INSULATION COORDINATION FOR AC HIGH VOLTAGE CIRCUIT BREAKERS

Stephen R. Lambert, Fellow Shawnee Power Consulting, LLC Williamsburg, VA

Abstract: Circuit breaker insulation paths are defined

1. Preinsertion Resistor 2. Grading Capacitor 3. Interrupter

and voltage stresses on those paths are examined. Insulation capability and testing procedures as defined by various standards are presented, and the effect of increasing altitude on the capability of external insulation is discussed.

I Circuit Breaker Insulation Circuit breakers typically have three major insulation paths:
4. Support Column

1. 2. 3.

phase to ground across the open interrupter (longitudinal path) phase to phase

There are external insulation paths which typically involve porcelain surfaces in contact with air, and internal paths in which the insulation media could be air, vacuum, oil, SF6 or some new medium. Figure 1 shows a representation of a typical EHV live tank, SF6 circuit breaker and will be used as an example. In the open position, the line to ground insulation path consists of an external path across the parallel group of one interruption chamber (3), the grading capacitor (2) and the pre-insertion resistor (1), if present, in series with the porcelain support column (4). There also exists an internal path in SF6 across the interrupter and the operating rod which is internal to the support column. The longitudinal path across the open breaker includes the interrupters, grading capacitors and pre-insertion resistors. When closed the porcelain column is the external path with the internal path consisting of SF6 in the pole column and the insulated rod. For circuit breakers with individual poles, phase to phase insulation paths are usually not an issue, but they may be important in lower voltage, three pole units.

Figure 1 Insulation Paths

II Voltage Stresses Circuit breaker insulation can be subjected to a number of different overvoltage voltage stresses: 60 Hz Switching surges Lightning surges 60 Hz Overvoltages Usually 60 Hz voltages are not threatening to breaker insulation as the test levels are high,

especially for lower voltage breakers 3-5 pu for lower voltage breakers and 2-2.7 pu for EHV breakers. During fault conditions, voltages on unfaulted phases can rise to 1.73 pu of nominal phase to ground voltage for lower voltage breakers; at higher voltage levels, rises rarely exceed 1.5 pu. One concern is for open circuit breakers where the voltages across the open gap can reach 2.2 pu. Switching Surge Overvoltages Switching surges occur when lines are energized, reclosed onto a trapped charge, upon fault initiation, fault clearing and line dropping. Phase to ground surge magnitudes typically can be as high as 3.0 pu if no closing resistors are employed, and surges can occasionally reach 4.0 pu when reclosing into a faulted line. Figure 2 shows the maximum phase to ground surge which occurred when a long 345 kV transmission line was three phase energized with a single line to ground fault at open line end. The surge shown was the most severe, 2.90 pu, for 100 random pole closing with no closing resistors employed and no surge arresters were applied. As will be seen later when the test levels are presented, such a surge level would threaten EHV breaker insulation (the phase to ground test for 345 kV circuit breakers is 2.79 pu).
800

oxide surge arresters are often applied to limit surges to acceptable levels, however, there are tradeoffs that need to be considered 2 (although that subject is beyond the scope addressed here). Figure 3 shows the effect of the application of a 276 kV rated arrester at the open line terminal on the surge shown in Figure 2. The arrester limits the 2.90 pu surge to about 1.83 pu. In this case the arresters absorbs about 0.6 MJ of energy with its capability being about 1.7 MJ.
600

400

200

kV

0 20 30 40 50 60 70 80 90 100 110 120

-200

-400

-600

Time (ms)

Figure 3 Application of a 276 kV Rated Arrester Lightning Surge Overvoltages Lightning flashes usually consist of 1 to 9 strokes per flash, with the average being 3 strokes per flash. Strokes typically occur roughly in 0.5 second intervals. Other than direct strikes into a substation (which should never occur if the station is properly shielded), lightning surges can strike transmission lines and enter the substation in two ways: backflashovers and shielding failures. Backflashovers are the result of lightning strokes which strike shield wires or the tower top. Voltage is developed at the crossarm (base of the phase insulator) due to stroke current going down the tower (and hence through the tower footing resistance) and the shield wires. If the developed voltage is sufficient to flashover a line insulator, some of the surge enters the station on the flashed over phase conductor. Backflashovers do not usually occur on EHV systems, especially for strikes to the line for the first couple of kilometers out from the station, as considerable care is usually given to minimize the tower footing resistance and hence lower the surge magnitude, and the line insulation is sufficiently high so as to not result in a flashover.
2

600

400

200

kV

20 -200

30

40

50

60

70

80

90

100

110

120

-400

-600

-800

-1000

Time (ms)

Figure 2 2.90 pu Phase to Ground Switching Surge Preinserting resistors in the closing sequence of a breaker is quite effective in reducing the switching surge magnitudes 1 , and typically involves inserting 300 to 600 resistors for 120o to 180o. The application of preinsertion resistors is still popular, but to much less of an extent than over the last 30-40 years. Today, zinc

Shielding failures occur when a lightning stroke directly strikes a phase conductor and the surge enters the station. For EHV lines, stoke currents exceeding say 20 kA are usually effective shielded and will strike the shield wire or tower rather than strike the phase conductor directly. Only the exposure of the first couple of kilometers of transmission line out from the substation need be considered as attenuation reduces the surge magnitude for strikes further out on the line to negligible levels 3,4 . Figure 4 shows the phase to ground surge voltage at an open circuit breaker for a 10 kA stroke (1.2 x 50 s wave shape) causing a shielding failure 1.6 km out from the station. The instantaneous system voltage at the time of the surge is -449 kV (550 kV system), and the surge polarity is opposite that of the 60 Hz voltage. The stroke current does not generate sufficient voltage to cause a line insulation flashover, and when the surge reaches the open breaker and reflections occur, the magnitude reaches a value of 2900 kV. Obviously the station buswork or the breaker insulation will fail under the stress of such a surge. Methods of limiting the surge to acceptable levels will be discussed in a later section.
3500

switching impulse, and lightning impulse tests. Production tests are performed on all breakers to check the quality the unit. Production tests include only 60 Hz tests 60 Hz Voltages Early standards (early 1900s) provided only for power frequency tests, and the 60 Hz dry test was set at 2.25 times the rated voltage plus 2000 V and was applied for 1 minute. The 60 Hz wet test was applied for 10 seconds, and the test magnitude was set at 2 times rated voltage plus 1000 V. C37.04 5 defines the rating structure for circuit breakers, and the testing procedure is defined in C37.09 6 . Test values are given in C37.06 7 , and Table 1 indicates the present day test levels.
Rated Maximum Voltage (kV, rms) 15.5 25.8 38 72.5 123 145 170 245 362 550 800 Power Frequency Test 1 Minute Dry 10 Second Wet (kV, rms) (kV, rms) 50 45 60 50 80 75 160 140 260 230 310 275 365 315 425 350 555 860 960 -

3000

2500

Table 1 Power Frequency Test Voltages The test is performed by applying a 60 Hz sine wave having the indicated voltage as follows:
a) With the circuit breaker contacts open, apply the specified test voltage to each terminal of the circuit breaker individually, with all other terminals and the frame of the circuit breaker grounded. b) With the circuit breaker contacts closed, apply the specified test voltage to each phase of the circuit breaker individually, with the other phases and the frame of the circuit breaker grounded. There shall be no flashovers during the tests and no damage to the insulation shall be observed after the tests.

2000

1500

kV
1000 500 0 5 -500 7 9 11 13 15 17 19 -1000

Time (s)

Figure 4 - Phase to Ground Lightning Surge Voltage at Open Circuit Breaker

III Insulation Capability and Testing Circuit breaker insulation testing consists of design tests and production tests. Design tests are performed on representative breakers to prove the adequacy of the design to meet its assigned ratings and to prove it can operate satisfactorily. Design tests include 60 Hz,
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In is interesting to note the ratio of the 1 minute dry test voltage magnitude to the rated maximum voltage as shown in Table 2. As the system

voltage levels have increased, the ratio of the test to the rated maximum voltage has significantly decreased.
Rated Maximum Voltage (kV, rms) 15.5 25.8 38 72.5 123 145 170 245 362 550 800 Power Frequency Test 1 Minute Dry In pu of Rated L-G Voltage (kV, rms) 50 5.59 60 4.03 80 3.65 160 3.82 260 3.66 310 3.70 365 3.72 425 3.00 555 2.66 860 2.71 960 2.08

changed to the 1.2 x 50 s waveshape in use now Figure 5 Both full wave and chopped wave tests are required, with the chopped wave having a slightly higher magnitude and is chopped 2 s from the initiation of the impulse. The test values are shown in Table 4. Note that the rated values are considered to have a probability of external flashover of 10% or less. Additional impulse tests are required for outdoor circuit breakers rated above 100 kV that have isolating gaps in series with the interrupting gaps or have additional gaps in the resistor or capacitor circuits. See Section 4.4.5 of C37.09 for further information.
1.2

Table 2 Ratio of Test Voltage to Rated Maximum Voltage Contamination Capability and Testing Recognizing that contamination is present and may be an issue, minimum creepage requirements from C37.06 are shown in Table 3. The values coincide with a value of about 27.7 mm/kVrms, phase to ground, which is appropriate for a light contamination environment. For environments with higher contamination levels (salt fog, heavy industrial contamination areas), longer creepage distances may be required, and special bushing may be needed. Rated Maximum Voltage (kV, rms)
15.5 25.8 38 72.5 123 145 170 245 362 550 800 Minimum Creepage to Ground (mm) 250 420 610 1170 1990 2340 2750 3960 5850 8890 12900
V

0.8

0.6

0.4

0.2

0 0 10 20 30 40 50 60

Time s

Figure 5 Lightning Impulse Waveshape

Rated Maximum Voltage (kV, rms) 15.5 25.8 38 72.5 123 145 170 245 362 550 800

Lightning Impulse Chopped Wave Full Wave (2s) 110 142 150 194 200 258 350 452 550 710 650 838 750 968 900 1160 1300 1680 1800 2320 2050 2640

Table 3 Minimum Creepage Distance Table 4 Lightning Impulse Test Values Lightning Impulse Voltages Lightning impulse testing was begun in the early 1930s, and the magnitude was set at 2 times the low frequency test plus 40 kV. Originally the full wave waveform was defined as having a 1.5 x 40 s shape, and this was later
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The test procedure is defined as follows:

a) With the circuit breaker contacts open: 1) Apply three consecutive positive lightning impulse voltage waves to each terminal of the

circuit breaker individually with all other terminals and frame grounded. 2) Apply three consecutive negative lightning impulse voltage waves to each terminal of the circuit breaker individually with all other terminals and frame grounded. b) With the circuit breaker contacts closed: 1) Apply three consecutive positive lightning impulse voltage waves individually to each phase of the circuit breaker with the other phases and the frame grounded. 2) Apply three consecutive negative lightning impulse voltage waves individually to each phase of the circuit breaker with the other phases and the frame grounded.

initiated as a design test for ratings of 362 kV and higher. Table 6 shows switching impulse test requirements, and the test is performed with a 250 x 2500 s waveshape (both positive and negative polarities). Both wet and dry tests are also required. The test is performed in a fashion similar to that used for lightning impulse tests i.e. the 3-9 test, however, there is one difference. In the open position, an external flashover to ground is considered to be a withstand across the open break and is not counted as a failure. Note that the rated values are considered to have a probability of external flashover to ground of 10% or less.
Switching Impulse Terminal to Terminal Breaker Closed Breaker Open (kV, cr) (kV, cr) 825 900 1175 1300 1425 1500

If during a test group no flashovers occur, the test is passed. However, if one flashover occurs during the first three impulses, then nine additional tests are required and no flashovers are allowed in the nine tests in order to pass the test. Table 5 shows the ratio of the full wave test voltage magnitudes to the crest of the rated line to ground voltage. As with the 60 Hz voltage tests, the ratio has dropped with increasing system voltage.
Rated Maximum Voltage (kV, rms) 15.5 25.8 38 72.5 123 145 170 245 362 550 800 Lightning Impulse In pu of Rated L-G Crest Voltage Full Wave 110 8.69 150 7.12 200 6.45 350 5.91 550 5.48 650 5.49 750 5.40 900 4.50 1300 4.40 1800 4.01 2050 3.14

Rated Maximum Voltage (kV, rms) 15.5 25.8 38 72.5 123 145 170 245 362 550 800

Table 6 Switching Impulse Test Values Table 7 shows the switching impulse voltages as a pu of the rated line to ground crest voltage. Note that these values are below the expected switching surge magnitudes that would be experienced on an EHV system, and it is clear that some means, such as the application of surge arresters on preinsertion resistors will be necessary to limit the surges to acceptable levels.
Switching Impulse Terminal to Terminal Breaker Closed In pu of Rated L-G Crest Voltage (kV, cr) 825 2.79 1175 2.62 1425 2.18

Table 5 - Ratio of Full Wave Test Voltage to Rated Maximum Voltage (l-g crest) Switching Impulse Voltages Switching Impulse testing was not developed until the early 1960s as the 60 Hz tests and the lightning impulse tests were thought to be sufficiently severe as to cover any reasonable switching surges that might be experienced. However, with the increase in system voltages to 362 kV and higher, switching surge magnitudes were sufficient to stress the insulation, and switching impulse testing was

Rated Maximum Voltage (kV, rms) 362 550 800

Table 7 - Ratio of Switching Surge Test Voltage to Rated Maximum Voltage (l-g crest)

IV Protection When a breaker is closed and a lightning surge enters the station, station arresters will usually provide adequate protection to the breaker. However, when in the open position, say following clearing a fault caused by a lightning strike, the breaker is exposed to subsequent strokes from the same flash. The stroke enters the station and approximately doubles in magnitude when it reaches the open breaker. Gaps installed line to ground have been used to protect open circuit breakers, and Figure 6 shows the effect of a typical 2 m gap (500 kV system) located 80 m from the breaker (at the takeoff tower). The gap does not limit the surge voltage caused by a 10 kA shielding failure to acceptable levels. If the gap were located much closer to the open breaker, it is possible that it could protect the breaker. However, in this case the gap has a switching surge withstand of about 2.3 pu requiring that switching surges be reduced by the application of preinsertion resistors or some other mechanism.
2000

kV surge, even with an 80 m separation distance, will not threaten the breakers phase to ground insulation.
2000

1500

80 m separation 40 m 0m

1000

kV
500 0 5 7 9 11 13 15 17 19 -500

Time s

Figure 7 Phase to Ground Lightning Surges Effect of Arrester Separation Distance Figure 8 shows the surge voltage across the open breaker for the same scenario. Here the 1980 kV or higher surge levels do threaten the breakers across the open gap insulation when the separation distance exceeds about 40 m.
2500

1000

2000

80 m separation 40 m

0 5 7 9 11 13 15 17 19

1500

kV

-1000

2 m Rod Gap
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kV
1000

No Protection
500

-3000

0
-4000

Time (s)

11

13

15

17

19

Time s

Figure 6 Phase to Ground Lightning Surge Voltage on Open Circuit Breaker Applying surge arresters is an effective means of reducing the lightning surges to acceptable levels, however it is important to carefully consider the separation distance between the circuit breaker and the protecting surge arrester. Figure 7 shows the effect of arrester separation distance on the surge magnitude impressed on the breaker insulation for a range of separation distances from 0 to 80 m (15 kA stroke, 396 kV arrester). As the breaker lightning full wave impulse capability is 1800 kV, the 1500
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Figure 8 Surge Voltage Across Open Breaker V Effect of Altitude Circuit breakers are tested at NTP (normal temperature and pressure) conditions, i.e. sea level, and applying breakers at altitudes higher than sea level results in the reduction of the capability of external insulation exposed to air 8 . Roughly, the capability drops about 10% for every 1000 m change in elevation. The equation for the correction is:

kd = e

m (

H ) 8150

Brune and J. R. Eaton, AIEE Transactions, Vol. 50, 1931, page 1132.
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where the gap factor, m, equals 1 for power frequency, lightning and phase to phase switching impulses, 0.9 for insulation across the isolation gap, 0.75 for phase to ground switching surges, and H is the altitude in meters. Figure 9 shows the correction for lightning and phase to ground switching surges.
1.05

Distortion of Traveling Waves by Corona, H. H. Skilling and P. K. Dykes, AIEE Transactions, Vol. 56, 1937, page 850.

IEEE C37.04 1999, IEEE Standard Rating Structure for AC High-Voltage Circuit Breakers IEEE C37.09 1999, IEEE Standard Test Procedure for AC High-Voltage Circuit Breakers Rated on a Symmetrical Current Basis. IEEE C37.06 2000, AC High-Voltage Circuit Breakers Rated on a Symmetrical Current Basis Preferred Ratings and Related Required Capabilities for Voltages above 1000 Volts. IEEE C37.100.1 - 2007, Standard of Common Requirements for High Voltage Circuit Breakers Rated Above 1000 V.

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Switching Surge to Ground Lightning

Altitude Density Correction Factor

0.95

0.9

0.85

0.8

0.75

0.7

8
0.65

0.6 0 500 1000 1500 2000 2500 3000 3500 4000

Alltitude Above Sea Level, m

Figure 9 Altitude Correction Factor Thus, at 2000 m the 825 kV switching surge capability of a 362 kV class breaker is reduced to about 684 kV, a 17% reduction. Although the correction begins at altitudes greater than zero, corrections need not be considered for altitudes below 1000 m. VI References
1

Switching of Extra-High Voltage Circuits, II Surge Reduction with Circuit Breaker Resistors, D. E. Hedman, I. B. Johnson, C. H. Titus, and D. D. Wilson, IEEE Transactions on Power Apparatus and Systems, Vol. PAS-83, December 1964, pp. 1196-1205. Effectiveness of Zinc Oxide Surge Arresters on Substation Equipment Probabilities of Flashover, S. R. Lambert, IEEE Transactions on Power Delivery, Vol. 3, No. 4, October 1988, pp. 1928-1934. Experimental Studies on the Propagation of Lightning Surges on Transmission Lines, O.
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