ANSI DESIGN TEST REPORT Report No. EU1295-H-00 Type PVN Station Class Surge Arrester

ANSI DESIGN TEST REPORT Report No. EU1295-H-00 Type PVN Station Class Surge Arrester This report records the results of the design tests made on Type PVN Station Class surge arresters in accordance with IEEE Standard C62.11-1999 IEEE Standard for Metal Oxide Surge Arresters for AC Power Circuits (> 1kV). To the best of our knowledge and within the usual limits of testing practices, tests performed on the Type PVN arresters demonstrate full compliance with the relevant clauses of the referenced standard. M.G. Comber Manager, Engineering Dennis W. Lenk P.E. Principal Engineer Date: July, 2001 Separate reports provide details of the tests, according to the following table: Report No. Description Clause Issue Date EU1295-H-01 Insulation Withstand 8.1 7/31/2001 EU1295-H-02 Discharge Voltage 8.3 7/31/2001 EU1295-H-03 Disc Accelerated Aging 8.5 7/31/2001 EU1295-H-04 Polymer Accelerated Aging 8.6 7/31/2001 EU1295-H-05 Contamination 8.7 7/31/2001 EU1295-H-06 Internal Ionization and RIV 8.9 7/31/2001 EU1295-H-07 High Current, Short Duration 8.10.1 7/31/2001 EU1295-H-08 Transmission Line Discharge 8.10.2 7/31/2001 EU1295-H-09 Duty Cycle 8.11 7/31/2001 EU1295-H-10 Temporary Overvoltage 8.12 7/31/2001 EU1295-H-11 Pressure Relief 8.13 7/31/2001 EU1295-H-12 Maximum Design Cantilever Load-Static 8.19 7/31/2001 EU1295-H-13 Thermal Equivalency Test 7.2.2 7/31/2001

TYPE TEST REPORT No. EU1295-H-01 Insulation Withstand Tests on PVN Arrester Housing CERTIFICATION This is to certify that insulation withstand design tests have been successfully performed on Ohio Brass Type PVN Station Class surge arresters. Michael G. Comber Manager Engineering Ohio Brass & Chardon Products Dennis W. Lenk P.E. Principal Engineer July, 2001 Attachments

DESIGN TEST REPORT Type PVN Station Class Surge Arrester TITLE: Arrester Insulation Withstand Tests: INTRODUCTION: The following table lists the Type PVN arresters minimum strike distance, 1.2/50 required and actual impulse withstand levels, and 60 HZ required and actual dry and wet withstand levels as defined in Section 8.1.3 of IEEE C62.11-1993 Standard.. CONCLUSION: All housings meet or exceed these levels of voltage. 60 HZ 60 HZ 60 HZ 60 HZ Strike Imp w/s Imp w/s Dry w/s Dry w/s Wet w/s Wet w/s Arrester Distance Req d Actual Req d Actual Req d Actual MCOV (in) (KVc) (KVc) (kvrms) (kvrms) (kvrms) (kvrms) 2.55 8.9 60 120 21 88 20 57 5.1 8.9 75 120 27 88 24 57 7.65 8.9 95 120 35 88 30 57 8.4 8.9 ---- 120 ---- 88 ---- 57 10.2 11.5 110 161 50 113 45 74 12.7 11.5 110 161 50 113 45 74 15.3 11.5 ---- 161 ---- 113 ---- 74 17.0 16.6 150 241 70 163 60 109 19.5 16.6 150 241 70 163 60 109 22.0 16.6 ---- 241 ---- 163 ---- 109 24.4 16.6 200 241 95 163 80 109 29.0 16.6 200 241 95 163 80 109 31.5 21.8 250 321 120 213 100 145 36.5 21.8 250 321 120 213 100 145 39.0 21.8 250 321 120 213 100 145 42.0 27.0 206 401 ---- 264 85 182 48.0 27.0 234 401 ---- 264 95 182 57.0 32.3 274 450 ---- 295 112 200 70.0 42.3 345 639 ---- 415 141 295 76.0 42.3 368 639 ---- 415 150 295 84.0 47.8 413 700 ---- 450 168 320 88.0 47.8 413 700 ---- 450 168 320 98.0 43.7 467 660 ---- 428 198 306 106 43.7 518 660 ---- 428 220 306 115 53.8 552 817 ---- 530 234 385 131 70.0 624 1050 ---- 560 265 400 140 70.0 647 1050 ---- 560 276 400 144 70.0 665 1050 ---- 560 283 400 152 70.0 720 1050 ---- 560 306 400 180 98.0 843 1520 ---- 720 359 500 2

TYPE TEST REPORT No. EU1295-H-02 Discharge Voltage Characteristic CERTIFICATION This is to certify that the discharge voltage characteristic design tests have been successfully performed on Ohio Brass Type PVN Station Class surge arresters. Michael G. Comber Manager Engineering Ohio Brass & Chardon Products Dennis W. Lenk P.E. Principal Engineer July, 2001 Attachments

TITLE: Discharge-voltage characteristic DESIGN TEST REPORT Type PVN Station Class Surge Arrester TEST OBJECTIVE: These measurements are used to obtain the maximum discharge voltages at various current magnitudes and waveshapes. TEST PROCEDURE: Discharge voltage tests were performed on three prorated test samples consisting of two MOV disks, an aluminum end terminal, solid steel spacer, and contact spring plate. The material selection and configuration facilitated an accurate proratio of inductive and resistive effects of all components in the impulse path of a full arrester. Tests were conducted in accordance with clause 8.3 of ANSI/IEEE Standard C62.11-1999 IEEE Standard for Metal-Oxide Surge Arresters for AC Power Circuits (>1kV). Prorated test sections were subjected to 8/20 current waves with magnitudes ranging from 1.5 ka through 20 ka. In addition, Front-of-wave and switching surge discharge voltage tests were performed. TEST SAMPLES: Arresters are assembled from discs accumulated within 10 ka IR ranges as specified for each arrester rating. To verify catalog maximum IR levels were not exceeded, a discharge voltage ratio was established at each current level based on the test sections 10 ka IR (Table 2). That ratio was multiplied by the maximum 10 ka IR accumulation specified for each rating. As summarized on Table 3, the IR calculated based on the prorated test sections were under the maximum declared catalog levels. TEST RESULTS: The following oscillograms show the results of the individual discharge voltage tests. At the end of this section, a summary table compares the catalog protective characteristics versus the measured values extrapolated from the test data. The test specimen with a 10 Ka 8/20 IR of 11.35 Kv represents the maximum discharge voltage for a 3.85 Kv rms Type PVN arrester. A. 8/20 Discharge Voltage Oscillograms: Tests were performed per Section 8.3.1 for nominal 8/20 discharge current waveshapes. 1.51 Ka, 9.46 Kv, 8.4/18.0 2

3.14 Ka, 10.03 Kv, 8.0/19.3 5.14 Ka, 10.52 Kv, 8.6/18.9 9.99 Ka, 11.35 Kv, 8.6/18.8 3

19.94 Ka, 12.38 Kv, 8.8/20 40.46 Ka, 13.97 Kv, 8.8/20.3 B. FOW Oscillograms: Tests were performed per Section 8.3.2.1 for nominal 10 Ka current surges with times to voltage crest approaching.5 microseconds. 10.18 Ka max @ 3.0 us 11.71 Kv max @ 2.7 us 3.0/6.8 waveshape 4

10.03 Ka max @ 1.5 us 11.94 Kv max @ 1.3 us 1.5/3.3 wavashape 10.25 Ka max @.85 us 12.34 Kv max @.5 us.85/1.9 waveshape C. Switching Surge Oscillograms: Tests were performed per Section 8.3.2.2 for switching surge current magnitudes of 500 and 1000 amps. 5

514 Amps, 8.74 Kv, 49.3/101 1058 Amps, 9.11 Kv, 41.2/89.6 6

Arrester MCOV PROTECTIVE CHARACTERISTICS COMPARISON TABLE 10 ka FOW IR Catalog Max. (kv) 10 ka FOW IR Prorated Measured (kv) (1) Amp SS IR Catalog Max. (kv) (1) Amp SS IR Prorated Measured (kv) 10 ka 8/20 IR Catalog Max. (kv) 10 ka 8/20 IR Prorated Measured (kv) 40 ka 8/20 IR Catalog Max. (kv) 40 ka 8/20 IR Prorated Measured (kv) 2.55 8.4 8.2 6.0 5.8 7.6 7.55 9.6 9.3 5.1 16.7 16.4 11.9 11.6 15.2 15.1 19.1 18.6 7.65 25.0 24.6 17.8 17.4 22.7 22.6 28.3 27.9 8.4 27.8 27.0 19.8 19.1 25.3 24.8 31.8 30.5 10.2 33.3 32.7 23.7 23.2 30.3 30.1 38.1 37.2 12.7 41.7 40.7 29.7 28.9 37.9 37.5 47.6 46.1 15.3 50.1 49.1 35.6 34.8 45.5 45.2 57.2 55.6 17 56.3 54.5 40.1 38.6 51.2 50.2 64.4 61.8 19.5 63.9 62.5 45.5 44.3 58.1 57.5 73.0 70.9 22 72.9 70.6 51.9 50.0 66.3 64.9 83.3 80.0 24.4 80.4 78.2 57.2 55.4 73.1 72.0 91.9 88.6 29 95.9 93.0 68.3 65.9 87.2 85.5 109.6 105.4 31.5 104.2 101.0 74.2 71.5 94.7 93.0 119.0 114.5 36.5 120.9 117.0 86.1 82.9 109.9 107.7 138.1 132.6 39 128.7 125.0 91.6 88.6 117.0 115.0 147.1 141.7 42 144.4 141.1 102.8 99.9 131.3 129.8 165.0 159.8 48 163.5 160.3 116.4 113.5 148.6 147.5 186.8 181.6 57 191.8 186.0 136.6 131.7 174.4 171.0 219.2 210.8 70 241.8 234.0 172.1 165.8 219.8 215.5 276.3 265.2 76 257.4 251.0 183.2 177.1 234.0 230.0 294.1 283.5 84 288.9 282.5 205.6 199.8 262.6 259.5 330.1 320.0 88 288.9 282.5 205.6 199.8 262.6 259.5 330.1 320.0 98 326.9 321.0 241.3 236.7 297.2 295.0 373.6 364.0 106 362.7 351.0 267.7 259.2 329.7 323.0 414.4 398.0 115 386.1 376.0 285.0 276.9 351.0 345.0 441.2 426.0 131 445.0 440.3 330.0 325.2 409.0 405.0 503.0 499.0 140 455.0 451.2 338.0 333.3 419.0 415.0 516.0 511.0 144 476.0 471.8 354.0 348.5 438.0 434.0 539.0 535.0 152 508.0 502.2 377.0 371.0 467.0 462.0 575.0 569.0 180 604.0 599.0 448.0 442.5 556.0 551.0 684.0 679.0 (*) Measured prorated discharge voltage at specified waveshapes equals (arrester MCOV/3.85) times disc measured IR at the specified waveshape. (1) 500 amp IR for 2.55-88 kv MCOV; 1kA IR for 98-180 kv MCOV. 7

TYPE TEST REPORT No. EU1295-H-03 Disc Accelerated Aging CERTIFICATION This is to certify that the disc accelerated aging design tests have been successfully performed on Ohio Brass Type PVN Station Class Surge arresters. Michael G. Comber Manager Engineering Ohio Brass & Chardon Products Dennis W. Lenk P.E. Principal Engineer July, 2001 Attachments

TITLE: Accelerated aging procedure DESIGN TEST REPORT PVN Station Class Surge Arrester INTRIODUCTION: This test is performed to measure the mov disc aging characteristic. The measured watts values are used to develop elevated voltage ratios kc and kr which are used in the duty cycle and discharge current withstand tests to simulate the performance of arresters that have a service life equivalent to 1000 hours at 115 o C. SAMPLE PREPARATION: Three 60 mm diameter x 23 mm long discs and three 60 mm diameter x 41 mm long discs were selected for testing. The three 23 mm long discs are designated as samples #1, 2, & 3 while the 41 mm long discs are designated as samples #4, 5, & 6. TEST RESULTS: The test was performed per Section 8.5 of ANSI/IEEE C62.11-1987 Standard. The three test samples were placed inside a 115 plus/minus 2 o C. oven and energized at MCOV for 1000 hours. The watts loss of each sample was measured at MCOV and duty cycle rated voltage three hours after energization and at the completion of the 1000 test duration. The following table summarizes the results of the 1000 hour accelerated aging tests. All watts values were measured with the samples at 115 o C. INITIAL FINAL INITIAL FINAL SAMPLE WATTS WATTS WATTS WATTS NO. @MCOV @MCOV @RATING @RATING 1 1.71 1.51 3.53 3.10 2 2.15 1.86 3.51 3.33 3 2.05 1.79 3.70 3.33 4 2.66 2.59 6.87 6.24 5 2.36 2.26 7.12 6.31 6 2.68 2.50 7.23 6.39 CONCLUSION: For each test sample, the final watts loss at MCOV and rating is less than the initial watts measured. Therefore, the kc and kr factors equals 1.0 in the design tests requiring demonstration of thermal stability. 2

TYPE TEST REPORT No. EU1295-H-04 Polymer Accelerated Aging CERTIFICATION This is to certify that the polymer accelerated aging design tests have been successfully performed on Ohio Brass Type PVN Station Class surge arresters. Michael G. Comber Manager Engineering Ohio Brass & Chardon Products Dennis W. Lenk P.E. Principal Engineer July, 2001 Attachments

DESIGN TEST REPORT PVN Station Class Surge Arrester TITLE: Accelerated aging tests of external polymeric insulating systems : INTRODUCTION: This test was performed per Section 8.6 of IEEE Standard C62.11-1999. TEST PROCEDURE: Accelerated aging tests by exposure to light were performed per Section 8.6.1, Test Method 8.6.1.2.c). Tests were performed on polymer housing and insulating bracket material using the fluorescent UV technique described in ASTM G53-1991. Test duration was 1000 hours on three samples of each material. Accelerated aging tests by exposure to electrical stress were performed per Section 8.6.2. Three PVN arrester housing configurations were tested. Each housing configuration consisted of (2) 8.4 kv MCOV housings connected together with the insulating collar used to assemble higher rated arresters. The total MCOV rating of this housing configuration is 16.8 kv rms. The specification requires that the applied test voltage represent the highest gradient stress per mm of creepage distance. To achieve this required high gradient, the arrester internal mov disc elements were removed and replaced with an insulating core. This allowed the applied voltage of 30 kvrms to be applied without failing the test sample. This represents the highest MCOV stress based on leakage distance. Tests were performed by attaching arresters to a vertical ferris wheel. As the wheel rotates, each arrester is sequentially dipped into a 400 ohm-centimeter water bath. Each arrester is allowed to drip-off excessive contaminant and is then energized at MCOV to force the arrester housing into a dry banding condition. The arrester test is performed until each arrester has been subjected to 1000 hours on voltage. Results: Per Section 8.6.1, the polymer material passed the test requirement as there were no cracks greater than the allowed.1 mm depth. Per Section 8.6.2, the specimens passed this test as there was no evidence of external flashovers, punctures, or internal breakdowns during the described tests. There was no evidence of surface tracking on the arrester housings or the insulating collars after the 1000 hour on-voltage test. The required 10 ka IR measurements could not be performed on these arresters as the internal mov discs had been replaced by an insulating section so that the required high voltage stress could be applied to the arrester housings during the 1000 hour test. Conclusion: The PVN arrester housing design has met the accelerated aging requirements as specified in Section 8.6 of IEEE C62.11-1999 Standard. 2

TYPE TEST REPORT No. EU1295-H-05 Contamination Test CERTIFICATION This is to certify that the contamination design test has been successfully performed on Ohio Brass Type PVN Station Class surge arresters. Michael G. Comber Manager Engineering Ohio Brass & Chardon Products Dennis W. Lenk P.E. Principal Engineer July, 2001 Attachments

TITLE: Contamination tests: DESIGN TEST REPORT PVN Station Class Surge Arrester INTRODUCTION: This test was performed per Section 8.7 of IEEE Standard C62.11-1999. The tests were performed on a three unit (144 kv MCOV size) and a four unit (180 kv MCOV size) arrester. TEST PROCEDURE: The partial wetting test procedure was performed per Section 8.7.3 of C62.11-1999 Standard. Prior to the application of contaminant (455 ohm-cm resistivity), the arrester was energized at MCOV for 1 hour. After 1 hour of energization, the arrester was de-energized and slurry contaminant was applied over the entire porcelain surface of the bottom half of the arrester. After a 2-3 minute wait, the arrester was energized at MCOV for 15 minutes, at which time the voltage was turned off and the bottom half of the arrester resprayed with contaminant. Within 5 minutes of deenergization, the arrester was reenergized at MCOV. After 15 minutes, the arrester resistive component of current was recorded. After 30 additional minutes at MCOV, remeasurement of the resistive current confirmed thermal stability and the test was completed. TEST RESULTS: In both cases, the arresters demonstrated thermal stability after the second partial wetting test series. No unit or arrester flashover occurred during the above testing. Disassembly of the test arresters revealed no damage to the internal components as a result of the partial wetting contamination test. 2

TYPE TEST REPORT No. EU1295-H-06 INTERNAL IONIZATION and RIV CERTIFICATION This is to certify that the internal ionization and RIV design tests have been successfully performed on Ohio Brass Type PVN Station Class surge arrester. Michael G. Comber Manager Engineering Ohio Brass & Chardon Products Dennis W. Lenk P.E. Principal Engineer July, 2001 Attachments

DESIGN TEST REPORT PVN Station Class Surge Arrester TITLE: Internal-ionization voltage (IIV) and RIV tests: TEST PROCEDURE AND SAMPLE: Internal ionization and RIV testing was performed per clause 8.9 of IEEE Standard C62.11-1999. The test was performed on a 180 kv MCOV PVN arrester. TEST EQUIPMENT: Equipment and test methods conformed to NEMA LA 1-1992 requirements. Prior to the test, the Stoddart Noise Meter NM-25T was calibrated using a General Radio Signal Generator Type 1001-A. TEST RESULTS: A background noise level of 5 µv was measured at an open circuit voltage of 189 kv (105%MCOV). With the 180 kv arrester placed in the circuit, a noise level of 7 µv was measured. CONCLUSION: The 180 kv MCOV PVN arrester passed test requirements per Section 8.9 of IEEE C62.11-1999 Standard, as measured noise levels were within the 10 µv IIV test limit. 2

TYPE TEST REPORT No. EU1295-H-07 HIGH CURRENT, SHORT DURATION TEST CERTIFICATION This is to certify that the high current, short duration design test has been successfully performed on Ohio Brass Type PVN Station Class surge arrester. Michael G. Comber Manager Engineering Ohio Brass & Chardon Products Dennis W.Lenk P.E. Principal Engineer July, 2001 Attachments

DESIGN TEST REPORT PVN Station Class Surge Arrester TITLE: High Current, Short Duration Discharge Withstand Test SAMPLE PREPARATION: This test was performed per Section 8.6.1 of ANSI/IEEE Standard C62.11-1999. The test was performed on a thermally prorated section of a full size arrester. The MCOV and duty cycle rating of the prorated section are assigned to represent the most severe condition; i.e., the minimum allowed discharge voltage level. TEST PROCEDURE: Before and after the high current, short duration test, the 10 KA 8/20 discharge voltage of the test sample was measured. The test sample was subjected to (2) 100 KA 4/10 discharges. Sufficient time was allowed between discharges for the sample to cool to ambient temperature (25oC.). Within 5 minutes after the second high current discharge, the sample remained energized at MCOV and the sample watts loss was monitored until thermal stability was demonstrated. TEST RESULTS: The prorated section was subjected to two nominal 100KA 6.2/13.2 high current discharges. The following traces show the actual current values. Discharge # 1 (108.1KA) Discharge # 2 (105.4KA) 2

Within 5 minutes of the second high current discharge, the sample was energized at 1.055 times MCOV (12.25KV RMS). The sample remained energized until thermal stability was demonstrated. The following table summarizes the measured watts of the test sample during the recovery portion of the test. Applied Voltage Time Sample (KV RMS) (Minutes) Watts ======== ======== ====== 12.25 0+ 6.50 12.25 2 5.35 12.25 5 4.60 12.25 15 3.75 12.25 20 3.55 12.25 30 3.23 The sample 10 KA 8/20 discharge voltage was measured before and after the high current test. The measured values are summarized below. 10 KA IR Before = 33.61 KV 10 KA IR After = 33.82 KV 3

TEST SUMMARY: The prorated test sample successfully completed the high current test and demonstrated thermal stability during the recovery test when energized at MCOV. The 10 KA 8/20 discharge voltage changed an acceptable +0.6%, within the allowable 10% acceptance limit. Disassembly revealed no evidence of physical damage to the test sample. Therefore, the test sample has successfully fulfilled the high current, short duration requirements of the Station Class arrester. 4

TYPE TEST REPORT No. EU1295-H-08 TRANSMISSION LINE DISCHARGE TEST CERTIFICATION This is to certify that the transmission line discharge design test has been successfully performed on Ohio Brass Type PVN Station Class surge arrester. Michael G. Comber Manager Engineering Ohio Brass & Chardon Products Dennis W. Lenk P.E. Principal Engineer July, 2001 Attachments

DESIGN TEST REPORT PVN Station Class Surge Arrester TITLE: Transmission Line Discharge Test: SAMPLE PREPARATION: This test was performed per Section 8.6.2.1 of ANSI/IEEE Standard C62.11-1993. The test was performed on a thermally prorated section of a full size arrester. The MCOV of the prorated section is assigned to represent the most severe condition; i.e., the minimum allowed discharge voltage level. TEST PARAMETERS: The test setup is intended to model a 140 kv MCOV arrester applied on a 230 kv system. The system parameters were derived from Table 5 of the C62.11 Standard. The system and prorated section parameters are defined as follows: System Surge Impedance System Charge System Capacitance Line Length Equivalent Duration (TD)* Prorated Test Sample MCOV 400 Ohm 513 kv 2.45 Microfarad 175 Miles 1890 Microseconds 8.97 kv RMS Proratio Factor (K) 15.61 Required Generator Surge Impedance Required Generator Charge Required Generator Capacitance Measured Generator Impedance (Zg) Measured Line Discharge Duration Equivalent Generator Line Length 25.62 Ohm 32.85 kv 38.2 Microfarad 20.8 Ohm 1983 Microseconds 184 Miles Number of Generator Sections 16 *TD = miles times 10.8 2

Test Procedure Before and after the transmission line discharge test, the 10 ka 8/20 discharge voltage of the test sample was measured. The procedure was performed per Section 8.6.2.1.3 of the C62.11 Standard. The procedure consisted of subjecting the test specimen to three groups of six consecutive operations followed by one group of two operations with a time interval between consecutive operations of one minute. The test specimen was allowed to cool to ambient between Shots No. 6 and No. 7 and between Shots No. 12 and No. 13. After the eighteenth shot, the test sample was placed inside an oven and heated to 66 o C. After the heated test sample was subjected to Shots No. 19 and No. 20, the sample was energized at 1.04 times mcov and thermal stability was demonstrated. TEST RESULTS: Figure No. 1 measures the surge impedance and confirms the duration of the transmission line generator. Figure 1 Zg = 16.83 kv/808 Amps Zg = 20.8 Ohms Duration = 184 Miles Figure 2 is an oscillographic record of the first transmission line discharge through the test sample. 3

Figure 2 Shot 1 After successful completion of the (18) shot test, the sample was preheated to 60 o C. and subjected to two additional transmission line discharges spaced one minute. Figure No. 3 is an oscillographic record of the 20th shot. Figure 3 Shot 20 After the 20th shot, the sample was energized at 1.04 times MCOV ( 9.33 kv RMS ). The sample remained energized until thermal stability was demonstrated. The following table summarizes the measured watts of the test sample during the recovery portion of the test. 4

Applied Voltage Time Sample (kv RMS) (Minutes) Watts 9.34 0+ 6.66 9.34 2 5.67 9.34 5 4.96 9.34 10 4.36 9.35 20 3.76 9.35 30 3.39 The sample 10 ka 8/20 discharge voltage was measured before and after the duty cycle test. The measured values are summarized below. 10 ka IR Before = 25.90 kv 10 ka IR After = 26.09 kv CONCLUSION: The prorated test sample successfully completed the transmission line discharge test and demonstrated thermal stability during the recovery test when energized at 1.04 times MCOV. The 10 ka 8/20 discharge voltage changed an acceptable +.7%, within the allowable 10% acceptance limit. Disassembly revealed no evidence of physical damage to the test sample. Therefore, the test sample has successfully fulfilled the transmission line discharge requirements of a PVN 140 kv MCOV Station Class arrester applied to a 230 kv system. 5

TYPE TEST REPORT No. EU1295-H-09 DUTY CYCLE TEST CERTIFICATION This is to certify that the duty cycle design test has been successfully performed on Ohio Brass Type PVN Station Class surge arrester. Michael G. Comber Manager Engineering Ohio Brass & Chardon Products Dennis W. Lenk P.E. Principal Engineer July, 2001 Attachments

TITLE: Duty Cycle Test: DESIGN TEST REPORT PVN Station Class Surge Arrester TEST OBJECTIVE: Section 8.11.1.3 specifies that the 20-shot rated voltage and 2-shot recovery portion of the Duty Cycle test on Intermediate Class arresters be performed with 5 ka 8/20 lightning impulses. The actual Duty Cycle tests were performed per the more severe Heavy Duty Distribution arrester requirements, which subjects the test sample to 20-10kA impulses and then 2-40 ka impulses during the recovery portion of the Duty Cycle test. SAMPLE PREPARATION: This test was performed per Section 8.7 of ANSI/IEEE Standard C62.11-1987. The test was performed on a thermally prorated section of a full size arrester. The MCOV and duty cycle rating of the prorated section are assigned to represent the most severe condition; i.e., the minimum allowed discharge voltage level. TEST PROCEDURE: Before and after the duty cycle test, the 10 KA 8/20 discharge voltage of the test sample was measured. The test sample was then energized at duty cycle rated voltage and subjected to (20) 10 KA 8/20 discharges spaced one minute apart. Per the standard, these 5 KA discharges were electrically timed to occur at approximately 60o before 60-Hz voltage crest. The test sample was next preheated to 60oC. and subjected to two additional 5 KA 8/20 duty cycle operations while energized at MCOV. After the second duty cycle operation, the sample remained energized at MCOV and the sample watts loss was monitored until thermal stability was demonstrated. TEST RESULTS: The prorated section was energized at duty cycle rated voltage ( 14.92 KV RMS ) and subjected to (20) 10 KA surges spaced one minute apart. The sample watts was monitored throughout the test. The watts increased from 30 after the first discharge to 124 immediately after the twentieth discharge. Figure 1 illustrates a typical duty cycle discharge operation. Figure 1 2

After successful completion of the (20) shot test, the sample was preheated to 60oC. and subjected to two additional 10 KA surges spaced one minute apart with the sample energized at 1.05 times MCOV ( 12.2 KV RMS ). The sample remained energized after the second 10 KA surge until thermal stability was demonstrated. The following table summarizes the measured watts of the test sample during the recovery portion of the test. Applied Voltage Time Sample (KV RMS) (Minutes) Watts ======== ======== ====== 12.2 0+ 3.80 12.2 1 3.00 12.2 5 2.85 12.2 10 2.79 12.2 20 2.65 12.2 30 2.50 The sample 10 KA 8/20 discharge voltage was measured before and after the duty cycle test. The measured values are summarized below. 10 KA IR Before = 33.51 KV 10 KA IR After = 33.55 KV 3

TEST SUMMARY: The prorated test sample successfully completed the duty cycle test and demonstrated thermal stability during the recovery test when energized at 1.05 times MCOV. The 10 KA 8/20 discharge voltage changed an acceptable +.1%, within the allowable 10% acceptance limit. Disassembly revealed no evidence of physical damage to the test sample. Therefore, the test sample has successfully fulfilled the duty cycle requirements of the Station Class arrester. 4

TYPE TEST REPORT No. EU1295-H-10 TEMPORARY OVERVOLTAGE TEST CERTIFICATION This is to certify that the temporary overvoltage design test has been successfully performed on Ohio Brass Type PVN Station Class surge arrester. Michael G. Comber Manager Engineering Ohio Brass & Chardon Products Dennis W. Lenk P.E. Principal Engineer July, 2001 Attachments

DESIGN TEST REPORT PVN Station Class Surge Arrester TITLE: Temporary over-voltage tests (TOV): INTRODUCTION: This test was performed per Section 8.12 of IEEE Standard C62.11-1999. The tests were performed on (5) prorated test samples, selected to represent the most severe design conditions, i.e., the minimum allowed discharge voltage level. TEST PROCEDURE: Per Section 8.12.1, each prorated sample is tested in (5) different time ranges ranging from (.01-.1 seconds) to (1001-10,000 seconds). Per Section 8.12.2, the test is performed to demonstrate the temporary overvoltage capability of the design under "no prior duty" conditions. For each TOV voltage setting, the test circuit applies the voltage to the sample (preheated to 60oC) for a time duration sufficient to exceed that claimed on the "no prior duty" curve. Within 100 milliseconds after the TOV, a recovery voltage is applied for (30) minutes to demonstrate thermal stability. The recovery voltage level takes into account the maximum allowed watts loss for the sample. Prior to and after the TOV application, the 10 ka discharge voltage of each sample is measured. TEST RESULTS: Tests were successfully completed on (5) prorated samples in the required (5) time ranges. Each sample demonstrated thermally stability after TOV exposure. The 10 ka 8/20 discharge voltage of each sample changed less than 1.0 as a result of the TOV duty. There was no evidence of physical damage caused by the TOV testing. The following table summarizes the claimable TOV values for 3-228 kv rated PVN arresters for "no prior" and "prior" duty conditions. TOV DURATION NO PRIOR DUTY TOV PRIOR DUTY TOV (SECONDS) (PER UNIT MCOV) (PER UNIT MCOV) ============= ================== ================.02 1.605 1.560.10 1.550 1.500 1.0 1.465 1.415 10 1.385 1.355 100 1.335 1.315 1000 1.295 1.270 The following curve plots the individual "no prior duty" TOV data points on the claimed TOV capability curve. 2

PVN 60 HZ TEMPORARY OVERVOLTAGE CAPABILITY CURVE PER IEEE C62.11 STANDA 1.7 1.6 Per Unit Times MCOV 1.5 1.4 1.3 1.2 0.01 0.1 1 10 100 1000 10000 Time-Seconds Data Points No Prior Duty Curve Prior Duty Curve 3

TYPE TEST REPORT No. EU 1295-H-11 PRESSURE RELIEF TEST CERTIFICATION This is to certify that the pressure relief design test has been successfully performed on Ohio Brass Type PVN Station Class surge arrester. Michael G. Comber Manager Engineering Ohio Brass & Chardon Products Dennis W. Lenk P.E. Principal Engineer July, 2001 Attachments

DESIGN TEST REPORT PVN Station Class Surge Arrester TITLE: Pressure Relief Test For Polymer Housed Station Class Arrester: INTRODUCTION: The high current and low current pressure relief tests were performed per Section 8.13 of ANSI/IEEE C62.11-1999 Standard. For the high current tests, an additional timed reclose was performed on each test specimen approximately 20 cycles after completion of the required 12 cycle test. The high current tests were performed in the IREQ High Power Laboratory in Montreal on March 2, 1993. SAMPLE PREPARATION: Per Section 8.13.1.1, fuse wire was used to short out the mov disc elements. Two shorting methods were used. The "shorted" mode of failure consisted of externally locating a fuse wire along the outside contour of the stack of mov disc elements between the mov discs and the fiberglass-epoxy wrap. The "puncture" mode of failure consisted of drilling a 4 mm diameter hole through the center of each mov disc and then running a wire through the center of the stack of discs. For the high current tests, the longest available single unit arrester ( 48 kv MCOV ) was tested. TEST PROCEDURE: To achieve the high levels of fault current, the high current pressure relief tests were performed per Section 8.13.3.4 with a reduced voltage source of 11.1 kv rms. Since the arrester arc resistance can significantly affect the required asymmetry, the claimable symmetrical rms current for the high current test procedure is calculated by dividing the 1st loop peak current by 2.6. The low current pressure relief tests were performed per Section 8.13.4. TEST RESULTS: The following table summarizes the results of the pressure relief testing. The low current sample successfully vented within.23 seconds after fault initiation. The high current tests were performed on the longest arrester units. In addition to the initial 12 cycle fault current duty required per the standard test procedure, both the "punctured" and the "shorted" test samples were immediately subjected to a fault current reclose condition. Both arresters successfully vented. The highest claimable symmetrical fault current of 83.4 ka rms for 12.5 cycles, followed in 20 cycles by a claimable 81.5 ka rms 3 cycle reclose was recorded on the "shorted" design. The lower peak ka values recorded on the "punctured" arrester configuration were the result of the high arc resistance of that design when subjected to the reduced voltage test procedure. Initial Fault Reclose Fault =========================== =========================== 1 st 1st Mode Test Loop Actual Claimable Fault Loop Act Fault Condition Sample of Voltage Peak Symm. Symm. Durat. Peak Sym Durat. Of Sample MCOV Failure (kvrms) (kac) (karms) (karms) (Cyc) (kac) (karms) (Cyc) After Test ===== ==== ===== === ===== ====== ==== === ===== ==== =========== 2.55 Shorted 15.0.48.48 29 Module Intact Housing Split 48 Shorted 11.3 217 120 83.4 12.5 212 122 3 Module Intact Hsg Separated 48 Punctured 11.2 181 121 69.6 12.5 229 124 3 Module Intact Hsg Separated 2

TYPE TEST REPORT No. EU1295-H-12 MAXIMUM DESIGN CANTILEVER LOAD-STATIC TEST CERTIFICATION This is to certify that the maximum design cantilever load-static design test has been successfully performed on Ohio Brass Type PVN Station Class surge arrester. Michael G. Comber Manager Engineering Ohio Brass & Chardon Products Dennis W. Lenk P.E. Principal Engineer July, 2001 Attachments

DESIGN TEST REPORT PVN Station Class Surge Arrester TITLE: Maximum Design Cantilever Load-Static Test TEST SAMPLES: The maximum design cantilever load (static) test was performed on a PVN 19.5 kv MCOV arrester. Tests were performed to validate the claimed 10,000 inch-pound continuous cantilever rating. TEST PROCEDURE: Testing was performed per the procedures specified in Section 8.19.2 of IEEE Std C62.11-1999. The test arrester was rigidly mounted at its base and top end loading applied to develop 10,000 inch-pound cantilever load. With the arrester under load, the arrester was energized at 1,05 times MCOV and internal ionization was measured. Successive testing was performed at 0 o, 90 o, 180 o, and 270 o. Per paragraph d), the arrester was placed inside a thermal cycling oven for 96 hours and subjected to a combination of 10,000 inch-pound load rotations and temperature excursions as specified in Figure 3 of C62.11-1999 Standard. After completion of the thermal cycling test, the IIV was remeasured in the four quadrants with the arrester energized at 1.05 times MCOV. TEST RESULTS: The following table summarizes the results of the IIV tests with.6 microvolts of circuit background noise. Arrester # Direction of Applied 1200 in-lb Load (Degrees) IIV Testing Prior to and After Thermal Cycling IIV @ 1.05 Times MCOV before Thermal Cycling (Microvolts) IIV @ 1.05 Times MCOV after Thermal Cycling (Microvolts) 1 0 1.6 2.0 1 90 2.0 2.0 1 180 2.0 2.0 1 270 2.0 2.0 CONCLUSION: Per Section 8.19.3, the internal ionization levels measured with the arrester loaded to 10,000 inch-pounds were unchanged as a result of the thermal cycling test. Visual examination revealed no evidence of mechanical damage. The above tests validated the electrical integrity of the PVN arrester assembled with a 3-lug base end casting when loaded to the 10,000 inch-pound continuous cantilever rating 2

TYPE TEST REPORT No. EU 1295-H-13 VERIFICATION OF THERMALLY PRORATED SECTION CERTIFICATION This is to certify that verification tests demonstrating thermal equivalency were successfully performed on Ohio Brass Type PVN Station Class surge arrester. Michael G. Comber Manager Engineering Ohio Brass & Chardon Products Dennis W. Lenk P.E. Principal Engineer July, 2001 Attachments

DESIGN TEST REPORT PVN Station Class Surge Arrester TITLE: Verification of thermally prorated arrester section: OBJECTIVE: Tests were performed per IEEE Standard C62.11 to validate the thermally prorated arrester section used on specified durability tests. TEST SAMPLES: The longest PVN module was assembled with thermocouples located in the bottom quarter, center, and upper quarter locations. The average temperature of the three thermocouples was compared with the temperature of the thermally prorated section. In both cases, thermocouples were located between two adjacent MOV disks. The longest module was chosen to represent the highest percent MOV mass per unit arrester length. TEST PROCEDURE: The full size arrester and the prorated section were heated up by applying a temporary overvoltage to the test samples. The full size arrester unit was instrumented with three (3) internal thermocouples, located at 1/4, 1/2, and 3/4 locations in the mov disc stack. The average temperature of the three arrester thermocouples was calculated for each 5 minute interval to develop the arrester unit cooling curve. The prorated section was instrumented with a single thermocouple and its cooling rated monitored at 5 minute intervals. CONCLUSION: Upon achieving the desired target temperature, the thermocouples were attached to a data logger and temperature was monitored continuously for 120 minutes. Figure 1 contains cooling curves verifying the longest PVN module arrester cooling rate was always greater than the prorated thermal test section. 120 Figure 1 TYPE PVN ARRESTER THERMAL COOLING CURVES FOR ARRESTER VERSUS PRORATED SECTION TEMPERATURE-DEG C. 100 80 60 40 20 0 0 10 20 30 40 50 60 70 80 90 100 110 120 COOLING TIME-MINUTES PRORATED SECTION TEMP AVERAGE ARRESTER TEM 2