specification and testing
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Understanding Surge Arresters
Specification and Testing
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Specification and Testing
Content
Content
Surge Arrester Selection Parameters
Applicable Standards
Testing
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ABB GroupDecember 10, 2013 | Slide 3
IEC 60099-4 as the only valid standard just be sure it is the current edition
COV Uc no more than Um/3 needed (plus perhaps additional harmonics)
TOV important to be correctly determined and specified
Desired protection levels realistic and relevant
Line Discharge Class higher gives better protection for most important equipment
Energy demands realistic, relevant & well-defined; no unnecessary added margin
Environmental considerations ambient temperature, altitude, pollution, etc
Mechanical demands limited wherever possible by installation
Thereafter, manufacturer ideally to be given freedom to
optimize his design
higher COV is unnecessary
rated voltage not specified by user
Otherwise risk for sub-optimized solutions since users
cannot know design specifics
Specification and Testing
Surge Arrester Selection Parameters: AC Arrester Specification
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ABB GroupDecember 10, 2013 | Slide 4
Specification and Testing
Surge Arrester Selection Parameters: Electrical
Electrical
selection
complete
Uc > Um/3
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ABB GroupDecember 10, 2013 | Slide 5
Specification and Testing
Surge Arrester Selection Parameters: Mechanical
Mechanical
selection
complete
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ABB GroupDecember 10, 2013 | Slide 6
Specification and Testing
Surge Arrester Selection Parameters
How much insurance to buy?Choose the surge arrester that provides optimum protection with
suitability to the application at a value for money price and not simply
based on up-front cost.
Which Surge Arrester
can I afford not to choose?
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Specification and Testing
Content
Content
Surge Arrester Selection Parameters
Applicable Standards
Testing
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ABB GroupDecember 10, 2013 | Slide 8
IEC (International Electrotechnical Commission)
IEC 60099-4 (Edition 2.2, 2009-05) #)
"Metal-oxide arresters without gaps for a.c. systems
IEC 60099-5"Surge arresters - Selection and application recommendations
IEC 60071-1"Insulation co-ordination - Definition, principles and rules
IEC 60071-2"Insulation co-ordination - Application guide
IEC 60815-1, -2, -3"Guide for the selection of insulators in respect of polluted conditions"
IEEE (Institute of Electrical and Electronics Engineers) IEEE C62.11 (2012)
Metal-Oxide Surge Arresters for AC Power Circuits (>1 kV)
#) Forthcoming Edition 3 (prelim release 2014)
New concept of arrester classification and energy withstand testing Requirements and tests for UHV arresters
Specification and Testing
Applicable Standards
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ABB GroupDecember 10, 2013 | Slide 9
Edition 1 only considered porcelain-
housed arresters and much testing of
ZnO arresters was based on the old
gapped arrester standard 99-1
Edition 2 2004
Polymer arresters now
considered
Amendment 1 2006
Edition 2.1
Short circuit testing defined
Amendment 2 2009
Edition 2.2
Mechanical testing defined Forthcoming Edition 3 (prelim release 2014) New concept of arrester classification
and energy withstand testing Requirements and tests for UHV arresters
Specification and Testing
Applicable Standards: IEC 60099-4 Development
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ABB GroupDecember 10, 2013 | Slide 12
Residual voltage
Long duration current impulse withstand
Operating duty tests
Accelerated ageing
Insulation withstand
Short circuit
Sealing / moisture ingress (porcelain / polymer)
Mechanical
Weather ageing (polymer-housed arrester)
Artificial pollution (porcelain-housed multi-unit arrester)
Internal partial discharge / RIV
Environmental
Tests of arrester disconnectors
Current distribution test (multi-column)
Specification and Testing
Applicable Standards: Type Testing to IEC 60099-4 IEC 60099-4 defines well
the type tests to be
performed on
Elements
Sections
Complete design
to represent actual
performance
as applicable for
Individual test Design concept
DVD
MO RESISTOR
HOUSING
OTHER
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Specification and Testing
Content
Content
Surge Arrester Selection Parameters
Applicable Standards
Testing
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ABB GroupDecember 10, 2013 | Slide 14
Not all arrester manufacturersmake their own MO resistors bought as a commodity
Which block make is used
in a particular arrester?
Are arrester type test reports
available for every make of block
used? otherwise
published performance is worthless!
Specification and Testing
MO Resistors: Consider Source of Supply
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ABB GroupDecember 10, 2013 | Slide 15
What are the routine and
sample tests on MO resistors
and what are the pass criteria?
How are claimed type test dataassured on a daily bases in
production?
How is the energy capability
defined and how is it assuredin daily production?
If some special energy capability is
claimed, how can it be traced back to
routine test requirements?
Specification and Testing
MO Resistors: Relevant Questions to Ask
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ABB GroupDecember 10, 2013 | Slide 16
Are the MO resistors manufacturedin house or bought from anothermanufacturer?
If bought from others Are type tests performed on all block
types used?
How is the quality assured?
What steps are taken to ensure the
blocks have never been exposed tomoisture (eg. during transport)before being assembled in thearrester?
Are routine tests performed in-houseon the blocks bought or are onlydata from the supplier used for thedesign?
Specification and Testing
MO Resistors: Relevant Questions to Ask
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IEC60099-4, Amendment 2 (Ed. 2.0)Edition 2.2, 2009-05
Specification and Testing
Bending Moment
IEEE standard still remains behind the technology change(considers moisture ingress on polymer arrester but not effects of cyclical fatigue)
ABB GroupDecember 10, 2013 | Slide 17
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Initialmeasurements
1000-cyclesat SLL
Bending momenttest at SSL
Test evaluation
Terminal torque
(30 sec)
Thermo mech
cycling (4x24h)
42 h in boilingsalt water
60-90 sec
Nm
42 hours
Boiling deionized water
with 1 kg/m of NaCl
1000cycles-SCL
1 cycle0.01-0.5 Hz
+SCL
SSL SSL
Time
+45 C
-25 C-40 C
Temp
24 h 48h 72 h 96 h
0 180 270 90
+60 C
Load direction:
Specification and Testing
Mechanical testing for polymer housings
Visual inspection
Measurement ofwatt losses
Partial dischargemeasurement
Measurement ofelectrical values
3 32
1
3 3
1
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Specification and Testing
Permissible deflection Focus should not only be on level of SLL & SSL
but also deflection under load
An arrester with insufficient stiffness againstmechanical load can jeopardize required
clearance distances leading to increased risk
for flashover with time
Through prudent designation of permissible loads,adequate clearances can be maintained under all
conditions to ensure deflection does not increase
during lifetime
ABB GroupDecember 10, 2013 | Slide 19
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Only in the case of overload
Failure mode isinternal short-circuit
Explosive failure can resultif internal arc is notrelieved fast (< cycle)
Controlled external flashover
ensures personnel/equipmentsafety
Solid polymer designs must allow multipleperforations to externalise arc while holdingin internal components
Designs with enclosedair/gas volume requireventing devices to safely
relieve internal pressure
ABB GroupDecember 10, 2013 | Slide 20
Specification and Testing
Short Circuit Safety
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Failure mode depends on arrester design:
Design A arresters have a design in which
a gas channel runs along the entire length ofthe arrester unit and fills 50 % of the
internal volume not occupied by the internal
active parts.
Design B arresters are of a solid designwith no enclosed volume of gas or having an
internal gas volume filling < 50 % of the
internal volume not occupied by the internal
active parts.
Uprefail >> Ur , 5+3 min
"External fuse wire"
along surface of activepart
Design A arresters
"Pre-failing"
by overvoltageapplication
Design B arresters
Active parts are ZnO-discs and spacers in series with them
Specification and Testing
Short Circuit Testing: IEC & IEEE Failure Modes
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Allowed to be found outside the circle
Fragments < 60 g from ceramic material like MO-varistors and/or porcelain
Pressure relief vent covers and diaphragms
Soft parts of polymeric material
Other parts inside circular enclosure
Allowed to be found outside the circle
Fragments < 60 g from ceramic material like MO-varistors and/or porcelain
Pressure relief vent covers and diaphragms
Soft parts of polymeric material
Other parts inside circular enclosure
H
d
h > 0,4 m
D = 1.2* (d + 2H) > 1,8 m
Circular enclosure D
Arrester unit
max. 60 g
No violent shattering Thermal breaking is allowed
Self extinguish within 2 min.
ABB GroupDecember 10, 2013 | Slide 22
Specification and Testing
Short Circuit Testing: Pass Criteria and Set-Up
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Specification and Testing
Short Circuit Testing: ABB Safety Belt Winding
ABB GroupDecember 10, 2013 | Slide 23
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Specification and Testing
Short Circuit Testing: Solid Design After Short Circuit Tests
with belt-windingwithout belt-winding
ABB GroupDecember 10, 2013 | Slide 24
The belt-winding holds the
internal components in place.
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Counters exposed to same short-
circuit currents as the arrester
At present, no requirements inIEC 60099-4 for any form oftesting or verification
Performance depends on design
ABB GroupDecember 10, 2013 | Slide 25
Specification and Testing
Short Circuit Testing: Surge Counters are in the Same Circuit
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Specification and Testing
Short Circuit Testing: Pass-Through DesignTo arrester
terminal
To ground
mA
Negligible additional residual voltage
Short-circuit safe no risk of explosive failure
ABB GroupDecember 10, 2013 | Slide 27
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ABB GroupDecember 10, 2013 | Slide 28
Selection Parameters - Keep to the Facts Electrical
Mechanical
Optimum Protection by Value for Money
IEC 60099-4 (Edition 2.2) Type testing Edition 3
Short Circuit Test Behaviour ABB Safety Belt Winding on PEXLIM
ABB Surge Counter Short Circuit Tested
Specification and Testing
Summary
Ensure the insurance you buy is what you need and
that it is verified through correct and necessary testing!
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