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Switchgear

In an electric power system, switchgear is composed of electrical disconnect switches, fuses or

circuit breakers used to control, protect and isolate electrical equipment. Switchgear is used
both to de-energize equipment to allow work to be done and to clear faults downstream. This
type of equipment is directly linked to the reliability of the electricity supply.

High-voltage switchgear
A section of a large switchgear panel.

Tram switchgear
This circuit breaker uses both SF6 and air as insulation.

The earliest central power stations used simple open knife switches, mounted on insulating
panels of marble or asbestos. Power levels and voltages rapidly escalated, making opening
manually operated switches too dangerous for anything other than isolation of a de-energized
circuit. Oil-filled switchgear equipment allows arc energy to be contained and safely controlled.
By the early 20th century, a switchgear line-up would be a metal-enclosed structure with
electrically operated switching elements using oil circuit breakers. Today, oil-filled equipment
has largely been replaced by air-blast, vacuum, or SF6 equipment, allowing large currents and
power levels to be safely controlled by automatic equipment.

High-voltage switchgear was invented at the end of the 19th century for operating motors and
other electric machines.[1] The technology has been improved over time and can now be used
with voltages up to 1,100 kV.[2]

Typically, switchgear in substations is located on both the high- and low-voltage sides of large
power transformers. The switchgear on the low-voltage side of the transformers may be located
in a building, with medium-voltage circuit breakers for distribution circuits, along with metering,
control, and protection equipment. For industrial applications, a transformer and switchgear line-
up may be combined in one housing, called a unitized substation (USS). According to the latest
research by Visiongain, a market research company, the worldwide switchgear market is
expected to achieve $152.5 billion by 2029 at a CAGR of 5.9%. Growing investment in renewable
energy and enhanced demand for safe and secure electrical distribution systems are expected
to generate the increase.[3]
 Components

A switchgear assembly has two types of components:

Power-conducting components, such as switches, circuit breakers, fuses, and lightning

arrestors, that conduct or interrupt the flow of electrical power.

Control systems such as control panels, current transformers, potential transformers,

protective relays, and associated circuitry, that monitor, control, and protect the power-
conducting components.

Functions

One of the basic functions of switchgear is protection, which is interruption of short-circuit and
overload fault currents while maintaining service to unaffected circuits. Switchgear also
provides isolation of circuits from power supplies.Switchgear is further used to enhance system
availability by allowing more than one source to feed a load.

History

Early switchgear (about 1910)

Switchgear is as old as electricity generation. The first models were very primitive: all
components were simply fixed to a wall. Later they were mounted on wooden panels. For
reasons of fire protection, the wood was replaced by slate or marble. This led to a further
improvement, because the switching and measuring devices could be attached to the front,
while the wiring was on the back.[4] The tumbler switch with ordinary fuse is the simplest form of
switchgear and was used to control and protect lights and other equipment in homes, offices
etc. For circuits of a higher rating, a high-rupturing capacity (H.R.C.) fuse in conjunction with a
switch may serve the purpose of controlling and protecting the circuit. However, such
switchgear cannot be used profitably on a high-voltage system.[5]

Housing

Switchgear for lower voltages may be entirely enclosed within a building. For higher voltages
(over about 66 kV), switchgear is typically mounted outdoors and insulated by air, although this
requires a large amount of space. Gas-insulated switchgear saves space compared with air-
insulated equipment, although the equipment cost is higher. Oil insulated switchgear presents
an oil spill hazard.

Switches may be manually operated or have motor drives to allow for remote control.

Circuit breaker types

A switchgear may be a simple open-air isolator switch or it may be insulated by some other
substance. An effective although more costly form of switchgear is the gas-insulated switchgear
(GIS), where the conductors and contacts are insulated by pressurized sulfur hexafluoride gas
(SF6). Other common types are oil or vacuum insulated switchgear.

The combination of equipment within the switchgear enclosure allows them to interrupt fault
currents of thousands of amps. A circuit breaker (within a switchgear enclosure) is the primary
component that interrupts fault currents. The quenching of the arc when the circuit breaker pulls
apart the contacts (disconnects the circuit) requires careful design. Circuit breakers fall into
these six types:

Oil
…
Cutaway model of an oil-filled high-voltage circuit breaker

Oil circuit breakers rely upon vaporization of some of the oil to blast a jet of oil along the path of
the arc. The vapor released by the arcing consists of hydrogen gas. Mineral oil has better
insulating property than air. Whenever there is a separation of current carrying contacts in the oil,
the arc in circuit breaker is initialized at the moment of separation of contacts, and due to this
arc the oil is vaporized and decomposed to mostly hydrogen gas and ultimately creates a
hydrogen bubble around the electric arc. This highly compressed gas bubble around the arc
prevents re-striking of the arc after current reaches zero crossing of the cycle. The oil circuit
breaker is one of the oldest types of circuit breakers.

Air …
Air circuit breakers may use compressed air (puff) or the magnetic force of the arc itself to
elongate the arc. As the length of the sustainable arc is dependent on the available voltage, the
elongated arc will eventually exhaust itself. Alternatively, the contacts are rapidly swung into a
small sealed chamber, the escaping of the displaced air thus blowing out the arc.

Circuit breakers are usually able to terminate all current flow very quickly: typically between
30 ms and 150 ms depending upon the age and construction of the device.

Gas
…
Gas (SF6) circuit breakers sometimes stretch the arc using a magnetic field, and then rely upon
the dielectric strength of the SF6 gas to quench the stretched arc.
Hybrid
…
Hybrid switchgear is a type which combines the components of traditional air-insulated
switchgear (AIS) and SF6 gas-insulated switchgear (GIS) technologies. It is characterized by a
compact and modular design, which encompasses several different functions in one module.

Vacuum
…
Circuit breakers with vacuum interrupters have minimal arcing characteristics (as there is
nothing to ionize other than the contact material), so the arc quenches when it is stretched by a
small amount (<2–8 mm). Near zero current the arc is not hot enough to maintain a plasma, and
current ceases; the gap can then withstand the rise of voltage. Vacuum circuit breakers are
frequently used in modern medium-voltage switchgear to 40,500 volts. Unlike the other types,
they are inherently unsuitable for interrupting DC faults. The reason vacuum circuit breakers are
unsuitable for breaking high DC voltages is that with DC there is no "current zero" period. The
plasma arc can feed itself by continuing to gasify the contact material.

Carbon dioxide …
Breakers that use carbon dioxide as the insulating and arc extinguishing medium work on the
same principles as a sulfur hexafluoride (SF6) breaker. Because SF6 is a greenhouse gas more
potent than CO2, by switching from SF6 to CO2 it is possible to reduce the greenhouse gas
emissions by 10 tons during the product lifecycle.[6]

Protective circuitry

Circuit breakers and fuses …

Circuit breakers and fuses disconnect when current exceeds a predetermined safe level.
However they cannot sense other critical faults, such as unbalanced currents—for example,
when a transformer winding contacts ground. By themselves, circuit breakers and fuses cannot
distinguish between short circuits and high levels of electrical demand.

Merz-Price circulating current scheme

…
Differential protection depends upon Kirchhoff's current law, which states that the sum of
currents entering or leaving a circuit node must equal zero. Using this principle to implement
differential protection, any section of a conductive path may be considered a node. The
conductive path could be a transmission line, a winding of a transformer, a winding in a motor, or
a winding in the stator of an alternator. This form of protection works best when both ends of
the conductive path are physically close to each other. This scheme was invented in Great
Britain by Charles Hesterman Merz and Bernard Price.[7]

Two identical current transformers are used for each winding of a transformer, stator, or other
device. The current transformers are placed around opposite ends of a winding. The current
through both ends should be identical. A protective relay detects any imbalance in currents, and
trips circuit breakers to isolate the device. In the case of a transformer, the circuit breakers on
both the primary and secondary would open.

Distance relays
…
A short circuit at the end of a long transmission line appears similar to a normal load, because
the impedance of the transmission line limits the fault current. A distance relay detects a fault by
comparing the voltage and current on the transmission line. A large current along with a voltage
drop indicates a fault.

Classification

Several different classifications of switchgear can be made:[8]

By the current rating.

By interrupting rating (maximum short circuit current kAIC that the device can safely interrupt)
Circuit breakers can open and close on fault currents

Load-break/Load-make switches can switch normal system load currents

Isolators are off load disconnectors which are to be operated after Circuit Breakers, or
else if the load current is very small
By voltage class:
Low voltage (less than 1 kV AC)

Medium voltage (1 kV AC through to approximately 75 kV AC)

High voltage (75 kV to about 230 kV AC)

Extra high voltage, ultra high voltage (more than 230 kV)

By insulating medium:
Air

Gas (SF6 or mixtures)

Oil

Vacuum

Carbon dioxide (CO2)

By construction type:
Indoor (further classified by IP (Ingress Protection) class or NEMA enclosure type)

Outdoor

Industrial

Utility

Marine

Draw-out elements (removable without many tools)

Fixed elements (bolted fasteners)

Live-front

Dead-front

Open

Metal-enclosed (ME) — A switchgear assembly completely enclosed on all sides and the
top with sheet metal.[9]

Metal-clad (MC) — A more expensive variety of metal-enclosed switchgear that has the
following characteristics: the main switching and interrupting device of removable type;
grounded metal barriers to separate compartments and enclose all major circuits and
parts; mechanical interlocks; insulated bus conductors and other features.[10][11]

Cubicle

Arc-resistant

By IEC degree of internal separation[12]

No Separation (Form 1)

Busbars separated from functional units (Form 2a, 2b, 3a, 3b, 4a, 4b)

Terminals for external conductors separated from busbars (Form 2b, 3b, 4a, 4b)

Terminals for external conductors separated from functional units but not from each
other (Form 3a, 3b)

Functional units separated from each other (Form 3a, 3b, 4a, 4b)

Terminals for external conductors separated from each other (Form 4a, 4b)

Terminals for external conductors separate from their associated functional unit (Form
4b)
 By interrupting device:
Fuses

Air Circuit Breaker

Minimum Oil Circuit Breaker

Oil Circuit Breaker

Vacuum Circuit Breaker

Gas (SF6) Circuit breaker

CO2 Circuit Breaker

By operating method:
Manually operated

Motor/stored energy operated

Solenoid operated

By type of current:
Alternating current

Direct current

By application:
Transmission system

Distribution

By purpose
Isolating switches (disconnectors)

Load-break switches.[13][14]

Grounding (earthing) switches

A single line-up may incorporate several different types of devices, for example, air-insulated
bus, vacuum circuit breakers, and manually operated switches may all exist in the same row of
cubicles.

Ratings, design, specifications and details of switchgear are set by a multitude of standards. In
North America mostly IEEE and ANSI standards are used, much of the rest of the world uses IEC
standards, sometimes with local national derivatives or variations.
 Safety

245 kV circuit breaker in air insulated substation

420 kV gas insulated switchgear

To help ensure safe operation sequences of switchgear, trapped-key interlocking provides

predefined scenarios of operation. For example, if only one of two sources of supply are
permitted to be connected at a given time, the interlock scheme may require that the first switch
must be opened to release a key that will allow closing the second switch. Complex schemes
are possible.

Indoor switchgear can also be type tested for internal arc containment (e.g., IEC 62271-200).
This test is important for user safety as modern switchgear is capable of switching large
currents.[15]
Switchgear is often inspected using thermal imaging to assess the state of the system and
predict failures before they occur. Other methods include partial discharge (PD) testing, using
either fixed or portable testers, and acoustic emission testing using surface-mounted
transducers (for oil equipment) or ultrasonic detectors used in outdoor switchyards.
Temperature sensors fitted to cables to the switchgear can permanently monitor temperature
build-up. SF6 equipment is invariably fitted with alarms and interlocks to warn of loss of
pressure, and to prevent operation if the pressure falls too low.

The increasing awareness of dangers associated with high fault levels has resulted in network
operators specifying closed-door operations for earth switches and racking breakers. Many
European power companies have banned operators from switch rooms while operating. Remote
racking systems are available which allow an operator to rack switchgear from a remote location
without the need to wear a protective arc flash hazard suit. Switchgear systems require
continuous maintenance and servicing to remain safe to use and fully optimized to provide such
high voltages.[16]

See also

Arc flash

Circuit breaker

Disconnector

Electrical safety

Electric arc

High voltage

Remote racking system

Short circuit

References

1. British Pattern GB 20069 Improvements in Apparatus for Controlling the Application or Use of Electric
Currents of High Tension and Great Quantity in 1893 (http://v3.espacenet.com/origdoc?DB=EPODOC&ID
X=GB189320069&F=0&QPN=GB189320069) , on espacenet.com

2. Lin Jiming et al., Transient characteristics of 1 100 kV circuit-breakers, International Symposium on

International Standards for Ultra High Voltage, Beijing, Juillet 2007.
 3. " "The worldwide switchgear market is expected to achieve $152.5bn by 2029", says Visiongain report" (ht
tps://www.visiongain.com/the-worldwide-switchgear-market-is-expected-to-achieve-152-5bn-by-2029-say
s-visiongain-report/) . Visiongain. 2019-09-05. Retrieved 2019-09-06.

4. (German) Allgemeine Elektricitäts-Gesellschaft (ed) AEG Hilfsbuch für elektrische Licht- und Kraftanlagen
6th Ed., W. Girardet, Essen 1953

5. "What is Switchgear? | Features, Components and Classification" (https://studyelectrical.com/2015/07/w

hat-is-switchgear-features-components-hv-mv-lv.html) . StudyElectrical.Com. 2015-07-19. Retrieved
2019-02-01.

. "Switzerland : ABB breaks new ground with environment friendly high-voltage circuit breaker" (http://ww
w.thefreelibrary.com/Switzerland+%3A+ABB+breaks+new+ground+with+environment+friendly...-a030098
7882) . Retrieved 9 July 2013.

7. Robert Monro Black (January 1983). The History of Electric Wires and Cables (https://books.google.com/
books?id=HUCieJjeQ-wC&pg=PA101) . IET. pp. 101–. ISBN 978-0-86341-001-7.

. Robert W. Smeaton (ed) Switchgear and Control Handbook 3rd Ed., McGraw Hill, New York 1997 ISBN 0-
07-058451-6

9. IEEE Std C37.20.2-1999. IEEE Standard for Metal-Clad Switchgear.

10. IEEE Std C37.100-1992. IEEE Standard Definitions for Power Switchgear.

11. "Metal-Clad vs Metal-Enclosed" (http://eeame.com/portal/contents-mainmenu-29/opinions-mainmenu-6

3/109-metal-clad-vs-metal-enclosed.html) . ELECTRICAL ENGINEERS AND MASTER ELECTRICIANS
PORTAL. November 4, 2008. Retrieved June 28, 2016.

12. IEC Standard EN 60439 part 1 Table 6A

13. (in French) Norme CEI 60265-1 Interrupteurs pour tension assignée supérieure à 1 kV et inférieure à 52
kV (http://domino.iec.ch/preview/info_iec60265-1%7Bed3%2E0%7Db.pdf) Archived (https://web.archiv
e.org/web/20070930171034/http://domino.iec.ch/preview/info_iec60265-1%7Bed3%2E0%7Db.pdf)
September 30, 2007, at the Wayback Machine

14. (in French) Norme CEI 60265-2 Interrupteurs pour tension assignée supérieure à 52 kV (http://domino.ie
c.ch/preview/info_iec60265-2%7Bed3%2E0%7Db.img.pdf)

15. https://www.energy.siemens.com/cms/00000013/aune/Documents/Medium%20Voltage%20Arc%20Faul
t%20Containment.pdf Archived (https://web.archive.org/web/20090318070617/https://www.energy.si
emens.com/cms/00000013/aune/Documents/Medium%20Voltage%20Arc%20Fault%20Containment.p
df) March 18, 2009, at the Wayback Machine

1 . "Switchgear Systems and Services" (https://johnsonphillips.co.uk/services/switchgear/) .

johnsonphillips.co.uk. Retrieved 2018-05-15.

External links
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