A

REPORT
ON
CONDITION MONITORING
OF LIGHTNING ARRESTERS

PREPARED DURING THE SPECIAL COURSE

FOR SAG AT IRIEEN, NASIK

FROM: 14.02.2005 TO: 08.04.2005

BY:

NASIM UDDIN
CHIEF ELECTRICAL DISTRIBUTION ENGINEER
NORTH CENTRAL RAILWAY
ALLAHABAD

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 INDEX

Sr. Contents Page No.

No.
1. Introduction 1

2. Principle of Operation of Lightening Arrester 1

3. Energy Handling Capacity and Thermal Stability of 4

ZnO Arrester

4. Important Definitions 4

5. Information required for Selection of a Zinc Oxide 5

LA

6. Provision of LAs in Traction Sub-Stations and 5

Rolling Stock

7. Failure Modes of LA 5

8. Existing methods of conditions monitoring of LA 6

9. Monitoring of leakage current in LAs 7

10. Proposed method for measurement of leakage 9

current

11. Case study of Lightning Arrester failure 10

12. Experience of other Utilities 10

13. Conclusion 11

14. References 12

15. Annexure-1 13

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 A Report on condition monitoring of Lightning Arresters

1. Introduction
High voltage power systems including traction power supply experience over
voltages, which are generated through occurrence faults, switching operations and
lightning discharges. The duration of the over voltages vary from a few micro
seconds few seconds depending on the type of surges. Similarly, the magnitude of
over voltages varies from 1.5 to 4 times of the normal operating voltages. Under
these severe overvoltage conditions, the insulation of the power
system/equipments undergoes stresses that could lead to catastrophic failure.
Hence it is imperative that the power system equipments are protected from these
over voltages at the time of occurrence. Using a device with variable impedence
with respect to voltages can provide the protection of power equipments from
overvoltages. This kind of overvoltage protection device is connected in parallel
to the system/equipments to be protected. An effective surge Protection device
must satisfy the following conditions:

• Conduct only during over voltages.

• Low power loss under normal operating conditions.
• High energy handling capability.
• High reliability and long life.

Usually, metal oxide (Zinc Oxide) type of Lightning Arrester (LA) is used for
protection of system/equipments from overvoltages.

2. Principle of Operation of Lightening Arrester

The primary function of a zinc oxide surge arrester is to protect the power
equipments from overvoltages and to absorb electrical energy resulting from
lightning or switching surges and from temporary over voltages. These gapless
metal oxide arrestors consist are of active part, which is a highly non-linear
ceramic resistor, made of essentially zinc oxide. Fine Zinc Oxide crystals are
surrounded by other metal oxides (additives). The microstructure at an element of
LA is shown in Fig. 1.

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As shown in Figure 1 that Zinc Oxide elements are made by mixing Zinc Oxide
with small amount of additive materials such as Ba2 O3. The mixture is, then,
granulated, compacted and fired or baked. The equivalent electrical circuit of an
LA is a Parallel Combination of capacitance and variable resistance. The current
flowing through LA is the total leakage current (It) having capacitive leakage
current (Ic) and resistive leakage current (Ir) components. Normal operating
voltages cause ageing of Zinc Oxide elements/blocks whereas
Switching/Lightning overvoltages may cause overloading of all or part of the Zinc
Oxide blocks. Due to various electrical stresses, the granulated layers/barriers
break down causing the conduction. The increase in the voltage stresses on
healthy granulated layers results in the higher resistive leakage current (Ir)
amounting to higher total leakage current in LA.
The non-linear characteristics of these Zinc Oxide blocks is shown in Fig. 2.

In Fig.2, X-axis is in logarithmic scale. This special characteristic is the heart of

protection technology.

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The lower linear part A is temperature dependent, and exhibits a negative
temperature coefficient. The arrester is designed in such a way that the applied
operating voltage gets located around point O. This results in a continuous
resistive current of few micro amps flowing through the resistor elements. Under
overvoltage condition, the voltage increases and shifts operating point
momentarily for overvoltage duration to point near B. This results in a resistive
current of few milli amperes flowing through the resistor elements. As soon as the
overvoltage disappears, the operating point will shift back to O. In the event of
transient switching or lightning overvoltages, the operating point will shift to
portion C.

For the transient of a few micro seconds, it will draw current in the rage of 5/ 10
KAmps. In the event of very high lightning current of the order of 40 to 100
KAmps peak, the operating point will shift to portion D. However, on expiry of
transient of few milliseconds the operating point will come back to point O.

Thus, the operating point of these arresters is normally located at point O called
Maximum Continuous Operating Voltage (MCOV) & the point B of Fig. 2
indicates approximately the rated voltage of arrester. The arrester can stay at point
O, i.e., MCOV, all along its life but it can stay at point B (fault condition), i.e..
Rated Voltage, for only 10 seconds (It is presumed that system breakers will
operate to isolate the fault within 2 seconds). The energy that gets dissipated, i.e.
(1²R) during continuous or overvoltage condition decides the size (dia.) of ZnO
resistor element.

Various types of Zinc Oxide elements typically used in LAs are shown in figure-3

The active part of Zinc Oxide arresters is made up of a column of stacked

cylindrical resistor. The number of resistors in the stack depends upon the
continuous operating voltage of the arrester. The column is installed in a
hermetically sealed either in porcelain or in polymer housing. In the railway

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 applications particularly for a 39 KV class lightning arrestors, 12 nos. Zinc Oxide
blocks/elements of 3.25 KV rating each are used.

3. Energy Handling Capacity and Thermal Stability of ZnO Arrester

The application of ZnO ceramic elements for over voltage protection also calls for
energy handling capacity which is defined as Energy E= V x I x t.

The energy handling capacity of the commercial ZnO arresters is in the order of
150 Jouls/cm³.

The Energy absorption and dissipation being dependent on this specific energy
handling capacity, the energy discharge of Zinc Oxide Block is basically
dependent on its volume.

The rated voltage of Zinc Oxide element is proportional to the height. The energy
level increases with the increase in area of the Zinc Oxide block.

Concept of thermal behaviour of ZnO arrester is an important application

consideration. Thermal capability of a design takes advantage of overvoltage
capability. The thermal capability of ZnO arrester depends on the assembly
structure of the arrester.

As long as the heat generated from the ZnO elements due to continuous operating
voltages and surges is less than the thermal power dissipation of the housing, the
elements will remain in an undamaged condition, capable of performing their
protective function.

4. Important Definitions

4.1 Arrester discharge current

The current that flows through an arrester resulting from an impinging surge.

4.2 Arrester discharge voltage

The voltage that appears across the terminals of an arrester during the passage of
discharge current,

4.3 Lightning overvoltage

The crest voltage appearing across an arrester or insulation caused by a lightning
surge.

4.4 Maximum continuous operating voltage (MCOV) rating

The maximum designated root-mean-square (rms) value of power frequency
voltage that may be applied continuously between the terminals of the arrester.

4.5 Rated Voltage

The rated voltage is the maximum power frequency voltage that is applied in the
operating duty test for 10 seconds.

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4.6 Standard lightning impulse
The wave shape of the standard impulse used is 1.2/50 μA.
4.7 Temporary overvoltage
An oscillatory overvoltage, associated with switching or faults (for example, load
rejection, single-phase faults) and/or nonlinearities (ferroresonance effects,
harmonics), of relatively long duration, which is undamped or slightly damped.

5. Information required for Selection of a Zinc Oxide LA

For selection of an appropriate ZnO arrester, the following information need to be
collected:
(i) nominal system voltage.
(ii) maximum system voltage.
(iii) system overvoltages (type, magnitude and frequency of occurrence) from
past records.
(iv) ambient conditions (temperature, pollution level etc.).
(v) grounding condition of the system.
(vi) insulation strength of the equipment/system to be protected.
(vii) the distance between the arrester and the equipment to be protected and
(viii) geographical location of installation etc.

6. Provision of LAs in Traction Sub-Stations and Rolling Stock

In the earlier stage of railway electrification, Silicon Carbide (SiC) Gap type
lightning arrestors were provided on 132 KV as well as 25 KV side of the
Traction Sub-Station in order to protect the traction equipments including the
transformers. However, the presence of series gaps in this class of arresters
reduced both the degree of protection and reliability. With the advent of Zinc
Oxide type gapless lightning arresters with superior voltage-current
characteristics, the gap type Las were extinct. However, there is a large number of
gap type LAs still in service in Traction Sub-Stations, which are to be replaced,
by Zinc Oxide type over a period of time.

Similarly, rod type gap (ET-1 & ET-2) arresters were provided on 25 KV on the
roof of the electric locomotives in order to protect the Power equipments of the
Locomotives, CLW has now cut in the provision the Zinc Oxide type Lightning
arresters in place of rod-type gap (ET-2).

7. Failures Modes of LA
Approximately 5000 nos. of Zinc Oxide type Lightning Arresters each on 132 KV
and 25 KV side of Traction Sub-Stations are in service. LAs provided on 132 KV
side are identical in design as on 25 KV side except the number of Zinc Oxide
blocks used for different voltage applications. Similarly, about, 500 nos. Zinc
Oxide LAs have been provided on electric locomotives, so far.

Incidentally, the exact rate of failure of LAs on Indian Railways is not accurately
available except the cases of bursting of LAs.

Further, the failure rate of Power equipments such as Transformers etc. are also
not fairly known on account of defective LAs or unprotected circuit in service.

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 However, as per the field survey of power utilities and cases reported by Central
Railway for bursting cases of dc Lightning Arrester on dc EMUs, a general
pattern of porcelain housed LA failures have been identified which is summarised
in Figure-4.

100
90
90 Ingress of moisture
%age of total failures

80
70
60
50
40 Premature ageing
of ZnO blocks
30
20
10
10
0
1 2
Causes of failures

Figure - 4

8. Existing methods of conditions monitoring of LA

As per the international norms, various techniques are available for the health
monitoring of Las in service. Some of the techniques are mentioned below:

a. Insulation Resistance measurement.

b. Total leakage current measurement.
c. Third Harmonic resistive leakage current monitoring.

Presently, the health of an LA provided for Railway applications is monitored by

periodically measuring the Insulation Resistance (IR) by using 1000V meggar.
Usually, the allowable range of IR value for LA should not be less than 1000
Mega Ohms. The measurement of IR value of an LA apparently gives an
indication of degradation due to ingress of moisture. In addition to this, some of
the high voltage Las are provided with an Ammeter connected in series to indicate
the total leakage current flowing through the LA while in service.
The measurement of Insulation Resistance of LA does not provide any significant
information about the health/degradation of metal oxide elements while in
service. The insulation resistance of an LA may remain high even though the LA
might be on the verge of failure due to various reasons including the ingress of
moisture. Hence, the value of IR of an LA cannot be taken as a criterion for

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 accurate monitoring the health of an LA. Therefore, practically no real time
system for monitoring the health of LAs exists on Indian Railways. Even, if the
measurement of total leakage current is monitored, then also a database is
required to be built up by the Railways in order to prescribe a threshold limit for
various make of Lightning Arrestors for taking the decision of replacing the LA.

9. Monitoring of leakage current in LAs

9.1 Significance of leakage current flowing through LA
In normal service, the Metal Oxide Lightning Arrestors are exposed to different
kinds of stresses such as the normal operating voltage, temporary overvoltages,
switching overvoltage, lightning overvoltages and external pollution.. All these
stresses, separately or together in different combinations, may cause an increase
in the resistive component of the continuous leakage current through the arrester.
This increase may exceed the critical limit and cause arrester failure, for instance
if the arrester rated voltage has been selected too low, if ZnO blocks have been
cracked or punctured due to overvoltages or if some special fault situations that
cause high temporary overvoltages have occurred in the network. In addition,
general ageing may also be the reason for increased leakage current and often
accelerated due to pollution on the arrester housing.

Thus, the measurement of leakage current flowing through LA under normal

situations gives the information about the real operating condition of an LA,
which may help to:

• prevent arrester failures by replacing aged arresters before breakdown.

• increase the safety for the utility/maintenance staff.
• avoid disturbances in the electric power supply.
• reduce the risk for damages to other equipment due to arrester
failures, for instance transformer bushings.

9.2 Importance of monitoring of Resistive leakage current

As discussed in para-7, the measurement of total leakage current flowing through
an LA under normal conditions is also used as one of the health monitoring
techniques. However, the total leakage current measurement does not indicate the
severity of degradation of Zinc Oxide elements as the resistive current (Ir) is only
15-25% of the total leakage current. Hence, a sharp increase in resistive current
due to degradation/ageing of Zinc Oxide blocks does not affect the total leakage
current considerably. The higher resistive leakage current may ultimately bring in
the LA to thermal instability and may result in complete failure/breakdown of the
Arrester. Hence, the resistive leakage current is the true indicator of health of an
LA in service.

9.3 Influence of temperature and operating voltage

The resistive leakage current depends on the arrester temperature (in practice the
ambient temperature) and the operating voltage. If the temperature and voltage are
not taken into account (uncorrected values), the measured value of the resistive
leakage current strongly varies. Thus, uncorrected leakage current data should not
be trusted to give reliable information about the arrester condition.

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 However, by using arrester system data and measuring the ambient temperatures
and operating voltage at the same time as the condition monitoring is performed,
it is possible to recalculate the leakage current data to a common reference. The
resistive leakage current values will then be approximately the same independent
of the test conditions. In other words – by taking account of the ambient
temperature and operating voltage, measurements performed under different
conditions can be directly compared and the measured values will be a reliable
indicator of the arrester conditions.

9.4 Third harmonic resistive leakage current

A voltage-current characteristics of a typical metal oxide LA when a sinusoidal
voltage is applied to it, is shown in the figure-2, The non-linear characteristics of
Zinc Oxide blocks, then introduce a third harmonic resistive current in the leakage
current. This current component is therefore generated by the arrester itself and
will be an indicator of changes in the non-linear characteristics of Zinc Oxide
blocks for a period of time due to ageing phenomenon.

The resistive current consists of fundamental, third harmonic, fifth harmonic and
seventh harmonic components. The harmonic contents depend on the magnitude
of the resistive current and on the degree of non-linearity of the voltage current
characteristics of zinc oxide blocks. Further, the harmonic contents also are the
function of temperature of LA. The third harmonic is the largest harmonic
contents of the resistive current and most commonly used for monitoring
purposes.

In addition to the above, the harmonic contents in operating voltage also increase
the harmonic contents in the leakage current. The system harmonics will interfere
with the harmonics generated by the arrestor itself. This implies that with the
presence of harmonics contents in the system voltage, if any, cannot be ignored
for the purpose of evaluation of the resistive leakage current. In other words – if
the harmonic contents of the system voltage are ignored, then it will not be known
if an apparent increase in the third harmonic resistive leakage current (Ir) is really
due to ageing phenomena of the arrester or it is a ‘false’ increase due to varying
harmonic contents with time.

Thus, it is necessary that a measurement of third harmonic resistive current duly

compensated for third harmonics present in the system be made for monitoring
the health of an LA in service. Further, it is not only the measurement of third
harmonic resistive current for one time, but also a data base for this resistive
leakage current are to be built up for monitoring the periodical changes due to
normal/abnormal ageing phenomena. Sudden rise in third harmonic resistive
current or very high value of third harmonic resistive current indicates
degradation of Zinc Oxide blocks and calls for a corrective actions required to be
taken in advance in order to prevent a catastrophic failure of LA in service. Thus,
it is recommended that Railway should go for a periodical measurement of third
harmonic resistive leakage current through LA in service.

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10. Proposed method for measurement of leakage current
As already explained in the previous Para that only third harmonic resistive
leakage current is important for evaluation of the performance of LA in service.
Depending on the value and trend in rise of third harmonic resistive leakage
current, a decision can be taken either for close monitoring or for replacement of
an LA. Various kinds of instruments are now available in the market, which can
be used for measurement of third harmonic resistive leakage current flowing
through an LA under normal working conditions. A schematic diagram for the
measurement of third harmonic leakage current by using such instruments is
shown in figure –5.

Figure –5.

Presently, the availability of such indigenous measuring instruments is limited.

The imported instruments are quite expensive and are in the range of Rs.10 to 15
lakhs. Therefore, there is a need to develop a cost effective equipment
indigenously so that each depot/shed can keep it for measurement of third
harmonic resistive current periodically say every year on all the arrestors under its
jurisdiction. The value of third harmonic resistive current recorded during the
measurement are to be analysed and a data base is to be developed (LA make
wise) so that a threshold/critical value of third harmonic resistive leakage current
can be decided for taking the corrective actions for LAs in service

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11. Case study of Lightning Arrester failure:

11.1 Failure Investigations

Zinc oxide Lightning Arrester commissioned on 08.10.2001 on 25 KV side
failed/burst on 07.07.04 at Traction Sub-Station in Bhandai of Agra Division on
North Central Railway. RDSO/Lucknow made an investigation into the failure of
this LA and the following observations were made:
• Rusting marks were noticed inside the arrester at diaphragm, stack plate and
fasteners.
• Flash over marks were noticed on the Zinc Oxide blocks.
• Rubber gasket on the top casting was found to be eccentric at its seating between
ceramic and the top cover plate.

For the above observations, the following conclusions were drawn to explain the
failure of the above Lightning Arresters:

Flash over and short circuit of the metal blocks took place due to ingress of
moisture, which was confirmed by looking at the rusted parts of the Lightning
Arresters.
The ingress of moisture was due to improper fitment of the gasket between the
porcelain housing and the top cover.

Hence, from the above observations, it was confirmed that the above Lightning
Arrester failed on account of ingress of moisture due to improper fitment of
rubber gasket between porcelain housing and the top cover. A few photographs
taken for the failed Lightning Arresters are reproduced and placed at Annexure-1.

11.2 Corrective actions suggested

The following corrective actions are suggested to avoid the ingress of moisture
into the Zinc Oxide type of Lightning Arrester with ceramic housing:

i) Quality of the neoprene rubber gaskets and the dimensions including the
concentricity are to be ensured before the fitment on the Lightning
Arresters.
ii) Use of stainless steel fasteners in order to prevent the rusting/corrosion.
iii) Use of ‘O’ ring in place of gasket between porcelain housing and the top
cover for better sealing.

12. Experience of other Utilities

Power Grid Corporation of India Limited (PGCIL) reported that about 200
Lightning Arresters provided on 400 KV and 200 KV side were monitored and
results obtained during sample checks are as below:

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 System Range of THRC* Range of THRC* Remarks
voltage Make A Make B
Normal range Abnormal Normal range Abnormal
range range
400 kV 10-100 μA 150-400 30-150 μA 300-500 μA Five surge
μA arresters
were
showing
upto 2100
μA
220 kV 20-40 μA 200-400 20-40 μA 200-400 μA Three Surge
μA arresters
were
showing
upto 1000
μA

* THRC – Third Harmonic Resistive Current

The value of the third harmonic resistive leakage current was recorded generally
in the range of 10-15 micro amperes for new LAs whereas for 12 to 15 years old
LAs, the value was in the range of 200-300 micro ampere.

A similar kind of study is also to be made by RDSO/ Railways in order to arrive

at a threshold/ critical value of Third harmonic resistive leakage current in order
to take necessary corrective actions for those LAs, which are having large third
harmonic resistive leakage current.

13. Conclusion
As explained earlier, LA is one of the most vital devices used to protect the power
equipments such as transformers etc. against over voltages including lightning
surges. Therefore, it is quite imperative that the health/condition of the LAs
provided on electrical rolling stock and Traction Sub-Stations is to be monitored
at a regular interval by measuring third harmonic resistive leakage current with
the help of measuring instruments. Further, a database for the third harmonic
resistive leakage current for all the LAs (make wise) is to be developed and
analysed. A threshold/critical value of third harmonic resistive leakage current is
then to be specified based on the database developed over a period of time.

As discussed earlier, the following major reasons have been identified for LA
failures:

1. Ingress of moisture through sealing system/gasket leading to degradation/flash

overs of Zinc Oxide blocks.
2. Accelerated ageing/degradation of Zinc Oxide blocks possibly due to
manufacturing defects.

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 In order to avoid the ingress of moisture into the porcelain housing of LAs
through the sealing system, the LAs with polymeric housing have been developed
and about 150 such LAs have already been put into the service on the electric
locomotives built by CLW a few years ago. No failures of these LAs with
polymeric housing have been reported so far. However, a close monitoring is
required for these kind of LAs in order to establish their efficacy against the
ingress of moisture etc.

In the light of the foregoing discussions, the following practices for maintenance
and condition monitoring of LAs in service are suggested:

Sr. Proposed Practices Periodicity

No.
1. Cleaning of LA housing Every year
2. Measurement of Insulation Resistance (IR) Value Every year
of LAs by using 1000 V meggar – usually the IR
value should not be less than 1000 M.Ohms.
3. Measurement of Third harmonic resistive leakage Every year
current through LA as proposed in Para-6
4. Preparation of database (LA make wise) by To be updated regularly
RDSO/ Railways for Third harmonic resistive
leakage current for deciding the threshold/critical
valve for each type of LAs.
5. Decision is to be taken for either close monitoring
or replacement of LAs in service depending on -
the value/ steep rise/ trend in the rise of Third
harmonic resistive leakage current.

14. References

[1] Distribution Arrester Research; M.V.Lat, J.Kortshinski; IEEE Transaction on

Power Apparatus and Systems, Vol. PAS-100-No.7, July 1981.

[2] Maintenance of Surge Arrester by Portable Arrester Leakage Current Detector;

S.Shirakawa, F.Endo, H.Kitajima, S.Kobayashi,, K.Kurita; IEEE Transactions on
Power Delivery, Volume 3, No.3 July 1988.

[3] Surge Arrester Monitorintg and Failure Investigations; Ravindra Kumar Tyagi,
S.Victor, Narendra Singh Sodha; PGCIL, Gurgaon.

[4] Surge Arrester Application and Selection Guide; IEEMA-20-2000.

[5] IEC 99-4.

Metal Oxide Surge Arresters without gaps for ac systems.

[6} RDSO’s Specification No. EIRS/SPEC/LA/0005, July 1999.

Specification for 10 KA, 25 KV Gapless Surge Arrester.

[7] Leafless of M/s Crompton Greaves Limited.

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 ANNEXURE-1

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