Dr Anders Holmberg and Magnus Svanberg, ABB Composites, Sweden
Svensk Kompositforskning 2014, Lund, April 2-3 2014.
Design and qualification of composite
apparatus insulators
© 2013, ABB AB
Slide 1
Outline
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Introduction
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Transmission apparatuses
§
Why composite insulators
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Composite insulator design concept
Mechanical design and qualification
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Concept of damage limit
§
Electrical design and qualification
§
UHVDC 1100 kV
© 2013, ABB AB
Slide 2
1
Applications of Composite Apparatus Insulators
72 – 1200 kV AC and DC
Circuit
Breakers
Cable
Terminations
Bushings
Instrument
Transformers
Surge
Arresters
© 2013, ABB AB
Slide 3
Composite Apparatus Insulators
Used in all environments
© 2013, ABB AB
Slide 4
2
Composite Apparatus Insulators
Advantages over ceramic insulators
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Explosion proof
Maximum safety of personnel and equipment
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Hydrophobic surface
Possible to reduce apparatus length
Reduced risk for flashover
No cleaning
§
Outstanding seismic performance
For best safety and reliability
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Low weight
Easier handling and reduced foundation loads
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Non-brittle
Reduced handling damage risk
© ABB Group
April 15, 2014 | Slide 5
Composite Apparatus Insulators
Design concept
Glass fiber reinforced
epoxy resin tube
Silicone rubber sheds
Aluminum end fitting
© ABB Group
April 15, 2014 | Slide 6
3
Composite Apparatus Insulators
Tailoring to apparatus requirements
© 2013 ABB AB
Slide 7
Apparatus insulators – overview of loads
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Mechanical
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Environment
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Internal pressure
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UV
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Cantilever bending
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Salt fog
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Thermal cycling
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Rain
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Pollution
Electrical
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Internal insulation
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Operating voltage
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Lightning impulse
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Mineral oil
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Switching impulse
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Synthetic oil
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Gas: SF6, N2, CO2
© 2013, ABB AB
Slide 8
4
Insulator specification template
Customer specification
• Cantilever load
• Internal pressure
• Temperature range
• Arcing distance
• Creepage distance
• Internal media
© ABB Group
April 15, 2014 | Slide 9
Load combinations and safety factors
Ceramic insulators
Rarely occurring extreme loads
Loads
Routinely
Alternative 1 Alternative 2 Alternative 3
expected loads Short-circuit load Ice load
Seismic load
Design pressure
100%
100%
100%
100%
Mass
100%
100%
100%
100%
Rated terminal load
100%
50%
0%
70%
Wind pressure
10%
100%
0%
10%
Short-circuit load
0%
100%
0%
0%
Ice load
0%
0%
100%
0%
Seismic load
0%
0%
0%
100%
Safety factor
2.1
1.2
1.2
1
© 2013, ABB AB
Slide 10
5
Mechanical Design Composite Apparatus Insulators
Damage Limit Concept & Mechanical Type tests
Internal pressure
Cantilever bending
© 2013, ABB AB
Slide 11
Damage development during Pressure Type Test
Transverse cracking > 2 x MSP
Liner cracking > 4 x MSP
© ABB Group
April 15, 2014 | Slide 12
6
Load combinations and safety factors
Composite vs Ceramic insulators
Rarely occurring extreme loads
Routinely
Alternative 1 Alternative 2 Alternative 3
expected loads Short-circuit load Ice load
Seismic load
Loads
Safety factor (Ceramic)
2.1
1.2
1.2
1
Safety Factor DML (Composite)
1.5
1.2-1.5
1.2-1.5
1-1.2
Safety Factor SML (Composite)
2.5
2.0-2.5
2.0-2.5
1.7-2.0
Deflection also design consideration for composite insulators
© 2013, ABB AB
Slide 13
Electrical and environmental qualification, IEC
Verification of interfaces and connections
1.
Thermal-Mechanical pre-stressing
1.
Water immersion pre-stressing
2.
Steep-front impulse test
3.
Dry power frequency test
4.
Internal pressure test
5.
Gas leakage test
© 2013, ABB AB
Slide 14
7
Thermal and mechanical qualification, ANSI
Verification of pressure cycling resistance
10 000 cycles 0 to MSP at -40°C
90 000 cycles 0 to MSP at +100°C
© 2013, ABB AB
Slide 15
Example of apparatus requirement and verifying test
Seismic qualification of 550 kV bushing
© ABB AB
Slide 16
8
Example of apparatus requirement and verifying test
Internal arcing, 400 kV dry bushing
© ABB Group
April 15, 2014 | Slide 17
Electrical design of insulator
Design considerations
• Corona on metal parts
• Dielectric strength of insulating materials
• Water droplet corona on polymer surface
• Lightning impulse withstand
• Wet switching impulse withstand
• Pollution performance
Electric field on station post insulator
© 2013, ABB AB
Slide 18
Wet SI
flashover test
9
Electrical design of insulator
Design for pollution performance
Shed profile requirements:
• Long creep
• Self cleaning
• Water roll off in rain
• No arc bridging
• Low E-field on shed tip
Shed radius 1.0 mm
a
b
Shed radius 2.3 mm
© 2013, ABB AB
Slide 19
Electrical and environmental qualification, IEC
Verification of tracking and erosion resistance
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§
Mandatory: 1000 h salt fog test
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Continuous voltage
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Continuous salt fog
Optional: 5000 h multiple stress test
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Continous voltage
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Intermittent
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Salt fog
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Rain
§
Humidity
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UV
§
Heat
© 2013, ABB AB
Slide 20
10
Composite Apparatus Insulators
Field Test verification, KIPTS – Very heavy pollution
© ABB Group
April 15, 2014 | Slide 21
Composite Apparatus Insulators
Field Test verification, KIPTS – Very heavy pollution
ABB Production insulator after test
Competing solution after test
© ABB Group
April 15, 2014 | Slide 22
11
ABB develops world’s most powerful high-voltage
direct current converter transformer
ABB develops world’s most powerful high-voltage direct current converter transformer
Zurich, Switzerland, July 3, 2012 – ABB, the leading power and automation technology group has
successfully developed and tested an 1,100 kilovolt (kV) ultrahigh-voltage direct current (UHVDC) converter
transformer breaking the record for the highest DC voltage levels ever, and facilitating more power to be
transmitted efficiently over longer distances.
The new 1,100 kilovolt (kV) converter transformer technology will make it possible to transmit more than
10,000 megawatts (MW) of power across distances as long as 3,000 km.
Development of the 1,100 kV transformer addressed several technology challenges such as the sheer size
and scale, electrical insulation including bushings and thermal performance parameters.
“This new 1,100 kV transformer technology will make it possible to transmit even more electricity efficiently
and reliably, at higher voltage levels, across greater distances with minimum losses,” said Bernhard Jucker,
head of ABB’s Power Products division. “Technology and innovation are at the core of ABB’s culture and this
is yet another example of our pioneering spirit.”
© ABB Group
April 15, 2014 | Slide 23
Insulator characteristics
Length:
Weight :
Cantilever strength:
12 m
3 000 kg
> 1 000 kNm
© 2013, ABB AB
Slide 24
12
© ABB Group
April 15, 2014 | Slide 25
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