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Presentation on Surge Arresters
2
Surge Arresters and Recent Developments
Why Surge Arresters ?
Aggressor
ProtectorPotential
victim
Surge Arrester Applications
Definition as per IEEE standards
As per IEEE standards, Surge / Lightning Arrester is“ a protective device for limiting
surge voltages on the equipment by diverting surge current and returning the device to its original status. It is capable of repeating these functions as specified”
Over Voltage ProtectionBasic function of a surge arrester is to limit over-voltages to acceptable limits
Causes for over-voltage / Surges in a system
Main causes for over-voltages in electrical system :
1. Lightning over-voltages ( micro seconds )
2. Switching over-voltages ( milli seconds )
3. Temporary Over-voltages ( Seconds )
Over-voltages & electrical system
Electrical equipments like transformers,motors are designed to withstand pre-determined values of impulse voltages.
Higher levels & multiple strikes of impulsevoltages cause the insulation to break downthus creating chaos in the system.
Over-voltages in electrical system
Protection of electrical devises are madepossible by connecting protective devises -Surge Arresters in parallel.
These devises should have variableresistance as a function of the voltagemagnitude to divert over-voltage to ground.
Gapless Zinc Oxide Surge Arresters arethe latest protective devises used to keepthe system voltages well within limits.
Current absorbed by Lightning arrester
Surge Voltage on Transformer
65kA
Equipment BIL
Surge Arresters / Over-voltage protection• Basic function of a surge arrester is to limit over-
voltages to acceptable limits.
– Acceptable limit means • Limiting over voltages to below BIL of equipment being
protected. • Protecting consumers and their equipmentSources of over-voltages:
– Temporary over-voltages: Earth faults, etc.. – Transient overvoltages, (impulses):
• lightning• switching
Surge arresters basic principles:Usually installed between phase
and earth/neutral
Under normal operating conditions, acts as an insulator• When subjected to an transient over-voltage,
it switches and diverts current to ground, thus limiting the over-voltage.
• Returns to insulator function: – ..if energy rating is not exceeded– damaged by internal short circuit.
• Must be thermally stable and able to withstand datasheet defined temporary over-voltages for period from seconds to hours, (depending on system).
Typical application:
Transformer protection
Earth
Arrester
HV
Expensive transformer damagesCost of TRAFO replacement
Cost of outage
Cost of oil clean up
Cost of arrester
Evolution of surge arrester
Arcing HornsBasic arcing horns are:
Simplest of Surge Arresters.
Can be provided with all equipments withbushings.
Difficult to maintain spacing / setting.
Difficult to monitor
SiC ArrestersSilicon Carbide Gapped arresters, assembled with SiC resistors and plate spark gaps:
Creates short circuit to earth when the voltage rises due to the spark gaps.
Series connection of SiC resistors limits the follow current from power supply - arcs disappear across gaps when next current zero occurs
Difficult to maintain gaps and monitor
Metal Oxide ArrestersZinc Oxide Gapless arresters, assembled by stacking ZnO blocks and placing same in insulating housings:
Extremely non-linear characteristics and so do not require any spark gaps.
Current starts to flow through arrester before the over voltage reaches the peak value.
Reduces the over voltage faster than the sparked gap arrester.
TWO SIGNIFICANT DEVELOPMENTSFollowing two significant fundamentaldevelopments occurred in the arrestertechnology:
SiC resistors and plate spark gaps werereplaced by Metal oxide resistors withoutplate gaps.
Housings of the arresters made ofporcelain were replaced with new onesmade of polymer material.
Arrester with Porcelain housing
Arrester ClassificationArresters can be classified based on following:
Based on type of housinga) Porcelain Housed Arrestersb) Polymeric Housed Arresters
Based on Energy HandlingDistribution class Station class I to IV
Surge Arrester Major ComponentsThe major components of LA’s are:
• Outer housing - porcelain or polymeric.• ZnO Blocks.• Springs to keep blocks in place.• Spacers / Heat sinks • Pressure Relief vents • End caps for preventing moisture entry.• Terminals for connecting to line & earth.• Mounting clamps
Outer Housing
Main functions are:
• Provide the contained space in which the ZnO Blocks are assembled.
• Ensure heat transfer from the blocks tooutside atmosphere.
• Have necessary parameters to ensurewithstand of electrical system properties.
• Prevent tracking and flashover.
Zinc Oxide Blocks
HEART of the Surge Arrester:
• Must remain as a non-conducting path during the normal operating voltage &ensure only over-voltages are conducted to earth.
• Minimum leakage current & have good heatdissipation.
• Quick response - absorb incoming surgeswithout time delay.
• Maintain good thermal stability for long life.
ZnO blocks
Electrode
Collar
1. Characterised by Uref, Ures, KV/mm field strength, electrode metallization, collar coating.
1. Quality of block determines Long Duration current2. Diameter = energy handling (assumes same
quality)3. Height = voltage. Typically 3kV =40mm.
2. Electrode is usually aluminium or silver based, used to optimise electrical contact between blocks.
3. Insulating collar used to prevent surface flashover
Microstructure of ZnO materialIdeal material structure
ZnOZnO
A = ZnO B = Spinel C = Bismuth
Optimum structure, perfectly homogeneous, i.e.
no weak points/paths
Homogeneity / thermal behaviour of the block:
Inhomogeneous - Homogeneous
High current impulse, (or thermal runaway)
Weak paths detected in “1”
Excessive local temperature ride along weak paths in samples “1” – leading to fracture & short circuit failure
What is thermal balance ?
ZnO Element Contd...
ARRESTER MANUFACTURING PROCESS
RAW MATERIAL
MIXING & SPRAY DRYING
PRESSING SINTERING LAPPING GLASS COLLARING
ANNEALING METALSPRAY TESTING
( BLOCKS )
ASSEMBLY TESTING PACKING
Ultimate test of varistors and arrester: Independent type testing,
IEC 60099-4 Surge Arrester Type Testing• Insulation withstand tests• Residual voltage tests• Long duration current withstand test• Operating duty test• Power frequency voltage versus time curve• Short circuit (pressure relief) test• Partial discharge test
Latest edition of IEC 60099-4 released 2006
Insulation withstand testInsulation w ithstand test of the arrester
housing:
Arrester housing should be able to withstand the lightning impulse protection level of arrester multiplied by 1.3
Design feature: Flash over distance of the housing
Samples tested: Arrester housing with insulating
core.
Surge arresters / Overvoltage protectionBasic function of a surge arrester is to limit
overvoltages to acceptable limits
Residual Voltage testResidual voltage testing of pro-rated test
samples:
The purpose of the measurement of residual voltage is to obtian the maximum voltages for a given design for all specified currents and waveforms.
Design feature: Related to disc specification
Samples tested: Prorated arrester samples.
Residual voltage determines protection level of arrester when subjected to certain wave forms. Its output also sets the limits for reference voltage routine testing in the factory.
IEC 60-1; Standard lightning waveform definition:
T1/T2;
8/20 waveform
8 µs T1T2 = 20µs
Current absorbed by Lightning arrester
Surge Voltage on Transformer
Equipment BIL
Standard phase to phase lightning insulation levels
Note: Taking the example of the 12kV system, the decision for lightning rating is dependant on statistical likely-hood of lightning, type of neutral earthing and type
of over-voltage protection used as standard.
Residual voltage dropIn order to ensure no loss of residual voltage the surge
arrester should be mounted directly on the transformer.
If it is not then quite a dramatic increase in effective residual voltage will occur. The actual loss will depend on the size of the impulse in kA and the frequency of the wave form.
For example if the arrester is 4m from the transformer and the incoming impulse is 5kA on a 8/20 then the rise in residual voltage will be 5kV. If the impulse is 20kA then the loss will be 20kV.
If the incoming wave is 4/10 then the rise will be 10kV on a 5kA impulse
Influence of surge arrester placementPotential difference across an inductor is given by the equation:
For a transformer lead the inductance L is approx 1μH per metre length of lead wire.
The lead length used to calculate inductance L is twice the transformer lead length (H) because the travelling wave sees the transformer as a near open circuit and is reflected back to the arrester.
e.g. for a 20kA 8/20μs impulse with a 4m transformer lead length the potential rise is calculated as:
Inductance L = 2 x 4m x 1μH/m = 8 μH
kVs
kAHV
208208 Rise Voltage
=
×=µ
µ
dtdiLV =
Lead Length from arrester to transformer = H
EarthThus we can estimate the voltage rise beyond a surge arrester with various lead lengths and surge kA as follows for a typical 8/20 lightning impulse
5kA 10kA 15kA 20kA 40kA0.5m 0.6kV 1.2kV 1.8kV 2.5kV 5.0kV1m 1.2kV 2.5kV 3.7kV 5.0kV 10kV2m 2.5kV 5.0kV 7.5kV 10kV 20kV4m 5kV 10kV 15kV 20kV 40kV6m 7.5kV 15kV 23kV 30kV 60kV
N.B.: For 4/10μs impulses such as the 65kA high current the voltage rises are doubled because the dt time value is half that of an 8/20 μs impulse
Transformer degradationWell designed, well
made, well maintained Poorly designed, poorly made, poorly maintained
Time in Years
BIL
90
75
60
0 5 10 15 20
Normal max operating point for transformer oil is about 80˚C. For every 6˚C above 92˚C rate of aging doubles.
Breathing system maintenance can have very significant bearing on insulation life as moisture content, acidity and oxygen content dramatically effect aging.
Energy AbsorptionLightning is a multi-component event called a flash, (1-2s)A single transfer of current from cloud to ground is called a stroke, (µs)
Positive or negative
Long stroke
First short stroke±i High current
operating duty
Long duration
I peak
Long duration current withstand
Test to confirm that arrester can withstand rated long
duration line discharge duty.
The purpose of the measurement of LD test is to verify the arrester ability to withstand multiple long duration impulses, i.e. Switching / multipulse induced overvoltages while energised at power frequency voltage.
Design feature: Energy handling, thermal stability.
Samples tested: Prorated arrester samples.
Long Duration Current test sequence
Example test for 5kA arrester:
Check reference voltage
Inject 18 impulses of “200A(min), 2ms duration”
Verify Uref is within 5% of original value
Operating duty testTest to confirm that arrester can withstand a combination of stresses
that an arrester is faced with in service while energised at power frequency voltage.
The main requirement to pass this test is that the arrester is able to cool down in between impulses while under power frequency voltage, i.e. Thermal run away does not occur.
Design feature: Impulse stability, energy handling,
thermal stability.
Samples tested: Prorated arrester samples.
Operating Duty Test
20 shotsPreconditioning
5kA 8/20µs
Rated voltage
Continuous Operating voltage
65kA 4/10µs
1. Measure Residual Voltage
2. Energise to 1.2 times MCOV
3. Precondition with 20 shots of 5kA, 8/20µs4. One shot of 65kA, 4/10µs for 5Ka arrester (100kA for 10Ka arrester)
5. Heat to 60˚C
6. Second shot of 65kA, 4/10µs
7. Apply rated voltage for 10 seconds
8. Apply continuous operating voltage for 30 minutes
9. Measure residual voltage again. Must be within 5% of original value
Revision of Standard
IEC 60099-4, 2006
finally caught up with
State-of-the-ArtSurge Arrester
Technology
New Requirements
Moisture Ingress Test;
Weather Ageing Tests;
(Tracking & Erosion Performanceof Housing)
Short Circuit Tests (Test procedure still informative but commonly accepted with distribution type arresters, more realistic failure simulation)
Routine testing: PD < 10pC,
Aging addressed.
Tightness Test (Moisture ingress)IEC 9.7.9
• Terminal torque Pre-conditioning• Thermo-mechanical pre-conditioning
(4 x 24 hours)• Boiling in salty water
Why is this important?
Screens poor seals;
(after mechanical stressing)
Not every design can pass this test
-25°C +60°C
+45°C-40°C
42 h
Moisture Ingress Test
• Mechanical changes to be reported
• Increase of power loss < 20%
• Partial discharges not exceeding 10pC
• Change of residual voltage @nom. discharge current not exceeding 5%
• No breakdown visible in voltage and current oscillograms
Porcelain Failure due to moisture ingress
Moisture Ingress paths
Moisture Ingress paths
Moisture ingress results in internal flashover / surge arrester failure
No tracking or erosion
Salt fog test
• No tracking
• No erosion through entirethickness of external coating
• No puncturing of sheds and housing
• Decrease of reference voltage should not exceed 5%
• Partial discharges should not exceed 10 pC
Product materials testing
Tracking and Erosion Resistance, TERT.• TERT is used a measure of the tracking and erosion resistance
of materials. • It is a good measure used to rank materials relative
performance, at the screening stage. Though this ranking may not always reflect exact ranking in the field, it is considered a good screening test.
Two tert tests;-Step test: Voltage is increased each hour and contaminant rate
increased periodically-Constant Voltage test: Voltage and contaminant flow rate maintained
for set time
In either test method, the material must be non-tracking with eventual failure by erosion only. Flame failure is not allowed.
Tracking and Erosion Resistance, TERT.
Tracking and Erosion test set-up (TERT)
Conductivecontaminant(ammoniumchloride)
ElectrodesElectrodes
Tert plaque (6mm thick)
TERT - Key Failure Mechanisms
Tracking failure(rapid process)
Erosion failure (slow process)
Sample - Front View Side View Sample - Front View Side View
1000 hours continuous salt fog at continuous operating voltage UcSamples energised at Uc in an enclosed chamber 10m^3A mist is generated with a salt concentration of between1 -10kg/m^3Test run for 1000hr min
No tracking and erosion should occur. Outcome?
FAIL FAIL
Weather Ageing Test: 1000hr salt fog
Short Circuit Test
• No violent shattering
• No fragments outside enclosure(except soft polymeric material,fragments less than 10 g,pressure relief vents, ...)
• No open flames after 2 min
After short circuit test withElectrical pre-failingmethod
Short Circuit Test
Failure modes
Risk: Fire, danger, collateral damage
Specific Advantages of Polymeric Housing
• No internal air space, no chance of moisture ingress.• Vandal proof.• Non-explosive failure mode.• High thermal conductivity. Rapid heat dissipation.• Low weight and small size.• Suitable for pollution environment.• Resistant to transport damage and careless handling.• Stud, pedestal or bracket mounted.• Good for abnormal service conditions like enhanced external
insulation where operation is under high or low temperature oraltitudes over 1000m etc
• Easy to install.
Porcelain vs. polymeric
Porcelain disadvantages• Poor resistance to moisture
penetration• Heavier and brittle (note cracked
shed)• Short circuit pressure relief only
for EHV and Station class arresters
• Thermally insulating design reduces energy handling and TOV performance of block gets affected
• Poor pollution flashover performance.
Porcelain housed arrester Contd...
Arrester Selection
For a network with solid earthed neutral, following is the formula for selection of Maximum Continuos operating voltage of arrester
1.4 x UmUc = --------------
1.28 x _/3
- Um : Maximum Voltage- Phase voltage does not exceed 1.4 p.u- Factor 1.28 considered assuming maximum time for clearance for earth fault is 3 sec
For more details contact:anitagupta@ieema.org
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