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The material used for MO varistors is in Fig. 1 has a diameter of the required electrical and
approximately 90% zinc oxide (ZnO) approximately 70 mm. mechanical properties for the specific
with 5% bismuth oxide (Bi2 O3 ), Previously, surge arresters which application as well as resistance to
doped with 5% other metal oxides. contained silicon carbide (SiC) and the specified ambient conditions.
As can be seen in Fig. 2, the featured a series gap were used. Previously, porcelain was the only
microstructure of an MO varistor These are no longer manufactured, suitable material for insulated
consists of zinc oxide grains with a but are still found in some power housings, but polymer housings are
diameter of around 10 to 50 µm, systems. now also available, allowing for
which are separated by bismuth- certain design innovations.
oxide-rich phases during production. 3. Types of MO Surge
During this process, every boundary Arresters for Electric 3.2. MO Surge Arresters with a
between the essentially electrically Porcelain Housing
conductive zinc oxide and bismuth
Railway Systems
The classic insulation material for
oxide forms a potential barrier of
approximately 2.9 V, resulting in an surge arrester housings in the power
3.1. General engineering sector and for railway
overall electrical performance that is
The electrical dimensioning of surge traction systems is porcelain. Fig. 3
similar to a statistical series-parallel
circuit of many Zener diodes. For a arresters produces a stack of MO shows a typical arrester with a
varistors with a specific height and a porcelain housing for a DC traction
given grain size of the MO ceramic
specific diameter. This stack is system. The stack of MO varistors is
material, the protection level
provided by the surge arrester is enclosed in a housing which, for the tensioned with a construction of
entire life of the arrester, must retain fibreglass-reinforced plastic (FRP)
determined by the height of the MO
varistor or stack thereof. A typical,
specific figure for the normal-
gradient varistors commonly used for
rail traction systems is approximately
300 V/mm height, i.e. the varistor
stack in the surge arrester described
in Fig. 1 is about 16 mm high.
MO surge arresters used in traction
system applications absorb large
amounts of energy when a surge
occurs and the varistors can undergo
a significant temperature rise of up to
50°K as a result. To prevent
overheating of the surge arrester, it
must contain sufficient material to
provide an adequate heat storage
capability. This is assured for a given
protection level by providing Fig. 3: Surge arrester type 3EC3 with porcelain housing for DC traction systems
elements of appropriate diameter. For (Table 1). Total height 233mm
example, the surge arrester illustrated 1 case 3 MO-Varistors 5 seal
2 compression spring 4 flange 6 pressure relief membrane
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bolts, contact and pressure springs 3.3. MO Surge Arresters with a porcelain housing before it, is a
and retaining plates. It is contained Polymer Composite Housing mechanically stable, hermetically
inside a porcelain housing. The sealed system and therefore requires
The availability of polymer materials
flange-like metal end fitting is a pressure relief system to prevent its
with the right properties for power
fastened to the porcelain housing explosive disintegration in the event
engineering applications has also led
using sulphur cement. This has of a short-circuit. However, it differs
to more surge arresters with polymer
significant advantages in terms of from the porcelain housing in that the
housings being used in traction
production over Portland cement, material properties of the FRP tube
systems for electric railways.
which can also be used, particularly do not allow for any thermal
Initially, the previously described
because it becomes stable under load secondary breakdown and also
design features of surge arresters
soon after pouring. The end fitting is because the housing retains a
with porcelain housing were adopted
also equipped with a pressure relief bending moment of at least 75% of
and only the material or design of the
and sealing system, which are vital the original figure following a short-
housing was modified. A surge
for reliable surge arrester operation. circuit. This type of housing is
arrester with a polymer composite
Although modern MO surge arresters therefore the safest version from the
housing designed for DC or AC
are exceptionally reliable items of point of view of personnel and plant
traction systems is shown in Fig. 4.
equipment, adverse conditions, e.g. protection, despite being the most
As these diagrams show, the internal
incorrect dimensioning, direct complex and expensive of the
configuration of MO varistors and
lightning strike or voltage overspill various alternatives available.
retaining device conforms with that
can nevertheless cause them to fail.
of the surge arrester with porcelain
In such cases, a short-circuit occurs 3.4. MO Surge Arresters with a
housing. Where the design differs,
inside the surge arrester and the Directly Moulded Polymer
however, is with regard to the
resultant arc produces a significant Housing
insulating enclosure, which consists
pressure increase inside the housing.
of an FRP tube with integral Commercial demand for cost-
To prevent the housing from
injection-moulded shielding of optimised surge arresters for electric
exploding, which would be
silicone elastomer or with power systems has resulted in the
hazardous for personnel and
individually bonded shields. In this development of directly moulded
materials, the surge arrester flange is
design configuration, the FRP tube designs. With this design, a
sealed with a fine metallic membrane
gives the housing its mechanical mechanically stable, sealed housing
only a few tenths of a millimetre
strength, while a coordinated system has been dispensed with in favour of
thick, which quickly ruptures in the
of FRP tube and silicone elastomer a very much simpler structure and
event of a short-circuit, so protecting
shielding safeguards the arrester’s minimised use of materials. The disk-
the housing against internal
electrical properties. The FRP tube is like MO varistors and their
overpressure. This process, known as
bonded to the flange, so permitting respective end fittings are fastened
blowout, also expels the arc from the
maximum bending moments. The together by means of FRP rods,
housing where it can continue to burn
polymer composite housing, like the screws or loops to form a self-
until the power system has been shut
down.
While surge arresters with a
porcelain housing must never be
allowed to explode after shorting, a
so-called thermal secondary
breakdown as defined in EN 50123-5
or IEC 60099-4 [1] is permissible. In
this situation, the thermal stresses
produced by the action of the electric
arc on the porcelain cause the
housing to break down. This
disintegration is a depressurised
event, however; in other words,
fragments merely drop off the
housing.
The pressure relief system must be
reliably sealed for the entire service
life of the surge arrester, a criterion
which is met through meticulous yet
relatively uncomplicated design
principles and the selection of
suitable and, above all, correctly
Fig. 4: Surge arrester type 3EB1 for DC- or AC traction system with polymer
coordinated materials. composite housing (Table 1) mounted on ICE 2 power car.
Total height 296 mm
1 compression spring 3 FRP tube 5 flange with seal and
2 MO-Varistors 4 HTV s ilicone sheds pressure relief membrane
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supporting configuration around However, the arc accompanying a are absorbed by the housing and the
which the silicone elastomer is then short-circuit generally damages the only mechanical load on the MO
moulded. This design is similar to surge arrester’s mechanically self- varistors comes from their spring
that of a reinforced concrete bridge in supporting internal structure loading which is necessary to ensure
that its mechanical stability relies on seriously enough to destroy its perfect electrical contact. Table 1
a sufficiently high level of pre- mechanical stability, with the result compares the permitted bending
stressing; in other words the MO that it is no longer able to absorb moments of Siemens surge arresters
varistors are mechanically pre- forces from bolted on busbars or of the various types described above.
stressed. The term “direct moulded“ connecting cables, for example.
indicates that the silicone elastomer Another possible scenario, similar to 4. Use of MO Surge
is applied directly to the surface of that occurring with thermal Arresters in DC Traction
the MO varistors. Directly moulded secondary breakdown of a surge
surge arresters are now used almost arrester with a porcelain housing, is
Systems as per VDV 525
exclusively in medium-voltage three- that internal fragments of the arrester Publication No. 525 [3] of the
phase systems, and they will become or of the MO varistors may be Association of German Transport
increasingly commonplace in high- expelled from the housing. Undertakings (VDV) gives operators
voltage three-phase systems in However, short-circuit tests on the of DC traction systems
future. Surge arresters with directly surge arrester performed in the recommendations on effective surge
moulded polymer housings are also context of its type testing are protection in the event of lightning
available for the power systems of required to demonstrate that any strikes. It first of all distinguishes
electric railways, and appropriately fragments ejected in this manner between external and internal
modified directly moulded surge merely drop away loosely from the lightning protection, whereby
arresters are frequently used for housing and that there is external lightning protection applies
medium-voltage three-phase systems. consequently no risk to personnel or directly to the overhead traction line
The design of such surge arresters is adjacent plant components from systems, and also the running rails in
remarkably uncomplicated and high-speed splinters. the case of traction systems with
essentially consists of metallic The mechanical strength of directly contact lines, while an overhead
terminal fittings with the MO moulded surge arresters, particularly contact line acts as a lightning
varistors fastened between them by their permitted bending moment, is arrester device. Internal lightning
means of FRP tensioning elements. generally significantly lower than protection refers to measures
The housing is then formed by that of alternative designs with a implemented in the substations, but
moulding a layer of silicone porcelain or composite polymer also encompasses the use of surge
elastomer directly onto these housing. Moreover, forces applied arresters in low-voltage systems or
elements, as shown in Fig. 5; this through the connections are added to signalling and communications
design has no pressure relief or the pre-tensioning force applied to equipment close to or in the tracks.
sealing system. the MO varistors, the elements
The arc produced in the event of a responsible for the surge arrester’s 4.1. Earthing of Power Systems
short-circuit exits to atmosphere electric response, potentially for Electric Railways
through the mechanically weak resulting in imperceptible damage to
silicone elastomer layer, and the MO varistors through improper The planning of lightning protection
continues to burn there without any handling. There is no chance of such concepts pays particular attention to
explosive destruction of the housing. damage with surge arresters with a the earthing of power systems. If the
Even without a pressure relief porcelain or composite polymer rails of DC traction systems are
system, therefore, there is no high- housing because mechanical forces insulated to earth to reduce stray
speed ejection of housing fragments.
Permissible
bending Moment Nm 2000 2600 1250
Fig. 5: Surge arrester type 3EB2 with
directly moulded polymer housing Application stationary mainly mainly
(Table 1). and on cars on cars stationary
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current corrosion, as is required for
new tracks, they are unsuitable as
earth terminations. In such
applications, low-resistance tower
footings, driven poles, reinforced
concrete guideways or separate earth
rods must be used as earth
terminations, depending on local
track conditions. Where the rails
have been laid without any additional
insulating measures, however, they
generally exhibit only minimal
leakage resistance and can be used as
earth terminations. In such cases,
however, the discharge current is
conducted to earth via the rails, Fig. 6: Protection of the overhead contact line by A1 surge arresters (from [3]).
which poses a risk for electrical and
electronic equipment close to or
actually in the track. An effective
means of protecting against
overvoltages resulting from this
process is to provide additional surge
arresters in the actual equipment.
Substation earthing arrangements are
unproblematical because the
structure’s own earthing system
serves as an efficient, low-resistance
(≤ 2 Ω) earth electrode for lightning
protection measures.
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References
[1] IEC 60099-4, Edition 1.2, 2001-12
Metal-oxide surge arresters without
gaps for a.c. systems
[2] Fien H., Hinrichsen V., Pelmer J
Hochspannungs-Metalloxid-Ableiter:
Auslegungs- und
Konstruktionskriterien.
Elektrizitätswirtschaft, Vol. 93
(1994), Issue 19, pp. 1148-1156
[3] VDV Schriften 525 12/01: Schutz der
Fahrstromversorgungs-anlagen von
Gleichstrombahnen bei
Blitzeinschlag , Verband Deutscher
Verkehrsunternehmen (VDV),
Karnekestraße 37-39, 50672 Cologne
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