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MV Metal-Clad SwitchgearThe safest, most reliable Switchgear in the market today

February 2008


Arc-Resistant Standards

Introduction – Today’s Topics

What is Arc Flash and the risks it represents

Arc-Resistant Switchgear Standards

ABB Switchgear Offering

Characteristics of SafeGear Arc-Resistant Switchgear

Other Safety Features available in Switchgear today


What is an Arc Flash? The result of a rapid release of energy due to an arcing fault between phases, neutral or a ground.

An arc arises when at least part of the current passes through a dielectric, usually air

Maximum peak power up to 40 MW

Arc temperature up to five times the surface temperature of the sun (20,000°C)

Light intensity more than 2000 times that of normal office light

Volumetric expansion approximately 40,000+ - 1

Temperature of the sun surface is about 5000°C.


Arcing Incidents Do Happen

Fault characteristics

An arc arises when at least part of the current passes through a dielectric, usually air

Maximum peak power up to 40 MW

Arc temperature up to five times the surface temperature of the sun (20 000°C)

Light intensity more than 2000 times that of normal office light


Arc Flash Danger Statistics Currently, OSHA lumps Arc Flash incidents in with

electrical incidents.

A recent survey showed that 5-10 people per day go to burn centers due to arc flash incidents – that does not include those going to local and regional hospitals

That is 2000-3500 people a year in the US!

With the high mortality rate of burn injuries, this can translate to hundreds of deaths a year

IEEE did a study with a large utility and over the last 53 years, they have had 1 arc flash incident every 18 months.


Arcing Incidents Do Happen

Security Video of Arc flash incidentDistributed by NFPA


Arc-Resistant Switchgear Causes of internal arc faults

Improper maintenance, mechanical, and interlock failures

Failure to follow procedures Gradual component or insulation breakdown Foreign objects, rodents, snakes, etc.

Effects of an internal arc fault Pressure increase in an enclosed compartment Function of arc voltage, current, number, and duration

of arcs, volume Rapid onset (10-15 ms) results in explosive forces Thermal effects, hot gases Catastrophic to nearby personnel and equipment


Evolution of Arc-Resistant Standards

Interest in Europe – uninsulated bus was common

Annex AA to IEC 298 was approved in 1981

EEMAC G14-1 was published in 1987 in Canada Type A – arc-resistant construction at the front only

Type B – arc-resistant construction at the front, back, and sides

Type C – arc-resistant construction at the front, back, and sides, and between compartments

IEEE C37.20.7-2007 includes Type 1 – similar to EEMAC Type A above

Type 2 – similar to EEMAC Type B above

Annex A addresses suffixes “B” and “C”

Type 1C – Type 1, but also with arc-resistance designs or features between adjacent compartments

Type 2B – Type 2 with LV instrument compartment door open – relay and maintenance personnel survive

Type 2C – Type 2 with arc-resistance features between adjacent compartments – switchgear survives with minimum damage

Type 2BC – The ultimate in protection – combines types 2B and 2C


Industry Recognized Arc-Resistant Standards

OSHA 29 Code of Federal Regulations (CFR) Part 1910, Subpart S

NFPA 70E-2004, “Standard for Electrical Safety in the Workplace”

IEEE 1584-2002, “Guide for Arc Flash Hazard Analysis”

IEEE C37.20.7-2007, IEEE Guide for Testing Medium-Voltage Metal-Enclosed Switchgear for Internal Arcing Faults


Arc-Resistant Standards

Current Requirements and How They Apply

OSHA 29 Code of Federal Regulations (CFR) Part 1910, Subpart S Safe practices to prevent electrical shock or burns must be

implemented Mandates that exposed workers must be qualified Requires provisions for the appropriate personnel protective

equipment (PPE)

NFPA 70E-2004, “Standard for Electrical Safety in the Workplace”

Details steps to comply with the OSHA requirements Worker training Appropriate, safe tools Safety program Arc flash hazard calculations PPE Equipment warning labels


THE NEW NFPA 70E – 2009, TABLE 130.7 (C) (9) Arc-Resistant SWITCHGEAR TYPE 1 OR 2

Hazard/Risk Category for Arc-Resistant Switchgear

Applies to clearing times of <0.5 sec with a perspective fault current not to exceed the arc-resistant rating of the equipment.

Insertion or removal of CBs from cubicles, doors open 4

CB operation with enclosure door closed 0

Insertion of removal of CBs from cubicles, doors closed 0

Insertion or removal of ground and test device with door closed 0

Insertion or removal (racking) of voltage transformers on or off the bus, door closed

0

Work on control circuits with energized electrical conductors and circuit parts 120V, exposed

2


Arc Flash Introduction - Mitigation Techniques

Redirecting energy away from workers Reducing the arcing current (En ~Ia)

Not effective method as test data is required for current limiting devices (fuses)

Increasing the working distance (E~1/D) Using remore racking device, remote operating devices

incident energy might be reduced Reducing the clearing time (E~t)

Zone selective interlocking slow (100ms) + breaker operate time) can not be used for retrofit installations

Bus bar protection expensive to install due to number of CT’s

Light Detection


ANSI C37.20.7 Accessibility Types 1

Front only 1C

Front plus between compartments within a section or between adjacent vertical sections (except main bus compartment)

2 Front, back, and sides

2B Isolation of the Low Voltage Compartment with the instrument door open

2C Front, back, and sides, plus between compartments within a section or between adjacent

vertical sections (except main bus compartment) 2BC

Offers compartment to compartment and low voltage isolation. Offers the very best solution for personnel protection and system reliability.

SafeGear meets IEEE C37.20.7-2007 Type 2, 2B, 2C and 2BC!


Arc Faults

SafeGearConventional Switchgear


Pressure Buildup

0

100

200

300

400

500

600

700

800

900

1 3 5 7 9 11 13 15 17 19 21 23 25 time (ms)

PS

I

enclosure rupture

Pressure measurements

vent flap opens

Successful SafeGear test

SafeGear

conventional


Introduction to ABB ANSI Switchgear

5 to 15 kV metal clad switchgear Advance

Traditional non-arc-resistant switchgear

SafeGear Meets ANSI Standard C37.20.7-2007 for arc-resistance Four versions – Types 2, 2B, 2C and 2BC available

Vacuum circuit breakers AMVAC

Magnetically actuated mechanism

ADVAC Spring operated mechanism


Ratings

Nominal Voltage 4.16 7.2 13.8

BIL (kV) 60 95 95

Continuous Current (A) 1200 1200 1200Main Bus 2000 2000 2000

3000 3000 3000Forced Air Cooled* 4000 4000 4000

Short Circuit (kA) 20 20 20K Factor = 1.0 25 25 25

31.5 31.5 31.540 40 4050 50 50

Ratings

4000 A rating available for Advance only.


ABB Metal-Clad Switchgear Features

Galvanic construction Hem bending Modular design

Bolted frame Instrument compartment Breaker compartment Bus and cable compartment Potential transformer compartment

Arc-resistant switchgear SafeGear Power distribution center Plenum

Circuit breaker technology ADVAC AMVAC magnetically actuated circuit breaker

option


Galvanic Construction

Resistant to rust, corrosion and scratches

No paint required

Highly reflective

(Side view with covers removed)


Hem Bending

No sharp edges for increased safety

Improved rigidity

Reduces arc propagation

Forms a self-supporting structure

Hem bending creates a rigid structure and sturdyconstruction in metal-clad switchgear (reinforced,

arc-resistant door construction shown).


Modular Design

Bolted construction enables faster replacement and modification in the field

Allows for easy replacements, repairs, and specialized configurations

Maintains the smallest, compact product


Instrument Compartment Total isolation from medium voltage

components No instruments on breaker door

Galvanic interiors provide superior reflectivity inside compartments

Available in four sizes 19”, 38”, 57”, 95”

Gasketed door

Easy accessibility for operators

Truck operated cell switches located in the low voltage compartment for easy access and to minimize exposure


Breaker Compartment

Dual safety shutter actuators

Interlock prevents manual operation

Mechanically forced by breaker movement

Shutters grounded by cable

Clear Lexan shutters available

Position indicator

Connected

Test

Disconnected


Breaker Compartment

Automatic secondary disconnect

Provides improved safety for workers while operating the breakers when using SafeGear

Single or double plug secondary contacts

Grounding contact

Interference block

Prevents installing undersized breakers


Bus & Cable Compartments

Copper bus

Epoxy coated bus insulation system

No sleeve insulation

Silver plating standard

Tin plating available

Porcelain or glass polyester standoff insulators

Molded vinyl boots with re-useable hardware

Catalog number embossed on each boot to make reordering easy

No tape used


PT Compartments One to three potential

transformers (PTs)

In SafeGear, less than 40kA duty is 19 inches high. 40kA and 50kA duty is 38 inches high

Closed door racking in and out adds element of safety

Drawout construction with extension rails makes the compartment easily accessible

Lift truck not required to replace fuses

Delrin snuffer contact technology


CPT Compartments 15 kVA, single-phase, truck mounted

Larger size CPT’s are fixed mounted in the rear compartment

Fuse truck with fixed mounted CPT

Closed door racking adds element of safety

Drawout construction with extension rails makes the compartment easily accessible for fuse replacement. Compartment is 38 inches high

Lift truck not required to replace fuses

Delrin snuffer contact technology


Arrangements


SafeGear Arc-Resistant Switchgear

Enhanced safety for personnel and equipment

Flap/vent system to relieve pressure Patented collection chamber Gases are safely expelled out the roof

through the plenum

Built to EEMAC G14-1 1987 type B and C construction and IEEE C37.20.7-2007 Types 2, 2B, 2C and 2BC

More than 25 years experience in arc- resistant switchgear

Design allows for flexibility in configurations and promotes superior safety performance

Certified by an independent test lab


SafeGear Demonstration


ONE-HIGH 1200A 1200A W/2 VT UNITS TWO-HIGH 1200A

1200A W/FUSED CPT 2000A W/1 VT UNIT ONE-HIGH 3000A

Location of Flaps and Vents in SafeGear


SafeGear Patented Internal Collection Chamber


SafeGear Construction

Breaker doors secured with heavy duty hinges and bolts

Multi-point handle and latching available

Double thickness of steel

Gasketed construction

Seals gases inside

Lexan arc-resistant window – largest in industry – allows the operator to check position and status of circuit breaker without opening the cell door


Plenum Benefits

Channels gases out of PDC

Provides room for flap operation

Allows gases to expand

Protects cable trays

Maintains weather protection

Allows lower building height

PlenumPDC ceiling

PDC Aisle

Two-high SafeGear


Plenum Design

Sealed duct across top of switchgear, covering all vent flaps

Sized and shaped to minimize turbulence and back-pressure

Allows room for cable trays and conduit entry

Channels gases safely out of building, through wall penetration and vent


Plenum End Flap

Flaps normally closed

Opens with pressure in case of arc fault


Circuit Breaker Closed door racking to all positions adds

element of safety Three position breaker Positive stop in all positions Breaker positively latched in the compartment

(Disconnect) Racking mechanism is integral to the breaker

element Auxiliary switches are breaker-mounted and

wired out through the secondary disconnect, eliminating the need for separately mounted mechanism operated cell switches

Front access mechanism Centered racking mechanism for easy

alignment Embedded pole design


ADVAC® Circuit Breaker

Manual open andclose push buttons

Non-re-settableoperations counter

Open/close indicator

Racking access port

Manual springcharge port

Spring chargestatus indicator

Cell locking tabsand handles

Racking release lever

Racking padlock provision forlockout and safety procedures


ADVAC® Circuit Breaker

Precision cam

On-board auxiliary contactseliminate the need for cell-mounted MOC switches and related mechanical linkages

4a, 4b standard 9a, 8b optional

Auxiliary switchoperating shaft

Main drive shaft

Charging motor

Toroidalspring

Close &trip coils

Simple, front-accessible operating mechanism and control components


AMVAC Circuit Breaker

Operating mechanism rated for 100,000 operations

10 times ANSI requirement

Interrupter assemblies rated for 30,000 full load operations

Virtually maintenance free (minor lubrication needed)

Only seven moving parts 90% less parts

Permanent magnet for holding force and latch

Dual capacitors store energy Full operation for up to 90 seconds

after loss of control power Interchangeable with ADVAC


AMVAC Circuit Breaker 1. Upper Primary Terminal

2. Vacuum Interrupter

3. Epoxy Potting Compound

4. Lower Primary Terminal

5. Flexible Connector

6. Wipe Springs

7. Insulated Pushrod

8. Jackshaft

9. Stroke Adjustment

10. Position Sensors

11. Close Coil

12. Permanent Magnets

13. Armature

14. Open Coil

15. Manual Opening Actuator

16. Mechanism Enclosure


AMVAC Circuit Breaker

Manual opening mechanism

Auxiliary contacts

Sensor for switching position detection

Magnetic actuator

Electronic controller

Electrical energy storage


AMVAC vs. ADVAC

AMVAC’s simple design reduces moving elements and the need for spare parts


Accessories Racking crank, manual close bar

Test cabinet

Test jumper

Ground & test device

Electric racking device

Lift truck

Ramp

Shutter actuator truck

Breaker release handle

Wear test device

Dummy circuit breakers

Slow close device

IR Viewing Ports


Arc Flash Mitigation Relays

REA 101 Arc Protection Relay Fast trip time (< 2.5 ms)

Unique fiber optic sensor technology with self supervision

Current supervision for secure and reliable arc detection

Easy to configure via front mounted dip switches

Suitable for existing LV / MV switchgear installations or new applications

Minimize potential risk of injury or death while increasing reliability

Includes standard 12 year warranty


Arc in the right bus compartment with the tie breaker open

Right REA 101 detects overcurrent

Right REA 101 detects light

REA 101s send the current information to all connected unitsRight bus is disconnected

REA Application Example #1

REA101

REA101

REA105

REA105

REA105

REA105


IR viewing Ports

SAFE: Successfully Arc-Flash tested in accordance with IEEE C37.20.7

RUDGGED: Certified by UL, SIRA and Lloyds of London for installation into both indoor and outdoor equipment

FLEXIBLE: Broadband optic suitable for all IR cameras.

SECURE: Unique mounting system allows for safe, single person installation & retro-fitting with No dangerous internal fasteners required.

1. Eliminate need to enter the switchgear while energized.

2. Frequent monitoring possible without impacting production.

3. Easy to use system requires little training


Product description

Applicable to any unshielded medium voltage system – from 3 kV to 36 kV

For permanent installation – information on voltage presence available all the time

Outdoor and indoor application

Good visibility under all lighting conditions

Maintenance free; passive device – no power supply needed

Simple and robust construction – resistant to overvoltages(does not use electronic elements)

Very compact construction

Easy to install

Economical solution

Indicator of voltage presence installed directly on bus bars,

conductors etc.

Advantages of VisiVolt™


In Summary

Advance & SafeGear available at 5 and 15kV SafeGear arc-resistant switchgear – Types 2, 2B, 2C and 2BC –

provide the highest level of personnel protection

AMVAC breaker 100,000 mechanical operations mechanism

30,000 load break operations interrupter

Virtually maintenance free

REA Relays Protects you personnel and equipment with the most advanced arc

flash mitigation relays on the market.