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LONG TERM PERFORMANCE OF POLYMER HOUSED MO-SURGE ARRESTERS

B. RICHTER*, W. SCHMIDT K. KANNUS, K. LAHTI

ABB SWITZERLAND LTD. TAMPERE UNIVERSITY OF TECHNOLOGY
(Switzerland) (Finland)

V. HINRICHSEN C. NEUMANN W. PETRUSCH K. STEINFELD

DARMSTADT UNIVERSITY RWE NET AG FGH MANNHEIM SIEMENS AG
OF TECHNOLOGY
(Germany)

Years after the market introduction of metal oxide (MO) surge arresters with polymeric housings in
medium voltage (MV), high voltage (HV) and extra high voltage (EHV) systems an IEC-standard [1]
was published recently, dealing with test procedures for this type of surge arresters. Besides
mechanical tests, climatic tests, and the short circuit test, which is still under consideration, the long-
term tests have led to controversial discussions. One reason is that it is virtually almost impossible to
define a test procedure, which considers the features of hydrophobic (e.g. silicone) and non-
hydrophobic (e.g. EPDM) materials at the same time. Further on, HV MO-surge arresters can
generally not be tested completely in long-term cyclic tests, while MO-surge arresters for MV systems
can be tested completely in the today existing test labs. This is important, because not only the
insulating material of the housing has to be tested. New test procedures and long-term tests have been
developed in close cooperation between manufacturers and users under guidance of research institutes.
The aim of the long-term tests is to prove the validity of existing test methods, to develop new tests,
and to compare artificial lab tests with real existing stresses in the system. The test results show that
the design of the MO-surge arresters (internal structure), the material of the housing, and the quality of
the production process have significant influence on the performance of the arresters. The overall
experience with polymer housed MO-surge arresters in MV, HV, and EHV systems is very good.
Long-term tests (testing time longer than two years) under very high humidity proved, that directly
moulded (e.g. by silicone) designs show the best performance.

Keywords: MO-surge arresters – polymeric housing – silicone – long-term tests – humidity

1. INTRODUCTION

Surge arresters are indispensable devices within electrical power supply systems to ensure appropriate
insulation coordination and to protect valuable equipment like power transformers, GIS, cables etc.
from lightning and switching overvoltages. They have undergone considerable technical changes
during the last two decades. A today’s modern surge arrester has only few things in common with a
surge arrester for the same application but 25 years ago.
The first change was the transition from gapped silicone-carbide (SiC) to gapless MO-surge arresters.
This development started at the end of the 1970s, and latest by end of the 1980s MO-surge arresters
had definitely been established as state of the art, since their technical and commercial benefits are
quite evident. There is in general no indication for any severe degradation of the MO material even
after more than 20 years of service. The failure rates of MO-surge arresters are in the range of 0.1%/a

* bernhard.richter@ch.abb.com
to 1%/a (with geographic variations) in MV, and virtually zero in HV systems. The very simple and
robust structure of an MO-surge arrester – the active part basically consists of a stack of cylindrical
MO resistor elements – also pushed another development only a few years later: the increasing
application of polymer instead of porcelain housings. Polymer housed arresters were introduced for
the first time in the mid 1980s in MV systems. A main driving force might have been the partly poor
performance of several porcelain housed MV arrester designs, which often suffered from sealing
deficiencies, extreme sensitivity to pollution and an unsatisfying overload performance. While sealing
problems are not automatically solved when using a polymer housing, it turned out that this
technology offered some more advantages with respect to automation of production, lead time,
transportation, handling, and so on. Today the market share of polymer housed MV arresters is close
to 100 %. The situation is somewhat different for HV arresters. First polymer housed HV arresters
appeared on the market around 1990, being niche products in this time. The actual share of polymer
housed HV arresters is estimated to be 25% to 30%, with increasing tendency. It has to be noted that
MO-surge arresters with polymeric housings are used more and more in railway facilities (a.c. and
d.c.), generator protection, cable and cable sheath protection and other special applications.

2. DESIGN OF MO-SURGE ARRESTERS

After about 15 years of development some few basic design principles of polymer housed MO-surge
arresters can be distinguished with a variety of individual sub-solutions. In principle MO-surge
arresters consist of two main parts: the active part and the housing. The active part consists of a stack
of MO resistors with a highly non-linear voltage-current characteristic, kept together by a mechanical
structure. An insulating housing gives protection against the environment. The arrester designs can be
grouped according to the manufacturing technique and internal structure.

2.1 Design principles of polymer housed HV arresters

It is suggested to make a differentiation between designs using a hollow core insulator with an
intentionally enclosed gas volume and such designs, where the housing is put onto the MO column
without any intentional gas volume [2]. The mechanical designs can be characterized as follows:

Type A: This design – the “tube design” – is a more conventional approach, looking quite similar to
that of porcelain housed arresters. The stack of MO resistors is mechanically supported by an internal
cage structure, for example made from FRP (fibre reinforced polymers) rods or loops. This insert is
clamped between the end flanges. What is important (and sometimes criticised) is the fact that this
arrester due to its enclosed gas volume needs sealing and pressure relief systems. This has in fact to be
designed and manufactured with the same high care as it is the case with porcelain housed arresters.
But just for this reason this does not constitute a real problem for an experienced manufacturer of HV
arresters. Some of the potential benefits of a Type A design are high mechanical strength, safe short
circuit performance, and the possibility of producing tall units, which can serve as single-unit arresters
up to 300 kV systems.

Type B: Here we have to differentiate between the so called “wrapped design” (B1) and the “cage
design” (B2) [2]. Both designs were first introduced for MV arresters, and then adopted to HV
arresters [3]. Fig. 1 shows photographs of real arrester modules, produced by two different
manufacturers. Main technical advantages of the “cage designs” are that they offer comparatively high
mechanical strength combined with an inherent good short circuit performance.

As for the mechanical design, there are numerous possibilities to realize the outer housing and sheds.
With regard to material, however, with only few exceptions, there has been a clear tendency towards
SR (silicone rubber). All the other materials are usually not excepted in HV systems. The reason is
quite obvious: only SR offers hydrophobicity (i.e. the ability to repel water from its surface) which
lasts for decades, and from its chemical structure it is inherently less sensitive to solar radiation.
 FRP loop

FRP tension rod

MOV column

End fitting

Fig.
Fig. 1:1: Internal
Internal mechanical
mechanical structure Fig. 2: Principle designs of Fig. 3: Internal
of Type B2ofarresters,
structure type B2 „cagearresters,
design“. MV arresters. Left: Group I, structure of a MV
Left: Loop design, right: rod
cage design“ Left: loop design design. right: Group II (III). arrester, Group I.

2.2 Design principles of polymer housed MV arresters

MV arresters designs can be grouped according to the manufacturing technique and the internal
structure, similar to the differentiation of the design principles of HV arresters. In the MV field only
very few designs have a Type A design, and if so, for special applications only. In [4] the designs of
MV arresters are differentiated as follows:

Group I: The polymeric material (e.g. silicone) is directly moulded onto the internal parts, the MO
resistors and the mechanical structure. A primer is used to ensure chemical bonding of the different
materials with the silicone. End caps are not needed.

Group II: The insulating housing is pressed or slipped over the separately manufactured active part.
The materials are only attached mechanically one to the other. A sealing system with end caps is
needed.

Group III: As Group II, but with considerable internal gas space. This gas space may be intended,
due to the design, or not intended, due to an uncontrolled manufacturing process.

The differences in the design differentiation of HV and MV arresters are due to the fact that in HV the
mechanical strength is more important, while in the MV field the production process is of higher
importance. The design principle B2 for HV arresters is almost identical to Group I for MV arresters.

2.3 Pollution performance and radial electric field strength

The internal axial voltage distribution of an MO-surge arrester is nearly even, due to its high self
capacitance, and, in the case of HV arresters, additionally controlled by grading rings. The external
distribution shows statistical behaviour in case of surface conductivity due to pollution. The electric
potential of an intermediate fitting or flange may be transferred along the insulator, and thus a high
electric field stress may occur between the outer surface of the housing and the MO column, see Fig.
4. In case of a Type A arrester, which has a gas-filled gap between the housing wall and the MO
column, the highest fraction of the radial voltage drops across the gap due to the geometry and the
ratios of different dielectric constants of the materials. The electric field stress at the MO column can
therefore reach values above the initiation level of partial discharges. There are two means to make a
Type A arrester resistant against this effect: one is to apply a sufficiently large gap. Investigations
under salt fog stress have shown that a gap distance of 10 mm to 20 mm for polymer housings with SR
 MO column
Gas
Conductive Type X, boiling
Solid layer Type Y, boiling
Type X, + 70°C

Uaxial, int
Type Y, + 70°C

Uradial

Fig. 4: Possible voltage distributions of an Fig. 5: Water immersion test with two different
arrester unit under polluted condition. water temperatures. Test duration up to 800 h.

sheds is sufficient to effectively avoid internal partial discharges. Additionally, exclusively materials
and MO resistors should be used, which are insensitive to possible partial discharges.
Radial field stress is also a concern for Type B arresters. Here the radial voltage drops across the small
distance of only few millimetres between the outer surface and the MO column, and a week design
may be punctured by this stress. For this reason the actual arrester standard [1] requires a weather
aging test (which includes salt fog stress under applied voltage) at the longest unit for all polymer
housed arrester types.

3. TESTS

Recently an IEC-standard (IEC 60099-4, Ed. 1.2, 2001-12) [1] was published, including test
procedures for polymeric housed MO-surge arresters. Besides mechanical, climatic, and the short
circuit test (which is still under consideration), the long-term tests have led to controversial
discussions. One reason is, that it is virtually almost impossible to define a test procedure, which
considers the features of hydrophobic (e.g. silicone) and non-hydrophobic (e.g. EPDM) materials at
the same time. Additional it is not possible to cover all climatic requirements world wide in one test.
The idea to apply modified material or insulator tests (e.g. acc. IEC 61109) as test for electrical
equipment leads to some problems. Equipment with active internal parts exhibit electrical field
stresses very different from those of e.g. insulators and therefore require other test procedures and
criteria than pure material tests.
HV MO-surge arresters can generally not be tested completely in long-term cyclic tests. This is
possible on sections or units only. For MV MO-surge arresters the situation is different, it is possible
to test complete MV arresters in the today existing test labs. This is important and necessary, because
not only the insulating material of the housing is of importance, but the complete design and the
processing. This is especially true when long-term tests are performed.

3.1 Long-term performance of the outer insulation

Several procedures have been developed in the past to check the performance of polymeric insulators
under severe ambient conditions. Most of the tests are long-term tests, lasting for 1000 h or 5000 h.
The tests are performed with medium voltage, this means, as already mentioned, that from HV
arresters only pro rated sections can be tested. An overview about the most common procedures and
information about the correlation between test procedure and stresses in the system is given in [5] and
[6]. It is obvious, that for the time being only insufficient knowledge is available for the definition of
cyclic tests. One important point is, that the test procedure should consider the polymeric material
used. Decisive for the long-term performance of polymeric material is the dynamic behaviour of the
hydrophobicity. Depending of the material a loss of the hydrophobicity can be permanent (no
regeneration, e.g. EPDM) or temporary (regeneration after a stress period, e.g. silicone).
Based on the existing standardized test procedures (e.g. VDE 278 for cable terminations (1970s), VDE
441 for line insulators (1982), IEC 61109 for line insulators (1992), and IEC 61462 for hollow
insulators (1998)) it was tried to establish a long-term test for HV arresters with polymeric housings,
in which the longest unit had to be tested. This may give problems, because the existing test labs can
perform salt fog tests with test durations of 1000 h and more only with test voltages in the range of
100 kV to 150 kV. Cyclic tests with 5000 h test duration can be performed practically only with MV
arresters.

3.2 Standardized tests for arresters

For MO-surge arresters with polymeric housings a “weather ageing test” is given in [1]. Two test
series are specified: test series A is a 1000 h salt fog test, while test series B is a 5000 h cyclic test. It is
mandatory to run at least one of them on the longest unit of a design. It has to be noted, that the 5000 h
cyclic tests are given just as examples. Any other cycle fulfilling the requirements given in the
standard may be chosen.
As long as it is not sufficient to test only the outer insulation, but the complete design of an arrester, an
additional test is given in [1]. This “moisture ingress test” is a sealing test. In a preconditioning
sequence the arrester is stressed mechanically in different directions, simultaneous with thermal
cycles. Afterwards the arrester is kept in boiling water for 42 h. After cooling down in the water to
ambient temperature some electrical a.c. measurements are repeated, and the results are compared with
previous measurements. There should be no relevant changes in the electrical characteristics, and no
sign of water ingress into the design.

3.3 Non-standardized tests

To get more information and better understanding about the different designs and materials used
special tests have been developed in close cooperation between manufacturers and users, under
guidance of research institutes. Tests, as for instance given in the “which”-reports by ea-technologies,
UK, are comparing tests, checking the performance of different designs under very severe stresses. In
such test procedures emphasis is given to the hydrophobicity, the long term behaviour under salt fog,
and the performance under extreme temperature cycles in air, water (including icing) or in liquid
(water with additives). Tests, performed at the Tampere University of Technology, Finland, had the
purpose to evaluate different designs of MV arresters under severe long-term stresses, and to compare
new test methods with the standardized procedures.

3.3.1 Water immersion tests

Two different MO-surge arresters with silicone housing, both of design Group I (here named X and Y)
have been immersed in de-ionised water with 1 kg/m3 of NaCl. The water ingress was detected by
accurate d.c. leakage current measurement. Two water temperatures (70°C and 100°C, boiling) have
been chosen to study the influence of the water temperature. The resistance to moisture penetration
was quite different in the performed test, see Fig. 5. Arrester Y withstood more than 100 h of boiling,
before a significant change in the leakage current could be observed. Arrester X had a relatively low
resistance to water penetration. It took only some hours to reach leakage currents of some µA. The
temperature of the water has a significant influence on the leakage current growth rate. It has to be
mentioned, that both the types X and Y withstood the moisture ingress test acc. to [1] without any
problem.

3.3.2 Recovery tests

The same procedure and the same measuring technique as for the water immersion test have been
used. The recovery was measured after the water immersion for the same two MV arresters X and Y.
 Type X
Type Y

Fig. 6: Change of leakage current due to Fig. 7: Results of long duration moisture
diffusion of humidity into the design and ingress tests.
recovery in dry periods.

During the recovery period the test samples were stored under normal room conditions. Fig. 6 shows
that the recovery from moisture ingress is very fast for the tested arresters. Both MO-surge arresters,
belonging to design Group I, recovered almost completely. Not only the moisture ingress has to be
considered, but the recovery behaviour of a design as well. As long as humidity cannot condense in
the arrester and form water or water films along interfaces between different materials, the design is
not endangered by humidity.

3.3.3 Long-duration moisture ingress tests

This test gives emphasis to the diffusion of humidity into the arrester and the sealing system under
very long test times. In test sequence a total of seven different designs of MV MO-surge arresters have
been tested. The samples were placed in a chamber with high humid conditions (temperature 30°C to
35°C, relative humidity 95% to 100%). Additional rain was applied for 2,5 h each day. Alternating
voltage of 12 kV was applied. After each 4 weeks electrical and mechanical tests were performed for 5
days. This cycle was repeated for a total testing time of 780 days. Fig. 7 shows, that all designs from
Group II and III failed after a period of time. Especially endangered are designs of Group III, which
have remarkable gas volumes in the inside of the housing. Only the designs of Group I, where the
silicone is directly moulded onto the internal parts, and chemically bonded with a primer to the other
materials, withstood this severe long duration test.

4. FIELD TESTS

A total of 67 MV MO-surge arresters with polymeric housings of 8 different makes (age 4 to 15 years)
were taken from various 24 kV networks in Finland. The following measurements were performed:

1) Visual inspection
2) Insulation resistance measurement with a d.c. voltage of 1000 V
3) Measurement of the d.c. voltage at 3 mA d.c.
4) Measurement of the peak value of the total a.c. current at Uc
5) Measurement of the a.c. voltage and the power losses at a current of 3 mA (peak)
6) PD measurement at 1.05 Uc
7) Residual voltage at current impulses (2.5/70 µs), 3 positive and 3 negative impulses with I = 1.6 kA
to 2.5 kA, depending on type of arrester
8) Measurement of the d.c. voltage at 3 mA d.c. (repetition of 3))

All the studied MO-surge arresters with polymeric housings were in good conditions after being in
service for 4 to 15 years. Comparing measurements on some unused MO-surge arresters showed that
the protection levels remained stable, and the a.c. characteristics did not change remarkable.
5. OUTDOOR TEST STATIONS

MO-surge arresters with polymeric housings are installed in trial lines and outdoor test stations. For
example, MV arresters of type Y (design Group I, see 3.3.1) are installed in the ESKOM test station in
South Africa, directly at the shore of the sea, Fig. 8, withstanding the very severe stresses of salt from
the sea, sand from the desert, and the strong UV radiation for years without any failure.
The National Grid Company (NGC) from UK requires the proof from the manufacturer that the
arrester withstands the special ambient conditions close to the channel coast. For this the arrester has
to withstand at least two winter periods in the outdoor test station at Dungeness. The arresters are
stressed in this place almost constantly with a strong wind from the sea, and consequently have all the
time a pollution layer on the surface of the housing. Fig. 9 shows a HV arrester (420 kV system, Ur =
360 kV) in this station. After the two winter periods the arrester was brought back to the manufacturer
for final investigation. There was no relevant change in the hydrophobicity compared to the arrester in
new condition.

Fig. 8: MO-surge arrester for MV system in an outdoor Fig. 9: 420 kV MO-surge arrester
test station of ESKOM, South Africa. (Ur = 360 kV) with polymeric
Left: View of the test station, located directly at the housing (outer insulation: RTV-
shore of the Atlantic Ocean. Right: MO-surge arrester silicone) under test in Dungeness
with insulating bracket and disconnector under test. (NGC/UK).

MO-surge arresters with silicone housings for MV systems are installed in trial lines, close to cement
factories and in regions with extensive agriculture, in very different regions of the world, and show
everywhere a very good performance. It has to be noted that even in regions with severe pollution
standard creapage distances and single shed profiles are sufficient. The MO-surge arrester as shown in
Fig. 8 has a specific creapage of 28 mm per kV test voltage.

6. CONCLUSION

MO-surge arresters with polymeric housings can be grouped according to their internal structure and
the production process. Silicone as housing material shows generally better performance than other
polymeric materials.
In the MV field MO-surge arresters with polymeric housing have a market share of almost 100%.
They have now successfully been in service for nearly 20 years. Polymer housed HV arresters actually
have a market share of about 30%, with increasing tendency. First installations have been made
around 1990, and so far there is no indication that they will not show the same good performance as
MO arresters in general. Different design principles have emerged in the meantime, which basically
can be divided in “tube” designs and “wrapped” or “cage” designs. These different designs usually
serve different market segments. The technology can be considered mature. Thus it can be predicted
that the market share of polymer housed HV arresters will increase, because of the economical and
technical advantages against porcelain housed arresters.

In 2001 an IEC test standard [1] for gapless MO-surge arresters was published, including long-term
tests for polymer housed arresters. However, the discussion is still ongoing. Due to restrictions in test
labs it is not possible to test complete HV arresters in long-term test, especially when cyclic tests are
considered. The actually used material should be considered when long-term tests for the outer
insulation have to be performed. Polymers, which do not recover after severe pollution stresses
(complete loss of hydrophobicity), should preferably be tested by a 1000 h salt fog test. Polymers,
which recover after severe pollution stresses (e.g. silicones), should better be tested by cyclic tests.
Generally, the correlation of test results from lab tests and the performance of the different arresters in
the field is still questioned.

Long-term tests (testing time longer than two years) with MV arresters under high humidity proved,
that directly moulded (e.g. by silicone) designs show the best performance. Additionally it is very
important not only to consider the ingress of humidity into a design, but also the recovery under
normal ambient condition after a period of high humidity. It has to be ensured that there is no
accumulation of humidity in the design.

Large field studies and the experience from outdoor test stations in South Africa (ESKOM) and UK
(NGC) prove, that the overall performance of polymer housed MO-surge arrester in MV, HV and
EHV systems is very good. The different designs, developed for different applications, allow special
solutions for overvoltage protection and insulation coordination in general.

7. REFERENCES

[1] IEC 60099-4, Ed.1.2, 2001-12; Surge arresters – Part 4: Metal-oxide surge arresters without gaps
for a.c. systems

[2] V. Hinrichsen, “Latest Designs and Service Experience with Station-Class Polymer Housed Surge
Arresters”, [World Conference on Insulators, Arresters and Bushings, Marbella/Spain, November
16-19, 2003; proceedings]

[3] W. Schmidt, “New POLIM medium-voltage surge arresters with silicon insulation”, [ABB Review
2-96]

[4] K. Lahti, B. Richter, K. Kannus, K. Nousiainen, “Internal Degradation of Polymer Housed Metal
Oxide Surge Arresters in Very Humid Conditions” [Proceedings ISH London, UK, 1999]

[5] Oberflächenverhalten von Freiluftgeräten mit Kunststoffgehäusen. Technischer Bericht Nr. 291 der
FGH, Januar 1999 (in German)

[6] Natural and artificial ageing and pollution testing of polymeric insulators. CIGRE Brochure 142,
June 1999