicone makes it ideal for use as an electrical insulator due to its
superior properties in the following key areas:
Fig. 20
Methyl
CH 3
CH 3
Silicone
O Si O Si
Oxygen
CH 3
CH 3
n > 1000
EP-rubber
Carbon
H H H
H H H
C C C C C C
Hydrogen
H H CH 3 H CH 3 H m
m > 1000
Silicone has a wet-polluted withstand strength much greater than a similarly dimensioned porcelain
or alternative polymeric insulator. Experiments show that even with the deposit of extreme pollution,
silicone materials provide superior performance with respect to leakage current, electrical withstand
and anti-tracking when compared with other polymers and certainly porcelain.
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Fire self extinguishing and freedom from any toxic combustion products.
Due to an inherently high temperature index (temperature required to sustain burning in air),
silicone is the last to catch fire with increasing temperature and the first to self-extinguish. This
natural performance of silicone can be further enhanced by the addition of functional fillers
typically Aluminium Trihydrate (ATH) - which releases bound water at high temperature to cool the
arc resulting from the short-circuit after an arrester overload.
RTV 1 component
RTV 2 component
LSR is the generic group of Liquid Silicone Rubbers. These are two component addition
cured by platinum catalyst at high temperature. Typical application is injection moulding.
HCR is the generic group of High Consistency Rubbers. These are a one component solid
rubber compound which crosslinks at high temperature (130 190 oC) with the aid of either a
peroxide or platinum catalyst. Typical applications are injection moulding and extrusion, and
includes the HTV (High Temperature Vulcanised) silicone used for ABB type PEXLIM surge
arresters.
HCR currently holds around 85% of the insulator market at high voltage, but LSR market use is
growing (particularly in niche markets). HCR is a solid rubber material while LSR has a pasty to
liquid consistency, which lends them to use in different applications and different processing
methods.
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5.4.1.1
LSR
Processing
Allows the use of low pressure injection systems, leading to lower investment costs
Can be fully automated
Fast cycle times at relatively low temperature
Physical properties compared to HCR
Higher mechanical strength
Lower specific gravity (weight)
Lower hardness, more flexible
Permits more angled shed profile
Electrical properties compared to HCR
Lower dielectric constant
Higher dielectric strength
Similar tracking resistance
Erosion resistance similar to common HCR, but not as good as the best HCR
5.4.1.2
HCR
Processing
Needs high pressure & clamp force injection machine, leading to high investment costs
Platinum cured HCR faster cure rate than peroxide cured HCR, but slower than LSR
Mould may not need as close tolerances as for LSR, leading to lower cost
Physical properties compared to LCR
Elongation and tear strength relatively low
Higher hardness
Specific gravity is typically between 1.5 1.65
Electrical properties compared to LCR
Higher tracking resistance
Best material shows no erosion at 3.5, 4.5, 6.0kV tracking and erosion test
5.4.1.3 Application
All groups belong to the silicone family and therefore each permit the fundamental and generic
advantages of silicone to be utilized. However, since there is an expectation of a long in-service
life for HV surge arresters, a high degree of security is required. The manufacturer must
carefully consider the complete design as a whole including the choice of housing material - to
ensure the final product has adequate performance in all key areas of concern for a given
application and not just excellent in one specific area at the expense of others.
For example, ABB type PEXLIM surge arresters utilize a housing moulded from a specially
formulated HTV-silicone in order to ensure excellent performance in all key areas; including:
Physical properties
Wet electrical performance
Tracking and erosion resistance
Salt-fog performance
Electrical properties
Hydrophobicity recovery
Environmental ageing resistance
Flame retardancy
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6.
There are a variety of parameters influencing the dimensioning of an arrester, but the demands as
required by a user can be divided into two basic categories:
Protection against overvoltages
High reliability and a long service life
Additionally, there is the requirement that the risk of personal injury and damage to adjacent
equipment shall be low in the event of an arrester overloading. Users are also beginning to put
requirements on environmental aspects, for example that arresters should be separable,
recyclable and only contain non-hazardous materials.
The above two main requirements are somewhat in contradiction to each other. Aiming to
minimise the residual voltage normally leads to the reduction in the capability of the arrester to
withstand power-frequency overvoltages. An improved protection level may therefore be achieved
by slightly increasing the risk of overloading the arresters. The acceptance for increase of this risk
is, of course, dependent on how well the amplitude and duration of the temporary overvoltages
(TOVs) can be predicted. The selection of an arrester is therefore always a compromise between
protection levels and reliability.
A more detailed classification could be based on what stresses a surge arrester is normally
subjected to and what continuous stresses it shall withstand. For example:
Continuous operating voltage
Ambient temperature
Rain, pollution, sun radiation
Wind and possible ice loadings as well as forces in line terminal connections
and additionally, non-frequent, abnormal stresses, for example:
Temporary overvoltages, TOVs
Overvoltages due to transients, which affect
thermal stability and ageing
energy and current withstand capability
external insulation withstand
Large mechanical forces (e.g. from earthquakes)
Severe external pollution
and finally, what the arrester can be subjected to only once:
Internal short-circuit
For transient overvoltages, the primary task for an arrester is to protect. But it must also normally
be dimensioned to handle the current through it, as well as the heat generated by the overvoltage.
The risk of an external flashover must also be very low.
Detailed test requirements are given in International and National Standards, where the surge
arresters are classified with respect to various parameters such as energy capability, current
withstand, short-circuit capability and residual voltage.
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6.1
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For a given pollution level, the performance of gapless arresters can be generally improved by
employing any or all of the following measures:
Increasing the creepage distances of the housings to reduce external leakage current
Using ZnO blocks of larger volume to improve the energy absorption capability
Improving the TOV capability, i.e. by increasing the rated voltage (Ur) for the same
arrester type
Improving the heat transfer mechanism
Using blocks with lower losses at Uc
A well-designed arrester should already employ blocks with very low losses and the heat
transfer mechanism should be optimized for these blocks. Thus, in practical terms, pollution
performance is usually improved by using one or more of the first three methods. In this regard,
it is important to note that an increased Uc without corresponding improvement in TOV capability
is not effective.
6.1.4 Wind, ice, external forces
A surge arrester is not a post insulator and should not be used as such, since normally its
mechanical strength is limited. In all but extreme cases, wind and ice loads are usually not a
problem for surge arresters. It is only if hurricanes (gales) could be expected at the arrester
location, that a detailed check is necessary of whether or not a standard arrester will mechanically
withstand the wind forces. By suitable selection of the housing strength or its physical mounting, a
surge arrester may be designed to withstand very high winds. Similarly, severe ice storms are
normally required to build up sufficient ice to load the arrester significantly.
The most suitable way to connect an arrester to the overhead line is to arrange the tee-off
vertically and slack to the line terminal of the arrester to minimize the bending moment on the
arrester. Since surge arresters have a certain maximum bending moment for each design type,
expressed in Nm, the maximum force at the line terminal is lower for a tall arrester than for a
shorter one of the same type.
6.1.5 Considerations for polymer arrester designs
The design for continuous stresses on polymer arresters must also take into consideration their
effect on the behaviour and characteristics of the polymer material. For example, polymeric
materials can potentially be more affected by ageing due to partial discharges and leakage
currents on the surface, UV radiation, chemicals, etc, compared to porcelain. Further, polymers,
as a rule, become softer at higher temperatures with a higher degree of creeping (cold flowing),
while at cold temperatures the material becomes brittle.
Many of these characteristics are strongly dependent on temperature and load time. It therefore
is of great importance that the arrester design is tested with different temperature and load
combinations to verify that all possible sealings operate adequately over the entire temperature
interval.
Composite materials, such as glass-fibre joined in a matrix with epoxy or other polymeric
materials, can exhibit behaviour changes at high loading. The rate of this material degradation is
determined by temperature, applied force, velocity of the applied force, humidity and the time
during which the load is applied. It is therefore not sufficient to simply dimension the arrester with
respect to its breaking force, but rather consideration must also be taken to how the arrester
withstands cyclical stresses.
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6.2
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The TOV is generally regarded as a stiff voltage source, i.e. the surge arrester cannot influence
the voltage amplitude. For the dimensioning to fulfil a certain TOV level, the varistor characteristic
must be chosen such that the current through the arrester, and consequently the energy
dissipation, will not result in a temperature above the thermal instability point.
The TOV capability given for a certain surge arrester should always be assumed with a stiff
voltage source. However, if this is not the case, the TOV capability of the arrester is, generally,
significantly higher.
An important parameter concerning the dimensioning for TOV's is to accurately control the kneepoint voltage, since the non-linearity of the characteristic is at its most extreme in the TOV range.
This is best achieved by defining a reference voltage close to the knee-point on the voltagecurrent characteristics, and then checking through routine tests that every arrester has a
reference voltage above a guaranteed minimum voltage.
A manufacturer is relatively free to assign any data for the arresters. A given arrester with ZnO
blocks capable of absorbing a certain amount of high energy could therefore be assigned a high
line discharge class with low TOV capability or, conversely, a low line discharge class with high
TOV capability. The ideal should naturally be to assign the highest line discharge class with the
highest possible TOV capability.
6.2.2 Transient overvoltages - Protective function
The arrester shall, for an expected maximum current, limit an overvoltage to a level well below the
insulation withstand level of the protected equipment.
The protective characteristic for a ZnO varistor is slightly dependent on the steepness of the
expected current. The below Figure 23 shows the characteristics for a specific arrester for three
different current shapes given in the Standards.
Fig. 23
Example of protective
characteristics for a specific
ZnO surge arrester.
The protection level is given
in % of the residual voltage
at a current impulse with
wave-shape 8/20 s and
amplitude 10 kA.
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As can be noted from the diagram, the protection level for currents having a front time of 1s are
approximately 10% higher compared to currents with a wave form 8/20s or longer. However,
even more important than this marginal increase for steep current waves, is the effect of
positioning the arrester in relation to the protected equipment and the length of the connections.
There is also an effect as a result of the arresters own height (length). These effects add
inductance (L) into the circuit, typically 1H/m for outdoor arresters, which results in a further
increase in the overall residual voltage against steep current impulses according to the formula
U = L.di/dt.
In order to obtain an efficient protection against fast transients, for example caused by
backflashover close to a substation, large margins are therefore required between the protection
level of the surge arrester and the protected equipments insulation level.
A ZnO block with larger diameter normally has a better protection level with maintained
overvoltage capability. A better protection level, in this case, also automatically results in a better
energy capability.
Computer programs are used to make accurate calculations of the resulting overvoltages in a
substation originating from lightning and detailed models of the transmission line and substation
are made. In these type of calculations, a ZnO arrester may be modelled as shown in Fig. 24.
L1
L2
ZnO
Fig. 24
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Class 1
Class 2
Class 3
Class 4
Class 5
0
1.2
1.4
1.6
1.8
2.2
2.4
2.6
2.8
0
1.2
1.4
1.6
1.8
2.2
2.4
2.6
2.8
Potentially even more confusing for the ordinary user is the classification as per the IEEE
standard, as depicted in the above Figure 25b. The diagram is drawn for lowest used rated
voltage on highest existing system voltage in each class. The highest relative energy occurs for
the Class 326 to 400 kV. In general, the energy is lower in IEEE than for the IEC classes. On the
other hand, the Line Discharge test as per IEEE shall be performed with 18 impulses in only 3
groups of 6 impulses, compared with IEC which prescribes 6 groups with 3 impulses in each
group. The interval between the impulses in each group shall be 50 - 60 seconds and full cooling
is allowed between groups.
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The energy absorption capability of an arrester is only defined in IEC as per the previously
mentioned Line Discharge classification. Different manufacturers assign the energy capability in
different ways. For example, the energy capability may be given as:
kJ/kV Ur, kilojoule per kilovolt rated voltage which is possibly complemented with the
shortest time during which the energy can be absorbed
the sum of the energy resulting from two line discharges separated 50 60 seconds in
compliance with IECs line discharge classification
possibly
Therefore a surge arrester may be described with at least three different energy values, which is
why it is essential to state how the energy for a specific arrester has been given. As an example,
the following energy capabilities can be given for the same ABB arrester type EXLIM P (Class 4):
10.8 kJ/kV Ur, two line discharge impulses in compliance with IEC 60099-4
The ZnO blocks are normally able to withstand considerably higher energies with longer durations
(seconds), compared to shorter durations (milliseconds). Expressions like kJ/kV Ur or kJ/kV are
therefore meaningless unless the shortest time for which the arrester can be subjected to the
given energy is also stated.
As mentioned previously, a high voltage arrester is normally designed in compliance with a
chosen line discharge class as per IEC with respect to energy. For non-standard stresses, such
as capacitor discharges or high energies due to lightning, the design may need to be made with a
lower energy stress per varistor.
Aside from withstanding the energy from current impulses, the ZnO blocks must also have a
sufficiently high dielectric withstand so as to ensure that the voltage across the block will not result
in a puncture or a flashover across the block. To ensure a sufficient insulation withstand margin
for normal stresses, the ZnO blocks (together with all internal parts in a high voltage arrester) are
dimensioned to withstand current impulses with an amplitude of at least 100 kA, having a wave
form of 4/10 s.
Requirements for high energy absorption capability can be solved by increasing the block volume
- either by using blocks with larger diameter or by paralleling block columns and/or arresters. To
ensure that the latter designs will operate correctly during service, a very careful procedure is
required to ensure a good current sharing between the block columns and/or arresters connected
in parallel. Furthermore, possible changes of the block characteristic due to the normal applied
service voltage as well as energy and voltage stresses must be extremely small.
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When the earthquake is defined as a maximum horizontal acceleration, the bending moment
can be easily calculated when considering the arrester as a rigid body. When more accurate
calculations are necessary, the elasticity and damping of the arrester must first be determined in
a snap-back test.
Knowledge about elasticity, resonance frequencies and related damping
is also required when the earthquake is specified by a frequency
spectrum, In such cases, a specially developed computer program will
need to be used. However, a reliable calculation needs to also have
adequate information about the structure on which the arrester is
erected. For example, mounting the arrester on a support structure
which has a sufficiently high natural frequency (e.g. a large power
transformer) may reduce or remove the seismic loading on the arrester.
Since polymer-housed arresters are more or less elastic, temporary loads
- including short-circuit forces and earthquake forces - can be looked
upon differently compared to rigid bodies like porcelain insulators. The
reason for this is that the forces do not have time to act fully due to the
elasticity of the material and mass inertia, i.e. the forces are spread out in
time leading to the arrester not encountering any high instantaneous
values. These advantages, combined with a design with small mass
participation, have been fully utilised by ABB for the 550 kV arrester
shown opposite in Figure 26. This arrester withstands a ground
horizontal acceleration in excess of the highest seismic demands as per
IEEE standards.
Seismic qualification testing has also been successfully made on other
standard ABB type PEXLIM surge arresters (without additional bracing),
even at the arduous 1.0g ZPA level. Alternatively, suspending polymer
surge arresters directly from the overhead line is a viable mounting
alternative to eliminate seismic and other large cantilever loads
altogether.
Experience has shown that loads from short-circuit forces, wind and ice
have not had a significant influence during past earthquakes and
therefore arresters need not be designed for such loads to act
concurrently with an earthquake.
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The problems for arresters with porcelain housings installed in extremely polluted areas have
historically been solved by greasing the insulator, thus improving the pollution performance. The
aim of the greasing is to reduce the leakage currents on the insulator surface. Hydrophobic
materials, like silicone, give a similar effect. This is one of the strongest motivations for why
silicone has been seen as an attractive insulator material.
A common belief is that all polymer-housed arresters have better pollution performance
compared to arresters with porcelain housings. However, a more correct statement would be
that hydrophobic materials (like silicone) have better performance in polluted areas due to
reduced external leakage currents. In contrast, EPDM rubber, which can lose its hydrophobic
properties quickly, should be designed in the same manner as porcelain from a pollution
performance point of view.
It is very difficult to avoid internal corona during severe external pollution on arresters containing
an annular gap between the ZnO blocks and the insulator, irrespective of whether the insulator
is made of porcelain or a polymeric material. The design of such arresters must therefore be
able to withstand corona during such pollution episodes.
Some rules-of-thumb for designs such as these are:
No corona during dry conditions
Minimise the use of organic materials in the arrester. When organic materials are used,
they must have been thoroughly tested and subjected to realistic corona tests
Prevent the possibility of electrical discharges directly onto the ZnO blocks
For polymer-housed arresters which do not have any annular gap, large radial stresses may
occur between the blocks and the outside of the insulator during severe external pollution
episodes. It is therefore very important that the rubber insulator is sufficiently thick to avoid a
puncture of the material. Furthermore, steps need to be taken to avoid large air pockets or
cavities, otherwise corona may occur that would eventually lead to an arrester failure.
To avoid external flashover, the creepage distance of the arrester, i.e. the shed form and the
length of the insulator, is typically designed in compliance with the same criteria valid for other
insulation at the actual site.
Possible thermal stresses are determined by the leakage currents that might be present on the
outer surface of the insulator. For porcelain arresters, it has been shown that the integral of the
leakage current, i.e. the charge, can be regarded as independent of the creepage distance, and
instead is approximately linearly dependent on the diameter of the housing. An insulator with a
larger diameter thus may give rise to higher thermal stress during conditions with external
pollution, provided the service conditions are otherwise the same.
For applications requiring arresters with parallel housings and several units connected in series,
the general rule is that the units should not be connected in parallel except at the top and bottom.
This is because, during pollution episodes, the ZnO blocks in one unit could conduct the external
leakage current from all of the parallel connected arresters which consequently may give an
increased thermal stress on that unit.
Since the ZnO blocks have a negative temperature coefficient in the leakage-current region, i.e.
the leakage current increases with increased temperature, the heating of one unit will lead to a
reduction of the voltage characteristic with subsequent increase of the current. An increased
current through the unit leads to higher power losses with increased temperature, and so the cycle
continues. Not even a careful current-sharing test (matching) of the arrester units will be of help
below the knee-point of current-voltage characteristic.
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For a given pollution level, the performance of gapless arresters can generally be improved by
employing any or all of the following measures:
Increasing the creepage distances of the housings to reduce external leakage current
Using ZnO blocks of larger volume to improve the energy absorption capability
Improving the TOV capability, i.e. by increasing the rated voltage (Ur) for the same
arrester type
Improving the heat transfer mechanism
Using blocks with lower losses at Uc
Lower leakage currents on the insulator surface is achieved with a hydrophobic surface, i.e. the
use of silicone insulators. The below Figure 27 shows leakage currents as measured on a
porcelain insulator and a polymer-housed arrester having a silicone insulator. The values are
taken from testing at NGCs test station at Dungeness on the English Channel.
Daily
maximum
currents
inover
a 16adays
period
at
Daily
maximum
currents
16 day
period
Dungeness
test
station
at Dungeness
test
station
30
Arrester with silicone insulator
Porcelain insulator
25
Current (mA)
20
15
10
Days
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The concept of thermal stability can be depicted with the help of a heat loss input balance
diagram, as depicted in the following Figure 28. This shows principally how the ability of an
arrester encapsulation to dissipate heat and the temperature dependent power losses of the
blocks result in a working temperature at a certain ambient temperature and chosen voltage
stress (A in the Figure). An upper maximum temperature also exists (B in the Figure), above
which the design is no longer thermally stable for a given voltage stress.
It can also be seen from Figure 28
that the instability threshold is very
much dependant on the applied
power frequency voltage. As the
power losses curve is non-linear, a
lower applied service voltage than
verified in test, for example, would
shift the upper intersection point
further to the right, thereby
increasing
significantly
the
temperature limit at which thermal
runaway becomes a risk.
Fig. 28
Thermal capacity for an
arrester housing and power
losses for ZnO blocks at
different relative voltage stresses
(ambient temperature +40 C)
Porcelain curve
3
Losses at 0.9*Uref
2
Losses at 0.8*Uref
Losses at 0.7*Uref
Losses at 0.6*Uref
0
40
80
To explain the concept further: The power losses of a typical ZnO varistor (curved line) due to a
constant applied power frequency voltage is extremely temperature dependent. At the same
time, the ability of the arrester assembly to dissipate heat is generally linear (straight line) and
proportional to its thermal design and temperature rise above the ambient temperature.
Consequently, there are two intersections of the two curves: one at low temperature a so
called stable operating point, and the other at high temperature a so called instability
threshold. To obtain thermal stability, the temperature rise due to power losses in the ZnO
varistors must be balanced against heat dissipation to the environment.
If power losses exceeds heat dissipation, then excess energy is stored in the varistors and their
temperature slowly increases. Conversely, if heat dissipation exceeds power losses, the
temperature of the varistors decreases. The varistor temperature may well increase significantly
due to the application of transient or temporary overvoltages, but will always ultimately settle
back at the stable operating point, as long as the varistor temperature does not exceed the
instability threshold. As the two characteristics diverge beyond the instability threshold point, a
thermal runaway will invariably occur from varistor temperatures above this point, whereby the
temperature will continue to increase until the arrester ultimately fails.
Some rules-of-thumb for ensuring a design with good heat dissipation, and thereby low risk for
thermal runaway:
Low-loss blocks
Reduced voltage stress/mm
Increased block size
Homogenous block material
Non-ageing blocks
Good mechanical design with regards to thermal heat transfer
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7.
According to the IEC 60099-4 standard, surge arresters are classified by their nominal
discharge current.
The test requirements and performance characteristics related to the
different classes must be upheld. These currents do not, however, reflect the limits of the
characteristics. For example, an arrester with nominal discharge current of 10kA can withstand
current impulses of significantly higher amplitude without damage or deterioration.
Standard nominal discharge current
20 000 A
10 000 A
5 000 A
2 500 A
1 500 A
Ur < 132
Ur < 36
Under consideration
4 or 5
1, 2 or 3
Table 2
The classification as per the IEEE C62.11 standard is shown below (Table 3).
Arrester classification
Station
Station
Station
Intermediate
Distribution, Heavy Duty
Distribution, Normal Duty
Distribution, Light Duty
Table 3
800
550
< 550
All
All
All
All
20
15
10
5
10
5
5
The switching surge protection level is defined at a current impulse with virtual front time of
30 to 100 s (IEC) or 45 to 60 s for time to actual crest (IEEE). The current amplitudes are
given in Table 4 below.
Arrester classification
IEC, 20kA, LDC 4 and 5
IEC, 10kA, LDC 3
IEC, 10kA, LDC 1 and 2
IEEE, Station
IEEE, Station
IEEE, Station
IEEE, Intermediate
Table 4
----
326 900
151 325
3 150
3 150
2000
1000
500
500
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8.
In order to fulfil the requirements of users, Standards specify uniform tests and test methods
aimed at verifying an arresters:
ability to protect against overvoltages
reliability and long lifetime
The protective function is verified with different measurements of the voltage level for different
current amplitudes and current waveforms (residual voltage tests) and the reliability is checked
through a number of electrical and mechanical tests. An important part of the electrical tests is the
operating duty tests in which an arrester, or a pre-scaled model of the arrester, is subjected to a
combination of stresses representing anticipated service stresses that an arrester might be
subjected to during its lifetime. The lifetime is further verified by subjecting the ZnO blocks to an
accelerated ageing test procedure.
According to Standards for testing of arresters, the tests can be divided into three main
categories:
Type tests (Design tests according to IEEE)
Routine tests
Acceptance tests (Conformance tests according to IEEE)
These test categories can be defined as follows:
Type tests are performed after completion of the development of a new arrester design to
establish representative performance and to demonstrate compliance with the relevant
standard. Once made, these tests need not to be repeated unless the design is changed
in a way which may negatively influence the performance. Only the relevant tests need to
be repeated in such a case.
Routine tests are made on each arrester or arrester unit, as well as components, as a
quality control integrated in the production. Their aim is to ensure that the products meet
the design specification.
Acceptance tests are made on a number of randomly chosen arresters from a delivery
lot when it has been specially agreed between the manufacturer and the purchaser at the
time of ordering. Acceptance tests should not be confused with routine tests.
Specifically how surge arresters shall be tested is defined in detail in the Standards, with the two
most widely accepted being IEC 60099-4 (International Standard) and IEEE C62.11
(American National Standard).
Since the IEC standards are international and thereby have a wider scope for use, the coming
sections focus primarily on the requirements specified by IEC 60099-4.
For comparison
purposes, a summary of the major differences between the IEC and IEEE standards is given in
Table 5.
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Table 5
Product
Arrester classification
and (ANSI/IEEE) impulse
classifying currents
Rated voltage, Ur
Continuous operating
voltage
Relation between
Ur and Uc/MCOV
Impulse classifying
current
Switching surge
classifying current
Insulation withstand
IEC 60099-4
IEEE C62.11
Peak
currents (A)
20 kA,
2000
LDC 4 and 5
10 kA, LDC 3
1000
500
10 kA,
LDC 1 and 2
For 20 and 10kA arresters a
line discharge test with 5
classes. 20 kA arresters either
class 4 or class 5. 10 kA
arresters class 1, 2 or 3.
For 5kA arresters a rectangular
current impulse test with 75 A
and 1ms duration. For 2.5 kA
arrester a rectangular current
impulse with 50A and duration
0.5ms.
See Table 9
10 kA
5 kA
5 kA
Station
class
(A)
2000
Intermediate
class
(A)
-
151-325
3-150
1000
500
500
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IEC 60099-4
Arrester
classification
High-current impulse
IEEE C62.11
Peak current
(kA)
Arrester classification
20 kA
100
10 kA
100
5 kA
65
2.5 kA
25
1.5 kA
10
A quite complex test procedure
intended to determine possible
temperature rise with respect to
the site pollution classification.
A simplified method is allowed
to determine if a pollution test
is necessary or not. No test
specified yet for polymer
housed arresters
Test procedure well specified
for different designs and
housing types. Includes high,
intermediate and low test
currents. Clear distinction
made regarding specific
requirements particular to
polymer-housed arresters.
Polymer housed
arresters
Station
65
Intermediate
65
Distribution, heavy duty
100
Distribution, normal duty
65
Distribution, light duty
40
Two test cycles with application of a
pollutant to half the length of the
arrester and thereafter energizing at
MCOV. Test applicable to porcelainand polymer-housed station,
intermediate and distribution class
arresters.
Test procedure well specified for
different designs and housing types.
Includes high, intermediate and low
test currents. Clear distinction made
regarding specific requirements
particular to polymer-housed arresters.
Intention was to harmonize with the
IEC standard, but some slight
differences remain.
Distribution arresters considered
separately, but otherwise test
procedures only for salt fog, cantilever
load and moisture ingress. Short circuit
current test requirements also
specifically considered in common
clauses. Extended weather ageing test
in an Annex as informative.
Class 1
Class 2
Class 3
Class 4
Class 5
1
0
1.2
Peak current
(kA)
1
1.4
1.6
1.8
2.2
2.4
2.6
2.8
0
1.2
1.4
1.6
1.8
2.2
2.4
2.6
2.8
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The Standard IEC 60099-4 supersedes the old Standard for gapped silicon-carbide surge
arresters, IEC 60099-1, which is not applicable to ZnO arresters. Many countries also have their
own National Standards which more or less comply with IEC or IEEE. Changes to the IEC
Standard (from Amendment 2 in 2001) deal with specific issues of importance, including: polymer
housed arresters, short-circuit tests, accelerated ageing, voltage distribution, environmental and
weather ageing tests and mechanical testing.
The tests in the IEC 60099-1 standard are not generally applicable to ZnO arresters, and
IEC 60099-4 reflects a completely different approach on how to select test sections and verify the
protection characteristics.
Some of the major differences between these two IEC Standards are listed in Table 6.
IEC 60099-1
IEC 60099-4
Type Tests
Sparkover voltage test
No pre-heating
Pre-heating to +60 C
Strictly specified how the test sections
shall be selected and how the rated
voltage of the section shall be determined
Routine Tests
50 Hz sparkover voltage test
Table 6
Comparison between test requirements according to IEC 60099-1 and IEC 60099-4
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10 000 A
5 000 A
2 500 A
1 500 A
Ur < 132
Ur < 36
Under consideration
Lightning and
switching impulse
voltage test
If Ur > 200 kV
Lightning and
switching impulse
voltage test.
If Ur < 200 kV
Lightning impulse
and power
frequency voltage
test
Lightning impulse
and power
frequency voltage
test
Lightning impulse
and power
frequency voltage
test
Lightning impulse
and power
frequency voltage
test
b) Lightning impulse
residual voltage test
c) Switching impulse
residual voltage test
Long duration current
impulse test
Operating duty test
a) High current impulse
operating duty test
Not required
Not required
Not required
LDC 4 or 5
LDC 1, 2 or 3
75 A, 1 ms
50 A, 0.5 ms
Not required
Not required
LDC 1
with 100 kA
With 65 kA
With 25 kA
With 10 kA
LDC 2 and 3
Not required
Not required
Not required
---
X
X
X
X
X
X
X
X
X
X
---
---
---
b) Switching surge
operating duty test
Short circuit
Arrester disconnector
(when fitted)
Polluted housing test
for porcelain-housed
multi-unit arresters
Internal partial
discharge test
Bending moment
Environmental tests
Seal leak rate test
for arresters with
enclosed gas volume
and separate sealing
system
Radio interference
voltage (RIV)
Moisture ingress test
for polymer-housed
arresters
Weather ageing test
for polymer-housed
arresters for outdoor
use
Lightning impulse
discharge capability for
arresters to be installed
in overhead lines
Table 7
Type test requirements for gapless ZnO arresters as per IEC 60099-4
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8.1
Type Tests
In general. set requirements on arresters and their dimensioning are considered to be
satisfactorily verified by subjecting the arresters to the following generic tests:
The above tests are considered to be type tests (design tests) but some of these may instead
be performed during the manufacturing process and/or assembly as part of a manufacturers
quality assurance. This is acceptable, and even preferable, provided that the type test criteria
are fulfilled during the routine testing. ABB has chosen to do this for testing of internal partial
discharge, seal leak rate and current distribution (multi-column arresters), as applicable for
specific designs.
Regarding polymer-housed arresters, the test procedures in IEC 60099-4 differ somewhat from
previous tests on porcelain designs. The above tests by topic are also generally applicable to
polymer designs, with the main exception being that there is no artificial pollution test yet
specified for polymer arresters. Instead, a Weather Ageing test for the polymer material has
been devised. Further, the sealing test requirements are more well defined in the form of a
Moisture Ingress test, as are the criteria for mechanical loading and short circuit safety.
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*)
Residual voltage and long duration current impulse tests are performed on three new
samples, which may be either resistor elements, arrester sections or complete arresters.
**)
For porcelain housed arresters the blocks must be in the same atmosphere as found in
the actual arrester. For polymer-housed arresters the blocks must be surrounded by the
same material as used in the actual arrester.
Table 8
For all tests with energy injections, it is important that the test section fulfils the following
requirements:
The block volume shall not be greater than the minimum block volume specified for the
complete arrester, scaled down with respect to the rated voltage of the prorated test section
The energy injected into the test section must correspond to what a test section comprising
ZnO blocks with a minimum voltage-current characteristic would have been subjected to
It is equally important during tests with temporary overvoltages that the test voltage is scaled
down with respect to the reference voltage of the test section and the minimum reference voltage
assigned to the complete arrester.
Test sections comprising non-encapsulated ZnO blocks are well defined, but verification tests are
necessary to design a thermally correct test section. A thermal section shall, in principal, be a
cross section of the complete arrester. However, the heat transfer in the middle of a long arrester
unit takes place mainly in the radial direction, and hence a conservative model of the arrester
must be thermally insulated at both ends to avoid heat transfer axially. The principal design of a
thermal section for polymeric arresters is shown in the following Figure 29.
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Electrical
connection
Electrical
connection
Sheets of compressed
Sheets of
wool
Glass bolt
fibre
Glasfiber
bolt
Insulator
Insulator
compressed wool
Sheets of compressed
wool
ZnO
block
ZnO
blocks
Electrical
connection
Electrical
connection
Insulation
Fig. 29
It is, however, not sufficient to specify only the design of a section; it must also be verified through
tests. The verification of the thermal section is made by heating a complete arrester unit and a
thermal section to around +120 C by the application of voltage. Thereafter, the ZnO block
temperatures in the unit and the section are measured during the cooling time. A correctly
designed thermal section shall not cool faster than the arrester unit. The below Figure 30 shows
cooling curves from a test on a thermal section and a complete arrester. The Figure additionally
shows the cooling for a section designed according to requirements given in IEEE C62.11, which
also requires that verification tests be carried out.
Relative temperature above ambient temperature
1
Complete
Completesurge
surgearrester
arrester
Thermal
Thermalsection
sectionaccording
according to
to IEC
IEC
Thermal
Thermalsection
sectionaccording
according to
to IANSI/IEEE
IEEE
0.9
0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
20
40
60
80
100
120
Time (minutes)
Fig. 30
Verification of thermal section and comparison of specifications between IEEE and IEC
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It is of course possible that switching events or a fault can result in steeper current pulses than
30 s, or that the current at lightning overvoltages may show both shorter or longer front times
than 8 s. For switching surges with longer front times, the deviation in the residual voltage from
the 30/60 s wave for the same current amplitude is very small; within a few percent. For
lightning surges having a shorter front time, the residual voltage shows an increase of less than
10% with a reduction in front time from 8 to 1 s.
Residual
current
impulse
Residualvoltage
voltage for
for 1/2
1/2s
current
impulse
Residualvoltage
voltage for
for 8/20
8/20s
current
impulse
Residual
current
impulse
Voltage (kV)
12
8
Fig. 31
Comparison between residual
voltage levels for current
pulses 8/20s and 1/2s.
4
0
Currentimpulse
impulse
Current
8/20s
8/20
-4
Current
impulse
Current
impulse
1/21/2s
-8
-12
Current (kA)
10
20
30
40
50
Time (microseconds)
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By testing with different current amplitudes for each of the current-shapes, a complete protection
characteristic is obtained for each waveform. For current impulses with the same amplitude, the
residual voltage level increases slightly for shorter front-times. This frequency dependence is
illustrated below (Fig. 31), showing results from a test with 10 kA for waveforms 8/20 s and
1/2s. The steeper front, 1 s, may be the result of a lightning stroke very close to a substation
protected by surge arresters. Further, inductance effects can become significant with steep
current impulses, and IEC specifies that the steep current impulse residual voltage tests may
need to be corrected to account for the possible inductive voltage drop between the arrester
terminals.
In order to generate the specified current pulses an impulse generator is needed with the
capability to create currents up to 40 kA. To be able to create such currents through a complete
arrester at high voltages would require very large impulse generators, since the test equipment
must principally be able to simulate full-scale lightning. Tests on complete arresters are however
not necessary, nor desirable for reasons of accuracy. IEC therefore recommends that the residual
voltage tests are made on scaled-down models of the arrester and specifies also how the
measured values shall be re-calculated to be valid for a complete arrester.
According to IEC, the objective of the residual voltage type tests is to verify the claimed protection
levels by checking the relationship of protection levels at different current waveforms and
amplitudes to a level which is checked in routine tests on all arresters. Normally the residual
voltage at 10 kA with waveform 8/20 s is used as a reference. This means that the 10 kA level
with this waveform must be verified in a routine test and given for all manufactured arresters. The
requirement for a routine test can be fulfilled by measuring the residual voltage for each individual
block within the arrester and summing up the result. This procedure will be correct, since all
blocks in a single column arrester will be subjected to the same current.
8.1.3 Long Duration Current Impulse Withstand Test
A surge arrester limits incoming overvoltages by diverting the surge current. The energy the
arrester absorbs is given by the equation:
W = (u * i ) dt
0
where
The arresters must withstand this energy without thermal instability or damage to the blocks in any
way. It is equally important that the characteristics of the arrester are not changed due to repeated
energy stresses. This could not only jeopardize the protection function of the arrester, but also the
current sharing between parallel block columns in an arrester, or between several parallel
arresters, that have been matched with respect to current sharing to cope with large energy
requirements.
Requirements for very high energy capabilities are solved by utilizing many parallel block
columns. For such designs, it is required that changes in the protective characteristic of the blocks
is low. From a protection point of view, it is acceptable that the residual voltage decreases with
repeated current impulses, but if blocks are connected in parallel, the acceptable changes are
much lower than what is allowed by the Standard.
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Aside from discharge of capacitor banks, the highest arrester energies for high voltage AC
arresters are obtained from switching of long transmission lines. Simplified, the arrester will be
subjected to a current impulse of rectangular shape, with the duration of the impulse being
determined by the length of the line. The current amplitude through the arrester is given by the
prospective overvoltage (without a surge arrester), the surge impedance of the line and the
characteristic of the arrester. By tradition, the energy capability of an arrester has been defined
with respect to the withstand capability for rectangular current impulses.
The test with long duration current impulses is made on arrester sections. For arresters having a
nominal current class 10 kA and 20 kA, the tests are defined as line discharge tests where the test
circuits wave impedance, charging voltage and duration of the current impulse are defined in the
Standards. The resulting energy is dependent on the protection level of the arrester, which is why
the energy must be defined and be given in the test report.
According to IEC 60099-4, the test energy must be higher than or equal to a value determined
by a formula based on the specified test parameters and the protection level of the test
sections. The required protection level is according to the lowest value of the switching impulse
residual voltage measured for the lower current value specified in IEC 60099-4 for the
respective Line Discharge Class. The actual current applied in the long duration test is
thereafter determined by the choice of circuit parameters in order to obtain the required energy.
As a result, the value of this applied current is of lesser consequence - what is the determining
factor is the amount of energy applied and absorbed by the test sample in order to fulfil a given
Line Discharge Class. In fact, the value for "withstand current" is not an IEC 60099-4 term. It is
however common to be listed by manufacturers, since it serves as an indirect measure of the
arrester's single-impulse energy absorption capability - also undefined in IEC - when applied in
multiples (18 discharge operations, divided into 6 groups of 3 operations). Hence, to keep in
line with IEC, a direct analysis can best be made by considering the amount of energy
absorbed, rather than the unspecified current applied.
A desired energy capability for the arrester can then be given indirectly by defining line
parameters, or directly in kJ/kV rated voltage. However, it must be emphasized that any value
given as kJ/kV rated voltage without specifying test procedures is undefined and thus of little
value.
Arresters having a nominal current class of 2.5 kA and 5 kA are not tested with line discharges,
and instead tests with rectangular current impulses are specified with given amplitudes and
durations.
8.1.4 Operating duty test
The purpose of this test is to verify that the arrester withstands all the kinds of electrical stresses
which are likely to occur during its lifetime. This is schematically shown in the following Figure 32.
The standardized operating duty test therefore includes different stresses and sequences of
current pulses and voltage amplitudes representing possible events in a power system.
Originally, the operating duty test was used to verify an arresters ability to handle lightning
currents while being simultaneously subjected to maximum allowable operating voltage. For
gapped arresters this meant that, apart from the lightning current stress, they were subjected to a
power frequency follow current before the gaps were able to extinguish the arc at voltage zero.
If the arc was not extinguished at the first voltage zero, the arrester normally failed.
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ZnO arresters do not contain any gaps, but an operating duty test is nevertheless still useful to
check that the arrester is thermally stable after having absorbed large amounts of energy under
severe ambient conditions with respect to temperature and voltage. These energy inputs could
come from energy discharges as well as from Temporary Overvoltages (TOV) on the system.
How the operating duty test shall be carried out for different Line Discharge Classes is illustrated
in the following Figures 33 and 34.
Type of fault
Stress
Duration
Normal service
Uf = Um / 3
Continuous
Lightning
impulse
s-impulse
Earth fault
Uf < Um / 3
0.1 - 10 s *)
Breaker operation
Uf 0
0.3 - 1 s
Re-closing
switching
ms-impulse
Uf = ke*Um /3
0.1 - 10 s
Breaker operation
Uf Um /3
0.3 - 1 s
Re-closing
switching
ms-impulse
Normal service
Uf = Um / 3
Continuous
Voltage profile
Possible faults:
*)
Fig. 32
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Elevated rated voltage Ur* and continuous operating voltage Uc* only if the accelerated ageing
test procedure gives increased power losses. Otherwise, Ur and Uc are applied.
In = Nominal discharge current
Explanation of the numbers:
1
2
Preparatory measurements
Conditioning
Fig. 33
3
4
Operating duty test on 10 kA surge arresters with line discharge class 1 and arresters of class 1.5 kA,
2.5 kA or 5kA.
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Elevated rated voltage Ur* and continuous operating voltage Uc* only if the accelerated ageing
test procedure gives increased power losses. Otherwise, Ur and Uc are applied.
In = Nominal discharge current
Explanation of the numbers:
1
Preparatory measurements
Conditioning
Fig. 34
Operating duty test on 10 kA surge arresters with line discharge class 2 or class 3
and 20 kA arresters with line discharge class 4 or 5
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The test sequence starts with a conditioning phase, where the test objects are subjected to a
large number of current pulses to take into consideration possible changes of the block
characteristic during actual service conditions due to repeated stresses. After this sequence, the
part of the test commences which shall verify the arresters thermal stability and designated rated
voltage.
This part of the test shall therefore be made fulfilling the following requirements:
The prorated test section must be thermally equivalent to a complete surge arrester
The test objects must be heated before the test to a temperature being representative of
the worst possible service conditions
The test must be made on previously non-tested blocks. Consideration must be taken of
possible ageing of the blocks by applying correction factors (giving Ur* and Uc*) according
to the guidelines in IEC 60099-4.
Finally, it is required that the arrester withstands the operating duty test without change to its
electrical properties beyond acceptable limits. The residual voltage level at nominal discharge
current is therefore checked before and after the test sequence.
The operating duty test is normally performed on arrester sections. To fulfil the requirement for
thermal equivalency, the section is principally a cross-section of the complete arrester.
IEC 60099-4 requires preheating of the thermal pro-rated section to +60 C before the energy
injections. This temperature is thought to represent an ambient temperature of +40 C together
with solar radiation, self-heating of the blocks due to power losses and some influence from
pollution. For ZnO blocks with low power losses at normal service voltage, +60 C is a
conservative value, and the operating duty test consequently gives a safety margin with respect
to thermal stability limits.
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An important parameter during the ageing test is the selection of the voltage stress on the
blocks. The test voltage must reflect the highest possible local voltage stress in the arrester
when it is energized at the highest possible continuous operating voltage, Uc, assigned to the
arrester. A thorough electrical field calculation therefore must be made for each arrester type
and rated voltage which, in turn, is the basis for determining the relevant voltage stress during
the accelerated ageing test procedure. Influence from all phases in a three-phase configuration
must also be taken into account when performing the calculations.
A ccelera ted a g ein g test o n Z n O v a risto rs ty p e P E X L IM Q
at 1 1 5 C w ith a v o ltag e stress o f 0 .9 7 * referen ce v o ltag e, U ref
P o ly m eric in su lato r m o ld ed d irectly o n th e Z n O b lo ck
T est tim e: 1 1 2 2 h o u rs
1 .2
1
0 .8
0 .6
0 .4
0 .2
0
0
100
200
300
400
500
600
700
800
900
1000
1100
1200
T im e (h o u r s)
Fig. 35
Example of power losses during an accelerated ageing test procedure for ABBs ZnO blocks.
ZnO blocks are normally manufactured in batches of some thousands of blocks, and variations
(even minor ones) may have a negative influence on the block characteristics. From a quality
point of view, it is thus necessary to perform ageing tests as sample tests on blocks from each
manufactured batch.
Separate from the type test, ABB further verifies the stability of every production batch of ZnO
blocks by routinely performing an accelerated ageing test on some blocks picked out randomly
from the whole batch. Power losses after 1000 hours, extrapolated from a test with shorter
duration, at an elevated temperature of 115 C at 1.05 x Uc shall not exceed the losses at the start
of the test and not more than 10% above the lowest losses occurring during the test period.
Batches in which unapproved blocks appear are rejected.
It is however not sufficient to check only the characteristics of the blocks, but rather the entire
arrester must be seen as a unity. The ability of the arrester housing to dissipate heat must also be
adjusted to the power losses of the blocks during different service conditions with respect to
voltage, temperature and even frequency. This is necessary to ensure that the average block
temperature will not considerably exceed the ambient temperature, and thereby remain thermally
stable.
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SIWL
LIWL
Table 9
Ur < 200 kV
1.06 /2 x Ups
for arresters with
In = 10 or 20 kA
or
0.88 /2 x Upl
for arresters with
In = 1.5, 2.5 and 5 kA
Ur > 200 kV
Not applicable
Not applicable
1.25 x SIPL
1.3 x Upl for all arresters
0.82 x Ups
Not defined
1.42 x Upl at 20 kA
for all arresters
All distances between the arresters own parts, e.g. grading ring to flanges, must be checked with
respect to voltage stress and withstand, either by calculation or test. If actual tests are required
on complete multi-unit arresters, the blocks must be replaced with something giving the same
internal voltage grading as the blocks would give. Normally capacitors are used to replace the
ZnO blocks during such tests to model actual service conditions as closely as possible.
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High current
Arrester class = nominal
discharge current
A
20 000 or 10 000
20 000 or 10 000
20 000 or 10 000
20 000 or 10 000
20 000 or 10 000
20 000 , 10 000 or 5 000
10 000 or 5 000
10 000, 5 000,
2 500 or 1 500
10 000, 5 000,
2 500 or 1 500
Table 10
Low current
Reduced short-circuit
Currents (+ 10 %)
A
Short-circuit current,
with a duration of 1 s
A
50 000
25 000
25 000
25 000
12 000
12 000
6 000
6 000
25 000
12 000
12 000
12 000
6 000
6 000
3 000
3 000
600 + 200
600 + 200
600 + 200
600 + 200
600 + 200
600 + 200
600 + 200
600 + 200
3 000
1 500
600 + 200
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Fig. 36
It is therefore justified to specify the pre-failing method for Design B polymer-housed arresters,
which among the alternatives gives a reasonable compromise with regard to test severeness
and realism, and it automatically covers possible influences of material homogeneity.
Conversely, the pre-failing method may be less severe for a porcelain-housed Design B
arrester in the case where the arc develops elsewhere than in the solid material. To cover for
the worst-case scenario, Design B porcelain-housed should have a fuse wire drawn along the
surface of the ZnO block column as far away as possible from the gas channel.
Design
Design A
Housing
Porcelain
Polymer
Design B
Porcelain
Polymer
Table 11
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Porcelain-housed arresters
(C-connection)
Fig. 37
Polymer-housed arresters
(Z-connection)
For porcelain-housed arresters, the C-connection provides the most unfavourable conditions
during the initial phase of the test before venting occurs. Once the arc is externalized, it may
then be kept in close proximity to the arrester housing, resulting in a thermal shock effect
causing excessive chipping and shattering of porcelain sheds. During the remaining arcing time,
this routing forces the arc to move away from the arrester, and thus reduces the risk of the
arrester catching fire.
For polymer-housed arresters, the conductors should be routed as per the Z-connection. In this
way, the arc will stay close to the arrester during the entire duration of the short-circuit current,
thus creating the most unfavourable conditions with regards to fire hazard.
A specific exception is Design A arresters with polymeric sheds which are not made of
porcelain or other hollow insulator, but which are as brittle as ceramics. These shall be
considered and tested as porcelain-housed arresters.
It had been observed in many cases that after non-violent thermal breaking of the porcelain
housing the active part, completely intact, fell down such that its top end collided with the
enclosure (which previously had a radius equal to the arrester height) and some parts of its top
end fell just outside the enclosure. Though in these cases the short-circuit performance was
good, the arrester did not pass the test. In order to avoid this conflict the radius of the enclosure
has now been chosen to be 20% larger than the arrester height; dimensioned according to the
below formula or, in any case, at least D = 1.8m.
D
H
Darr
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The arresters shall be considered satisfactory provided no degradation in the sealing has
occurred.
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24 h
48h
72 h
96 h
Time
-25 C
-40 C
Load direction:
0
Load direction:
180
Load direction:
270
Load direction:
90
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There are a number of potential problems that can arise by exposing an arrester to a continuous
load that is too near to the breaking load. These include:
Damage to the housing of the arrester, which could cause the arrester structure to
completely collapse and break
Damage to internal parts of the arrester, for example damage to the ZnO blocks causing
electrical malfunction
Cracks in the polymer housing or sealing, which could lead to moisture ingress and
electrical failure
Of specific interest is the performance of polymer arresters under continuous loading of a cyclic
nature. Due to their construction, polymer arresters of all designs may flex under mechanical
load and, when this is repeated cyclically (as would occur over their service lifetime), may be the
primary factor which determines the true limit of permissible mechanical loading. A specified
short-term load verified on new arresters not previously subjected to any tests may thus give a
too optimistic value.
Subjecting the arrester, in a cyclic way, to continuous
load may result in significant deflection which in turn may
affect the likelihood of moisture ingress and/or jeopardise
the mechanical integrity of the metal oxide blocks.
Additionally, insulation withstand clearances to other
equipment may be compromised if the deflection is
extreme. Furthermore, the maximum short-term load that
can be applied without breaking may be significantly
reduced after the arrester has been subjected to a
continuous load in a cyclic manner. Hence, a test is
required to verify that an arrester, even after many years
in service and having potentially been mechanically
fatigued, can both remain sealed and still be capable of
withstanding a serious mechanical incident that occurs;
for example a short circuit or earthquake.
IEC 60099-4 specifies a mechanical test to be performed
on three complete arrester units with the highest rated
voltage of the unit, whereby each is subjected to a
cyclical bending moment at the specified long-term load
(SLL) for 1000 cycles. Thereafter, two of the arrester
units are subjected to a bending moment test at the short
term load (SSL), while the third undergoes thermomechanical preconditioning as discussed in section
8.1.12. All three units are then subjected to a water
immersion test (see also 8.1.12).
If the arrester passes 1000 cycles at the SLL and subsequent water immersion and evaluation
tests, it is considered likely that the arrester can continuously be subjected to the SLL
Furthermore, the test validates that the SSL is a load which the arrester could be subjected to
even after many years in service. For short polymer arresters, i.e. arresters for system voltages
not exceeding 52 kV, a cyclic load test has not been considered necessary; neither for
porcelain-housed arresters, considering the long experience of this type of arrester.
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8.2
Routine Tests
The ambition with the routine tests is to ensure that the produced arresters meet the design
specification. All test results have to be within preset limits to qualify the arresters for delivery.
The routine tests are consequently an integrated part of the quality control during manufacture.
As a minimum requirement for routine tests, IEC 60099-4 specifies the following to be
performed on each arrester or arrester unit:
This test serves to prove that the arrester will be free from internal corona at normal
service voltage. IEC permits a maximum level of 10 pC at a test voltage of 1.05 x Uc, but
manufacturers may set their own tougher criteria.
Leakage check of the sealed housing (for arresters with a sealed housing)
o
This proves that the guaranteed protection level of the arrester is not exceeded. If not
measured directly on the complete arrester, residual voltage can be measured on the
individual ZnO blocks or arrester units at a suitable lightning impulse current and then
summed together to give the value for the complete arrester.
The measured value of the reference voltage Uref must lie within the range allowed by the
manufacturer. The lower limit of the Uref guarantees the thermal stability of the arrester.
The higher the value of Uref, the smaller the power losses at Uc and therefore better
stability during network operation. The practical upper limit is determined by the operating
characteristic in order to pass the residual voltage test.
This test proves that the housing hermetically seals the active parts of the arrester.
Common test arrangements are helium-mass spectrometer, vacuum over water,
pressure or vacuum decay and halogen detection. This test is not applicable to certain
polymer arrester designs, when the active parts are directly sealed in the housing
material.
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8.3
Acceptance Tests
An acceptance test, as per IEC vocabulary, means a complete surge arrester should be tested,
i.e. preferably with all individual units connected in series as a fully operational arrester. The
number of arresters to be tested is the nearest lower whole number to the cube root of the
number of arresters in the delivery lot.
Acceptance tests according to IEC 60099-4 incorporate:
Measurement of power frequency voltage of the complete arrester at reference current
Lightning impulse residual voltage test on the complete arrester or arrester units
Internal partial discharge measurement on the complete arrester
Additionally, a Special thermal stability test is given as an option, which has to be specially
agreed upon. This is, in principle, a shortened version of the Operating Duty test, performed on
blocks from the same batch (or similar) as those used in the arresters from the delivery lot.
IEEE calls these conformance tests, and specifies the following:
Discharge voltage test, on the complete arrester or individual units
Internal ionization voltage (IIV) and Radio-influence voltage (RIV) on the complete arrester
8.3.1 Value of acceptance tests
There exists a degree of confusion as to the meaning, and thereby the value, of acceptance
tests on surge arresters. Unlike some other high voltage apparatus, acceptance tests on surge
arresters are not the same as repeated routine tests, particularly in the case of multi-unit
arresters. That said, the routine tests made after assembly of a single-unit arrester could
perhaps be regarded as an acceptance test, since the routine tests are then performed on a
complete arrester. However, to fulfil the requirements of the Standard, an additional lightning
residual impulse voltage test on the unit may be required if this is not performed as routine. It is
permitted, for example, as a routine test to measure residual voltages on individual ZnO blocks
for a specific applied current and then sum up the values to give the total residual voltage for the
unit. Because of the lower voltage required at the block level, this permits testing with high
lightning impulse currents (e.g. 10kA) and good measuring accuracy. Conversely, testing a
complete unit (or complete multi-unit arrester) at higher voltages can present problems
regarding circuit capacity to achieve high lightning impulse currents, as well as potential loss of
accuracy in the measured values compared with performing the test on individual blocks.
For a multi-unit arrester, consisting of several individual units, the units may be regarded as
impedances connected in series, where each individual unit has a specific voltage drop (or
residual voltage) for a specific applied current. Thus, measured values on units when summed
up can be regarded as valid for the complete arrester. Specifically in the case of reference
voltage measurement at reference current, provided that the current is high enough to not be
affected by stray capacitances during the measurement, then the summed values on individual
units can also be regarded as valid for the complete arrester. Similarly, for the internal partial
discharge test, provided the pro-rata voltage used during the routine test on individual units is
equal to or higher than the required test voltage during the acceptance test, then assembling
the units together will not influence the result with respect to internal PD measurement.
Consequently, acceptance tests need not be considered necessary provided already performed
routine, batch and sample tests are sufficient to ensure that the acceptance test criteria are
fulfilled. If this is the case, acceptance tests will then not give any additional information about
the surge arrester characteristics than obtained during the other tests, nor add value or security
to the arresters from a delivery lot.
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9.
ARRESTER SELECTION
This section contains only a brief guidance for selection of the most important parameters of HV
surge arresters used for standard applications such as transformer protection For a more
comprehensive guide, reference is made to IEC 60099-5 and ABB Application Guides. For
specialized applications, a more detailed system analysis or insulation co-ordination study may
be necessary to permit selection.
It is vital that the correct arrester is selected which will provide the desired protection, as well as
withstand normal and specified abnormal service conditions. The basic selection is carried out
in two major steps:
Match the electrical characteristics of the arrester to the systems electrical demands
Match the mechanical characteristics of the arrester to the systems mechanical and
environmental requirements
9.1
Matching the electrical characteristics
In selecting arresters in a 3-phase network, it is first of importance to know if they are to be
connected between phase-ground, neutral-ground or phase-phase. The most common practice
is to connect arresters phase-ground.
The simplified process for selection of the electrical characteristics is depicted in the following
flowchart (Fig. 42).
Uc > Um/3
Electrical
selection
complete
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9.1.1
The duration of the applied TOV during earthfault depends on the fault-clearance time. If this is
not known, it may usually be estimated to be in the range of 1 to 3 seconds for directly earthed
HV systems and 3 to 10 seconds for directly earthed distribution systems. For isolated neutral
or resonant earthed systems, the duration is important to determine more specifically, as it may
vary from a few seconds to some hours or even days; depending on whether fault-clearing is
used or not. For an anticipated fault duration over 2 hours, the TOV should generally be
considered (in most cases) as continuous, and the arrester rating chosen accordingly.
For the most common 3-phase systems, specific TOV and durations are proposed in Table 12.
The assumptions made for directly earthed neutral systems include some combined effects of
earth faults and load rejection; considering if an earth fault occurs during a load rejection, the
TOV on the healthy phases tends to rise further than it would if the events occurred separately.
TOV in p.u. of Um/3
Fault duration
Um < 123 kV
1.55
1s
Um > 123 kV
1.5
1s
1.73
10 s or 2 h
Table 12
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Generally, only the TOV during earth-faults and at load rejection are of interest. Certain network
configurations can however give resonance overvoltages. These may also arise during nonsimultaneous operation of breaker poles. Nevertheless, resonance overvoltages should be
avoided by proper system design (especially for normal AC transmission and distribution
systems) and usually should not need to be the basis for selection of the arrester TOV
capability.
In some cases, efforts are made to reduce the earth-fault current by selectively earthing the
neutrals of only a few transformers, yet maintaining an effectively-earthed system overall. In
such cases, there is a possibility that some parts of the system may become non-effectively
earthed (i.e. increase in value of ke) for certain periods of time when one or more of the earthedneutral transformers are out of service. An earth fault during this time may lead to higher TOV
and subsequent arrester failure if this contingency is not taken into account. Since such
occurrences are rare, it may be justified to accept a risk of arrester failure instead of selecting
an arrester with higher TOV capability and thus a higher protective level.
b) Select the Continuous Operating Voltage
In a 3-phase system with arresters connected phase-ground, the actual continuous operating
voltage, Uca, is not higher than Um/3. If the system does not have any abnormal service
conditions, Uc should therefore be equal to or higher than Um/3.
Special consideration applies to an arrester on the delta tertiary winding of a transformer where
one corner of the delta is permanently connected to ground. In such applications, the
continuous operating voltage applied to the arrester will be the full phase-phase voltage even
though the arresters are connected phase-ground.
Should a considerable amount of harmonics (> 10%) be present in the system, a safety factor of
1.05 (i.e. 5%) is recommended (IEC 60099-5) to account for the increase in peak value of Uca.
However, in systems with short automatic fault-clearance times, a safety factor of 1.0 is often
sufficient nevertheless since the limited duration is normally covered by the TOV characteristic
of the arrester.
It should be noted that any arresters with Uc > Uca are generally equally suitable, with regards
solely to continuous operating voltage.
The manufacturer should be consulted if abnormal service conditions exist which are outside of
those specified by the Standards: such as ambient temperature below 40 C or above +40 C,
frequencies under 48Hz or above 62Hz, presence of heat sources (e.g. furnaces) near the
arrester, etc. Such abnormal service conditions may lead to the need for selection of higher Uc
and/or rated voltage (Ur), unless the arrester has been designed and verified to withstand the
specified service conditions. All ABB arresters, for example, can withstand wider ranges of
temperature (50 C to +45 C) and frequency (15 Hz to 62 Hz), without the need for special
consideration.
c) Select a sufficiently high Rated Voltage to meet TOV demands
In general, surge arresters are not used to protect equipment against TOV as this would require
an enormous number of parallel columns of blocks. Such applications may be considered only
in cases of limitation or elimination of resonance TOV, and carefully detailed studies are then
required to select arresters with suitable energy capability.
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Factors affecting the TOV capability of an arrester are pre-energy absorbed (i.e. the initial
temperature of the blocks) prior to the application of TOV and the applied voltage following the
TOV.
For a given arrester type, the rated voltage (Ur), defined as per IEC, is a measure of its
overvoltage capability. Hence, the additional TOV capability of the arrester can be specified as
a multiple of Ur. A different philosophy adopted by some manufacturers is to give the TOV
capability in multiples of Uc.
The following procedure is suggested to select an arrester with sufficient TOV capability:
Select a preliminary rated voltage (Ur0) based on Uc, with Ur0 = Uc/0.8
where 0.8 is the design factor for ZnO arresters
Determine other temporary overvoltages TOV1, TOV2, TOVn with amplitude and
duration as calculated or estimated, e.g. using the common choice guide in Table 12.
Consider the possible energy absorption W (in kJ) prior to the TOV and calculate W/Ur0.
For each TOV, determine the minimum required rated voltages Ure, Ur1, Ur2, Urn by
dividing the determined TOV amplitude by the temporary overvoltage strength factor Tr
for a selected type of arrester for the actual duration of the TOV and the calculated
energy absorption W/Ur0. If the calculated specific energy absorption W/Ur0 is higher
than the value given for the first choice of arrester type, then increase Ur0 or select an
arrester type with a higher energy capability.
Thus Ure = TOVe/Tre, Ur1 = TOV1/Tr1, Ur2 = TOV2/Tr2, etc
Select a final rated voltage, Ur, which is the highest of the values Uro, Ure, Ur1, Ur2, etc.
If this is a non-standard rating, choose the next higher rating.
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As a general guidance, nominal discharge currents with an 8/20s waveshape as given in the
following Table 13 are proposed.
Maximum system voltage (kV)
800
550
245 < Um < 420
36 < Um < 245
< 36
20
20 (or 15 as per IEEE)
10 or 20
10
5 or 10
Table 13
1 p.u
Fig. 44
Surge
arrester
If the surge travel time of the line is short compared with one cycle of power frequency and Z1
presents a low impedance, the current through the arrester will have a rectangular shape with a
duration equal to twice the travel time T of the wave on the line. The current through the
arrester and its residual voltage at this current are given by the intersection of the relevant
switching surge characteristics and the load line, and can be determined by plotting a load
diagram, as depicted in Figure 45.
Fig. 45
Load Diagram
UL
UL
Z
Ia
Ups
Ups
Prospective overvoltage
Line surge impedance
Surge arrester current
Surge arrester switching surge
protection level (residual voltage)
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In reality, the arrester current does not have a purely rectangular waveform. The source
impedance, Z1, will affect the voltage imposed on the line at breaker closing, the voltage wave
will be distorted during its travel on the line, return waves will cause reflections at the sending
end and, for multi-phase systems, the phases will interact.
However, this simple single-phase model is useful in many cases. To avoid expensive
computer studies, the simplified method can be applied as a first attempt to estimate the
arrester stresses caused by switching. If these calculations reveal higher energies and the
need for more qualified studies than had been considered initially, a more accurate study would
be justified.
Different types and makes of arresters could also be easily compared when high absolute
accuracy in calculated stresses is not required.
In order to use the simplified method, the parameters in the above figure must be determined in
some way. Typical values for different system voltages are given in the following Table 14.
System voltage (kV)
Prospective overvoltage
without arresters, UL (p.u)
Under 145
145 to 345
362 to 550
765 (800)
450
400
350
300
3.0
3.0
2.6
2.2
Table 14
Proposed system parameters
The base for the per-unit values is the peak value of the highest system voltage phase-to-earth
It can be seen that the energy absorbed also depends on the protection level. Thus, a higher
protection level reduces the demands in kJ/kV.
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The energy absorption capability of ZnO arresters has to be proven in the so called line
discharge tests. The energy absorbed by an arrester in a line discharge test is a function of
both the line discharge class and the switching impulse protection level of the arrester.
For a given arrester, an estimate of the energy absorbed in the relevant line discharge test
could be obtained by using the arresters switching surge protective level from the catalogues
and checking for absorbed energy from the Line Discharge Class characteristic curves (e.g. as
per IEC; Fig. 46 below). This value is then compared with the required discharge energy (W)
calculated from the above equation.
CLASS 5
6
5
4
CLASS 4
CLASS 3
3
CLASS 2
2
CLASS 1
1
0
1 .0
1 .4
1 .8
2 .2
2 .6
3 .0
Ups/Ur
R E L A T IV E P R O T E C T IV E R A T IO , U
a /U r
If the chosen energy capability is not sufficient, the most economical solution is to increase the
arrester rated voltage. If this leads to an unacceptable protection level, then select another type
with a higher energy capability. For very high demands, parallel ZnO columns and/or arresters
may be needed to meet the energy requirements. In these cases, proper and careful matching
must be undertaken to ensure sufficiently equal current sharing, as full current sharing is not
necessarily assured with standard arresters.
At lower system voltages (below 245 kV), the energy due to switching will generally be low. At
the same time, less attention is often paid to effective grounding and shielding of such systems.
Hence the design capability will be determined by lightning stresses. A conservative estimate
for the arrester energy capability for lightning surges is obtained in the high current test using a
4/10s impulse with standardized peak amplitudes of 100kA or 65kA (IEC/IEEE). This wave
subjects the arrester to high energy during a very short time and hence to a thermal shock as well.
It is worth noting that discharges of the amplitudes stipulated in the tests rarely occur in reality,
and the real impulse durations seen in service may be longer than the stipulated test impulse
duration.
An arrester with blocks of larger diameter will withstand the lightning stresses better for two
reasons:
the current density will be lower
the residual voltage will be lower and consequently also the energy discharged
Hence, it is advantageous to choose an arrester with larger diameter blocks (and consequently
higher discharge capability) for
areas with high lightning activity
important installations and apparatus
lines and stations where grounding or shielding conditions are inadequate
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420 800
145 362
< 145
2
1
0.5
Table 15
Years
Fig. 47
Insulation withstand with time for paper and oil
insulated power transformers. Ageing reduces
insulation withstand of equipment and thus the
protection margin.
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S
v
L
Upl
Surge arrester
h
b
Fig. 48
The generally used formula to estimate the voltage increase due to distance effect is:
U = Upl + (2 * S * L) / v
where
U
Upl
S
L
v
Note! The distance effect reduction does not apply to the Ups margin since the front-time
of a switching surge impulse is longer.
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The protection margin will therefore dramatically reduce with increased separation distances, as
well as with increased steepness of the incoming wave. The latter is a function of how close to
the substation the lightning strikes the transmission line and risk for backflash or shielding
penetration. Steepnesses of 1200 kV/s and 2000 kV/s have been well established in
Standards and practical insulation co-ordination studies for HV sub-stations, and are often used
as reference surge steepnesses. Nevertheless, the determined strike rate leads to the choice of
actual steepness for a given application.
This simplified method must be used with caution as it is only an approximation. It does not
take into account any capacitance of the protected object, nor inductance effects nor the initial
voltage at the instant of surge. This simple method may not be sufficient in the case of small
margins between the arrester protection level and the objects LIWL; whereby more complex
computer modeling may then be necessary.
In all cases, the importance of short distances and connection lead lengths cannot be overemphasized.
9.1.7 Neutral-ground arresters
In those cases where efforts are made to reduce the local earth-fault currents by not earthing
the neutral of the transformer, each such neutral brought out through a bushing should be
protected against lightning and switching overvoltages by an arrester.
For neutral-ground arresters protecting fully insulated transformer neutrals, the recommended
rated voltage is approximately the maximum system voltage (Um) divided by 3, assuming a
relatively long fault duration. Short or very long fault durations may warrant selection of a
different rated voltage, after taking into account the specific TOV requirements. In addition,
special considerations must be taken for resonant-earthed systems with long radial lines, as a
higher rated voltage may be necessary. Alternative selection criteria may also apply in cases
with unusually low BIL or for neutrals of transformers with non-uniform insulation.
The neutral-ground arresters should preferably be of the same Line Discharge Class as the
phase-ground arresters on the same transformer. The electrical characteristics are then usually
identical to standard catalogue arresters with the corresponding rated voltage. However, for
arresters connected neutral-ground, Uc is usually zero, as they are not subjected to any
continuous voltage stress during normal service conditions. Consequently, demands for
creepage distance and voltage grading do not normally apply to these arresters.
For neutral-ground arresters specifically, it is a further advantage that the insulation withstand of
the arrester is approximately equal (or even below) that of the transformer neutral so that, in the
unlikely event of a flashover, it should occur in preference at the arrester. Consequently, these
arresters would typically be assembled in the shortest housing possible.
9.1.8 Special cases
In special applications e.g. transformers in arc furnace installations switching overvoltages
can occur which are not sufficiently limited by arresters between phase-ground. For these
cases, three arresters connected phase-phase are used in addition to three arresters phaseground. For the arresters connected phase-phase, Uc > Um.
Protection of special electrical equipment such as motors, generators, capacitor banks, etc,
typically require more detailed evaluation than afforded by the simplified approach, and are
therefore beyond the scope of this Guide.
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9.2
Matching the mechanical and environmental characteristics
he simplified process for selection of the mechanical characteristics is depicted in the following
flowchart (Fig. 49).
Mechanical
selection
complete
Light (L)
Medium (M)
Heavy (H)
Very Heavy (V)
16
20
25
31
Table 16
For porcelain-housed arresters, select the housing to give the desired creepage - generally the
same as for the other equipment in the same location. If the creepage demand exceeds
31 mm/kV, a special design may be required.
Silicone-housed arresters, being highly hydrophobic, are better suited for extremely polluted
areas than porcelain- or EPDM-housed arresters. Based on the experience from long-term
testing of silicone apparatus insulators, it is considered possible to reduce the creepage
requirements for silicone housings by at least one step lower specific creepage, i.e. 20 - 30%
less than for porcelain/EPDM.
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The background to this conclusion is presented in the Cigr document A3-104 Optimized use
of HV composite apparatus insulators: field experience from coastal and inland test stations [17].
IEC 60815-3 furthermore accepts that reduction of creepage distance is possible and
permissible from a pollution withstand or flashover point of view on specific polymeric insulators
based on field trials, test stations or historic data with the same design, materials and electric
stress. Hence, for example, if a specific creepage distance of 31mm/kV (Um) is deemed
necessary at a site based on porcelain-criteria, then 25mm/kV is considered adequate with the
silicone used in conjunction with the ABBs PEXLIM design. With such reasoning, 31mm/kV
would only be necessary on PEXLIM arresters in the case that the site conditions dictate higher
than 31mm/kV for porcelain.
Note that IEC 60815-3 introduces the new term unified specific creepage distance (USCD)
defined as the creepage distance of an insulator divided by the r.m.s. value of the highest
operating voltage across the insulator. This definition differs from that of specific creepage
distance where the line-to-line value of the highest voltage for the equipment is used (for a.c.
systems usually Um/3). For line-to-earth insulation, this definition will result in a value that is 3
times that given by the definition of specific creepage distance in IEC/TR 60815 (1986).
Regardless, the same reasoning for acceptance of reduced creepage distance by one pollution
level nonetheless applies.
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In the case of multiple loads acting in combination, the horizontal loads from individual forces
should be used to calculate the vector sum of the bending moments acting about the base, to
determine if the arrester housing can withstand them when applied simultaneously. Importantly,
this calculation should consider realistic combinations of loads (as would be applied in service)
against appropriate safety margins to the arresters static and dynamic mechanical strength,
and not simply as a sum of the maximum cantilever load applied at the top terminal.
This is illustrated in Figure 50, which shows that the arrester in question can withstand the
specified loads (safety factor > 1.0) when like loads are correctly considered to act about
different moment arms and not simply summed together and located solely at the line terminal.
Loads resulting from tensile and compression forces are not usually of concern, as these are
normally limited for standard applications and arrester housings are also typically strong in
these directions. Torsional loading on the arrester is also considered an abnormal service
condition, but may need closer consideration should it exist.
For connecting arresters to the line, a common solution is to use the same conductor as for
current-carrying equipment connected to the same line. However, this is often unnecessarily
large and over-dimensioned for the purpose - the continuous total current through an arrester is
of the order of only a few milli-Amps. The result is undue mechanical loading on the arrester.
Connecting the arresters to the line instead by light, vertical and slack tee-offs, can considerably
reduce the demand for mechanical strength, without requiring significant deviation from
common practice. See Figure 52.
Due to their flexible construction, there may be a visible deflection at the line-end of polymer
arresters under mechanical load. This may ultimately determine the limit of loading which is able
to be applied. However, since polymer arresters are light compared to equivalent porcelainhoused arresters, they permit innovative erection alternatives which could reduce the loading;
for example suspended or under-hung erection or special bracing.
Fig. 50 Example of
Estimated Loading Table
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I = Sk / (3 * Um )
where
I
Sk
Um
If Sk is not known, the breaking capacity of the associated circuit breaker can be used as a
guide for the short-circuit current.
9.2.4 Specification of high ambient temperature
Customer specifications occasionally state tough requirements for maximum ambient
temperature under which surge arresters are to operate. Whilst at the same time it is generally
understood that the average temperature over a 24 hour period will be less.
The influence from the sun radiation is sometimes thought to be significant, as one might
assume that sun radiation can result in considerably high surface temperatures. However, it is
the average surface temperature of the complete arrester that counts, and sun radiation falls on
less than half of the insulator surface at any point in time. In fact, the closer to the equator an
arrester is situated, the smaller the fraction of the insulator surface that is subjected to direct
radiation due to the sheds.
Temperature extremes are tracked and measured daily from multiple locations on earth. Highest
average annual mean temperature ever recorded was 34.4 C in Dallol, Ethiopia during the
period October 1960 December 1966. The following list shows the highest temperature ever
reported on a continent. Keep in mind that the data in older dates may be skewed because
standard temperature measurement techniques and equipment may have changed. Also note
that "Oceania" indicates any small location such as an island in the vast oceans of the world.
Continent
Africa
North America
Asia
Australia
Europe
South America
Oceania
Location
El Azizia, Libya
Death Valley, California
Tirat Tsvi, Israel
Cloncurry, Queensland
Seville, Spain
Rivadavia, Argentina
Tuguegarao, Philippines
Temperature extreme
57.8 oC
56.7 oC
53.9 oC
53.3 oC
50.0 oC
48.9 oC
42.2 oC
Date
September 13, 1922
July 10th, 1913
June 22nd, 1942
January 16th, 1889
August 4th, 1881
December 11th, 1905
April 29th, 1912
Noteworthy is that none of the temperature extremes have occurred since the introduction of
modern gapless arresters in the 1970s and hence specified requirements for other locations
are normally overstated.
ABB surge arresters have low power losses and hence self-heating is negligible. The effects of
direct sun radiation are accounted for in the IEC Operating Duty test of arrester sections, whereby
energy and thermal capacity are verified at a starting temperature of 60 C. This is actual ZnO
block temperature, which adds additional safety margin by ignoring that the average block
temperature will actually be well below the localized surface temperature possible from direct
sun radiation.
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Block type
2
3
4
R
Q
P
ABB type
Porcelain housing
Silicone housing
EXLIM R
PEXLIM R
EXLIM Q
PEXLIM Q
EXLIM P
PEXLIM P
HS PEXLIM P
EXLIM T
HS PEXLIM T
Table 17
Overview of ABB
surge arrester types
For ABB surge arresters, the type designation furthermore gives detailed information of the
rating and its application, as indicated below.
Suffix letters:
E
Non-standard electrical data
M
Non-standard mechanical data
P
Parallel columns
H
Underhung mounting
L
Line arrester
As a guide, the following diagrams give an overview of the typical applications by system
voltage for which the respective arresters would normally be applied. EXLIM porcelain-housed
(51a) and PEXLIM polymer-housed (51b).
Specific applications may dictate the need for a certain type outside of the common choice.
The respective arresters are nevertheless normally able to be tailored to cater for virtually any
rating or application.
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With reference to the considerations discussed in Chapter 9, the following rated voltages
(Ur) are recommended for the most common 3-phase systems with maximum system
voltage (Um) 52 550kV.
System
Fault clearance time
Mechanical load
Housing
LDC
ABB type
Um (kVrms)
52
72
100
123
145
170
245
300
362
420
550
Medium
Porcelain
2 or 3
EXLIM R
EXLIM Q
Um (kVrms)
52
72
100
123
145
170
245
300
Silicone
4 or 5
PEXLIM P-Y
HS PEXLIM P
HS PEXLIM T
192
228
276
330
420
Medium
Porcelain
2 or 3
EXLIM R
EXLIM Q
High
Silicone
Porcelain
2, 3 or 4
3, 4 or 5
PEXLIM R
EXLIM Q
PEXLIM Q
EXLIM P
PEXLIM P
EXLIM T
Rated voltage, Ur (kVrms)
48
48
66
66
96
96
120
120
132
132
162
162
228
228
276
276
48
66
96
120
132
162
228
System
Fault clearance time
Mechanical load
Housing
LDC
ABB type
High
Silicone
Porcelain
2, 3 or 4
3, 4 or 5
PEXLIM R
EXLIM Q
PEXLIM Q
EXLIM P
PEXLIM P
EXLIM T
Rated voltage, Ur (kVrms)
42
42
60
60
84
84
96
96
120
120
132
132
192
192
228
228
276
276
330
330
420
420
42
60
84
96
120
132
192
System
Fault clearance time
Mechanical load
Housing
LDC
ABB type
Um (kVrms)
52
72
100
123
145
170
Directly earthed
Max 1 second
Silicone
4 or 5
PEXLIM P-Y
HS PEXLIM P
HS PEXLIM T
228
276
Medium
Porcelain
2 or 3
EXLIM R
EXLIM Q
60
84
120
138
162
192
High
Silicone
Porcelain
2, 3 or 4
3, 4 or 5
PEXLIM R
EXLIM Q
PEXLIM Q
EXLIM P
PEXLIM P
EXLIM T
Rated voltage, Ur (kVrms)
60
60
84
84
120
120
138
138
162
162
192
192
Silicone
4 or 5
PEXLIM P-Y
HS PEXLIM P
HS PEXLIM T
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10.
INSTALLATION GUIDELINES
Upon arrival to site, the contents of all packages should be checked against the respective
packing lists and any shortages identified. During unpacking, a visual inspection should be
made for any obvious signs of transport damage.
Reference shall be made to the assembly and special instructions provided for details of correct
installation and these shall always be followed and take precedence.
Since ABB undertakes such extensive routine, batch and sample tests on the
ZnO blocks, surge arresters and counters/monitors (in excess of the requirements of the
applicable standards), additional testing or commissioning checks are not considered
warranted or necessary at installation or before taking EXLIM or PEXLIM arresters into service.
10.1 Conductor dimensioning
Under normal operating voltages the arrester represents a high impedance and hence only
milliamps of current are typically flowing constantly through the connecting conductors. Even
under surge conditions, although the current can be significant (10's of thousands of Amps) it is
only present for a very short time (microseconds). Such currents will have a negligible heating
effect on the conductor. Consequently, the question of conductor size and cross-sectional area
is perhaps not as important for surge arresters as it is for other high voltage apparatus.
The true criteria comes when the arrester has
overloaded and the system short-circuit current is
thereafter flowing through the arrester and its
conductors.
If the cross-section is thermally
insufficient for this condition, the connection may be
destroyed, i.e. melt before the protection has
operated to clear the fault. However, this may be
able to be accepted, since the arrester has to be
replaced anyway. If this is not acceptable, the crosssectional area for the conductors must be based on
the system short-circuit current and duration.
For the line conductors, the simple practical solution
is often to use the same conductor as for highcurrent carrying equipment connected to the same
line, e.g. dropper to current transformer. However,
as noted above, this is typically unnecessarily large
and may result in undue mechanical loading on the
arrester. Lighter droppers, connected as slack
vertical tee-offs, may be preferable, and even
recommended, for this reason.
Surge arresters shall be connected to the same
common earth grid as for the other HV apparatus in
the substation. The earth conductor cross section
shall be overridingly chosen in accordance with local
regulations and earth fault current requirements.
Fig. 52
Example of mounting and connection arrangement
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Connections to surge arresters in distribution systems are sometimes made via 600/1000 V
PVC insulated copper cables. The temperature rating for this type of cable is generally V75,
i.e. 75 oC. Two important factors should be considered before using this type of cable;
especially in HV applications:
Above 200 oC, copper anneals and loses about 70 percent of its strength, thus
compromising its ability to withstand short circuit forces. This increases the risk of
breakage from whipping.
Above 90 oC, standard PVC softens. With an ambient temperature of 40 oC, this permits
only 50 oC temperature rise. PVC begins to melt at 80 oC temperature rise, at which
point the risk of catching fire is very high.
The earth conductor between the arrester and counter should be insulated for at least
5 x L kV (LIWL), where L is the conductor length in metres between the arrester earth
terminal and the surge counter terminal. Note that the maximum permissible length L of
the earth conductor between arrester and surge counter is determined by the LIWL of
the insulated base which the arrester is mounted on as well as the counter itself
The LIWL of the insulating base and the counter must also withstand this induced
voltage; otherwise it will flashover and the impulse will be earthed through the structure
without passing through the counter.
Even if the LIWL of the insulated cable is sufficient, this lead must in any case be kept as
short as practicable since its inductance-drop adds to the protection level of the arrester.
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11.
A surge arrester does not contain any moving parts or items that can break. Consequently there
is nothing to maintain, adjust, correct or repair, which is why there is normally no need to perform
any form of periodical checking or monitoring. In general, a correctly chosen and installed
arrester is regarded as maintenance free during its entire lifetime. A correctly chosen arrester in
this context means that its electrical and mechanical characteristics are matched to actual service
conditions.
11.1 Mean Time Between Failure (MTBF) and Mean Time To Repair (MTTR)
The question of MTBF and MTTR is often asked for substation equipment. However, such an
analysis has no meaning or direct relevance for surge arresters. The design-life of a modern
gapless ZnO arrester can reasonably be expected to be at least as long as the equipment it is
protecting (nominally accepted to be 30+ years). However, this does not mean that it will
necessarily last as long as the primary plant. It must be remembered that a surge arrester is, in
principle, a sacrificial protective device, designed to operate to protect other electrical
equipment. During the normal course of events, it may need to sacrifice itself at any time to
protect the primary plant. It is therefore often very difficult to distinguish between a failure and
a correct operation as, depending on the nature of the electrical surge, an arrester could "fail"
internally during correct operation. But this should not be considered as a "failure" if it occurs
for genuine reasons; rather it is the function of a surge arrester.
Finally, an arrester which has failed must be taken out of service and disposed of according to
local regulations. It cannot be repaired or reworked.
11.2 Cleaning
Periodical cleaning of porcelain-housed arresters is usually only necessary after periods of
heavy marine or industrial pollution. Surge arresters may be washed under voltage (livewashing), following the same safety regulations as for any other high voltage equipment, plus
with the following additional precautions:
surge arresters normally employ shorter flashover distance compared to other insulators,
leading to an increased risk for external flashover during the washing
surge arresters with series connected units must have all units washed simultaneously to
avoid overheating of any unit
Arresters with silicone housing should, in general, not need to be washed at all. Nevertheless, it
is acknowledged that silicone insulators exposed to heavy pollution for long periods may
become discoloured and appear dirty over time. This is as a result of low molecular-weight
silicone oils diffusing to the surface, ultimately encapsulating the pollution layer and making the
housing appear dirty and difficult to clean. This function permits the housing to ultimately
recover its hydrophobicity, even after a temporary loss; a unique feature amongst insulators. Of
importance is that, unlike other types of insulators, this discolouration does not necessarily
mean that a silicone insulator's in-service pollution performance is affected. In fact, cleaning of
a silicone insulator can actually have the disadvantage of washing away the silicone oils
deposited on the surface, thereby reducing its hydrophobicity for a period.
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Fig. 54
Wettability class
(source IEC TS 62073)
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It
Ic
Ir
Fig. 55
Principle diagram for a gapless
ZnO arrester, where U is the
voltage across the arrester, It is
total leakage current and Ic and Ir
are the capacitive and resistive
components, respectively, of the
leakage current
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The specific capacitance of a ZnO varistor results in typical values of the capacitive current
ranging from 0.5 to 3mApeak, depending on the varistor diameter. For a complete surge arrester,
the capacitive current is further dependent on stray capacitances, pollution currents on the
insulator surface, number of varistor columns in parallel and the actual operating voltage.
Meanwhile, the resistive component of the leakage current of a varistor is at the same time in
the range 50 to 250Apeak, and is temperature and voltage dependant.
Since the capacitive component of the current dominates so greatly, the total leakage current
measured on a simple mA-meter will be very sensitive to the installation; making interpretation
of the readings difficult. Further, there is no evidence that the capacitive current would change
significantly due to deterioration of the voltage-current characteristic of the surge arrester.
Consequently, measurement of capacitive current cannot reliably indicate the condition of ZnO
arresters. Although increasing values may be of some use in indicating that cleaning of the
insulators is necessary.
Instead, it is generally recognised (IEC 60099-5) that the only reliable indicator for the condition
of a gapless arrester which can be assessed during normal service is to measure the resistive
component of the leakage current (or estimate it from the 3rd harmonic), and compare it with the
maximum allowable resistive current, as given by the manufacturer, under prevailing service
conditions i.e. temperature and applied voltage. Ageing of the ZnO varistors will generally cause
a gradual increase of the resistive leakage current with time.
Because of the order of magnitude difference (A vs. mA), a significant change in the resistive
current would be required before it could be noticed on a milliamp meter. Therefore, special
measuring apparatus are necessary to separate out the two components, and give a reliable
detection method for the analysis of the leakage current through gapless ZnO surge arresters.
Two such devices are ABB Surge Arrester Monitor EXCOUNT-II and TransiNor Leakage
Current Monitor LCM-II.
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12.
SPECIAL APPLICATIONS
With increased focus on system reliability, together with ongoing developments occurring in the
field of overvoltage protection, new and innovative applications are continuing to be found for
the use of surge arresters.
Many of these are, however, quite specialised and require more in depth discussion than is
considered possible within the scope of this Guide. Nevertheless, this section briefly discusses
a number of these topics, and refers the reader to other ABB technical information for further
reading should they be of interest. See References.
12.1 Reduced clearance distances
In order to reduce the risk of insulation failure to an economically and operationally acceptable
level, the insulation withstand of substation equipment is selected with regard to expected
overvoltages, taking into account the protective characteristics of the surge arresters.
The insulation withstand of the surge arrester itself has to be co-ordinated with its own
protective characteristics. The arrester has to be positioned with respect to grounded objects
and surge arresters in adjacent phases, without increasing the total risk for insulation failure.
The insulation withstand properties of surge arresters in a substation can be divided into:
insulation withstand of the surge arrester itself, including the insulation between flanges
and grading rings, etc.
insulation withstand between the surge arrester and grounded objects
insulation withstand between the surge arrester and other equipment connected to the
same phase, e.g. bushings
insulation withstand between surge arresters in adjacent phases
The insulation withstand should be the only constraint when selecting suitable clearances for
properly dimensioned surge arresters. Any effects which various phase-to-ground and phase-tophase clearances may have on the voltage distribution along the ZnO block column should have
already been accounted for in a well-made design.
The insulation withstand of the surge arrester itself should also have been thoroughly
considered at the design stage. Spacing between metal flanges, as well as spacing between
flanges and grading rings, should be designed to be sufficiently large to withstand overvoltages
appearing during current discharges; at least up to the design altitude (and perhaps more).
a) Phase-to-ground clearance
The phase-to-ground clearance in substations is usually based on the selected standard rated
lightning and switching impulse withstand voltages. International Standard IEC 60071-2, for
example, recommends minimum clearances.
In general, the clearance between a grounded object and a surge arrester should be the same
as the phase-to-ground clearance selected for other high voltage equipment in a substation. If it
is not possible to use the normal phase-to-ground clearance in special applications, a smaller
clearance may be chosen, considering the protective characteristics of the arrester, and after
correction for altitude. However, this is generally only possible if there is a fairly big margin
between the standard rated withstand voltage for a substation and the protective level of the
arresters.
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Surge Arresters
marked with blue
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Fig. 58
LSA on HV
transmission line
LSAs give complete protection against lightning flashovers for the actual line insulator.
Insulators in adjacent phases and in other towers, however, are not protected; which is why
LSAs are mainly installed on all phases on the towers that are intended to be protected. In
reality, LSAs are seldom installed throughout an entire line length, but instead only in areas
where lightning gives most problems due to exposed position, bad earthing conditions etc.
Modern localisation systems for lightning-storms in combination with traditional fault statistics
are excellent tools to identify towers where LSAs should be installed to be of most effective use.
The dimensioning of a LSA generally follows the same criteria as for an arrester in a substation.
However, it is of particular importance that the LSA is designed correctly with respect to energy
and TOV capability, since the stresses on the arrester at lightning are highly dependent on the
earthing conditions, presence of shield wires, etc. Similarly, the complete solution must be
physically and mechanically robust, since it is fully exposed to the elements and typically
inaccessible for close inspection or maintenance.
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Line Surge Arresters (LSA) of a gapless design offer a robust, efficient and cost-effective
alternative to those with series gap; External Gap Lightning Arrester (EGLA).
EGLA have the following inherent disadvantages in their functional operation:
Needs tailor-made design for each situation; making installation difficult and prone to error
Insulation co-ordination is difficult; since the gap characteristic is prone to change
Unpredictable energy sharing; increasing the risk for arrester failure
No switching impulsive overvoltage control; meaning outage rate remains high
Pollution effects unpredictable; increasing the risk for arrester failure
Signalling device needed to indicate failed arrester; but is rarely provided
Failed SA is weak point for repeated short-circuits
The final point is perhaps one of the most commonly overlooked. It is promoted that the series
gap will hold against power frequency voltage in the event of an arrester overload; which may
be true. However, the gap cannot be dimensioned to withstand lightning impulses. Hence, a
subsequent lightning strike to the line nearby the failed arrester will cause the gap to fire and a
permanent earthfault will occur, with consequential line outage. Without some kind of signalling
device (rarely provided) this failed arrester will be practically impossible to locate and repeated
flashovers and line trips will occur. The problem will be multiplied in the case that several
arresters along the line have failed.
In comparison. LSA have the following unique advantages:
Easy insulation co-ordination for both lightning and switching overvoltages
Flexibility in application; may be mounted in a way that best suits the tower configuration
User-friendly installation; simply connected without individual adjustment
Predictable energy sharing; predictable estimate of risk for overload
Self-disconnection means no permanent fault / weak-point
No signalling device needed
In contrast to EGLA, an LSA can be suspended from the line or mounted on the tower in a way
that best suits the overall configuration. By so doing, the arrangement can be made to ensure
that, in the event of an arrester overload, adequate clearance is assured to withstand not only
PFWL but also LIWL and SIWL. This is achieved through the clever use and placement of the
self-disconnecting device.
Manufacturers of EGLAs sometimes promote the disconnecting device on LSAs as a weak
point; prone to damage and premature disconnection. On some designs this may be the case.
However, ABBs LSA design is different since it uses common line hardware as well as specially
designed fittings to ensure the robustness of the solution as a whole. Furthermore, in contrast
to some solutions, ABB uses station class PEXLIM arresters for its LSA, meaning that the same
high quality and secure performance expected in substations is also achieved out on the
transmission lines. This is exemplified in the high values achieved during the lightning Impulse
discharge capability test according to Annex N of IEC 60099-4 (since Ed 2.1, 2006-07).
More information on the selection of surge arresters for this application is available in the ABB
brochure PEXLINK: Transmission-line protection for disturbance-free system operation.
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Fig. 59
Switchsync and CAT
relays in conjunction
with PEXLINK
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More information on the selection of surge arresters for this application is available in the ABB
Technical Information document Guidelines for selection of surge arresters for shunt
capacitor banks.
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Fig. 60
UHVDC arrester
Fig. 61
Multi-column, high
energy application
More information on the selection of surge arresters for this application is available in the ABB
Technical Information document Current sharing considerations.
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13.
[1]
REFERENCES
International Standards and Guides
IEC 60060-1
IEC 60068-2-11
IEC 60068-2-14
IEC 60068-2-42
IEC 60071-1
IEC 60071-2
IEC 60099-1
IEC 60099-4
IEC 60099-5
IEC 60507
IEC 60815 -1,2,3
IEC 61166
IEC 61462
IEC TS 62073
[2]
[3]
IEEE Standard for Metal-Oxide Surge Arresters for AC Power Circuits (>1 kV)
IEEE Guide for the Application of Metal-Oxide Surge Arresters for
Alternating-Current Systems
Recommended Practices for Seismic Design of Substations
[4]
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[5]
[6]
A.R. Hileman, Insulation Coordination for Power Systems, Marcel Dekker, Inc. 1999
[7]
[8]
[9]
L. Stenstrm, J. Lundquist, Selection, Dimensioning and Testing of Line Surge Arresters, presented at the
Cigr International Workshop on Line Surge Arresters and Lightning, Rio de Janeiro, Brazil, April 24 -26, 1996
[10]
L. Stenstrm, J. Lundquist, Energy Stress on Transmission Line Arresters Considering the Total Lightning
Charge Distribution, presented at the IEEE/PES Transmission and Distribution Conference and Exposition,
Los Angeles, September 15-20, 1996
[11]
[12]
L. Stenstrm, J. Lundquist. New Polymer-housed ZnO Arrester for High Energy Applications. Cigr 1994
Session August 28 to September 3, Technical Paper 33-202
[13]
S. Vitet, L. Stenstrm, J. Lundquist. Thermal Stress on ZnO Surge Arresters in Polluted Conditions Part I:
Laboratory test methods, presented IEEE, PES 1991 T&D Conference and Exposition, Dallas, Texas
September 22-27, 1991
[14]
S. Vitet, A. Schei, L. Stenstrm, J. Lundquist. Thermal Behaviour of ZnO Surge Arresters in Polluted
Conditions Part II: Field test results. presented IEEE, PES 1991 T&D Conference and Exposition, Dallas,
Texas September 22-27, 1991
[15]
S. Vitet, M. Louis, A. Schei, L. Stenstrm, J. Lundquist. Thermal Behaviour of ZnO Surge Arresters in
Polluted Conditions. Cigr 1994 Session August 30 to September 5, Technical Paper 33-208
[16]
J. Lundquist, L. Stenstrm, A. Schei, B. Hansen, New method for measurement of the resistive leakage
currents of metal-oxide surge arresters in service, presented at IEEE SM, Long Beach, California, July 9-14,
1989
[17]
[18]
R.P.P. Smeets, H. Barts, W.A.Van Der Linden, L.Stenstrm. Modern ZnO surge arresters under short-circuit
current stresses: Test experiences and critical review of the IEC Standard. Cigr 2004 Session, Technical
Paper A3-105
[19]
C. Neumann, V. Aschendorff, G. Balzer, H. Gartmair, E. Kynast, V. Rees, Performance of the switched gap of
SF6-HV circuit-breakers stressed by lightning overvoltages, Cigr 1996 Session, Technical Paper 13-102.
[20]
[21]
J. Taylor, ABB Power Products, Ludvika, Sweden, Short circuit behaviour Surge arresters and counters,
presented at INMR world congress and exhibition, Brazil, May 13 -16, 2007.
[22]
L. Stenstrm, J. Taylor, F. Persson, N.T. Osiptsov, Installation of LSA on a 400kV double-circuit line in
Russia, presented at Cigr colloquium Application of Line Surge Arresters in Power Distribution and
Transmission Systems, Cavtat 2008
[23]
ABB AB, High Voltage Products, Ludvika, Sweden, Mechanical testing and demands on HV surge arresters,
June 2008
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ABB
HV Components
Surge Arresters
SE-771 80 LUDVIKA, Sweden
Tel. +46 (0)240 78 20 00
Fax. +46 (0)240 179 83
E-mail: arresters.div@se.abb.com
Internet: http://www.abb.com/arrestersonline
ABB
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