solution for the weak link high voltage bolted couplers and adaptors
Post on 12-Feb-2016
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SOLUTION FOR THE WEAK LINKSOLUTION FOR THE WEAK LINK
HIGH VOLTAGE BOLTEDHIGH VOLTAGE BOLTEDCOUPLERS AND ADAPTORSCOUPLERS AND ADAPTORS
HIGH VOLTAGE COUPLERS REGARDEDHIGH VOLTAGE COUPLERS REGARDED AROUND THE WORLD AS THE WEAK LINK AROUND THE WORLD AS THE WEAK LINK
• Couplers have been Failing in Service• Failures were Unpredictable• Cause of Failures Unknown
• Decrease in Safety and Health• Decrease Production• Increase Operation Costs
WHY?WHY?
ASSOCIATED PROBLEMSASSOCIATED PROBLEMS
ACARP REPORT ON THE FAILUREACARP REPORT ON THE FAILURE OF 11kV PLUGS AND ADAPTORSOF 11kV PLUGS AND ADAPTORS
• Australian MiningAustralian Mining Industry ConcernedIndustry Concerned
• Invested Through ACARPInvested Through ACARP
EXAMPLES OF FAILED COUPLERS IN SERVICEEXAMPLES OF FAILED COUPLERS IN SERVICE
1
2 3
45 6
CREATING DEAD SHORTCREATING DEAD SHORT
SHORTSHORT
Australia South AfricaUSA Canada
RESEARCHING COUPLERS GLOBELY RESEARCHING COUPLERS GLOBELY
Research showed that all the designs were very similar. These similarities were:
• Insulators were all of a tower design
• When closed, all suffered from air being trapped around the insulator profile
• The same design flaws were present in all types of couplers
ACARP PROJECT C5032ACARP PROJECT C5032
Research into the Failure of 11kV Plugs and Adaptors used in Underground Coal Mines
Quote: Executive Summary:“A number of design weaknesses were identified that lead
to the generation of partial discharges within the assembled plug and adaptor”
DESIGN FLAWS FOUNDDESIGN FLAWS FOUND
• Large Volume Of Air Trapped Inside Coupler Enclosure
• High Discharge Creates Corona• Corona Converts Air To Ozone• Ozone Is A Conductor• Phase To Phase Flashover
AIR AND PARTIAL DISCHARGEAIR AND PARTIAL DISCHARGE
AIR
PARTIAL DISCHARGE
SOLUTIONSSOLUTIONS
• Remove Air with Silicon Rubber Insert
• Insulating Material Developed to Extinguish TrackingInsulating Material Developed to Extinguish Tracking
SiliconSiliconInsertInsert
InsulatingInsulatingMaterialMaterial
NO TRIPS OR ANY SIGNS OF FAULTNO TRIPS OR ANY SIGNS OF FAULT
PHASE SEGREGATION BY EARTHPHASE SEGREGATION BY EARTH
PHASE
PHASE
PHASE
Mining Industry Standard
EARTH
EARTH
EARTH
EARTH
A Phase to GroundFault was createdwith conductive
paint
Earth Star Placed Between Phases
A Through Fault Test was then performed on this solutionto see how it would perform in the field
FIRST SOLUTIONFIRST SOLUTION
REASON FOR FAILUREREASON FOR FAILURE
PHASE 1
EARTH
PHASE 2
PHASE 3
FINDING A SUCCESSFUL SOLUTIONFINDING A SUCCESSFUL SOLUTION
.
Equipotential Lines Good
Earth StarEarth StarEquipotential Lines Equipotential Lines
Crushed UpCrushed Up
Individually ScreenedIndividually ScreenedCableCable
EquipotentialEquipotentialLines GoodLines Good
SOLUTIONSOLUTION
New Design expels all airin face of coupler and phases
are segregated by ground
SEPARATESEPARATEINSULATORSINSULATORS
BODY SEGREGATESBODY SEGREGATESPHASESPHASES
EXPELS ALL AIREXPELS ALL AIR
• ALL TYPE TESTS PERFORMED WERE ALL TYPE TESTS PERFORMED WERE WITHIN CABLE SPECIFICATIONSWITHIN CABLE SPECIFICATIONS
COUPLERS HOMOGENEOUS COUPLERS HOMOGENEOUS WITH CABLEWITH CABLE
EARTHEARTH
COMPARISONCOMPARISON
ACARP PROJECT C5032ACARP PROJECT C5032
Research into the Failure of 11kV Plugs and Adaptors used in Underground Coal Mines
Quote: NEW DESIGN “Given the nature of the newdesign and the high voltage stress management issues thatit addresses, it is expected that other manufacturers willfollow this lead and produce their own variations of thedesign. “
PEACE OF MINDPEACE OF MIND
ANALYZING THE DESIGN ADVANTAGESANALYZING THE DESIGN ADVANTAGES
Increased Safety Increased ReliabilityIncreased Reliability Increased ProductivityIncreased Productivity Increased SecurityIncreased Security
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