—

A P P L I C AT I O N N OT E 2 . 2

Arc furnace transformers

Overvoltage protection
The APPLICATION NOTES (AN) are intended to be used in
conjunction with the

APPLICATION GUIDELINES
Overvoltage protection
Metal-oxide surge arresters in medium-voltage systems.

Each APPLICATION NOTE gives in a concentrated form

additional and more detailed information for the selection
and application of MO surge arresters in general or for a
specific equipment.

First published February 2019

 3
O V E R V O LTA G E P R OT E C T I O N

—
Overvoltage protection of
arc furnace transformers
Overvoltages due to switching and lightning phenomena require
additional MO surge arresters between the phases.

1 Introduction 2 Selection of the MO surge arresters

For general information about MO surge arresters The MO surge arresters have to be selected as
between phases see Application Note AN 1.3. ­described in the Application Guidelines and the
Application Notes AN 1.1 and AN 1.3.
In special cases, such as in arc furnace installa-
tions, switching overvoltages between phases Depending on the expected stresses, electrical
can occur that are insufficiently limited by arrest- and environmental, and the importance of the
ers between phase and earth. Two different equipment to be protected it is necessary to
­arrangements can be used when overvoltage ­decide which characteristics of the MO surge
­protection between phase-to-earth and phase- ­arresters are most important to provide best pro-
to-phase is required, the “six-arrester arrange- tection. In this way the type of arrester (arrester
ment”, see Figure 1, and the “four-arrester class etc.) can be chosen from the beginning.
­(Neptune) arrangement”, sometimes also called
“four-legged surge arrester arrangement”, see The examples given below guide through the
Figure 2. principle of the selection process step by step.

—
Figure 1: Six-arrester
arrangement for
arc furnace trans-
former protection. T
L1

L2

L3

T
— L1
Figure 2: Neptune
design with four L2
arresters (A1 to A4).

L3

A1 A2 A3

A4
4 A P P L I C AT I O N N O T E   A R C F U R N A C E T R A N S F O R M E R S

Supplied information Step e) Check lightning impulse protection level

• Protection of an arc furnace transformer Upl and withstand voltage LIWV
• System voltage Us = 36 kV Required is: Upl ≤ LIWV / Ks
• High ohmic insulated star point
• Industrial environment With LIWV = 170 kV and K s = 1.15, the maximum
allowed voltage at the electrical equipment
Without further information it is assumed results in 147.8 kV.
• Um = 36 kV The POLIM-S 38 N has an Upl of 114 kV and meets
• LIWV = 170 kV the demand with a good additional safety margin.
• Medium pollution (pollution class c, required
medium specific creepage 34.7 mm/kV) With the steps a) to e) the active part of the MO
• Continuous operation in case of an earth fault surge arrester is selected. It follows the selection
• Nominal discharge current In = 10 kA of the arrester housing and confirmation of
• Short circuit current of the system Is = 20 kA ­mechanical data.

In such applications like protection of arc furnace Step f) Creepage distance

transformers a high energy withstand capability With the assumption of medium pollution (pollu-
has to be assumed, as well as a low protection tion class c with 34.7 mm/kV) we have to calculate
level Upl of the MO surge arresters. For this the required creepage distance. As long as we as-
­reason a MO surge arrester of class SM sume continuous service in case of an earth fault
(i.e. POLIM-S..N) is recommended. we have to make the calculation based on
1.05 × Us. This results in a required minimum
The same procedure, equations and assumptions creepage distance of 1.05 × Us × 34.7 = 1312 mm.
are valid for transformers in delta-connection. For insulation material like silicone the minimum
required creepage distance can be reduced by
2.1 Six-arrester arrangement 20%. This results finally in 1050 mm minimum
Following the steps given in flow chart AN 1.1 A1, creepage distance. The POLIM-S 38 N provides
and the equations in AN 1.3, it follows: according data sheet a creepage distance of
1603 mm and meets the requirement with a good
Step a) Continuous operating voltage Uc additional safety margin.
In this case the continuous operating voltage is
Uc ≥ 1.05 × Us = 1.05 × 36 kV = 37.8 kV Step g) Flashover distance
The minimum necessary withstand values of the
Therefore, chosen is according data sheet a empty arrester housing are calculated according
POLIM-S .. N with Uc = 38 kV to IEC 60099-4, Ed. 3.0 as:

As mentioned above, for such applications a low Lightning voltage impulse 1.2/50 µs:
protection level is recommended. For this reason 1.3 × Upl = 1.3 × 114 kV = 149 kV
we don’t add a 10% safety margin for the Uc . This
would increase the protection level Upl by 10% as a.c. voltage test 1 min, wet:
well, which is not favorable in this application. 1.06 × Ups

Step b) Rated voltage Ur (switching current impulse

According data sheet the rated voltage 1000 A => Ups = 95.7 kV)
is Ur = 47.5 kV It follows Utest,pv = 1.06 × 95.7 kV = 102 kV.
This results in Utest =72 kV rms, 1 min wet.
Step c) Nominal discharge current In
The nominal discharge current is In = 10 kA The guaranteed withstand values according data
sheet are:
Step d) Charge Qrs and thermal rating Wth Lightning voltage impulse 1.2/50 µs: 359 kV
Based on the decision for POLIM-S .. N (class SM) a.c. voltage test: 102 kV, rms, 1min wet: 102 kV
the
• Repetitive charge transfer rating is Qrs = 2.0 C The housing of the POLIM-S 38 N has higher
• Rated thermal energy is Wth = 10 kJ/kVUc withstand values than are required by IEC.

Step h) Short circuit current Is

The POLIM-S 38 N was tested with a short circuit
current Is = 50 kA and meets easily the assumed
20 kA.
O V E R V O LTA G E P R OT E C T I O N 5

Step i) Mechanical loads This leads us to

Special requirements for mechanical loads are Upl ≤ LIWV / Ks = 170 kV / 1.15 = 148 kV.
not given. However, the type POLIM-S 38 N
provides very good mechanical withstand values, The two POLIM-S 24 N in series have in total a
see data sheet. Upl = 144 kV.

— This value meets the requirement, but provides

It follows: the POLIM-S 38 N is no additional safety margin.

the right arrester from all points Step f) Creepage distance

of view for this application, and Pollution effects and flashovers occur between
the terminals of the MO surge arresters. For this
should be installed between the reason, the creepage distance (as well as the
phases and the phases to earth. flashover distance) has to be calculated for the
single POLIM-S 24 N.
2.2 Four-arrester arrangement (Neptune design) We assume pollution class c with 34.7 mm/kV. In
The same provided information and the assump- the actual case we have to calculate with the con-
tions made apply for this example as well. We go tinuous operating voltage Uc = 24 kV. This leads
with a MO surge arrester of type POLIM-S .. N. to a minimum recommended creepage distance
of 24 kV x 34.7 mm/kV = 833 mm. With a 20% re-
2.2.1 Arrangement with four identical arresters duction due to the silicone insulation we finally
come to a value of 667 mm. The POLIM-S 24 N
Step a) Continuous operating voltage Uc provides a creepage distance of 983 mm and ful-
According Figure 4 in AN 1.3 we calculate the con- fills the ­requirement with a good margin.
tinuous operating voltage to
Uc ≥ 0.661 × Us = 0.661 × 36 kV = 23.8 kV Step g) Flashover distance
The minimum necessary withstand values of the
It follows from the data sheet with the next empty arrester housing are calculated according
higher value a continuous operating voltage of to IEC 60099-4, Ed. 3.0.
Uc = 24 kV, and we go for a POLIM-S 24 N. Here again we concentrate on the single MO
We don’t add a safety margin of 10% to the Uc, surge arrester POLIM-S 24 N, because the flash-
because we have in the four arrester arrangement over distance and related tests refer to the
in all cases two arresters in series, which results ­individual housing, independent of the final
in a total continuous operating voltage between ­arrangement.
the phases and phases to earth in Uc = 48 kV,
which is far above the system voltage of Lightning voltage impulse 1.2/50 µs:
Us = 36 kV. 1.3 × Upl = 1.3 × 72 kV = 93.6 kV

Step b) Rated voltage Ur a.c. voltage test 1 min, wet:

The rated voltage is according data sheet Ur = 30 kV 1.06 × Ups

Step c) Nominal discharge current In (Switching current impulse 1000 A => Ups = 60.5 kV)
The nominal discharge current for this type of It follows Utest,pv = 1.06 × 60.5 kV = 64.13 kV.
arrester (class SM) is In = 10 kA This results in Utest = 45.6 kV rms, 1 min wet.

Step d) Charge Qrs and thermal rating Wth The guaranteed withstand values according data
Based on the decision for POLIM-S .. N (class SM) sheet are:
the Lightning voltage impulse 1.2/50 µs: 239 kV
• Repetitive charge transfer rating is Qrs = 2.0 C a.c. voltage test 1 min, wet: 68 kV
• Rated thermal energy is Wth = 10 kJ/kVUc
The housings of the POLIM-S 24 N have higher
Step e) we have to check the lightning withstand values than are required by IEC.
impulse protection level Upl vs the withstand
voltage LIWV. Step h) Short circuit current Is
Required is Upl ≤ LIWV / Ks The POLIM-S 24 N was tested with a short circuit
current Is = 50 kA and meets easily the assumed
The LIWV for the equipment to be protected re- 20 kA.
mains the same. Therefore, we have to consider
LIWV = 170 kV. As can be seen from the arrange-
ment in Figure 4 in AN 1.3 we have to make the
calculation with two POLIM-S 24 N in series.
6 A P P L I C AT I O N N O T E   A R C F U R N A C E T R A N S F O R M E R S

Step i) Mechanical loads With the next higher value according data sheet
Special requirements for mechanical loads are we come to a POLIM-S 16 N for the MO surge ar-
not given. However, the type POLIM-S 24 N rester A4 between neutral and earth.
­provides very good mechanical withstand values,
see data sheet. Following the same steps a) to i) as in the above
examples we get the electrical and mechanical
— data for the two MO surge arresters POLIM-S 22 N
It follows: the POLIM-S 24 N is and POLIM-S 16 N as shown in Table 1.

the right arrester from all points In step e) we have to check the lightning impulse
of view for this application. protection level Upl vs the LIWV. The LIWV is given
to 170 kV. Considering the safety factor of 15%
2.2.2 Arrangement with three identical MO we come to 148 kV. We have to consider now two
arresters and one with lower Uc cases, the MO surge arresters between two
The same provided information and the assump- phases and the MO surge arresters between a
tions made apply for this example as well. We go phase and the earth.
with a MO surge arrester of type POLIM-S .. N.
Between two phases we have in any case two
Step a) Continuous operating voltage Uc POLIM-S 22 N in series. In this case we have a total
With the equations under chapter 3.2 in AN 1.3 lightning impulse protection level of Upl = 132 kV,
for a simp­lified calculation of the continuous which is below the required value.
operating voltage we come to
1.05 × Us 1.05 × 36 kV Between one phase and the earth we have in any
Uc ≥ UL-N = -------------- = ---------------- = 21.82 kV case a POLIM-S 22 N and a POLIM-S 16 N in series,
√3 1.732 which gives a total lightning impulse protection
The next higher value for the continuous operat- level of Upl = 114 kV. This is again well below the
ing voltage is according data sheet Uc = 22 kV. required value of 148 kV.

This leads us to a MO surge arrester

—
POLIM-S 22 N for the MO surge arresters A1 to A3 It can be concluded that the
between phases and neutral.
MO surge arresters POLIM-S 22 N
1.05 × Us
With Uc ≥ UN-E = 1.05 × Us - ------------- and POLIM-S 16 N fulfill all
√3
requirements for the intended
1.05 × 36 kV
= 1.05 × 36 kV - ----------------- application.
1.732

= 37.8 kV – 21.82 kV= 15.96 kV

Table 1: Technical data of the MO surge arresters for example 2.2.2

POLIM-S 22 N POLIM-S 16 N
Uc 22 kV 16 kV
Ur 27.5 kV 20.0 kV
In 10 kA 10 kA
W th 10 kJ/kVUc 10 kJ/kVUc
Qrs 2.0 C 2.0 C

required guaranteed required guaranteed

Creepage distance 642 mm 983 mm 465 mm 829 mm
Insulation withstand 1.2/50 µs 86 kV 239 kV 63 kV 209 kV
a.c. withstand 1 min, wet 42 kV 68 kV 31 kV 59 kV
Is 20 kA 50 kA 20 kA 50 kA
Mechanical loads no special requirements
O V E R V O LTA G E P R OT E C T I O N 7

3 Summary

Table 2: Continuous operating voltage Uc and protection level Upl for the examples above.

six-arrester four-arrester four-arrester

Arrester arrangement arrangement arrangement arrangement
All six arresters have All four arresters have Three arresters with
identical ratings identical ratings identical ratings,
one with lower Uc
Equation for Uc Uc ≥ 1.05 × Us Uc ≥ 0.661 × Us Uc ≥ 1.05 × Us / √3, L-N
(total Uc ≥ 1.322 × Us) Uc ≥ 0.444 × Us , N-E
Arrester type POLIM-S 38 N POLIM-S 24 N POLIM-S 22 N, L-N
POLIM-S 16 N, N-E
Total continuous operating voltage Uc 38 kV 48 kV 44 kV
phase-to phase
Total protection level Upl phase-to-phase 114 kV 144 kV 132 kV
Total continuous operating voltage Uc 38 kV 48 kV 38 kV
phase-to-earth
Total protection level Upl phase-to-earth 114 kV 144 kV 114 kV

The results of the three possible solutions are 4 Overvoltage protection of the low-voltage
summarized in Table 2. side

The four-arrester arrangement with identical For transformers with a delta-connected

­arresters provides an unfavorable higher pro­ low-voltage winding, arresters between phases
tection level Upl of 26% phase-to-phase and may be necessary on the low-voltage side to limit
phase-to-earth compared to the six-arrester inductively transferred overvoltages. These ar-
­arrangement. resters can also protect the medium-voltage side
of the transformer by absorbing the magnetic
The four-arrester arrangement with three identi- ­energy when switching off transformers.
cal arresters and one with lower Uc provides a
higher protection level Upl of 16% phase-to-phase
and the same Upl phase-to-earth compared to the
six-arrester arrangement.

—
It can be concluded that regard-
ing the overvoltage protection
of the equipment the six-arrester
arrangement gives the best
result.
—
ABB Switzerland Ltd.
PGHV
Surge Arresters
Jurastrasse 45
CH-5430 Wettingen/Switzerland
Tel. + 41 58585 2911
Fax + 41 58585 5570
Email: sales.sa@ch.abb.com

abb.com/arrestersonline

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