01-SWITCHGEAR & TRANSFORMER JUN 2024

MV & LV System Technical Sharing 2024
SUN POWER SYSTEM SDN. BHD.
MEDIUM VOLTAGE TECHNICAL SHARING
SWITCHGEAR ( 9am - 10am )

&
TRANSFORMER ( 10am - 11am )
Speaker : Deric Lim ( MV Division )
Date : 25th June 2024
CPD HOURS :
BEM , MBOT , CCD
SUN POWER AUTOMATION SDN. BHD.

was incorporated since 2004, specialist in Medium
Voltage & Low Voltage Automation Business,
servicing professionals Consultants, Contractors &
Panel Makers to provide the finest product range to
the market.
Since then, our company has growth rapidly to

become one of the leading electrical component
supplier for all range of projects development
throughout whole Malaysia.
With our excellent relationship with overseas

renowned manufacturer, we were appointed as
EXCLUSIVE AGENT in Malaysia for wide selection of
electrical product with multi-international brands.
Disclaimer: This presentation is intended to present our company products only, and do not replace independent
professional judgment. Each person who has received a copy of this presentation is deemed to have agreed not to
reproduce or distribute this presentation materials in whole or in part. 1
SUN POWER GROUP sunpowerberhad.com.my
w w w . s o n e p a r. c o m
SUN POWER AUTOMATION SUN POWER SYSTEM

___ ___
Established since 2004 Established since 2010
Switch
Distribution
Low Voltage Components Medium Voltage &
Board
Sockets
One stop solution for major & important electrical component.
Multi-International
Product
SUN POWER AUTOMATION SDN BHD

Specialize in Low Voltage Components
MCB & RCCB SPD

ACB MCCB Contactor & TOR
Protection Relay Switch & Socket

(EF/OC) Digital Power Meter Capacitor Bank VSD / Inverter
SUN POWER SYSTEM SDN BHD

Specialize in Medium Voltage & Distribution Board
§ Switchgear 12 KV § Transformer 12KV up to 36KV § Metal Clad DB

§ PVC Consumer Unit
SUN POWER Seminar Executive Personnel
SUNNY KOK
DIRECTOR
VICKY WINNY YI HAO

CRYSTAL Tech. & Spec.
COMMUNICATION MARKETING MULTIMEDIA
Manager
DERIC LIM PHILIP CHANG RAYMOND YONG JIAN

Product Manager Product Manager MV TECH. MV ASST.
SPEAKER ( MV ) SPEAKER ( LV )
Seminar Executive Personnel
JEFFREY YAP JAMES GAN

MANAGING DIRECTOR
EXECUTIVE DIRECTOR
SPEAKER (DELAB) SPEAKER (OBO)
J. L. GOH JACKSON LIM BENSON TING

ELECTRICAL ENGINEER MARKETING EXECUTIVE SALES ENGINEERING
MANAGER
About SUN POWER

Officially become A Sonepar Company on 1st June 2014.
sunpowerberhad.com.my
Established since 2004
About SONEPAR
www.sonepar.com B-to-B distributor of electrical products
HQ
The in Paris,
world’s no.1France
B-to-B distributor of electrical
products & related solutions.
EXCLUSIVE AGENT
MV SWITCHGEAR MV TRANSFORMER
POWER PROTECTION RELAY

DIGITAL POWER METER
MV SWITCHGEAR
MV VACUUM CIRCUIT BREAKER
LV CIRCUIT BREAKER
LV CONTACTOR & TOR
LV INVERTER
MV TRANSFORMER
POWER FACTOR CORRECTION

CAPACITOR
DISTRIBUTION BOARD SURGE PROTECTIVE DEVICE
Company Introduction Video

https://youtu.be/7ltJBE4uigo
SEMINAR & WEBINAR

2019
Conducted 7 seminars tour around Malaysia.
2020 à 2022
Conducted more than 60 webinars online.
2023
Conducted 20 webinars online.
Conducted 4 session technical sharing in Sun
Power office seminar hall.
Table of Contents
§ C.T Selection
§ Types Of Circuit Breaker
§ Comparison New IEC vs. Old IEC

§ Vacuum Interrupter ( VI )
§ Rated short-time withstand current

§ Stego Tulip Contact
§ Factory Acceptance Test Method ( F.A.T )

§ ( E2 List 3) & ( M2 & C2 ) Type Tested
§ JKR Specification L-S15

§ Advantage of Sun Power ESTA switchgear
§ Tech. Data ( Breaker & Panel )

§ Internal Arc Test ( IAC )
§ Case Study
§ Single Line Drawing & Panel Layout
IEC ( International Electrotechnical Commission )
IEC 62271-100 IEC 62271-200

Ø Part 100: Ø Part 200:
High-Voltage alternating-current circuit AC metal-enclosed switchgear & control
breakers. gear for rated voltages above 1KV and up
to and including 52KV.
IEC office :
3, rue de Varembē, PO Box 131, CH-1211
Geneva 20, Switzerland.
Website : http://www.iec.ch
IEC 62271 -- Switchgear Type Test

1. Clause 6.2 : Dielectric tests ( Power-frequency, Lightning impulse )
2. Clause 6.3 : Radio interference voltage ( r.i.v.) test
3. Clause 6.4 : Measurement of the resistance of circuits
4. Clause 6.5 : Temperature-rise tests
5. Clause 6.6 : Short-time withstand current and peak withstand current
6. Clause 6.7 : Verification of the protection ( IP & IK coding )
7. Clause 6.8 : Tightness tests
8. Clause 6.9 : Electromagnetic compatibility tests (EMC)
9. Clause 6.10 : Additional tests on auxiliary and control circuits
10. Clause 6.11 : X-radiation test procedure for vacuum interrupters
What is Type Test ( Switchgear )

Step : 1
Fabricate new Switchgear Panel .
Step : 2
Send to laboratory for conducting a type test according to IEC standard .
Step : 3
After successfully passed , future switchgear built in production must be
identical same process & similar design .
( This is truly declared as Type tested panel ).
SHORT-CIRCUIT TESTING LIAISON ( STL )

12 Laboratory Accredited
1. Intertek (ASTA), UK 2. KEMA, Netherlands 3. CESI, Italy 4. KERI, South Korea
5. SATS, Norway 6. CPRI, India 7. PEHLA, Germany 8. ZKU, Czech Republic
9. STLNA, USA 10. ESEF ASEFA, France 11. VEIKI, Hungary 12. JSTC , Japan
Table of Contents
Type Of Circuit Breaker
Types of Circuit Breaker

Medium Voltage 1kv – 52kv
1. Oil Circuit Breaker 3 Gas Circuit Breaker
ü
2. Air Blast Circuit Breaker 4. Vacuum Circuit Breaker
What is Vacuum Circuit Breaker
Circuit Breaker Vacuum Bottle Interrupter
Vacuum Circuit Breakers ( VCB )

• Fully Withdrawable Type
• Use vacuum interrupter to Quench the arc
• The arc extinguish in half cycle
Vacuum Circuit Breakers ( VCB )

Advantages
- Compact and reliable
- Longer life
- No risk of fire
- Arc extinction is very fast
- No need maintenance
- Frequent operation are allow
- VCB has a higher insulating strength.
- Breaker weight appro. 80kg to 90 kg only .
Table of Contents
Vacuum Interrupter ( VI )
Vacuum Interrupter ( V I )
§ Vacuum Interrupter Technology introduced since 1960

§ Vacuum Interrupter pressure maintained at 5 x 10-5 bar.
Contact Clearance 𝟏𝟏 𝒎𝒎 ± 𝟏 mm
Opening Time < 𝟒𝟎 𝒎𝒔
Closing Time < 6𝟎 𝒎𝒔
Vacuum Interrupter ( V I )
NEW OLD
Contact Design Contact Design
Radial Magnetic Field Axial Magnetic Field
( RMF ) (AMF)
Contact System
Contact System
“RMF – Mode”
“AMF – Mode”
Rotating column arc, to reduce the thermal local load at Diffuse arc covers the whole surface of the
the contact surface. ( carbon deposited less ) contact . ( Carbon deposited more )
Spiral Contact Flat Surface
Table of Contents
Stego Tulip Contact
Stego Tulip Contact ( IEC 62271-100 )

Main Circuit Structure With High Reliability
Structure of STEGO TULIP Terminal
Plate star: Supporting Tulip for position maintain and torsional flow
prevention
1) Optimal contact condition even some dimension 3) Good application for Oil & gas industry, heavy
deviated. industrial plant, Mixed development & etc.
2) Natural heat radiation by itself 4) Can minimize the aging.( life span > 30 years )
( Natural cooling ).
Table of Contents
E2 (List 3) Type Tested
Electrical Endurance
Type Tested ( IEC 62271-100 )
PASSED
§ Arc Energy
- E2 ( List 1 ) Test T10 ( 100% ) 1,000

- E2 ( List 2 ) Test T30 ( 125% )
operations
- E2 ( List 3 ) Test T60 ( 134% )
( T60 proven best efficiency interrupting test )
Table of Contents
M2 & C2 Type Tested
M2 & C2 Type Tested ( IEC 62271-100 )
PASSED
PASSED
Test to determine the mechanical durability grade. Test to verify the re-striking and C2 class is secured .
1. Inductive Load
2. Resistive Load
3. Capacitive Load
Table of Contents
Advantages Sun Power ESTA switchgear IEC

62271-200
Sun Power brand Switchgear
a. Switchgear Type Tested :
ü KEMA IEC 62271-100
ü ASTA IEC 62271-200
b. Internal Arc Tested.
Introduction
§ Life span up to 30 years with periodically check schedule.
§ Built in safety feature.
§ Product Warranty offer :

3 years upon delivery
OR
2 years upon CPC ( whichever come first ).
§ Cassette type is new evolution.
Main Features
§ Rated voltages from 3.3 kV up to 12 kV.
§ Rated currents from 630A & 1250A .
§ Rated short-time withstand currents is 25kA/3s.
§ Panel Dimension ( W600 x H2000 x D1700 mm) per Panel.
§ Easy & Safe to operate.

( O&M and Site training provided )
SIDE VIEW PANEL
1
3 SAFETY COMPARTMENTS
2
1. Low Voltage compartment
2. Breaker compartment
3. Busbar compartment
4. Cable compartment
4 5 5. P. T compartment
Easy and Safe Operation
§ Safety Mechanical operation

with doors closed provided.
§ Mechanical indication are provided for

( Test & Service position ).
§ Operator safety with interlock system within

Breaker & Earth switch.
Easy and Safe Operation
1 2 3
Service & Test Position indicator Earthing Switch :

Manual Emergency Operation Interlocking with cct breaker
with Front door close
ESTA SWITCHGEAR
( Withdrawable VCB ) Trolley Battery & charger TNB metering

DC 30V kiosk Panel
st
reque
NEW
cia l
Spe
Foldable
VCB Trolley VCB Trolley
• Trolley is foldable type &
save space.
• Can stack up & easy to keep

in sub-station .
Table of Contents
Switchgear Installation at Substation
CEILING
Minimum Clearance for
Minimum Clearance for arc pressure relief
arc pressure relief
> 1 Meter
Flip open
Flip open Flip open
W W 12kV
A A
L L Switchgear
L 2 Meter L Panel
installation
at Substation.
Back
Front
1.7 Meter 2 Meter
1 Meter Side View Panel
Total Depth = 4.7 Meter ( minimum requirement )
Table of Contents
Internal Arc Test ( IAC )
WHAT IS INTERNAL ARC TEST
§ A three phases internal short-circuited .
§ Injecting High Voltage 11kV with High Current 25kA for 1 sec.
§ Destructive test with great impact.
§ To determine the performance under the arc conditions .
Internal Arc Test

A F L R 25kA/1s ( IEC 62271-200 ) sub-clause 6.106
ü A -Authorized Personnel ( Chargeman )

ü F - Front Panel
ü L - Lateral ( side left & right )
ü R – Rear
To ensure human safety in substation.
Side view panel
Why Arc Flash Accident can be happened
Due to :
§ Human errors
§ Mechanical faulty
§ Bad connections
§ Pollution
§ Animals ( Rodent & Snake )
Arc Flash Causes >>
§ Human Injury
§ Physical Damage to Switchgear
§ Blackout
§ Cost & Time Incurred
How to Solve Arc Flash issue

§ Switchgear to provide 3 compartment Arc Flip
vertical opening
( must be type tested ).
§ Switchgear to provide 5 compartments

segregation.
§ Switchgear to prevent rodent/snake enter

inside.
§ Switchgear to provide Arc sensor to prevent

severe damage.
Internal Arc Test ( 62271-200 )

Maximum Safety
PASS ! Successfully tested against internal arc faults !
1. Cable Compartment 2. Busbar Compartment 3. Breaker Compartment
Arc Pressure Relief with 3 compartments is provided.
4 Types Categories Arc Flash Protection Rating

Sub-Station Safety
Required minimum arc rating for
Category Voltage
PPE
PPE-1 ≥ 4 calories/𝑐𝑚!
PPE-2 ≥ 8 calories/𝑐𝑚! LV ( below 1kV )
PPE-3 ≥ 25 calories/𝑐𝑚!
PPE-4 ≥ 40 calories/𝒄𝒎𝟐 MV ( 11kV to 33kV )

PPE
Personal Protective Equipment
- An exposure between 1 & 2 calories will cause second degree burn on human skin
- Arc flash typically release between 10 to 40 calories
ESTA PANEL
Internal Arc Tested
Watch Video
Table of Contents
LSC2B (Lost of Service Continuity)
Loss of Service Continuity
ESTA Panel Successfully tested with LSC2B

PASS !
( LSC ) consists 4 Categories in IEC standard :
LSC2B
LSC1 (Basic Spec) LSC2 LSC2A Higher Spec
Busbar Busbar Busbar

compartment compartment compartment
Disconnector Disconnector Disconnector Disconnector

earthing switch earthing switch earthing switch earthing switch
Busbar/CB/ CB compartment CB compartment

Connection Connection/CB
compartment compartment
Connection Connection
compartment compartment
No Partition Fully Segregated
Table of Contents
Single Line Drawing
Model: 1 IN 1 OUT SLD

1
1200mm
MODEL: 1 IN 1 OUT PANEL
600mm
2
600mm
DOOR HANDLE
2000mm
EARTH SWITCH
1700mm
OING
OUTG
MING
INCO
Model: IN/OUT Adapter Panel

3
1100mm
Model: IN/OUT Adapter Panel 600mm

4
500mm
DOOR HANDLE
2000mm
EARTH SWITCH
935mm
1700mm G
MIN
INCO
IN G
TGO
OU
Table of Contents
C.T
CURRENT TRANSFORMER
IEC 61869-2 : 2012
1. C.T 5P10 -- First digit 5 means,

5% accuracy limit of error.
-- Second digit 10 means,

10 times to the rated primary current of the C.T.
2. TNB Johor Bahru required Protection C.T in consumer substation is :

§ C.T shall be 5P20 class accuracy ( For Incoming panel only).
Transformer Starting Current

RATED CAPACITY : 10,000 KVA To find primary current :
PRI/SEC VOLTAGE : 33/11 KV
NOMINAL CURRENT : 175 A 10,000 𝑘𝑣𝑎
= = 175A x 10 = 1750A
33𝑘𝑉 × 3
Transformer Inrush Current Curve = 1710 A

1. If select CT 5P10
-- 10 times rated primary current 1750A
C.T Selection for Transformer 2000kVA

Table: C.T
Range
Example: Ampere
available
50A / 5
(𝑇𝑟𝑎𝑛𝑠𝑓𝑜𝑟𝑚𝑒𝑟 𝑘𝑉𝐴)
𝐼𝐹𝐿 = 75A / 5
(Full Load Current) 𝑉𝐿 𝑥 3 100A / 5
125A / 5
2000𝑘𝑉𝐴
= 150A / 5
11𝑘𝑉 𝑥 3 200A / 5
250A / 5
= 105 𝐴 ( select C.T 125A) Always select higher than calculated
ampere 300A / 5
350A / 5
#$%
Cross check:
#&%
= 84 % ( O/C relay settings range is 2% -- 200% ) 400A / 5
500A / 5
600A / 5
Table of Contents
Comparison New IEC vs. Old IEC
Switchgear Comparison – New IEC vs. Old IEC

NEW IEC ( ESTA LS ) OLD IEC
1. IEC Standard
62271-200 ( Latest ) 60298 ( Old )
2. IP Rating
41 3X
3. Mechanical Operation (Rack in)
Close door operation interlock Open door operation

(safe to operate) (high risk)
4. Short Time Withstand Current

25kA/3sec 20kA/3sec
5. Internal Arc test (11kV)
25kA/1sec Not mentioned in catalogue

6. Vacuum Interrupter
Enclosed with Epoxy Resin Open type (high risk)
(new design)
Open type
Insulation Protected Vacuum Interrupter
7. Main Isolating Contact

• Stego Tulip (100% grip with 360deg contact) Jaw Clip ( high risk )
• Natural cooling
Stego Tulip Jaw Clip

8. Segregation Compartment
5 Compartments:
1
• Low voltage 3 2
• VCB
Not mentioned in catalogue
• Cable
• Busbar 5
4
• P. T
9. Manual Emergency Operation ON/OFF
Available Not available

10. Breaker type
Cassette type Truck type

(smaller size & lighter) (bigger size & heavy)
11. Arc Pressure Relief

3 compartments provided
Not mentioned in catalogue
Cable Com partm ent Busbar Com partm ent Breaker Com partm ent

12. P.T withdrawable c/w door interlock (Front
Side)
P.T Withdrawable P.T Fixed type

at Front side at back side
13. Earth Switch Blade Physical monitoring (open/close position)

Yes, available through window viewing.
Not available
High Voltage Switchgear and Controlgear

No Description New IEC Old IEC
1 C o m m o n specifications 62271 – 1 IEC 60694
2 High-voltage alternating current circuit-breakers 62271 – 100 IEC 60056
3 High-voltage AC disconnectors and earthing

switches 62271 – 102 IEC 60129
Switches for rated voltages above 1 kV and less

4 62271 – 103 IEC 60265-1
than 52 kV
Alternating current (AC) switch- fuse

5
combinations
62271 – 105 IEC 60420
AC contactors and contact of-based motor-

6 62271 – 106 IEC 60470
starters
AC metal-enclosed switchgear & controlgear for

7 rated voltages above 1kV and up to and 62271 - 200 IEC 60298
including 52kV.
Table of Contents
Rated short-time withstand current
How to Convert 3 sec to 1 sec

Formula:
The rated short-time withstand current, I21 x t1
I2 =
together with the associated time to a maximum t2
I12 x t1 = I22 x t2
of 3 secs is given by : 2 I21 x t1
I x t = constant t2 = I22
Example:
I1 = 25 kA then: I2 = I12 x t1 = 252 x 3 = 43.3 kA

t2 1
t1 = 3 sec
t2 = 1 sec same as:
25kA/3sec = 43.3kA/1sec
I2 = ?
Rated Current Compensation in accordance with Ambient Temperature

Breaker 2000A used at 55°C ambient temperature
Calculation: Ia allowable continuous current in the actual
t Ot ambient temperature.
𝐼𝑎 = Ir × maxt a Ir rated current at 40°C ambient temperature.
r
tmax acceptable overall temperature of the hottest
spot.
55 O 50
𝐼𝑎 = 2000 × ta the actual ambient temperature expected at
65
-30°C to +60°C.
tr allowable temperature in the hottest place at
= 2000 × 0.877 rated current.
= 𝟏𝟕𝟓𝟒 𝐀
How to derate a switchgear for use at high altitudes

Switchgear install at 2500 meter above sea level
- Correction Parameter at 2500 meter is 1.2
Example:
Rated Voltage
12kV / 28kV / 75kV
( Each parameter shall
multiply by 1.2 )
Answer
14.4kV / 33.6kV / 90kV 1.2
Therefore
rated voltage 12kV breaker
shall select 17.5kV rated
voltage.
(See Table-1 next page)
Standard Rated Medium Voltage (Table-1)
Power Frequency Lightning Impulse

Rated Voltage
withstand Voltage withstand Voltage
ur (kV)
ud (kV/1 min) up (kV/1.2 x 50 micro/s)
7.2kV 20kV 60kV
12kV 28kV 75kV
17.5kV 38kV 95kV
24kV 50kV 125kV
36kV 70kV 170kV
Table of Contents
Factory Acceptance Test Method
Method Statement
Factory Acceptance Test ( F.A.T )
Step 1 :
VISUAL INSPECTION
i) Check approved drawing tally with actual fabrication panel ( Dimension ).
ii) Check the safety operation with door close .
iii) Check the copper busbar size & Current density as specified .
Step 2 :
C.T POLARITY P1P2 AND LABELLING
• Ratio - 200 / 5A
• Class Accuracy - 5P10
• Burden - 15VA
• Voltage - 12KV / 28KV / 75KV
Method Statement
Step 3 :
Insulation test using 5kV/ GΩ equipment.
Step 4 :
Pressure test (power frequency) 28kV for 1 minutes.
Method Statement
Step 5 :
Contact resistance test for VCB contact.
Step 6 : Functional test using 30VDC for :

-- Protection relay EF/OC
-- Shunt Trip Coil
-- Closing Coil
-- Indicating light.
Method Statement
Step 7 : Check Power Cables Entry
TOP ENTRY
BOTTOM ENTRY
Table of Contents
JKR Specification L-S15
JKR specification L-S15 ( July 2011 )

Metal Enclosed Switchgear 11kV
1. P.T Withdrawable type 3. Arc Sensor Protection
- To improve personnel safety
- To minimize damages at the swgr
- Photo Transistor Sensors
- Twisted Pair cable (Fibre Optic is optional )
- Protect 3 zone (Cable, Breaker, Main Busbar)
4. Copper Busbars
- High Conductivity Hard Drawn
2. C.T for instrument ( DPM ) - Pure Electrolytic Copper 99.96% (Tinned)
--> C .T Accuracy CL 0.5 - Current density must not more than 1.5A/mm2
--> DPM Accuracy CL 0.5 - Insulated sleeving (Heat Shrink )
5. Heater
DPM C.T - 2 units heater
( Busbar chamber & C.T chamber )
Type Test Earthing Switch Endurance Class

E0 Standard electrical endurance
No fault making capability.
E1 Extended electrical endurance
Capable of 2 fault making operations without

damage.
E2 Highest electrical endurance
Capable of 5 fault making operations without

damage.
Protective Earthing Busbar Calculation

( IEC 60364-4-41 & IEC 60724 ) Type Tested with 25ka 3sec
Example:
-- How to calculate cross-section of protective conductor.
-- Withstand thermal stress with duration from 0.2 sec up to 5 sec.

𝐼U 𝑥 𝑡 ≤ 𝐾 𝑥 𝑆 U
𝑆𝑝 = cross sectional area in mm 2
𝐼 = short circuit current ( KA ) 𝐼U . 𝑡

𝑆𝑝 ≥
𝐾
𝑡 = duration of the short-circuit current in sec.
𝐾 = factor of the protective conductor ( Final temperature ) 25𝑘𝑎U 𝑥 3

𝑆𝑝 ≥
250
𝑆𝑝 ≥ 𝟏𝟕𝟑 𝒎𝒎𝟐
Installed copper busbar size for earthing in the panel is 6mm x 30mm = 180mm2 c.s.a
LS Breaker ADVANTAGES
1. Cassette Type Tested as per latest IEC 62271-100.
2. Short time withstand current 25KA / 3 sec.
3. Vacuum Interrupter contact ( Radial magnetic field ).
4. Mechanical Endurance Class M2 ( 10,000 times ).
5. Electrical Endurance Class E2 List 3 ( 1,000 times ).
6. Main contact is stego tulip ( natural cooling system ).
7. Arcing contact is copper chromium with silver plated ( V.I ).
ESTA Switchgear ADVANTAGES
1. Type Tested & comply to latest IEC 62271-200.
2. Short time withstand current 25KA / 3 sec.
3. Internal Arc Fault tested 25KA for 1 Sec AFLR.
4. Arc Pressure relief 3 compartments provided

( breaker, busbar, cable ) .
5. Door close operation rack in/out ( safety for operator ).
6. Panel protection with IP 41 according to IEC 60529.
7. P.T withdrawable type ( optional ).
ESTA Switchgear ADVANTAGES
8. Fully segregated with 5 safety compartments.
9. Breaker fully interlock with earth switch ( safety for operator ).
10. Cu.bar with R5 edge for better dielectric strength.
11. Type tested with LSC2B ( Lost of service continuity ).
12. Registered & approved by JKR EMAL list.
13. New IEC 62271-200 have many advantage point over Old IEC 60298
(info).
Table of Contents
Tech. Data (Panel & Breaker)
Technical Data
Breaker Panel
ASTA & KEMA Type Test

(Accredited STL Lab)
S.T & JKR License Approval
ESTA Switchgear ( Supplied & Delivered )

Project Reference List ( Summary )
Year 2010 up to 2023 ( 13 years Record )
No Switchgear ( AIS ) Oty
1 VCB 630A 11kV 1568 Panels
Sub-total 1860 Panels

No Switchgear ( GIS SF6 ) Oty
1 LBS 630A 11kV 82 Panels
2 Vacuum Switch 630A 11kV 36 Panels
Sub-total 118 Panels
NEW
Introduction :
New VCB 12kV

Brand: FARADY
§ Competitive Advantage
§ Economical version
ASTA Type Test
No. Description Data
1. Brand Farady
N EW
2. IEC Standard Reference IEC 62271 – 100
Breaker 3. Type of Breaker Withdrawable Cassette Type
Technical Data 4. Rated Voltage 12 kV
5. Rated current 630A & 1250A
6. Power Frequency withstand voltage 42 kV, 1 Min
7. Lightning impulse withstand voltage 85 kV
No. Description Data
8. Short time withstand current 31.5kA / 4sec

N EW
9. Vacuum interrupter (Bottle) Orient Vacuum Electric
Breaker 10. Encapsulation material

Epoxy resin Embedded
pole casted
Technical Data
Farady Breaker ADVANTAGES
1. Epoxy resin embedded pole casted.
2. Embedded pole protect from impacts, dust, humidity & moisture.
3. Withstand higher short circuit 31.5kA / 4sec.
4. Withstand higher power frequency 42kv 1min.
5. Suitable for different climatic conditions.
6. Life span up to 30 years.
Project Reference in Malaysia

ESTA Air Insulated Switchgear: Farady VCB, 11kV, 630A, 31.5kA/4s
Completed
No Project Name No. of Panel Type
Year
1 Incoming
1 Duopharma K3 & K5
3 Outgoing 2021
2 Incoming
2 Commercial Building -Tetuan Paris Dynasty Land Sdn Bhd
2 Outgoing 2021
1 Incoming
3 Flight Simulator Training Centre - Tetuan PWN Excellence
1 Outgoing 2021
1 Incoming
4 Chambers Residences - Kuala Lumpur
2 Outgoing 2021
1 Incoming
5 Cubic Botanical - Pantai Dalam Kuala Lumpur
2 Outgoing 2021
2 Incoming
6 KSL Hotel
3 Outgoing 2021
2 Incoming
7 Expansion Electric Supply for 11KV - Tetuan HS Vision One Sdn Bhd
4 Outgoing 2021
1 Incoming
8 Factory in Melaka - Tetuan Leuze Electronic Assembly Malaysia Sdn Bhd
1 Outgoing 2021
1 RMU
9 Condominium in Johor Bahru- Tetuan Ultimate Asiapoint Sdn Bhd 2 Incoming
2021
3 Outgoing
2 Incoming
10 Commercial Building -Tetuan Himpunan Kencana Sdn Bhd
5 Outgoing 2022
Project Reference in Malaysia

ESTA Air Insulated Switchgear: Farady VCB, 11kV, 630A, 31.5kA/4s
Completed
No Project Name No. of Panel Type
Year
Factory in Selangor - Tetuan UMW Development Sdn Bhd 2 Incoming
11 2022
1 Outgoing
1 Incoming
12 Malaysia Steel Works (KL) Berhad 2022
2 Outgoing
1 Incoming
13 Warehouse in Klang- Tetuan Kenari Harapan Sdn Bhd 2023
3 Outgoing
Service Apartment in Petaling -Tetuan FDM Development Sdn Bhd 1 Incoming
14 2023
3 Outgoing
15 Commercial Building -Tetuan Jakel Properties Sdn Bhd 1 Standalone 2023

1 Incoming
16 Johor Golf Country Club 2023
1 Outgoing
2 Incoming
17 Mix Development- Tetuan lake city KL North Sdn Bhd 2023
3 Outgoing
5 Incoming
18 Mix Development- Tetuan Quantum Density 2023
5 Outgoing
Condominium at Kuala Lumpur - Tetuan CPI City Sdn Bhd 1 Incoming
19 In Progress
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Condominium at Kajang- Tetuan Top Home Builder Development Sdn Bhd 1 Incoming
20 In Progress
3 Outgoing
Case Study – No. 1

Rats bite control wires.

Rats make shelter inside
Breaker.

Rats dead.
Reason:
§ Due to power cable entry holes did

not close up properly.
( without silicon sealed )
§ Internal Arc faults occurs & the Arc

cover flip open automatically .
( with minor damaged )
Switchgear Explosion
Open-door Operation
( Unknown Brand )
Watch Video
Vacuum Circuit Breaker
LS Brand
Watch Video
ESTA Switchgear F.A.T Video

-
For any enquiries, please contact:
Mr. Deric Lim | Senior Product Manager ( MV Division )

Contact : 012 388 8916
Email : deric.lim@sunpowerberhad.com.my
General : general@sunpowerberhad.com.my
Q&A
MEDIUM VOLTAGE SYSTEM TECHNICAL SHARING
TRANSFORMER 12kV
Speaker : Deric Lim ( MV Division )
Date : 25th JUNE 2024
Time : 11am to 12 Noon
CPD HOURS :
BEM , MBOT , CCD
Table of Contents
• Transformer Introduction (IEC Standard) • Comparison Oil Immersed Vs Dry Cast Resin
• Oil Immersed
• Absorbed Power at Short Circuit Calculation
• Dry Type Cast Resin
- Class E2, C2, F1 • Aluminium Winding vs Copper Winding

- Insulation Class F & H
• Neutral Earth Resistance
- Temperature Rise
• Substation Air Natural Flow

• Transformer K Factor
- Enclosure Design
- Air Force Fan
Transformer IEC Standard
Oil Type Transformer Dry Type Cast Resin Transformer

IEC 60076-20 IEC 60076-11
Distribution Transformer
§ Purpose to distribute 433V or less.
Oil Immersed
§ Normally Step Down voltage Transformer
( 11kV / 433V or 33kV / 433V )
§ Off Load Tap Changer.
§ Manual Tap Changer. Dry type Cast Resin
Oil Immersed Transformer
§ HV / LV Winding & Magnetic Core

are built in the sealed tank.
§ Insulation Class A.
§ Insulation and cooling system

depends on the mineral oil.
Oil Transformer
ADVANTAGE DISADVANTAGE
§ Hermetically sealed tank.
§ Maintenance needed.
§ Cost lower.
§ Wide range capacity. § Check oil level and oil quality .
§ Design for Outdoor type. § Not environmental friendly.
§ Fire risk
§ Oil is flammable
OIL Transformer Explosion
Unknown Brand
WATCH VIDEO
TYPES OF OIL TRANSFORMER ( Distribution )
à CONSERVATOR TANK à HERMETICALLY SEALED
Advantages Of HERMETICALLY SEALED OIL IMMERSED
1. Compact design to minimize space in substation
2. Health and safety features as per regulations
3. Design to withstand maximum fault level & short circuit conditions
4. Customized solutions based on customer’s requirement
5. High durability and long life operational
OIL IMMERSED TRANSFORMER

w/o Cable Box With Cable Box
OIL TRANSFORMER with Cable Box

Busduct entry Cable entry
( LV Side ) ( LV Side )
Dry Type Cast Resin Transformer
3 Major important Parts:
A. Magnetic Core C B A
B. Low Voltage Winding
C. High Voltage Winding
DRY TYPE CAST RESIN TRANSFORMER
Metal enclosure
Transformer
IP20/21/23/30
Temperature sensor
Temperature Controller
Application of Dry Type Transformer
§ Oil and gas industry , Chemical plant
§ Commercial building , industrial and Residential
§ Fire-risk area
§ Inner-city substations
§ Indoor and underground substations
§ Renewable Power Plant
§ Environmental sensitive areas
Transformer Dry Type Cast Resin ( Full Type Test )

According to IEC 60076-11 : 2018
1. Clause 14.2.1 : Measurement of Resistance value
2. Clause 14.2.2 : Measurement of voltage ratio & displacement.
3. Clause 14.2.3 : Measurement of short-circuit impedance & load loss.
4. Clause 14.2.4 : Measurement of no-load loss & current.
5. Clause 14.2.5 : Applied voltage test. (AV)
6. Clause 14.2.6 : Induced Voltage withstand test. (IVW)
7. Clause 14.2.7 : Partial discharge test.
8. Clause 14.3.1 : Lightning impulse test.
9. Clause 14.3.2 : Temperature-rise test.
10. Clause 14.4.2 : Measurement of sound level.
11. Clause 14.4.3 : Short-circuit test.

§ Winding Cast Insulated :
Vacuum Cast or Vacuum impregnated
§ Winding Conductor Material :

Cu/Cu or Alu/Alu
§ Insulation class & withstand temperature :

Class F = 155°C or Class H = 180°C
§ Transformer Losses ( Kw ) :
Standard loss or Low loss
§ Metal Enclosure IP-20 with thickness 2mm mild steel.

( JKR project using – Electrogalvanised steel )
ADVANTAGE DISADVANTAGE
§ Maintenance free.
§ Exposed to environment, IP00.
§ Environmental friendly.
§ Safety for people & property. § Medium cost.
§ Non flammable material. § Capacity range limitation.

(Self extinguish)
§ High resistance to short circuit. § Mostly only suitable for Indoor Type.
§ Venting of toxic gas is not required.

IEC 60721-3-4
CLASS SYMBOL DEFINITION
E0 There is no condensation on the transformer and pollution is negligible.
Environmental E1 Occasional condensation can appear on the transformer.

Type Working in environment subject to frequent condensation or heavy
Tested E2 pollution or a combination of both.
Work at temperature not lower than -5°C but withstand temperature -25°C
C1
during the transportation and installation.
Climatic
Type
Work, transported and stored at temperature up to -25°C.
Tested C2
F0 No special fire risk, no special measure taken to limit the flammability.
Fire Behaviour
Type
Inflammability, low emission of toxic substances and emit fumes.
Tested F1

(Type Tested) IEC 60721-3-4
E2 TEST ( Environmental )
§ Condensation F1 TEST
§ Pollution ( Fire Behaviour )
§ Humidity § 800°C
Self Extinguish
C2 TEST( Climatic )
§ Working Temperature
below (-25°C)
Insulation Class ( IEC 60076-3 )
INSULATION CLASS ALARM TRIP SERVICE RANGE TEMPERATURE RISE
F 110°C 130°C 155°C 100 k
H 130°C 160°C 180°C 125 k
§ CLASS F : Class H :
Normally installed in : commonly use in Hazardous area like :
à Commercial building
à Oil & Gas plant ( Explosive atmosphere )
à Industrial building
à Residential building. à Chemical plant ( Dust fine particles )
Table 2 – Winding temperature-rise limits
Average winding temperature rise limits at rated

Insulation system thermal class
current
Deg. C
K
105 (A) 60
120 (E) 75
130 (B) 80
155 (F) 100

180 (H) 125
200 (N) 135
220 (R) 150
250 175
Temperature Rise ( IEC 60076-2 )
°C
180
15
160
15
140
120
Maximum
Winding Temperature 100 125
100 Hotspot temperatu re margin
Celsius (°C) 80
Permissible temperature rise
60
Maximu m ambient temperature
40
20 40 40
0
Insulation Class F H
155 °C 180 °C
Dry Type Cast Resin

Temperature Rise & Losses Measurement
To convert PK75 to PK120 Example 1
Calculation Example ( Transformer 1000KVA )
(235+120) / (235+75)
PK75 = 7.14 KW x 1.14 = 355/310
= 8.13 KW ( PK120 ) = 1.14
The below table load loss PK75 value shall multiply with 1.14 :
Transformer Temperature Rise 75K Temperature Rise 120K
Load Loss Load Loss
800 KVA 6.11 KW 6.96 KW
*1000KVA 7.14 KW 8.13 KW

1250 KVA 8.51 KW 9.7 KW
Temperature Controller via Smart Phone

1. Monitoring temperature 3 phase and ambient temperature
2. Monitoring Air Force fan ON OFF status.

Temperature
3. Automatically send alarm to mobile phone and PC computer. Controller
4. Internet Access : Wifi and LAN Cable
5. Protocol:
RS 485 (modbus RTU, 9600 baud rate) Distance < 1.2km
6. Thermistor sensor – PT 100 ( included )

( PTC -- Positive Temp. Coefficient )
7. Warranty : 2 years upon delivery Transformer equipped with

Intelligent Monitoring
System
Substation Air Natural Flow
P Transformer Total Losses in kW

H Height between two openings in meters
S2
Air Outlet
Example Calculation
𝑃 20 𝑘𝑊
𝑆1 = 0.18 × 𝑺𝟏 = 0.18 ×
𝐻 2
= 𝟐. 𝟓𝟎 𝒎𝟐
𝑆2 = 1.1 × 𝑆1 𝑺𝟐 = 1.1 × 2.5

S1
Air inlet
= 𝟐. 𝟕𝟓 𝒎𝟐
Transformer Installation with proper air ventilation
ü AIR FLOW
AIR FLOW
ü
1 AIR FLOW
2
AIR FLOW
ü x
AIR FLOW
AIR FLOW
3 AIR FLOW
4
AIR FLOW
Proposed using Suction Fan Ventilation Method
1. Install aluminium Flexible Air Ducting Hose.
2. Centralised all hoses to one Suction Fan.
3. Suction Fan with Thermostat Control to avoid fan operate non-stop.
Enclosure Design IEC 60529 ( IP-20 )

Plan View / Top View
Dimensions X in mm
INSULATION
(kV) Minimum distance
(mm)
7.2 300
12 300
17.5 400
24 400
36 500
Metal enclosure
AIR FORCE FAN SETTING
To BAS
Sensor
Temperature Controller
Class F Class H
Fan turn ON setting temp. ≥ 80℃ ≥ 80℃
Fan turn OFF setting temp. ≤ 70℃ ≤ 70℃
Temp. alarm trigger setting temp. 110℃ 130℃
Temp. alarm trip setting temp. 130℃ 160℃
AIR FORCE FAN
6 units
AN & ANAF
AN – Air Natural ( without air force fan )

§ Commonly used in small transformers below 500 kva .
§ This method depending on air natural flow in substation
ANAF – Air Natural Air Force

§ Recommended Installed in transformer above 630kva .
§ Air is forced on the core and windings .
( Air Force Fan blow upwards ) AIR FORCE FAN ( 6 units )
ADVANTAGE OF INSTALL AIR FORCE FAN

1. Provide overheat protection during hot weather .
2. Increase transformer capacity up to 40% during high demand for a short time period .
3. Maintain longer service life of transformer and accident-free.

4. Suitable for Poor ventilated and small size of substation room .
5. Suitable for daily average temperature higher than 30°C .
6. Improve stability of transformer & increase electrical insulation .
7. Absorbing some noise, improve the work efficiency and comfort for workers.
8. Effectively disperse electric static and reduce the incidence .
In Summary , cooling fan are necessary to protect transformer .

AIR FORCE FAN ( 6 units )
Air Force Fan Calculation

2000KVA , 11KV/433V , Total Losses = 20KW , AF-40%
Q = ( 4 x P ) ( K2 – 1 )
Q = ( 4 x 20 ) ( 1.42 – 1 )
= ( 80 ) ( 0.96 )
= 76.8m3/min (required) (m3/min) - Cubic meter/min
120m3/min x M
Let’s Select Fan 20m3/min ( Table )
Where M is Air Quality ; 0.5 ~ 1 ( 0.5 is bad quality air )
20m3/min X 6 units Fan
120m3/min x 0.7 = 84m3/min ( Available )
= 120m3/min ( Table next page )
v Air Volume of Fan 84m3/min are greater than 76.8m3/min.
Air Force Fan Table Selection ( by manufacturer )
No Model Voltage Frequency Air Volume

( m3/min )
1 GFD(S)370-150 240V 50Hz 14
2 GFD(S)420-150 240V 50Hz 15
3 GFD(S)470-150 240V 50Hz 20
4 GFD(S)490-150 240V 50Hz 22 Air Force Fan
5 GFD(S)590-150 240V 50Hz 25
Comparison
Dry-Type Oil-Type
Dry-Type Oil-Type
1. Cooling Medium
• Use Natural air or Air forced for cooling • Use Oil for cooling
• Safe to install everywhere • Dangerous in public places
2. Maintenance
Requires maintenance on regular basis
No maintenance is required Sample of oil for contamination
Absorbed power at short circuit ( IEC 60076-5 )
( 30% -- 130% ) Relating to the transformer reference.

Tender requirement (A) CHHG Type Tested (B)
Capacity 3000kVA 2000kVA
Impedance % Assume 7% 6%
Short Circuit Capacity 42,857kVA 33,333kVA
\ ^U,_`a bc\
Therefore = 𝑥 100% = 𝟏𝟐𝟖% Transformer must be:
] dd,ddd bc\
- Same type of winding conductors
The percentage above shown 128%, this is within the - Same manufacturer process
applicable range of 30% - 130% as per IEC, therefore the
transformer 3000kVA can comply to absorbed power at short - Same conceptual design
circuit & fully acceptable to be use. - Same arrangement & geometrical
sequence.

\ Ue,eee bc\
Therefore = 𝑥 100% = 𝟔𝟎% Transformer must be:
] dd,ddd bc\
sequence.

\ fe,eee bc\
Therefore = 𝑥 100% = 𝟑𝟎% Transformer must be:
] dd,ddd bc\
sequence.
Absorbed Power at Short Circuit ( Summary )
2000kVA are within the range of 30% - 130%
400kVA 2000kVA 3000kVA
≤ ≤
Tender Requirement CHHG Type Tested Tender Requirement
30% 130%
Transformer Losses ( kW )
§ Iron loss ( No Load Loss ) NLL
§ Hysteresis loss ( No Load Loss ) NLL
§ Eddy current loss ( Load Loss ) LL Winding losses ( I²R )
The above losses are known as magnetic

core losses.
What cause iron losses in transformer?

§ Due to induction of emf ( Electromotive force ) / Alternating flux
What cause transformer to fail ?

§ Line Surge
§ Voltage Spikes
§ Switching Surge ( In-rush current )
§ Line Faults
§ Distribution abnormalities
Resulted due to deteriorate of insulation materials such like over heated ,

oxidation, acidity and moisture.
How to reduce Transformer Noise

IEC 60076-10
§ Humming noise come from iron core
(expansion & contraction) due to magnetic
effect of Ac flowing through coil.
§ Noise cannot be eliminated but can be

reduced:
Ø By using 7 steps lamination instead of 5
steps of the iron core.
Ø Proper assembly lamination core without
any gap in between.
Ø Apply epoxy resin paint thicker on the iron
core surface.
Ø Add vibration rubber pads at bottom
mounting ( wheel to dismantle ).
Transformer IEC Tolerances ( 60076-1 )

Table 1
No Description Tolerance
a) Total losses ( NLL + LL ) + 10% of the total losses
+ 15% of each component loss, provided that the tolerance

b) Measured component losses
for total losses is not exceeded
Therefore : Tolerance are necessary on certain specified and design values.
Cost Saving
Comparison Std Loss vs. Low Loss
Example:
2000KVA ( 12 hrs ) Shopping Mall
Spec Load Loss Hr Sen/KwH Day Cost

(KW) (RM)
Std Loss 16 12 0.365 365 25,579.20
Low Loss 11.5 12 0.365 365 18,385.05
RM 7,194.15 ( per year )

TX 2000KVA ( unit price ) if to use Low Loss TX
Low Loss = RM 216,000 ( more expensive ) ( Saving electric bill )
Std Loss = RM 180,000

RM 36,000 ÷ RM 7,194.15 = 5 years ( pay back )
Routine Test at Factory
1.Applied voltage pressure test

2.Insulation resistance test
3.Ratio test
4.Winding resistance test
5.No Load test
6.Load test
7.Induced voltage test
Transformer Efficiency Calculation

Example
P = 11kV S= 433V No-load loss (NLL) 3.1 KW P. factor = 1

(Iron loss)
Capacity 2000kVA Load loss (LL) 13 kW (Copper loss)

Loading = 100%
𝒍𝒐𝒂𝒅𝒊𝒏𝒈 𝒓𝒂𝒕𝒆 × 𝒓𝒂𝒕𝒊𝒏𝒈 𝒄𝒂𝒑𝒂𝒄𝒊𝒕𝒚 × 𝒑𝒐𝒘𝒆𝒓 𝒇𝒂𝒄𝒕𝒐𝒓

( 𝒍𝒐𝒂𝒅𝒊𝒏𝒈 𝒓𝒂𝒕𝒆 × 𝒓𝒂𝒕𝒊𝒏𝒈 𝒄𝒂𝒑𝒂𝒄𝒊𝒕𝒚 × 𝒑𝒐𝒘𝒆𝒓 𝒇𝒂𝒄𝒕𝒐𝒓 5 𝒏𝒐 𝒍𝒐𝒂𝒅 𝒍𝒐𝒔𝒔) 5 (𝒍𝒐𝒂𝒅𝒊𝒏𝒈 𝒓𝒂𝒕𝒆 × 𝒍𝒐𝒂𝒅𝒊𝒏𝒈 𝒓𝒂𝒕𝒆 × 𝒍𝒐𝒂𝒅 𝒍𝒐𝒔𝒔 )
× 𝟏𝟎𝟎%
𝟏 × YZZZ ×[
= × 100%
𝟏 × YZZZ × [ \ ].[ \ ([ ×[ × [])
= 𝑬𝒇𝒇𝒊𝒄𝒊𝒆𝒏𝒄𝒚 𝟗𝟗. 𝟐𝟎%
MS 1525: 2019 ( Standard Malaysia ) Dry Type
Transformer Losses
Rated power No Load Loss Load Loss

Efficiency %
(kVA) (W) (W)
800 1300 8000 98.85
1000 1550 9000 98.96
1250 1800 11000 98.99
1600 2200 13000 99.06
2000 2600 16000 99.08

2500 3100 19000 99.12
3150 3800 22000 99.19
1 𝒙 2000 𝒙 1
𝒙 100%
1 𝒙 2000 𝒙 1 + 2.6 + (1 𝒙 1 𝒙 16)
= 𝟗𝟗. 𝟎𝟖 % Energy Efficient
JKR Specification ( L-S17 ) Dry Type
Transformer Losses
Rated power No Load Loss Load Loss

Efficiency %
(kVA) (W) (W)
300 400 2800 98.94
500 800 4100 99.03
750 1000 6000 99.08
1000 1200 7000 99.19
1250 1880 8200 99.20
1600 2300 10300 99.22
2000 2900 13000 99.21

1 𝑥 2000 𝑥 1
𝑥 100%
1 𝑥 2000 𝑥 1 + 2.9 + (1 𝑥 1 𝑥 13)
= 𝟗𝟗. 𝟐𝟏 % Energy Efficient
Transformer Impedance with Short Circuit Calculation
Example Full Load Current:

Formula
P = 11kV
𝑇𝑋 2,000,000
S= 415V = = 2,782.4 A
𝑉𝑜𝑙𝑡𝑎𝑔𝑒 𝑙𝑖𝑛𝑒 × 3 415 𝑉 × 3
Capacity 2000kVA
Impedance 6%
Short Circuit Current:
Formula
𝐹𝑢𝑙𝑙 𝐿𝑜𝑎𝑑 𝐶𝑢𝑟𝑟𝑒𝑛𝑡

2,782.4 𝐴
= = 46.37 kA
𝐼𝑚𝑝𝑒𝑑𝑎𝑛𝑐𝑒 6%
Short Circuit Current Calculation TNB Incoming

11KV 50Hz
(Three Phase)
Step 1
bc\ 2000 VCB 11KV
𝐼𝐹𝐿 = c 𝐼𝐹𝐿 = 630A 25KA/3sec
!× d 415 × 3
2000KVA
Full Load Current = 2,782 𝐴 11KV/415V
Z = 6% Dyn11
Step 2
*<= 2,782 𝐴 E Z=6% 46.37KA Short Circuit
𝐼𝑆𝐶 = 𝐼𝑆𝐶 = Fault level
+% 6% Z=7% - 39.74KA
ACB 3200A
Short Cct Current = 46.37 𝐾𝐴 415V 50Hz
4 pole
How to improve transformer efficiency
1. Use a better grade of core material, one with lower hysteresis and Eddy current losses.
( Pure Steel )
2. If using an iron core, further reduce eddy current loss by using thinner laminations
silicon steel as below :
0.23 mm 0.27 mm 0.3 mm 0.35 mm

0.18 mm 0.2 mm 0.5 mm
(M3) (M4) (M5) (M6)
Normal Tapping ( Manual Tap Changer )

IEC 60076-1 Clause 5
CONNECTION Tap Voltage LV Voltage
1-2 11550
2-3 11275
3-4
4-5
11000
10725
433
5-6 10450
Tap Changer Connection Diagram

1 3 5
2 4 6
11KV/433V
Normal Tapping ( Manual Tap Changer )

IEC 60076-1 Clause 5
CONNECTION Tap Voltage LV Voltage
1-2 11550
2-3 11275
3-4
4-5
11000
10725
422
5-6 10450
Tap Changer Connection Diagram

Calculation : 1 3 5
( V1/V1’ ) * V2 = V2’
2 4 6
( 11000/11275 )*433 = 422V
11KV/422V
Comparison
Aluminium vs Copper
No. Description Aluminium winding Copper winding
1. Price Much lower (20 - 30%) Higher & Speculate
2. Weight Lighter (15%) Heavier
3. Heat dissipates Fast Cooling (Low density) Normal Cooling
4. Winding Coil Process Flexible & Softer Harder
5. Delivery Time Shorter Time Longer Time
6. Losses (No Load & Load Loss) Similar Similar
7. Noise ( decibel ) <53 dB <50 dB
8. Dimension Bigger (5-10%) Straight up Medium Size
What is In-rush Current
§ An instantaneous high input current during turn ON the transformers initial stage.
§ Required 6 to 10 times of rated load current ( Rush through ).
How to Overcome this situation ( either )
§ Install Surge Arrester 12KV in switchgear panel.
§ Install C.T 5P20 instead of 5P10.
§ Install protection relay with in-rush blocking type.
Transformer Starting Current

RATED CAPACITY : 10,000 KVA To find primary current :
PRI. VOLTAGE : 33/11 KV
NOMINAL CURRENT : 175 A 10,000 𝑘𝑣𝑎
= = 175A x 10 = 1750A
33𝑘𝑉 × 3
Transformer Inrush Current Curve = 1710 A

Transformer installed 1000 Meter above sea level

IEC 60076-3
As altitude increase :-
§ Air become thinner
§ Density air reduce
§ Humidity higher by 85%
Resulted insulation deteriorate.
How to derate a transformer for use at high altitudes
Transformer install at 1000 Meter above sea level IEC 60076-3
1. Derating KVA by 0.5% for each 100 Meter.
2. Clearance shall increase by 1% for each 100 Meter.
3. Dielectric withstand increase by 1% for each 100

Meter.
4. Insulation test increase by 6.25% for each 500 Meter

(12/28/75).
5. Temperature rise decrease by 2.5% for each 500

Meter.
NER --- Neutral Earth Resistance
Duty of NER is to protect against fault current for Power Transformer.
Function of NER
1. Limit Earth Fault current to a safe value & prevent
heavy damage to transformer.
2. Allow Earth Fault current go to ground safely within

10 sec.
3. Limit the Fault Current to few hundred amp instead Resistor

of kilo amp.
NER --- Neutral Earth Resistance
Example Power Transformer Rating 10,000 kVA , 33kv/11kV , Z =10%
10,000 𝑘𝑉𝐴
Full Load Current 𝐼𝐹𝐿 = = 524.86 𝐴
11𝑘𝑉 × 3
𝑉𝑜𝑙𝑡𝑎𝑔𝑒 11,000 𝑉 ÷ 3
Resistance 𝑅= =
𝐴𝑚𝑝𝑒𝑟𝑒 524.86 𝐴
= 12 𝑜ℎ𝑚
Therefore, rated Current and Resistance of NER panel shall be selected as 600A , 12 ohm ( see next page )
NER Selection Table ( by manufacturer )

Model Rated voltage of Nominal Short-time Short-time
the system/KV resistance/ allowable current/A current time/S
(Ω±5%) Different resistors
can be made according to
NER6.6/9.1 6.6 9.1 400 10 customers’ requirements
as below:-
NER6.6/6 6.6 6 600 10
1. Current range:
NER11/12 * 11 kv 12 ohm 600 A 10 *
1A ~ 2000A
NER11/10 11 10 600 10
2. Resistance range:
NER22/31.7 22 31.7 400 10 1 ohm ~ 2000 ohm
NER22/21.2 22 21.2 600 10
3. Time range:
NER33/50 33 50 400 10 10sec ~ 60sec
NER33/25 33 25 800 10
NER33/20 33 20 1000 10
Transformer Star Point LV Neutral Earth Cable Size
Example 2000 KVA transformer, 11kV/433V
2,000 𝑘𝑉𝐴
𝐼𝐹𝐿 = = 2,666A ( Secondary Amp LV side )
433 𝑉 × 3
Assume TNB setting earth fault is 10%
2,666A x 10% = 266 A
Hence, 266A X 1.5 (safety factor) = 399A
Therefore, Cable size selection is 1c x 150mm² Cu. Cable LV non-Armoured ( see next page table )
Low Voltage XLPE Insulated Power Cables
Single core 600/1000V non-armored cables copper conductor

Cable Size (sq.mm) Ampere
50 185
70 235
95 290
120 340 A From previous page
150 ( sq.mm ) 400 A Calculated = 399A

185 455
240 545
300 630
400 735
500 850
630 985
800 1150
1000 1280
JKR Specification For 11kV Dry Type Transformer
Cross-Sectional Area of
Rated Power of Transformer
Neutral Earthing Conductor
kVA (mm2)
300 35
500 70
750 95
1000 95
1250 95
1600 120
2000 150 sq.mm
NEUTRAL POINT FOR TRANSFORMER ( LV )

1. Neutral is a return path of current .
2. Neutral wire always carry a return current in normal condition in AC circuit .
3. Neutral and Earth should never be bonded together in the system .
EARTHING POINT FOR TRANSFORMER

1. Earth wire hold the fault current to trip the breaker in protecting the person and the equipment.
2. Earth wire does not carry any electric current under normal condition , it carries current only when there is a
fault in the device .
3 Earth and Neutral should never be bonded together in the system .
Transformer Star Point LV Neutral Earth
N
2000kVA
Y 11kV / 433V
B
E
2 – 3mm x 25mm
cu. tape 2 – 3mm x 25mm

cu. tape 2 – 3mm x 25mm Separate Earth Chamber
2000kVA 2000kVA
11kV / 433V 11kV / 433V
2 – 3mm x 25mm cu. tape

2 – 3mm x 25mm
cu. tape 2 – 3mm x 25mm Separate Earth Chamber cu. tape 2 – 3mm x 25mm
2000kVA 2000kVA
11kV / 433V 11kV / 433V

What is K factor Transformer

1. K factor transformer is to deal with Harmonic Generating loads .
2. Harmonics is generating additional overheat in the transformer .
3. Select a transformer suitable to use with loads that draw non sinusoidal currents .
K Factor Waveform
“A” A single 50Hz cycle waveform

Fundamental Power Frequency
“B” Represents a 3rd harmonic 150Hz waveform.
“C” An example as to the impact of harmonic

load may have on the fundamental waveform.
Types of Definition ( K-Factor )
1. K Factor ( UL 1562 ) is mainly used in USA
2. Factor K ( BS 7821 ) is mainly used in Europe
3. Harmonic Loss Factor ( HLF ) definition given in IEEE C.57.110-2018
: K-Factor is the value that determines how effectively a

transformer can handle harmonics current within the limits.
Transformer K--Factor Table For Various Loads

Electronic = Nonlinear Loads
K-Factor Electrical = Inductive & resistive loads Loads
0% - Electronic
K-1 100% - Electrical
Motors , incandescent light , resistance heating .
25% - Electronic Welding , Induction heating , HiD lighting

K-4 75% - Electrical Fluorescent light , PLC , solid-state control .
50% - Electronic Industries & Offices with Non-linear loads , such like
K-9 50% - Electrical computers , Printers , Fax machine .
Telecommunications equipment , Classroom facilities ,
75% - Electronic
K-13 25% - Electrical
Healthcare facilities , Production lines , Uninterrupted
power supplies .
100% - Electronic Office buildings , Data processing equipment , Adjustable

K-20 0% - Electrical speed drives , Computer installations , Instrumentation .
What Will Happen if Transformer NOT follow K rated factor
1. Winding temperatures will increase due to the harmonic currents generated .
2. Overheating resulted in shorten the service life of transformer.
3. Affected vibration in the transformer and audible noise.
4. Temperature increase and insulation will failed resulted transformer failure .
Therefore : K-factor rated transformers are designed to compensate for the

presence of harmonic loading thereby preventing excess heating.
Transformer Before Switching On Power Supply

The following checklist are essential for cast Dry Type resin transformers :
Recommended :
1. If the transformer has been stored for a long period, must be carefully clean the surface
of the LV and HV windings from dust deposited , dirt and condensation .
2. Use a vacuum cleaner to avoid dispersion of dirt and dust on the transformer surface .
3. Make sure the room is dry and clean with sufficient ventilation and without the risk of
ingress water / moisture .
SUN POWER EXCLUSIVE DISTRIBUTOR
IEC 60076-11
Product of ITALY
IEC 60076-11: 2018
Product of CHINA
Mixed Development Winding

Alu/Alu
Proposed Transformer Application
Cast Resin Transformer Description Unit
IEC Standard IEC 60076-11
Rated Voltage 11KV / 433V
Tapping Range ±2 x 2.5%
Tapping Method Off load tapping
Vector Group Dyn11
Frequency 50Hz
Phase 3
Insulation Class ( HV / LV ) F/F
Temperature Rise 100K
Capacity KVA (Impedance)
Lightning Impulse ( HV / LV ) 75 / 0
§ 500KVA (Z=6%) § 1600KVA (Z=6%)
Partial Discharge < 10pC
§ 800KVA (Z=6%) § 2000KVA (Z=6%) Cooling Method AN ( AF-optional )
§ 1000KVA (Z=6%) § 2500KVA (Z=6%) Winding Material ( HV / LV ) Wire / Foil
§ 1250KVA (Z=6%) § 3150KVA (Z=6%) Core Material Cold Rolled Silicon Steel
Winding Casting ( HV / LV ) Vacuum Cast / Impregnated
Advantages of
GBE Cast Resin Transformer
Product Warranty
GBE Transformer are provided with: WARRANTY LETTER
§ 3 years warranty period upon delivered to site

or
2 years upon CPC.
(whichever come first)
Mixed Development Winding

Proposed Transformer Application C u/ C u
Cast Resin Transformer Description Unit

IEC Standard IEC 60076-11
Rated Voltage 11KV / 433V
Tapping Range ±2 x 2.5%
Tapping Method Off load tapping
Vector Group Dyn11
Frequency 50Hz
Phase 3
Insulation Class ( HV / LV ) H/H
Temperature Rise 100K
Capacity KVA (Impedance) Lightning Impulse ( HV / LV ) 75 / 0
§ 500KVA (Z=4%) § 1600KVA (Z=6%) Partial Discharge < 10pC

Cooling Method AN ( AF-optional )
§ 800KVA (Z=6%) § 2000KVA (Z=6%)
Winding Material ( HV / LV ) Wire / Foil
§ 1000KVA (Z=6%) § 2500KVA (Z=6%)
Core Material Cold Rolled Silicon Steel
§ 1250KVA (Z=6%) § 3150KVA (Z=6%) Winding Casting ( HV / LV ) Vacuum Cast / Vacuum Cast
Advantages of
CHHG Cast Resin Transformer
1. Size smaller ( Save space for sub station ). 8. Easy maintenance.
2. Heat dissipation faster. 9. Easy transportation.
3. Low noise level. 10. Crack-resistant.
4. Lower load losses. 11. Self-extinguishing material .
5. Higher mechanical strength.
12. Sustainable
6. Safe & Environment friendly.
13. Warranty Period :
7. Easy installation.
§ 3 years upon delivery to site
OR
2 years upon CPC
( whichever come first ).
ASTA Certificate
Complete Full Type Test
2000kVA
PROJECT REFERENCE
SUMMARY TRACK RECORD 11KV/433V

Year 2013 up to Year 2023
Dry Type Dry Type Oil Type11kV/433V
11kV/433V 11kV/433V
Alu/Alu Cu/Cu Cu/Cu

Total Qty 61 units 120 units 50 units
Capacity kVA 630 500 1000

800 630 1250
1000 750 1500
1250 800 1600
1500 1000 2000
1600 1250 2500
2000 1500
2500 1600
3000 2000
2500
3000
3500
Total kVA 54,380 kVA 98,800 kVA 50,500 kVA
SUMMARY TRACK RECORD 33KV/433V

Year 2013 up to Year 2023
Total Qty 20 units
Capacity kVA 1250

1500
2000
Total kVA 28,750 KVA
Site Case Study – No. 1

• Cables entry Holes did not close
properly.
( Dust & Rodent will drop inside )
• Power Cables touching enclosure.

( Vibration & Sound happened )

• Power Cables touching Delta Rod .
( resulted Delta Rod broken )

Power cables without proper support
( Resulted touching Delta Rod )
• Delta Rod was twisted during installation

at site .
( Resulted Flashover happened )
Unloading at site
à Using excavator & general workers
A Proper instruction
à Must using a skilled mover team
Pre & Post ( After Sales Services )

1. Provide Technical assistance ongoing support products ( before and after ) .
2. Our trained engineers are available to attend service/breakdown ( within 48 hours on-call ) .
3. To keep customers fully satisfied & providing prompt respond times .
4. To strive minimize downtime and maximize the performance of our products .
CHHG CHINA
TRANSFORMER FACTORY TOUR
WATCH VIDEO
Transformer Factory Acceptance Test
Watch Video
Sun Power Factory
Certificate of
Attendance
You’ll receive our email with a feedback

form by end of today, your feedback is
appreciated.
Certificate will be emailed to you

within 2 weeks.
For any enquiries, please contact:
Mr. Deric Lim | Senior Product Manager ( MV Division )

Contact : 012 388 8916
Email : deric.lim@sunpowerberhad.com.my
General : general@sunpowerberhad.com.my
Q&A

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MV & LV System Technical Sharing 2024

SUN POWER SYSTEM SDN. BHD.

MEDIUM VOLTAGE TECHNICAL SHARING

SWITCHGEAR ( 9am - 10am )

SUN POWER AUTOMATION SDN. BHD.

Since then, our company has growth rapidly to

With our excellent relationship with overseas

SUN POWER GROUP sunpowerberhad.com.my

SUN POWER AUTOMATION SUN POWER SYSTEM

Established since 2004 Established since 2010

One stop solution for major & important electrical component.

SUN POWER AUTOMATION SDN BHD

MCB & RCCB SPD

Protection Relay Switch & Socket

SUN POWER SYSTEM SDN BHD

§ Switchgear 12 KV § Transformer 12KV up to 36KV § Metal Clad DB

SUN POWER Seminar Executive Personnel

VICKY WINNY YI HAO

DERIC LIM PHILIP CHANG RAYMOND YONG JIAN

Seminar Executive Personnel

JEFFREY YAP JAMES GAN

J. L. GOH JACKSON LIM BENSON TING

About SUN POWER

Established since 2004

POWER PROTECTION RELAY

POWER FACTOR CORRECTION

Company Introduction Video

SEMINAR & WEBINAR

§ Comparison New IEC vs. Old IEC

§ Rated short-time withstand current

§ Factory Acceptance Test Method ( F.A.T )

§ JKR Specification L-S15

§ Tech. Data ( Breaker & Panel )

IEC ( International Electrotechnical Commission )

IEC 62271-100 IEC 62271-200

IEC 62271 -- Switchgear Type Test

What is Type Test ( Switchgear )

( This is truly declared as Type tested panel ).

SHORT-CIRCUIT TESTING LIAISON ( STL )

1. Intertek (ASTA), UK 2. KEMA, Netherlands 3. CESI, Italy 4. KERI, South Korea

5. SATS, Norway 6. CPRI, India 7. PEHLA, Germany 8. ZKU, Czech Republic

Type Of Circuit Breaker

Types of Circuit Breaker

What is Vacuum Circuit Breaker

Circuit Breaker Vacuum Bottle Interrupter

Vacuum Circuit Breakers ( VCB )

• Use vacuum interrupter to Quench the arc

• The arc extinguish in half cycle

Vacuum Circuit Breakers ( VCB )

§ Vacuum Interrupter Technology introduced since 1960

Opening Time < 𝟒𝟎 𝒎𝒔

Closing Time < 6𝟎 𝒎𝒔

Spiral Contact Flat Surface

Stego Tulip Contact

Stego Tulip Contact ( IEC 62271-100 )

Structure of STEGO TULIP Terminal

E2 (List 3) Type Tested

- E2 ( List 1 ) Test T10 ( 100% ) 1,000

M2 & C2 Type Tested

M2 & C2 Type Tested ( IEC 62271-100 )

Advantages Sun Power ESTA switchgear IEC

Sun Power brand Switchgear

a. Switchgear Type Tested :

ü KEMA IEC 62271-100

01-SWITCHGEAR & TRANSFORMER JUN 2024

01-SWITCHGEAR & TRANSFORMER JUN 2024