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INTRODUCTION
The purpose of this paper is to explore through
computation the effects of heat sinks between ZnO
elements of a surge arrester on power dissipation in
and thermal stability of the ZnO elements. Such heat
sinks have been used for many years in ZnO Test Time (not to scale)
arresters; however, a quantitative exploration of their
Figure 1. IEC type test process for stability of ZnO arresters
effect hast not been published. This problem is (not to scale). A short impulse of defined volumetric power
nearly impossible to explore through measurement, as 3 o
dissipation (250 J/cm ) is applied when the system is at 60 C,
the power dissipation as a function of axial and radial then the system is allowed to relax for 1 minute after which a
position within the ZnO element is of primary second identical impulse is applied. The system then relaxes
for 100 ms after which rated voltage (120% of maximum
interest. Thus such phenomena must be explored continuous operating voltage) is applied for 10 s, followed by
through computation, using software for axisym- maximum continuous operating voltage for 30 minutes.
metric 2-D transient nonlinear finite element analysis Table 1. IEC Standard for ZnO Arrester Type Test
with coupled thermal and electric fields. As part of a
program to develop software capable of simulating Time Action
the entire type test sequence of IEC60099-4, we have Long duration current impulse (250
undertaken a study of heat sink related issues. This 0 J/cm3) applied to arrester at
equilibrium temperature of 60 oC
work is a joint effort of a surge arrester manufacturer
0 ~ 60 s 60 s relaxation (no voltage)
and specialists in numerical analysis, so that the Long duration current impulse (250
parameters used in the computations reflect accurate- 60 s
J/cm3)
ly data measured for production arrester elements. 60 s ~ 60.1 s 0.1 s relaxation (no voltage)
60.1 s ~ 70.1 s 10 s rated voltage (312 kV)
Thermal stability under surge conditions limits the
30 minutes maximum continuous
rating of station class surge arresters and is often 70.1 s ~ 1870 s
operating voltage (252 kV)
defined in terms of the IEC60099-4 operating duty
type test described in Figure 1 and Table 1, which mined based on line discharge class 4, which normal-
consists of applying two surges one minute apart ly applies for 362 kV systems.
followed by the rated voltage of the surge arrester for The ZnO element conductivity as a function of elec-
10 s and then the maximum continuous operating tric field and temperature for this study is shown in
voltage for 30 minutes, to condition the arrester to an Figure 2. These data are based on measurements of
elevated temperature and see if it remains thermally production ZnO arrester elements. Inevitably such
stable during application of rated voltage followed by measurements contain some experimental error, and
maximum continuous operating voltage. engineering judgment has been used to “smooth” the
data to create a well-behaved plot. At high electric
In this paper, thermal stability of 312 kV rating surge field (current), the conductivity is essentially inde-
arrester, normally applied to 362 kV systems, is o
pendent of temperature to about 500 C. At low field,
discussed. The analysis is carried out on a design conduction is ohmic but a very strong function of
which employs 53 high gradient ZnO elements. The temperature. During the 10 s IEC rated voltage
values given in parentheses in Table 1 are for this phase, the peaks of the AC voltage typically extend
3
surge arrester. The energy absorption of 250 J/cm slightly into nonlinear conduction, while at maximum
resulting from application of each impulse was deter- continuous operating voltage, the entire AC wave-
form is in the low field, ohmic region. In both AC
phases of the type test, the conductivity and power
dissipation increase rapidly with temperature. As can
be seen from Figure 2, the low field conductivity and
power dissipation increase by roughly an order of
o 1e+2
magnitude for every 100 C increase in temperature.
tivity (S/m)
Thus applying rated voltage or maximum continuous 1e+1
uc
power dissipation in the elements may exceed the 1e-2
Electrical Cond
1e-3
heat loss from the surface of the elements. The ZnO
1e-4
thermal diffusivity used in these computation is also
1e-5 8
nonlinear and is shown in Figure 3.
m)
1e-6 7
6
/m
Qualitative Description of Physical Phenomena 1e-7 5
(kV
1e-8 4
ld
3
Fie
One method for improving thermal stability is to 300 2
250
200
tric
1
place heat sinks between the ZnO elements. This has 150
ec
100
Temp 50
El
three beneficial effects, viz., (i) in the short term, eratu
re (C
)
such heat sinks absorb heat from the ZnO elements to Figure 2. Typical electrical conductivity of ZnO as a function
lower their temperature and reduce power dissipation, of temperature and electric field. Under low field conditions,
(ii) in the longer term, the elements conduct heat the conductivity is a very strong function of temperature,
from the large ZnO–heat sink interfaces to the heat while under high field conditions, the conductivity is almost
independent of temperature.
sink–gas interface, thereby increasing heat transfer
from the elements to the surrounding gas, and (iii)
since the greatest reduction in ZnO temperature
occurs near the heat sink surface, this decreases the
ZnO conductivity in that region compared to the
middle of the ZnO element, which results in the
maximum power dissipation occurring near the ZnO–
heat sink interface where heat can be removed from
the ZnO element most efficiently. These thermal
phenomena occur because ZnO has a thermal conduc-
tivity of about 20 W/m-K while common heat sink
materials such as Al, have thermal conductivities in
the range of 250 W/m-K. ZnO and Al have similar
6
volumetric heat capacities, in the range of 2.5x10
3
J/m -K. The convective heat transfer coefficient
2
(HTC, W/m -K), determined by the solid-gas inter-
face conditions, is quite similar for both ZnO and the Figure 3. Thermal diffusivity of ZnO employed in the present
computations.
heat sink, so that thermal transfer to the insulating
gas depends primarily on the temperature difference Based on the above thermal conductivity and heat
between the solid and the gas. Since the heat sink capacity, the thermal diffusivity of ZnO near room
6 2
has a much greater thermal conductivity, it can temperature is about 8x10 m /s but decreases sub-
transfer heat from the center of the ZnO element to stantially with increasing temperature (Figure 2).
the gas much more efficiently than can the ZnO Thus heat diffuses 22 mm in ZnO in about 1 minute.
within the element. The thermal diffusivity of Al is about an order of
In our discussion below, we will consider ZnO ele- magnitude greater, so that the heat sinks come to
ments which are 22 mm thick and about 85 mm in thermal equilibrium within a few seconds for any
diameter. The heat sinks are of variable thickness reasonable thickness.
and of the same diameter as the ZnO elements. To consider the IEC Type Test of Figure 1 in greater
Unless otherwise stated, the heat sinks are placed detail, the first impulse causes adiabatic heating of
between adjacent pairs of ZnO elements, so that each the ZnO elements. During the one-minute relaxation
ZnO element is adjacent to only one heat sink, with before the next pulse, the ZnO elements and Al heat
the other side being another ZnO element. sinks come close to thermal equilibrium. Since we
2
have two ZnO elements for every heat sink and the NUMERICAL MODELING
volumetric heat capacity of the two materials is
similar, heat sinks of the same size as the ZnO The ZnO arrester geometry used in our simulations
elements absorb roughly one third of the heat includes the ZnO elements, heat sinks, and gas. The
dissipated during the surge, and in the process, the ZnO elements and heat sinks are cooled through
temperature rise in the ZnO elements is reduced by convection from the stack surface based on a fixed
2
about one third relative to the temperature immedi- convective heat transfer coefficient HTC (W/m -K). In
ately after the impulse. other simulations, we have included both radiation and
the ambient temperature of gas within an enclosure
The second impulse causes a second, similar temper- explicitly.
ature rise; however, heat in the ZnO can diffuse only
about 1 mm in the 0.1 s before the rated voltage is The entire IEC type test is simulated using transient
applied. Thus at the time the rated voltage is applied, nonlinear finite element analysis with coupled ther-
the temperature in the elements is substantially mal and electric fields [1,2]. In the computation, we
nonuniform with a large temperature gradient in the apply AC voltage to the ZnO stack and calculate the
ZnO layer adjacent to the heat sinks. During the electric field distribution therein as a function of
rated voltage phase, the power dissipation is sub- time, use the field distribution and known temper-
stantial and somewhat nonuniform as a result of the ature to calculate the electrical conductivity, compute
axial temperature gradient in the ZnO elements. the average power dissipation over an AC cycle from
During the 10 s rated voltage phase, the elements do the conductivity and electric field, and then use
not come to thermal equilibrium internally or with transient nonlinear thermal finite element analysis to
the Al heat sinks as a result of the short time compute a new temperature distribution from the
compared to the diffusion time across the ZnO ele- position-dependent power dissipation and the known
ments and the nonuniform power dissipation within (nonlinear) thermal properties. Computation of IEC
the elements. Type Test with heat sinks is particularly difficult as it
is truly an axisymmetric 2-D computation. Without
The power dissipation is reduced substantially during the heat sinks, the problem is really 1-D, as no axial
the maximum continuous operating voltage phase, temperature gradient should exist, and this allows
and the elements come close to equilibrium, both simplifications to be made which reduce the com-
axially and radially, with some temperature gradient putation time. However with heat sinks, the full 2-D
near the interface with the heat sink as a result of its computation must be undertaken, which means
large thermal conductivity. However, a minute into computing the power dissipation during an AC cycle,
the maximum continuous operating voltage phase, the including the nonlinear conductivity of the ZnO
axial and radial temperature variation in the ZnO is which becomes significant during the 10 s rated
only a few degrees unless thermal runaway is voltage phase.
imminent.
AC Rated Voltage Phase
Basically, thermal stability is determined by whether
the temperature in the ZnO elements increases or During the 10 s AC rated voltage phase, the ZnO
decreases with time after they come to near thermal elements are at substantially elevated temperature
o
equilibrium, soon after the maximum continuous (around 200 C at the end of the second impulse) and
operating voltage is applied. If the elements are in a are subjected to a large electric field which pushes
confined gas space, as in a tank-type arrester, the the ZnO slightly into nonlinear conduction at the
temperature of the gas surrounding the elements can peak of the AC voltage, as seen in Figure 4. The
increase over time, which can reduce heat transfer increase in power density with temperature is
from the elements to the gas. This can lead to “late” exponential under these conditions, as seen from
thermal runaway, a situation where the ZnO elements Figure 5.
start to cool slightly during the maximum continuous During the rated voltage phase, radial heat transfer is
operating voltage phase, after which the ZnO element much less than axial transfer to the heat sinks, as
temperature starts to increase as a result of the immediately after the second impulse and 0.1 s
increasing gas temperature. Obviously, this occurs relaxation (without applied voltage), the ZnO is much
only at the boundary between stable and unstable hotter than the heat sinks. The simulation results
operation. indicate that the radial temperature variation is negli-
gible, so we focus on the axial temperature variation
(Figure 6) and corresponding variation in axial power
3
dissipation (Figure 7). Figure 8 shows a comparison (Figure 7), we see that the heat sinks are very effect-
of the volume averaged power density and temper- tive in reducing ZnO temperature and power density.
ature vs. time with and without heat sinks. The effect
of the heat sinks in lowering the power dissipation is
180
dramatic.
170
Cumulative Heat (scaled to the maximum)
160
Temperature (C)
1.0 1.0
Power Density (scaled to the maximum)
0 5 10 15 20
-1.0 -1.0 Axial Distance from Heat Sink Surface (mm)
0 5 10 15 20 Figure 6. The on-axis axial temperature gradient within a
Time (ms) ZnO element as the function of the distance from the heat
Figure 4. Power density in a ZnO element at uniform sink, at various times during the 10 s rated voltage phase. The
2
0
temperature of 200 C during the rated voltage phase. The HTC at the ZnO and Al surface is 10 W/m -K, and the heat
solid line is applied voltage. The dashed line is the power sink thickness is the same as that of ZnO element, 22 mm.
density. The dotted line is the cumulative power dissipation One heat sink is placed between every pair of ZnO elements,
over one cycle. Most of the power dissipation occurs near the which results in twice as many ZnO elements as heat sinks.
peak voltage as a result of nonlinear conduction in the ZnO.
4
the one hand results in substantial current density and
power dissipation but, on the other, assures a
relatively uniform electric field as a result of the
strong field dependence of the conductivity so that
the power density, J E, is quite uniform in spite of the
large temperature variation.
The heat sinks also cause a substantial reduction in
the temperature after the second impulse, which
results much lower power dissipation during the rated
voltage phase, thereby improving thermal stability.
The power density with the same HTC but without
heat sinks is five times greater than the volume aver-
aged power dissipation with heat sinks (Figure 8).
Figure 9. On–axis power density during the 10 s rated voltage
phase with and without a heat sink of the same thickness as
the ZnO element (22 mm), assuming the same initial ZnO
temperature at the beginning of the rated voltage phase for
2
both cases. The HTC is 10 W/m -K and one heat sink is
placed between every pair of ZnO elements, resulting in twice
as many ZnO elements as heat sinks.
5
o
Table 2. Computed Gas-ZnO Surface Temperature ( C) 200 s From the performance indicated in Table 2, we can see
into the IEC Type Test with various heat sink thickness (ZnO a dividing line exists between the stable and unstable
element thickness is 22 mm, one heat sink is placed between
every pair of ZnO elements) and HTC as defined in the Table. cases with various combination of HTC and heat sink
0 mm thickness means no heat sinks are employed. Numbers thickness, which would provide the guideline for the
marked with * are for thermally unstable cases. system design or the evaluation of the system stability
HTC (W/m2-K) tolerance.
Heat Sink 1 10 100
Thickness (mm)
0 *252 *234 150
2.2 *230 214 139
11 *177 160 N/A 220
(K)
218
Temperature
216
perature is reduced but also much less power is
dissipated near the center of the element as a result of 214
the axial temperature variation. 20
212
)
The average surface and center temperatures during
m
15
(m
the tests for various heat sink thicknesses are plotted in 0
n
5 10
itio
10
Figures 12-15. Without a heat sink, the HTC must be
os
15
20 5
lP
2
increased to 100 W/m -K to maintain thermal stability 25
ia
Rad 30
Ax
(Figure 12). When a heat sink thickness of 2.2 mm is ial P 35 0
osit 40
2 ion
disposed between pairs of ZnO elements, a 10 W/m -K (mm
)
HTC will maintain thermal stability (Figure 13). With Figure 11. Temperature distribution within a ZnO element at
the increase of the thickness to 11 mm, the system is 200 s into the IEC type test with a heat sink of thickness 2.2
2 2
still marginally unstable under 1 W/m HTC, but when mm and a HTC of 10 W/m -K. One heat sink is placed
the heat sink is as thick as the ZnO element (22 mm), between every pair of ZnO elements (twice as many ZnO
2 elements as heat sinks). The heat flows axially towards the
1 W/m -K HTC maintains thermal stability (Fig. 14). heat sink and the system remains stable.
250
242 200
Temperature (C)
) (K
240
150
Temperature
Surface, 1 W/m2-K
238 Surface, 10 W/m2-K
100 Surface, 100 W/m2-K
236 Center, 1 W/m2-K
20 Center, 10 W/m2-K
234 15 50 Center, 100 W/m2-K
)
m
0
(m
Rad 20 5
os
ial P 25
30 Figure 12. Average surface and center temperatures of a ZnO
lP
osit 35
ion 0
ia
(mm 40 element during the IEC test with no heat sinks as a function of
Ax
) HTC. The black lines are for surface temperature and the red
Figure 10. Temperature distribution within the ZnO element lines are for center temperature. The system is thermally
2
at 200 s into the IEC type test with no heat sinks and a HTC at unstable at an HTC of 1 and 10 W/m -K, but stable at 100
2 2
the ZnO surface of 10 W/m -K. The heat flows radially to- W/m -K.
ward the ZnO surface. The system is thermally unstable.
6
this way we keep the total heat sink volume the same
although the number of heat sinks doubles in the
second case. We have computed the cases with a
200 2 2
HTC of 1 W/m -K and 10 W/m -K. As can be seen
from Figure 15, the system with a half heat sink
Temperature (K)
150
separating ZnO elements is far more stable than the
cases with one heat sink between every pair of ZnO
Surface, 1 W/m 2-K
elements (twice as many ZnO elements as heat sinks).
Surface, 10 W/m 2-K
100 Surface, 100 W/m2-K
This results from the much more rapid cooling of the
Center, 1 W/m2-K ZnO elements by the heat sinks during the over
Center, 10 W/m2-K voltage phase in the former case.
50 Center, 100 W/m2-K
180
160
Temperature (K)
140
Figure 15. Average surface temperatures of a ZnO element
120 Surface, 11mm, 1 W/m 2-K 2 2
during the IEC type test for 1 W/m -K and 10 W/m -K HTC
Surface, 11 mm, 10 W/m 2-K with two different heat sink placements. The black lines are
2
100 Surface, 22 mm, 1 W/m 2-K for the cases with 1 W/m -K HTC and the red lines are for the
2
cases with 10 W/m -K HTC. The solid lines are for the cases
Center, 11 mm, 1 W/m 2-K
80 with one heat sink (22 mm thickness) between every pair of
Center, 11 mm, 10 W/m 2-K ZnO elements (twice as many ZnO elements as heat sinks) and
60 Center, 22 mm, 1 W/m 2-K the dotted lines are for the cases with half heat sink (11 mm
thickness) separating each pair of ZnO elements. The overall
0 50 100 150 200 heat sink volume is the same for both cases.
Time (s)
As noted above, power dissipation in the ZnO during
Figure 14. Average surface and center temperatures of ZnO the 10 s rated voltage phase and 30 minute MCOV is
element during the IEC type test with various HTC and heat a very strong function of temperature, Heat sinks
sink thickness. The system is thermally unstable for 11 mm
2
heat sink thickness and 1 W/m -K HTC, but stable for 11 mm “work” by lowering the temperature rapidly after the
2
thickness with 10 W/m -K HTC and 22 mm thickness with 1 impulses, which results in lower power dissipation
2
W/m -K HTC. One heat sink is placed between every pair of during the AC voltage phases. The effect of heat
ZnO elements, resulting in twice as many ZnO elements as sinks on power dissipation at the center of the ZnO
heat sinks. elements can be evaluated quantitatively by taking
Placement of Heat Sinks the average temperature at the center of the ZnO
element during the rated voltage phase (60 to 70 s) or
In all of the above analysis, one heat sink is place the MCOV phase (>70 s) from figures 12-15 and
between every pair of ZnO elements, resulting in using Figure 5 to compute the power dissipation. As
twice as many ZnO elements as heat sinks. Obvious- the power density during the rated voltage phase
ly a heat sink separating every pair of ZnO elements increases by roughly an order of magnitude for a 100
is preferable but involves more complexity. We have o
C increase in temperature, a modest reduction in
computed cases of a heat sink between every pair temperature from a heat sink has a large effect on
ZnO elements (as above) with heat sink thickness power dissipation and subsequent temperature rise.
equal to the ZnO element thickness as opposed to a
half thickness heat sink separating ZnO elements. In
7
CONCLUSION arrester elements". IEEE Trans PD, Vol. 15. No. 1, Jan.
2000 pp. 128 –134
In the present contribution, we have quantified the Zhong Zheng is a Ph.D. candidate in the Department of
role of heat sinks in reducing power dissipation and Electrical and Computer Engineering, University of
improving heat transfer from ZnO elements. Heat Toronto, Canada. His research centers on the development
sinks cause a very rapid reduction in ZnO and application of programs for transient nonlinear finite
temperature after any sudden power dissipation in the element analysis with coupled fields. Zhong obtained his
Master’s degree in the Department of Electrical
ZnO and thereby lower subsequent power dissipation Engineering of Tsinghua University in China in 2000 with
at normal operating voltage. Heat sinks also improve a thesis on partial discharge detection. His Bachelors
heat transfer from the ZnO to the surrounding gas as Degree is from the Department of Electrical Engineering in
a result of their large radial thermal conductivity the Wuhan University of Hydraulic and Electrical
relative to the ZnO. Finally, heat sinks cause an axial Engineering in 1997 with the thesis on the electromagnetic
field calculations.
temperature gradient in the ZnO element which
reduces power dissipation near the center of the ZnO Susumu Nishiwaki (SM’00–F’02) received the B.S.
degree in electrical engineering from Yokohama National
element by reducing the current density on axis of the University, Yokohama, Japan, in 1969, and the Doctor of
element. Thus heat sinks have a beneficial effect on Engineering degree from Nagoya University, Nagoya,
arrester stability. We have also demonstrated that Japan, in 1982. Presently, he is with TM T&D Corporation,
during the 10 s rated voltage phase of the IEC type Kawasaki, Japan, a company formed when the T&D
test, the power dissipation as a function of axial operations of Toshiba, Kawasaki, Japan, and Mitsubishi,
Amagasaki, Japan, were combined in October 2002. In
position does not vary greatly in spite of a large 1969, he joined the Toshiba Corporation where he was
temperature variation along the axis of the ZnO engaged in research and development of gas-insulated
element. switchgear and surge arresters. Dr. Nishiwaki is a member
of IEE of Japan.
Perhaps most importantly, we have demonstrated the
ability to simulate the full IEC Type Test Sequence Takato Fukano received the B.S. and M.S. degrees in
electrical engineering from Miyazaki University, Miyazaki,
for a ZnO arrester using transient nonlinear finite Japan, in 1993 and 1995, respectively. Currently, he is with
element analysis with coupled thermal and electric TMT&D Corporation, Kawasaki, Japan, a company formed
fields, which opens the door to much more detailed when the T&D operations of Toshiba, Japan, and
design of ZnO arresters based on electrothermal Mitsubishi, Japan, were combined in October 2002. In
1995, he joined the Toshiba Corporation where he was
modeling. This has required substantial improve- engaged in development of surge arresters. He is a member
ments in computational efficiency. Using the ap- of IEE of Japan.
proaches outlined in [1], the computation time has Steven Boggs (F’92) received the B.A. degree from Reed
been reduced by a factor of 100 to 1000 for highly College, Portland, OR, in 1968, and the Ph.D. and MBA
nonlinear electric field problems relative to the degrees from the University of Toronto, ON, Canada, in
programs used in [3-5]. 1972 and 1987, respectively. Currently, he is Director of
the Electrical Insulation Research Center and Research
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of the IEEE for contributions to the field of SF6 insulated
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“Increased Energy Absorption in ZnO Arrester Elements
through Control of Electrode Edge Margin”. IEEE Trans.
PD. Vol. 15, No. 2, April 2000. pp. 562-568.
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dielectrics”. IEEE Electrical Insulation Magazine, Vol.
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"Electro-thermal-mechanical computations in ZnO