Corona discharge occasionally occurs to the contact box of switchgear due to condensation under high humidity and pollution conditions, which may result in a switchgear insulation fault. In this article, we develop an experimental platform for the condensation of contact boxes in switchgear. A metallographic microscope is used to measure the size and distribution characteristics of dewdrops on the surface of the contact box under various temperature, humidity, and pollution conditions. A simulation model for the distribution of dewdrops is established using fractal theory, and the simulation results match the measured results well. The corona onset voltage is predicted and verified by the UV imager’s measurements by substituting the electric field distribution around the contact box with different dewdrops into the streamer inception criterion. The research results indicate that higher humidity and temperature differences result in a larger dewdrop and a shorter condensation formation time, resulting in a lower corona onset voltage. The effect law is similar under high pollution conditions, but the dewdrop is larger, the condensation formation time is longer, and the corona onset voltage is significantly lower than under clean conditions. As a result, high humidity and pollution conditions must be avoided during the operation of switchgear.
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