The privatisation of the electrical distribution industry in the UK has resulted in increased demands on medium voltage switchgear. Products have been developed for the global market using both vacuum and SF6 switching technologies within air and gas insulated panels. Fixed pattern switchgear has the advantage of fewer moving parts, lower maintenance, greater reliability, compact dimensions and lends itself to gas-insulated switchgear (GIS) technology.
The privatisation of the electrical distribution industry in the UK has resulted in increased demands on medium voltage switchgear. Products have been developed for the global market using both vacuum and SF6 switching technologies within air and gas insulated panels. Fixed pattern switchgear has the advantage of fewer moving parts, lower maintenance, greater reliability, compact dimensions and lends itself to gas-insulated switchgear (GIS) technology.
The privatisation of the electrical distribution industry in the UK has resulted in increased demands on medium voltage switchgear. Products have been developed for the global market using both vacuum and SF6 switching technologies within air and gas insulated panels. Fixed pattern switchgear has the advantage of fewer moving parts, lower maintenance, greater reliability, compact dimensions and lends itself to gas-insulated switchgear (GIS) technology.
This article was published in the IEE Power Engineering Journal of December 2000, Volume 14 Number 6 - page 1/7
Switchgear for 2000
and beyond Introduction Customer values associated with medium voltage switchgear have undergone a significant shift during the last decade. The privatisation of the electrical distribution industry in the UK has resulted in increased demands on medium voltage switchgear in performance terms, including procurement and operating costs, ease of installation and reduced maintenance. Safety has remained of paramount importance and the environmental impact has become an essential element of designs. Switchgear manufacturers, have in recent years, risen to the challenges brought about by the privatisation o the electricity supply industry and have developed a new generation of medium voltage switchgear using state of the art technology. Products have been developed for the global market using both vacuum and SF6 switching technologies within air and gas insulated panels Fixed Pattern Switchgear A major part of switchgear business is in the field of withdrawable panels in the 12-24kV range. However, the well established fact that vacuum and SF6 circuit breakers are virtually maintenance free has led to a wide acceptance of fixed pattern switchgear. This configuration of switchgear has the advantage of fewer moving parts, lower maintenance, greater reliability, compact dimensions and lends itself to gas-insulated switchgear (GIS) technology. For example the ZX0 panel range comprises a vacuum circuit breaker, disconnector / earthing switch and busbars all contained within a single gas chamber. This maintains the integrity of the GIS technology with all live parts inclusive of busbars inside the gas chamber and not vulnerable to the environmental conditions. This provides optimum conditions for long lasting and wear free operation. 1. REF542 relay 2.Switch mechanism 3. Test socket 4. VCB mechanism 5. Cable terminations 6. CTs 7. Arc vent 8. Outgoing bushing 9. Vacuum CB 10. Discon/E switch 11. Busbars FIG 1: ABB fixed pattern type ZX0 switchgear Busbar Connections A patented method of tubular plug in busbar connections has been developed and adopted for use in medium voltage switchboards. This is a proven technology applied in movable electrical joints in high voltage circuit breakers and in high voltage GIS switchgear. The system employs a coil spring contact principle providing a large number of current transmission points, which result in a low contact resistance and consequently low losses. The system also simplifies any assembly/disassembly of the connected parts. The spring contacts have an IP6X degree of protection ( dust tight design ) which prevents environmental degradation in service. FIG 2 Plug in busbar connections applied to ABB BEU21 switchgear This article was published in the IEE Power Engineering Journal of December 2000, Volume 14 Number 6 - page 2/7 This technology has been adopted across the medium voltage switchgear range. The gas insulated ZX0 vacuum circuit breaker panel range and BEU21 SF6 circuit breaker panel range both use this technology for busbar connections between shipping units. This plug in method eliminates the need to access the gas tight compartments. Switchboard installation is simplified to positioning the panel sections, inserting the busbar plugs and then bolting the panel sections together. The possibility of loose busbar connections is eliminated and there is no need for handling SF6 gas on site thus protecting the environment by minimising the risk of release of SF6 gas into the atmosphere. FIG 3: The AX1 switchpanel makes exclusive use of plug in coil spring contacts The concept of tubular busbars and coil spring contacts is used to maximum benefit in the latest air insulated design, the AX1 switchgear range. This revolution panel uses coil spring contacts on all dismountable connections in the main circuit. With welded permanent connections there are no bolted connections, which results in very low contact resistances and losses in the switchgear. This provides an environmental benefit in reducing energy loss with associated cost savings. FIG4: Details of coil spring plug in connections in AX1 switchgear The AX1 panel tubular busbar system uses bare copper tubes configured to give a harmonious electric field distribution. The busbar system is very compact with small phase to phase clearances. Despite this the required dielectric strength is achieved with an ample margin above the values given in the standards. The triangular configuration also ensures that there is a low surrounding magnetic field. This increases the freedom of choice for the location of the switchgear when considering EMC effects. The use of bare copper busbars makes recycling of the copper at the end of life more efficient reducing the life cycle costs and consequently the environmental impact of the switchgear. Cable Terminations The development of outgoing power cable termination configuration has focussed around the use of proprietary cable termination systems. Typical cable terminations have single phase enclosures or boots, which are touch proof eliminating the risk of dangerous accidental contact and arcing. Installation is simple, as connectors are easy to fit on the cable without the need for any special tools. The terminations incorporate a test facility which simplifies the switchgear whilst improving performance This article was published in the IEE Power Engineering Journal of December 2000, Volume 14 Number 6 - page 3/7 FIG5: Proprietary cable termination systems provide improved safety and reliability The fixed pattern air insulated AX1 switchgear range allows a lower support frame to be set up before the installation of the rest of the cubicle providing plenty of space for the preparation of the cable terminations. The termination can be completely prepared with the help of a special adapter mounted on the lower frame prior to the delivery of main circuit enclosure to site. This facilitates installation of cables while other work is ongoing in the substation without exposing the switchgear to the risk of damage under construction site conditions. The final switchgear installation and cable connections can then be completed within a very short time interval. FIG6: The support frame for AX1 switchgear allows cable terminations to be prepared prior to panel installation Vacuum Circuit Breakers with Magnetic Actuators The well proven VD4 vacuum circuit breaker range has recently been extended by the introduction of the VM1 vacuum circuit breaker with a magnetic actuator replacing the spring charged operating mechanism. The actuators, which dramatically reduce the number of operating parts, are free of wear and thus are maintenance free. The magnetic actuator operating mechanisms are rated for 100000 operating cycles and the vacuum interrupters 30 000 cycles at rated current and 100 operations at short circuit current providing a truly long life circuit breaker. The magnetic actuator is controlled by an electronic controller with low power consumption of less than 4 watts at rest and only 2A recharging for a few seconds after an autoreclosing cycle. Sufficient energy is stored in capacitors to provide a 200 second buffer time on failure of the auxiliary supply. Switch position is sensed using proximity sensors, which eliminate the need for maintenance of auxiliary contacts. The VM1 circuit breaker range is dimensionally compatible with the VD4 circuit breaker and direct exchange of the breakers is therefore possible. The VM1 range is available with ratings up to 2500A and 31.5kA at 12kV. Embedded Vacuum Interrupters The VM1 circuit breaker also uses a specially developed embedding technology in which the vacuum interrupter is directly potted in epoxy resin to form an integrated circuit breaker pole part. External influences on the switching element are eliminated, improving reliability and reducing maintenance and costs. High Speed Transfer System HSTS The VM1 vacuum circuit breaker with magnetic actuators has made possible the development of a high speed transfer system used in applications which require high levels of quality of supply. Supply can be switched from one incomer to another in a total transfer time of 30ms. The system can avoid expensive downtime due to voltage disturbances. Applications include computer server installations, process industries and hospitals SF6 Circuit breaker Technology An auto-puffer breaking technique has been developed for the range of SF6 circuit breakers. This technology combines the This article was published in the IEE Power Engineering Journal of December 2000, Volume 14 Number 6 - page 4/7 advantages of the puffer type and the self blast interrupting principles. When switching low levels of load current the mechanical movement of the circuit breaker provides the flow of gas to extinguish the arc. The arc energy of fault currents is used to propel the contacts and provide an increased flow of gas necessary for arc extinction when clearing a fault. Operating mechanisms require less energy and are therefore lighter with longer life and lower maintenance requirements than for conventional puffer type circuit breakers. The auto-puffer technology type H BreaKing range of circuit breakers are supplied as standard withdrawable cassettes for use in traditional withdrawable air insulated panels or in a fixed format integrated into the AX1 and BEU21 switchgear ranges Integrated Apparatus Designs that integrate the circuit breaker and disconnector/earthing switch when applied in fixed pattern switchgear have been developed. The ZX0 vacuum circuit breaker integrates the disconnector / earthing switch onto the epoxy housing of the vacuum bottle resulting in a compact design which can be pre-assembled. This technology optimises the manufacturing and assembly processes enhancing quality and reducing cost. FIG7: Vacuum circuit breaker with integrated disconnector/earthing switch as used on ZX0 switchgear On the AX1 range the circuit breaker and disconnector/earthing switch are integrated with one another in a single epoxy chamber per phase. The chamber, which is filled with SF6 gas, protects the switching devices against corrosion and other external environmental influences. A further degree of integration is achieved by placing the Rogowski coil for the current monitoring inside the same enclosure. Thus the AX1 air insulated switchgear has all primary operational devices integrated into a single pole unit in each phase. FIG8: The complete AX1 switchgear primary part from busbar to cable connections FIG9: Integration of the SF6 auto puffer circuit breaker, disconnector/earthswitch and Rogowski coil current sensor for AX1 switchgear This article was published in the IEE Power Engineering Journal of December 2000, Volume 14 Number 6 - page 5/7 Intelligent Switchgear The concept of intelligent switchgear has been introduced where using data from different sensors a switchbay computer of the ABB REF54* range can execute intelligent commands such as tripping, interlocking, sounding an alarm, providing information about operating data and different events, announcing when maintenance is needed, and so forth. The bay computers can communicate on their own initiative or answer questions from operating staff via remote control. This ensures highly effective control and monitoring of the switchgear system, which leads to greater service reliability, and better operating economy. Periodic maintenance can be completely replaced by maintenance on demand. The bay computers give an alarm if any abnormal conditions exist in the switchgear or when service is necessary. The total monitoring covers, amongst other things, arc eliminators, circuit breakers, disconnectors and cables. All the arc eliminator functions are monitored The circuit breaker movement sensor provides information about the number of ON/OFF operations performed as well as closing and opening times, consequently giving the bay computer the necessary data for it to be able to give information in good time about when service must take place or the switching device requires exercising (inactivity alarm) If the opening/closing time of the disconnector is wrong, an alarm is given and the circuit breaker is blocked If an auxiliary cable in the operating or monitoring circuits is damaged, an alarm is given Because the circuit breakers and disconnectors/earthing switches are operated via the bay computer there are no pushbuttons, switches or knobs on the front of the switchgear. An emergency stop button is set up in a suitable place in the switchgear room. FIG10: The ABB REF542 switchgear control unit combines protection, control and monitoring of each circuit The flexibility of the bay computer in configuring the control, interlocking, measuring, protection and communication functions also allows a level of standardisation of hardware not previously possible. Secondary wiring is made to standardised designs with all customer specific requirements configured in the software. This allows switchgear lead times to be reduced and higher levels of consistency and quality to be achieved at lower costs. The bay computer also simplifies the switchgear in taking over all interlocking functions, which previously required mechanical interlocking. Use of the REF542 relay in the ZX0 range of switchgear has allowed the elimination all mechanical interlocks. All control and operation of the primary switching devices is undertaken through the REF542, which also incorporates all interlocking requirements. The REF542 does not allow the operator to perform any operations which are not permitted such as operating the disconnector/earthing switch while the circuit breaker is closed. Locking out is achieved by isolating the control supply to the circuit breaker and the disconnector/earthing switch through padlockable auxiliary switches, which prevent operation of the associated primary switches. This article was published in the IEE Power Engineering Journal of December 2000, Volume 14 Number 6 - page 6/7 The integrity of the interlocking is assured as this is programmed into the REF542 and cannot be changed on site. The control engineer is thus secure in the knowledge that the interlocks remain in their as built state. Individual solid state proximity switches provide positive sensing of open and closed positions. Failure of any switch would result in an alarm generated through the REF542 relay. Sensors Technology The application of the REF54* range of bay computers has facilitated the use of sensor technology other than the conventional current transformers and voltage transformers. Current sensing is achieved using Rogowski coils. Rogowski coils exhibit very low losses and are linear over their entire operating range from a few amperes to short circuit currents. One and the same size can measure currents up to 25kA. The sensor with its connection to the bay computer is jointly tested and any measurement errors are given in the form of a correction factor which corrects the error in the bay computer. FIG11: Modern sensors used with REF542 relays include the Rogowski coil current sensor and a resistive voltage divider Voltage sensing is achieved using resistive voltage dividers. Again these dividers are linear over their measurement range and have low losses. Designs have been developed integrating the voltage and current sensors into a single epoxy housing called a combi sensor. Use of combi sensors simplifies panel assembly resulting in quality improvements and cost reductions. Safety Arc Eliminator ABB has been in the forefront of developing switchgear which improved operator safety through such features as internal arc proof switchgear with pressure relief vents and arc ducts which would direct the arc away from the operational engineers and safely out of the substation. The development of the arc killer device is a further step in improving operator safety with the additional benefit of reducing down time and damage to the switchgear in the event of initiation of an internal arc. The arc is detected by an arc monitor, which sees an arc with the help of optical fibre sensors located in the switchgear bays. The arc monitor activates the arc eliminator, which short circuits the supply to earth within 10ms from the instant the arc developed. This prevents damage due to pressure and thermal effects. Furthermore toxic arcing gasses do not have time to be produced. A high level of personal safety is consequently achieved, and the switchgear can be immediately be taken back into operation again after the cause of the fault has been determined. The active arc protection ensures that no pressure relief is needed. FIG12: Operating sequence of the arc eliminator used in the AX1 switchgear range The arc eliminator is incorporated into the AX1 air insulated switchgear as a standard feature. The switchgear configuration with a single primary enclosure is ideally suited to the application of the arc eliminator technology and is further evidence of the advantages of this development in switchgear technology. This article was published in the IEE Power Engineering Journal of December 2000, Volume 14 Number 6 - page 7/7 Fast Recovery System When an internal arc occurs the pressure within the switchgear increases abruptly from a fraction of a bar to several bar. To achieve grading, normal protection would often require between 0.5 to 1 second to operate to clear the fault. The fast recovery scheme maintains this selectivity, but trips the circuit breaker on the supply side in under 100ms only in the event of an internal arc. Sensors in the various compartments detect the rising front of the pressure wave and open the appropriate circuit breakers a few milliseconds of the initiation of the arc. The system has a high index of reliability and limits the degree of damage to the switchgear in the event of an internal arc. Arc Ducting Apart from pressure relief vents which operate in the event of an internal arc the latest designs of switchgear incorporate arc ducts which are used to channel the arc away from personnel and out of the substation. Examples are evident on both the ZX0 and BEU21 panel ranges. The Sentinel 3 ring main unit incorporates an arc duct with various optional chimney configurations to direct the arc safely away from the operators. Environmental Impact ABB is fully committed to the protection of the environment. New developments in switchgear are evaluated to determine and minimise their environmental impact. For example the AX1 range has undergone a full lifecycle assessment where the environmental load of the product has been analysed and evaluated over the entire lifetime of the product from cradle to grave. The LCA covers raw materials, manufacturing, use, recycling and deposition. The factors accounting for the principal environmental impact in medium voltage switchgear are Materials used in the switchgear Operating losses during the life of the switchgear Recycling possibilities The switchgear makes extensive use of raw materials having a low environmental impact including aluminium, stainless steel, aluzink and bare copper. The compact designs also contribute to a reduction in the environmental loading. The coil spring plug in busbars and connections reduce contact losses and measuring sensors have much lower losses than conventional instrument transformers The end result is that the environmental loading of new switchgear such as the AX1 range is roughly half that of a conventionally built switchgear system Conclusion In conclusion the latest ranges of switchgear are a clear example of the successful application of state of the art technology to a well-established and traditional field of electrical engineering. Where applicable the technology has been applied to more traditional withdrawable switchgear in the form of circuit breakers with magnetic actuators, sensor technology and intelligent relays. However, the maximum benefit is derived by embracing the full spectrum of complementary new technologies as seen in switchgear ranges such as the ZX0, BEU21 and the AX1. Ken Bode Design Manager ABB Power T&D Ltd