Functionally graded materials (FGM) application with graded permittivity and conductivity is promising as an effective technique for electric field relaxation in SF6 gas around HVDC gas insulated switchgear (GIS)/gas insulated transmission line (GIL) spacers. To approach the practical application of FGM to HVDC GIS/GIL spacers, this article investigates the electric field reduction effect given by permittivity and conductivity graded materials ( $\varepsilon /\sigma $ -FGM) based on actual measured permittivity ( $\varepsilon $ ) characteristics of SrTiO3-filled epoxy composites and conductivity ( $\sigma $ ) characteristics of SiC-filled epoxy composites. In addition, theoretical discharge inception voltage (TDIV) of $\varepsilon /\sigma $ -FGM spacer is calculated under standard lightning impulse (LI) voltage based on the volume–time theory. The results show that the $\varepsilon /\sigma $ -FGM spacer with grading to lower permittivity (GLP) ( $\varepsilon _{r}$ from 12.7 to 4) containing 0–26.9-vol% SrTiO3-filled epoxy composite and U-shaped graded conductivity containing 5–10-vol% SiC-filled epoxy composite is effective for electric field relaxation under DC steady state (DC-SS) and LI voltage where both resistive and capacitive fields present. It is attributed to the higher $\varepsilon $ and $\sigma $ of FGM spacer near the HV conductor/spacer interface. TDIV under LI voltage is also estimated to be 26% higher at 0.5 MPa-abs, compared with the conventional spacer without $\varepsilon /\sigma $ grading.

Due to the ever-increasing demand for electricity in the one hand and the environmental constraints to use clean energy on the other hand, the global production of energy from remote renewable sources, particularly from large hydropower plants and offshore wind farms and their connection to the grid are expected to grow significantly in the future. Consequently, the demand to carry this electric power by high voltage direct current (HVDC) technology will increase too. The most suitable HVDC power transmission technology to deliver large amounts of power, exceeding a capacity of 5 GW per bipolar system over long distances with lower losses is by using compact HVDC gas insulated transmission lines (DC GIL) and gas insulated switchgears (DC GIS) with rated voltage (maximum continuous operating voltage) of ±550 kV and 5000 A which are presently under development worldwide. Among the critical challenges for the development of these HVDC gas insulated systems, there are the epoxy cast resin insulators that are used to separate gas compartments also called spacers. Indeed, thorough research studies have been and still being carried out to well understand and clarify the electrical insulation characteristics of HVDC spacers using mainly cylindrical samples and small insulator models, where useful results have been obtained and proposed for implementation in real compact gas insulated systems. However, few practical investigations have been undertaken on real size spacers (product scale) to verify such research outcomes and validate the reliability of the spacers to collect experiences or for commercial use. This paper reviews the current achievements of real size HVDC spacers development. It describes the basic electric field calculation and spacers design, the verification of the insulation performance and validation testing. It gives today’s commercially available compact HVDC GIS/GIL and finally it presents the envisaged future research and development.

Testing and validating the electrical insulation performance of full-size compact high-voltage direct current (HVDC) gas-insulated systems, gas-insulated transmission lines (GIL) and gas-insulated switchgears (GIS) is very costly and take long time. Therefore, a reduced scale system was designed and constructed to study thoroughly the spacer’s performance when subjected to higher electric fields under HVDC with different shapes, made of new advanced materials, and housed in new SF₆-free gas environment. Since the stationary DC electric field distribution along the spacer is controlled by spacer material conductivity and strongly depends upon its shape, this, the first part of two articles, proposes in a first step based on electric field calculations with COMSOL Multiphysics software, an optimized shape of a spacer model using a standard high-voltage alternating current (HVAC) alumina-filled epoxy material. Then, two novel types of materials were introduced and investigated: (i) modified filled epoxy material with a lower temperature-dependent conductivity than that of the standard HVAC material, which is interpreted by a lower thermal activation energy; and (ii) nonlinear resistive field grading material with a low nonlinearity coefficient, with and without the presence of a temperature gradient which occurs under operating service load. The numerical results show that, despite that the DC optimized profile of the spacer made of standard HVAC, alumina-filled epoxy is very effective in relaxing the electric field magnitudes along the spacer under uniform temperature—its distribution is significantly affected by the presence of a high temperature gradient causing the maximum electric field shifts along the spacer surface towards the earthed flange. Under this condition, the modified filled epoxy material with a weaker temperature-dependent conductivity results in a significant reduction of the electric field enhancement, representing thus a relevant key solution for HVDC GIL/GIS applications. Nonlinear resistive field grading material is also effective but seems unnecessary. The optimized DC spacer models are being fabricated for tests verification with C4-Perfluoronitrile (C4-PFN, 3M^TM Novec^TM 4710)/CO₂ and Trifluoroiodomethane (CF₃I)/CO₂ gas mixtures in the reduced scale gas-insulated test prototype.

Spacers for the HVDC GIS/GIL play an important role in mechanically supporting conductors and separating compartments. At the same time, their insulation performance affects the stability and safety of system operation. Design rules and knowledge specific to AC spacers do not apply to those of DC spacers. Considering the shape influence on the surface electric field intensity of the spacer under HVDC applied voltage, as determined in our previous work, an optimized shape of a spacer model based on finite element electric field calculations and using standard HVAC alumina filled epoxy material and two novel types of materials were studied. The simulation’s results show that the DC shape optimization of the spacers can effectively reduce the electric field magnitudes along the spacer under different temperature gradients. To verify practically these findings, this paper presents the reduced scale gas insulated prototype that was constructed, the optimized DC spacers that were fabricated and the DC testing results using SF₆-free surrounding gas: C4-Perfluoronitrile (C4-PFN, 3M^TM Novec^TM 4710)/CO₂ and Trifluoroiodomethane (CF₃I)/CO₂. The results show that the shape-optimized spacer models made of conventional HVAC filled epoxy material have successfully passed the tests up to the maximum applicable ±123 kV DC exceeding thus ±119 kV DC that corresponds to the nominal voltage ±500 kV DC of the full scale.