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Advanced insulation and switching concepts for next generation

High Voltage Substations

N. PRESSER, C. ORTH, B. LUTZ, M. KUSCHEL, J. TEICHMANN

Siemens AG
Germany

SUMMARY
SF6 gas is nowadays the most applied medium as arc-quenching and insulating gas in high-voltage
products and switchgear for grid stations in transmission networks. It has proven worldwide its
technical capabilities for more than 50 years for gas-insulated switchgear, circuit breakers and
instrument transformers as well as for gas-insulated transmission lines. SF6 gas technology represents
the state-of-the art, with very good arc-quenching properties and dielectric strength for insulation
purposes. SF6allows an easy and accurate gas density respectively leakage measurement. Moreover it
can be handled without health risks for human beings or the environment as it is non-toxic.
Nevertheless, SF6 has a significant potential impact on world ecological system with its contribution to
the Global Warming Potential (GWP), whenever emitted. Therefore, in parallel to the optimization of
the above mentioned factors in order to reduce gas emission and losses, the manufacturers of
transmission equipment have done extensive research and development activities to seek for
alternatives. These alternatives should have a lower environmental impact over their entire life-cycles.
Several alternative solutions for high-voltage products have been presented during the last 20 years.
For example, products from Asian and European manufacturers are already available with Dry
Air/CO2 insulation in the market. Applications with CO2 as arc-quenching gas have also been
presented and installed. At Cigré 2014, alternatives gases to SF 6 based on hydrofluorocarbons
including gas groups such as fluoroketones (perfluorinated ketones), or fluoronitriles (fluorinated
nitriles) with mixtures of N2 or CO2 were presented for arc-quenching and insulating purposes.
Another alternative technology to SF6 for switching is the utilization of vacuum interrupter units for
arc-quenching, which is a proven technology in medium voltage. Vacuum interrupter units have
proven reliable making and breaking capabilities through many switching operations without any
significant ageing of materials and depreciation of functionality. For example, 72.5 kV life- and dead
tank vacuum circuit breakers are successfully in operation at several European utilities. In conjunction
with alternative gases for insulation the solution can result in multifunctional compact switchgear
designs.
Siemens has started to implement GIS technology based on fluorine-free gas insulation with Clean Air
and vacuum circuit breaker. Hence this paper compares the new solution with the SF 6 GIS products
and other approaches with alternative gases. Operational experiences are presented as well as results
from testing of specific high-voltage products. Moreover the different SF6 alternative approaches are
discussed based on life cycle assessment to underline the environmental sustainable impact.

KEYWORDS
GIS, SF6 replacement, alternative gases, vacuum circuit breaker, insulation

nazmir.presser@siemens.com
1. Introduction
Investigations on alternative gases for replacement of sulfur hexafluoride (SF6) as insulating and arc
quenching medium in gas insulated switchgear have been performed since the early 1980s. Wootton
[1] identified some gases with higher dielectric strength compared to SF6 which were either toxic, with
high ozone depletion potential (ODP) or soot generating when exposed to electrical arcs. A study of
Niemeyer et al [2] focused on additional parameters like the Global Warming Potential (GWP), the
long-term stability in electric fields and the critical liquefaction temperature of alternative gases.
Another comprehensive study of Christophorou et al [3] [BL3] focused on gas mixtures including SF6
to reduce its GWP. A synergistic effect was found allowing for significant improvement of dielectric
strength with low amount of SF6 diluted in nitrogen (N2). However, the GWP of SF6/N2 mixtures still
remains high. Further investigations focused on the applicability of trifluoroiodemethane (CF3I)
diluted in nitrogen and carbon dioxide (CO2). Kamarudin et al [4] [BL4] observed that a mixture CF3I
/ CO2 (ratio 30:70, 0,1 MPa) can reach 70% of the dielectric strength of SF6 under same pressure.
However, the application of CF3I in GIS has to be questioned due to the possible risk of irreversible
effects (R68) and its classification as “harmful” within the European Union.
In the last years, also natural gases with fluorinated additives e.g. C5 / C6 fluoroketone (having 5 or 6
carbon atoms) and fluoronitrile have been introduced for medium and high voltage application ( [5],
[6], [7]). Investigations were performed to show the improvement of dielectric and switching
performance compared to already existing SF 6 replacements.
Siemens has implemented Clean Air (i.e. 80% N2 + 20% O2) as insulating gas for next generation GIS
products. Main reasons for the choice of Clean Air are the excellent long-term stability, liquefaction
temperature below -30°C, Global Warming Potential of zero, no toxicity and positive life cycle
aspects.

2. Alternative insulation approaches

Natural gases and its mixtures like nitrogen, carbon dioxide, N2/CO2 mixtures and Clean Air (i.e. 80%
N2 + 20% O2) are non-toxic and chemically stable and thus potential candidates for insulation in high
voltage GIS. A major drawback is the reduced dielectric strength of these gases which is by 60% to
70% lower compared to SF6 under equivalent pressure [8]. This has to be compensated by appropriate
design and pressure coordination for development of new GIS products.
Other possible candidates for SF6 replacement have been presented recently, e.g. gas mixtures
including fluoroketone or fluoronitrile. Mantilla et al [10] describe the effect of pressure on the
dielectric strength of gas mixtures with different perfluoroketones. The dielectric strength of SF 6 is
found to be reached by a pressure increase of 3 bar when using a gas mixture of 95% air and 5% C5-
Ketone (perfluoruoketone having 5 carbon atoms). Simka et al [11] postulate that air comprising 6%
C5-Ketone at a pressure of 0,7 MPa shows 95% of dielectric strength of SF6 gas at 0,45 MPa.
However, a major drawback of the gas mixtures tested in [10], [11] is its dew point temperature
greater than 0°C so that application for outdoor GIS (ambient temperature ≥ -30°C) is excluded. The
same drawback is given for gas mixtures comprising hydrofluoroolefin and fluoroketones which are
mentioned in [12].
Gas mixtures consisting of CO2 and fluoronitrile were presented in [5]. Depending on the mixing ratio,
those mixtures can reach 80% to 100% of the dielectric strength of SF 6. Gas mixtures with liquefaction
temperature of -25°C were observed to have 87% (0,67 MPa with 5,6 Vol% fluoronitrile diluted in
CO2) and 92% (0,77 MPa with 4,6% fluoronitrile diluted in CO2) of the dielectric strength of SF6 gas
with same pressure.
Finally, it has to be stated that no fully equivalent alternative for the replacement of SF6 as insulating
gas is available up to now. In any case, compromises and modifications in product design or product
specifications have to be found for SF6-free GIS.

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Siemens performed comprehensive investigations to evaluate the insulation capabilities of Clean Air
in gas insulated switchgear. Many tests were carried out with small-sized and real-sized GIS specimen
and prototypes to investigate the factors of influence on dielectric breakdown in Clean Air, i.e.:
- Influence of gas pressure
- Influence of surface quality and surface area of metal parts
- Influence of gas quality, especially gas humidity
- Influence of insulator surfaces
- Influence of field utilization factor
- Influence of defects, e.g. metallic particles
- Influence of voltage type, i.e. impulse and AC voltages
- Influence of test method, e.g. multi-level test vs. up and down method
Furthermore the influence of defect type and pressure on partial discharge behavior was investigated.
Based on the comprehensive test results and statistical analysis, criteria for reliable and safe
dimensioning of SF6-free GIS products were gained. An exemplary relationship between electric
breakdown field strength and gas pressure for different surface quality is shown in Figure 1.

Figure 1: Normalized electric breakdown field strength versus gas pressure for Clean Air and different voltage
type and surface quality without coating.

3. Alternative arc quenching approaches for circuit breaker, disconnector and earthing switch
As for dielectric strength, the arc quenching capability with alternative gases is significantly lower
compared to SF6. Therefore arc switching investigations are necessary for all switching components,
i.e. circuit breaker, disconnector, and earthing switch.
In order to qualify Clean Air as an arc quenching gas, several tests were performed with real GIS
modules. The results with Clean Air were compared to results obtained with SF6 and other alternative
gases.

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3.1 Circuit breaker
Two possibilities as alternatives for SF6 self-compression circuit breakers:
- Vacuum circuit breaker with SF6-free insulation
- Self-compression circuit breaker with alternative gas as arc extinguishing medium

In the late 1990s investigations on arc extinguishing capabilities of alternative gases and their mixtures
with SF6 were performed [13]. In the following years, focus was laid on CO2 as arc interruption
medium. In 2012 a live tank circuit breaker application was presented [14]. Investigation were also
performed on CF3I [15] for current interruption. Recently GIS with self compression circuit breakers
switching in fluoroketone [6] and fluoronitrile [5] were presented.
Vacuum technology is well known in medium voltage application and used for decades.
Advantages of vacuum technology are:
- High mechanical endurance
- High number of breaking operations at normal and short circuit currents
- Unaffected by low temperatures
- Long operational life
- No maintenance of switching unit

In recent years it was shown, that the positive vacuum properties can be extended from medium
voltage to high voltage range. Circuit breakers for 72.5 kV for live tank applications [16] (see also
chapter 5. Field experience) and GIS application [17] with vacuum interrupters were developed.
Circuit breakers for 126 kV live tank are also available [18]. Latest developments show first
applications for Clean Air and vacuum interrupter units for high-voltage GIS products, see Figure 2.

Figure 2: Example for 66 kV GIS with Clean Air for specific Windtower application [19] (left) and vacuum
interrupter units for 72.5 kV and 145 kV [18] (right)

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3.2 Disconnector Switch
Two test duties have to be performed by a disconnector switch:
- Bus transfer current switching (BTC)
- Bus charging current switching (BCC)
Bus transfer current switching (BTC) was tested according IEC 62271-102 (2013). Test current was
1600 A and test voltage 20 V. The arcing times of 100 breaking operations under Clean Air and SF6
are shown in Figure 3. It can be seen that the arcing times with Clean Air show no significant change
compared to the arcing times with SF6. Test with other alternative gases also showed, that no
significant change of arcing times could be seen [19].

Figure 3: Measured mean arcing times during bus transfer current tests for SF6 gas and Clean Air; the black bars
indicate the range of arcing times of one test series
Switching of bus charging currents by the disconnector switch is not a mandatory type test for rated
voltages below 300 kV. However for research purposes the switching capabilities of Clean Air were
investigated according to IEC 62271-102 Annex F (2013), including condition checks. All tests were
passed without any break-outs of the arc to the housing.
However, conductive soot generation was observed after BTC switching tests with C4-Nitrile gas
mixtures. Investigations show that additional share of oxygen in C4-Nitrile gas mixtures improve the
soot generation during low energy arcing, that should be taken into account for further developments.

3.3 Earthing switch

The earthing switch in high voltage application has to perform the following switching operations:
- Making of rated short-circuit current
- Switching of electrostatic induced currents
- Switching of electromagnetic induced currents.
During tests it was found out that for making of short-circuit currents and switching of electrostatic
induced currents, the arc switching performance of Clean Air is sufficient and no measures have to be
taken to pass the tests.

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For switching of electromagnetic induced currents it was found that for the arc quenching additional
measures have to be taken for all alternative gases on the design of the arcing contacts to support the
arc interruption in order to fulfill electromagnetic induced currents switching tests for Class B.

4. Safety, operation and maintenance aspects

For more than five decades SF6 is applied in high-voltage switchgear equipment. In this period a lot of
improvements were achieved resulting in today’s performance with the experienced GIS
manufacturers: high quality and reliability over an expected life-time of 50 years, compact and
modular design for space saving application, high switching and load carrying capabilities. Moreover
the volume of SF6 in gas-insulated switchgear has been drastically reduced. Also the required
maintenance intervals were reduced resulting in less gas compartments openings. Combined with the
meanwhile established SF6-handling instructions and regulations the SF 6 gas losses were reduced to its
minimum.
Alternatives should preferably have no restrictions on technical performance and on safety. Various
specific “technical” requirements besides the above discussed physical properties such as climate
neutrality, non-toxicology and environmentally friendliness are to be fulfilled. Figure 4 shows the
properties of different SF6 alternatives.

SF6 Clean Air Fluoronitrile C5-Fluoroketone

Chem. Formula SF6 N2 + O2 (80%/20%) (CF3)2CFCN (CF3)2CFC(O)CF3

CO2-Equivalent 22.800 0 2.210 1

Boiling point -64° < -183° -5° +27°

(Celsius)

Dielectric strength 1 (normalized) 0,43 2,2 1,7

Gas mixture

Carrier gas Pure or variable Not applicable ~ 90% CO2 ~ 90% CO2 with
with N2, CF4 N2 or O2

CO2-Äquivalent < 22.800 0 ~ 380 <1

Boiling point <- 64° (variable) < -183° ~ -25° +5°

(Celsius)

Arcing impact

Decomposition Hydrofluoric acid, None under normal Amongst others Decomposition

products sulphur dioxide, operation carbon monoxide, products
sulphur emission conditions carbon dioxide,
hydrofluoric acid,
In case of failure risk for generation
arcs: ozone, of hydrogen
nitrogen oxide cyanide

Toxicity of Toxic and irritated Irritated for eyes Toxic and irritated Toxicity of
decomposed gas for skin, eyes and and respiratory for skin, eyes and decomposed gas
respiratory organ organ respiratory organ

Figure 4: Properties of alternative insulation gases for HV switchgear application

The Clean Air approach represents the fluorine-gas free insulation. While SF6 has a Global Warming
Potential (GWP) of 22.800, Clean Air shows a GWP of 0. Moreover due to the lowest boiling point it
can be used in the entire temperature range even lower than -65 °C without any restrictions.

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Leakages of Clean Air are not considered to be reported to any public authority. Recycling cost of the
gas does not apply. Moreover Clean Air is like SF6 a non-toxic, non-harmful and safe medium. It is
possible and permitted to deliver the GIS filled with Clean Air at rated pressure from the factory to its
final destination. No special trained employees are required for the gas handling works compared to F-
gas solutions. Clean Air can be released in the atmosphere without any environmental impact, where
F-gas solution needs to be carefully evacuated via filters and stored in dedicated vessels.
To be noted are also the different decomposition products in the event of arcing. With Clean Air no
acids occur in comparison to F-gases. In planned or unplanned maintenance therefore more efforts are
needed to protect employees using F-gases, see Figure 5. Overall Clean Air has clear advantages from
health and environmental point of view.

SF6 Clean Air Fluoronitrile and Ketone

Eye and face protection Full face mask If so safety glasses Full face mask
Hand and skin Safety gloves, Work gloves Safety gloves (Nitrile/Butyl)
protection One time riot gear One time riot gear (dust-tight)
Breathing protection Full face mask with filter If so breathing Full face mask with filter A2 B2
A2 B2 E2 K1-P2 or protection E2 K1-P3
respirator
Figure 5: Human safety precautions for different insulation gases

5. Field experience
When vacuum switching technology was introduced in medium voltage networks in order to replace
oil or SF6 breakers, there was some lack of acceptance by the grid operating companies. Their main
concern was the physical behavior of vacuum interrupters in opening operation. Due to vacuum arc
characteristics current chopping events can occur with current values in the range of some amperes
causing over-voltages. With modern contact materials, the value of the chopping current was
minimized, generating acceptable over-voltages in the grid. Only for a small number of applications
especially in shunt reactor switching or motor switching the usage of surge arresters is recommended
by the breaker suppliers.

Figure 6: 72.5 kV live tank circuit breaker with vacuum interrupter and nitrogen insulation

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In order to secure the safe application of vacuum switching technology in the High Voltage grid a
huge variety of performance tests in the high power laboratories i.e. capacitance switching, inductance
switching etc. were performed [20]. Additionally five 72.5 kV live tank breakers have been already
installed 2010 in the rough environment of the real transmission grid. These circuit breakers are
located in the trans-European grid. In sum three utility companies have agreed to start a co-operation
with Siemens to gain field experience with this completely type tested outdoor vacuum circuit breaker.
Since the installation of the breakers in the substations they have operated in total more than 6500
switching operations of different load and short-circuit currents. Neither in the laboratory nor in the
grid the vacuum breakers showed any difference to the existing SF6 technology. The applications are
mainly switching of outgoing feeder bays or changing bus bars [21]. The feedbacks given by the end-
users are fully positive and no abnormalities have been observed during the test application phase.
Thus gives the evidence that the extension of the vacuum switching technology to high voltage
applications will not be limited by technical reasons. This technology is equal and for specific
applications even superior to SF6-breakers and is a suitable candidate for SF6-free high-voltage
switches in the near future.

6. Life cycle aspects

The development of next generation GIS products is driven by several aspects to be considered over
the whole life cycle. For that purpose, life cycle assessment according to ISO 14040/44 - with respect
to the impact category global warming potential (GWP100) - was performed for two different GIS
product scenarios for three-phase encapsulated cable bays for European market, for 123kV application
in a first step.
1. SF6 insulation and SF6 arc-quenching interrupter unit for standard GIS
2. Clean Air and vacuum interrupter unit technology

The global warming potential (GWP) of Clean Air GIS can be significantly reduced compared to SF 6
GIS. Figure 6 depicts the GWP over the whole life cycle that is reduced by more than 30% mainly due
to the following reasons:
- Although more hardware material like aluminum or steel is used for Clean Air GIS, the
contribution of material production to GWP is almost equal to SF 6 GIS. This is due to a lower
energy consumption to produce Clean Air in comparison to SF 6 as insulating gas.
- GWP caused by gas losses during manufacturing, transport, operation & maintenance are
significantly reduced as GWP of Clean Air is equal to zero.
- Reduction of total GWP by recycling is slightly higher for Clean Air filled GIS due to greater
amount of recyclable materials like aluminum or steel.
The absolute results of this life cycle assessment are design-specific and are not representative for
other GIS configuration and voltage ratings.

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Figure 6: Normalized CO2 equivalent over the whole life cycle for a 145 kV GIS filled with SF6
compared to a 145 kV GIS filled with Clean Air.

Source of Data:
The global warming potential was evaluated in terms of the normalized CO 2 equivalent (database
ecoinvent 2.2, May 2010) for four main life cycle stages using the following data:
Materials
The data involve the extraction of natural resources, transport to the processing sites, and the
production of raw materials including SF6 gas and Clean Air. Higher efforts for production of the
vacuum interrupter unit are included.
Manufacturing and transport
This stage covers all production processes including transport of the finished product to its installation
site. The essential data like energy, water, and gas consumption and gas losses are based on the annual
manufacturing data of the site. Transport figures are based on a transport performance of 1500
kilometers within Europe.
Operation and maintenance
The lifetime of gas-insulated switchgear is assumed to be 50 years. Operation and maintenance
include gas losses during operation (leakage rate ≤0,1% per year), maintenance (leakage of 0,01% per
service) and end-of-life emissions (leakage of 0,01%). The time intervals between maintenance
activities were assumed to be 25 years for both, SF6 and Clean Air. Energy consumption for heating of
e.g. drives is considered for the lifecycle assessment as well as energy losses in operation with 50%
rated current due to Joule heating (assumptions: lifetime 50 years, average European energy mix).
Higher energy losses due to higher contact resistance of the vacuum interrupter unit are included.

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Recycling
At the end-of-life the GIS is disassembled. Material recycling and thermal treatment of all recyclable
materials (including SF6) as well as the disposal of all other materials are considered for the life cycle
assessment. For metals like copper, steel, and aluminum, recycling significantly reduces the
consumption of raw materials. No recycling has to be done for Clean Air after end-of-life.
If gas mixtures with fluorinated additives are used to GIS, then further effects on global warming
potential and life cycle costs have to be considered, e.g.:
1. Heating of indoor GIS filled with gas mixtures including fluoroketones is neede to avoid
liquefaction (<5°C ambient temperature: this leads to an overall additional energy losses
2. Gas mixtures with fluoronitriles or fluoroketones gases are non-recyclable, therefore the
disposal after end-of-life needs additional energy
3. Negative effect of fluorinated compounds due to GWP greater than zero
4. Additional materials are required to ensure material compatibility (e.g. coatings) and long-
term gas stability (e.g. special desiccant for decomposition products)
5. Additional safety measures are key for the handling of toxic gases and their decomposition
products, e.g. monitoring of gas concentration
6. Insufficient long-term stability of fluorinated gases with low GWP, i.e. sensitive to
decomposition by UV radiation, leads eventually to shorter maintenance intervals
Finally, positive life cycle aspect with respect to the global warming potential can be attributed to next
generation GIS products with Clean Air insulation and vacuum switching technology. Compared to
SF6 filled GIS, the global warming potential can be significantly reduced.

7. Conclusion
Siemens implements in high voltage GIS products the technology based on fluorine-free gas insulation
with Clean Air and vacuum circuit breaker. Comprehensive investigations were carried out to define
criteria for reliable and secure design of GIS products with Clean Air insulation. Several tests were
performed to prove the functionality of disconnecting and earthing switches with Clean Air as arc
quenching medium. Positive test results and long-term experience with 72.5 kV vacuum interrupter
switches installed in the field is available. Moreover, further advantages of 145kV GIS with Clean Air
insulation and vacuum circuit breaker can be summarized:
- Clean Air GIS has a positive impact over the total life cycle, with a lower GWP than a SF6 GIS
- Clean Air has excellent long-term stability under electrical stress
- Clean Air as gas is not toxic and has an intrinsic GWP=0
- Clean Air can be applied for temperatures below -30°C
- Clean Air is more simple with respect to gas handling, resulting in lower life cycle costs
- Vacuum switching technology is available and proven with long-term field experience
- Vacuum switching behaviour is comparable to SF6 self-compression breakers
Considering these positive aspects, GIS products with vacuum circuit breaker and Clean Air insulation
are recommended for application in next generation high voltage substations as environmental friendly
alternative for GIS products based on SF 6 technology.

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