ICOQM-10 June 28-30, 2011

Development of 40kA Earthing Switch by Using Industrial Product Design

Model

Kelgandre Kiran
kelgandrekiran@gmail.com,kk_beprod@yahoo.in
Dept of Production Engineering,
VJTI, Mumbai, 400019,
Maharashtra, India

Dr. D. N. Raut
dnraut@vjti.org.in,raut_dn@yahoo.com
Head of Dept of Production Engineering,
VJTI, Mumbai, 400019,
Maharashtra, India

1. Introduction
The main function of earthing switch is to earth the residual current inside the switchboard cabling and current
carrying parts of copper and aluminum. It is used to earth the high voltage current coming through the source and
flow through the switchgear. There are different types and versions of earthing switch like high voltage, low voltage
indoor, outdoor earth switch.
Several versions of Earthing Switches for following applications:
1 - Maintenance Earthing Switches. These are single pole or three pole units; manually operating mechanism with
a provision of filling motor mechanism.
2 - High Speed Earthing Switches. These are operated by spring energy. Spring is charged by motor mechanism.
Earthing switch has ratings like 6kA, 12kA, 25kA, 31.5kA etc.
Earthing Switch is necessary to earth the conducting parts before maintenance and also to provide deliberate short-
current while testing. There can be three types of earthing switches in metal-clad Switches; manually operated,
automatic high speed Earthing Switch, protective Earthing Switch for earthing the installation.
Special high speed Earthing Switches with interrupting capability are also available. These are suitable for
interrupting capacitive and inductive current from parallel overhead lines. In certain cases, Earthing Switches are
fitted to the enclosure with interposed insulation. They are fitted with snap-action operating mechanism for
positive high closing speed and sustain to make the short circuit at high current rate. The speed of the snap action
closing operations is independent controls.
For the development of 40kA earthing switch we just go through the industrial product design theories and some
development models like French model, Nigel-cross model, pahl and beitz model, Rudimentary model, Pugh’s
model. The paper covers the development of earthing switch and test reports which is carried out on the newly
developed 40kA-3sec. earth switch.
Fig.1 31.5kA earthing switch

Source-siemens switchboard factory

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2. Literature Review

Vivian Walsh, discussed in his study that product design and development is a set of activity in which ideas and
needs are given a physical form initially as solution concept and then as a specific configuration..
T Ulrich, S.D. Eppinger, mentioned in there study that PD &D is the set of activity beginning with the perception of
market opportunity and ending with production sale and delivery of product. Fig 2. It shows the engineering design
is the centralized activity.
Fig. 2 Engineering design-centralized activity

There are different categories of design process models:

Original design is may use descriptive type or prescriptive type of methodology to develop the product. It requires
deep study of market, customer requirement, design, product characteristics. It consists of conceptual design,
analysis of design, detailing and drafting.
Adaptive design is the modification in the existing design as per customer requirement and market demand. It does
not require any type of conceptual designing. It uses the past design.
Meibner M, presented in their studies that variant design consists of design and generation is concerned with
defining configurable product platform via a modular approach to product definition and frequent reuse of existing
designs.
Earthing switch is not a single part or job. It can not work separately; it has to assemble with switchboard.
Earthing switches have three pairs of earthing blades which are located on the operating shaft and are freely movable.
The pairs of earthing blades are electrically connected each other by a short-circuiting bridge and to earth potential at
the bearing brackets by two stranded copper conductors.
Driver levers and compression springs located between the bearings Brackets are used to transmit the force during
the switching process like opening the earth switch. Fixing the active part on a torsionally rigid switchgear panel wall
or cross beam provides it with the necessary stability.
The earthing contacts designed to suit the relevant switch type are to be bolted to the conductor bars supported on
suitable insulating parts, e.g. pin type insulators or current transformers, on the opposite side and parallel to each
other, and the position adjusted until it conforms in drawings.
The earthing switch has a snap action closing mechanism which functions independently of the rotation of the drive
shaft. The switching speed and torque achieved in this process are independent of the actions of the operating
mechanism In the opening process, in contrast, the compression springs have no effect on the speed of contact
separation or suitable manual or motorized operating mechanism with the necessary torque for the type of switch and
an operating angle 90 can be fitted for operation of the switch.

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Earthing switches with fault making capacity can be reliably closed against short circuit currents, thus protecting the
operator and switchgear in the cause of inadvertent operation. Naturally, operation behind a closed compartment
door forms part of the overall cubicle safety..
Every earthing switch is fitted with a spring operating device which makes the closing capacity independent of the
operating speed. The control side of the earthing switch and direction of current flow can usually be chosen without
limitations except for a few models with integral current transformers.
Materials used in manufacturing the earth switch parts which is important are the frame is zinc plated steel plate, the
current carrying parts are silver plated copper and the insulators are made of cast epoxy resin.
Earthing switches do not need maintenance in normal service. They can withstand 2000 operations without load and
two operations under the full short current rating. The contacts can be changed if the closed position contact surface
is badly worn. A reasonable amount of switching arc burning around the knife edge or contact tips will not affect the
closing capacity of the earthing switches.
The contacts have been lubricated with special paraffin which does not normally need to be renewed. If required the
contact surfaces can be greased with lubricating stick.
Insulator support requires for the mounting of earth switch in the panel with proper sustaining capability which is
made up of epoxy resin.
Type tests are mandatory as per IEC standards. This test are carried out to prove the short-circuit making
performance of earthing switches, satisfactory operation at temperature limit and proper function of position
indicating devices.

3. Methodology
3.1 Adaptive design
As we have the reference of 31.5kA earth switch design, we can use the French model and pahl and beitz’s
model for new adaptive design. It follows the following tree diagram fig.3.
Fig. 3 French model

Customer requirement for 12KV -40kA-3s ES. M0-E1 class IEC

62271-102.

Understanding customer requirement and execution, collecting

requirement design data & references such as 31.5kA ES design

Panel details, installation; indoor /outdoor? Overall size of ES? Centre

to centre distance of bushing (210mm), Contact sizes-fix & moving.
No of poles etc.

1)Directly stretch the parts of 31.5kA ES 600W) 2)Increasing C/S area

of the copper parts keeping same length.

Selecting first design scheme due to 800W ES-customer requirement.

Detail design- Dimensions Material, Process, finish etc

It includes making all design of the parts as per 800w dimensions.

Forwarding detail design to manufacturer.

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Source- T Ulrich, S.D Eppinger

Design model as per customer requirment and our design scheme as shown in fig 4:

Fig. 4 (3D Solid Model of 40kA-3s earth switch/AutoCAD model)

Yoke-copper current
Mounting plate carrying part

Operating shaft
assembly.

Compression Moving contacts

spring (Cu)
dia.6.3mm

Source-Ideas model by Author

3.2 Final 40kA earth switch assembly with 12kV switchboard

Newly developed earth switch is successfully manufactured by vendor as per customer requirement and design
details. Possible cost reduction considered during design stage only.

Fig.5 12kV, 40kA Panel with Earth Switch

Source- Siemens switchboard factory.

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4. Experiment and test set up for STC-3Sec.

Test should be conducted to prove that a manually operated earthing switch will operate satisfactorily at the
minimum operating speed expected, as stated by manufacturer.
It consists of two test-making test and breaking test. This type of testing is carried out in two places in India at
ERDA (Baroda), CPRI (BANGLORE).It is a development test and the entire test set up is done by our self at the test
site. Test is carried out as per IEC-62271-102 standard.

4.1 Test set up for making and breaking test (2 shots):

The earthing switch under all tests shall be completely mounted on its own support or on an equivalent support.
Its operating device shall be operated in the manner prescribed, if it is electrically or pneumatically operated, it shall
be operated either at the minimum supply voltage or at the minimum air pressure, respectively.
Before commencing making and breaking tests, no load operations shall be made and details of the opening
characteristics of the earthing switch, such as speed of travel, closing time and opening time, shall be recorded.
Only single phase tests on one pole of a three-pole earthing switch need to be performed. single pole test are
adequate to demonstrate the making and breaking performance of earthing switch such that during arcing time no
arc-reach possibility to adjacent energized phase.

4.2 Earthing of test circuit and earthing switch

The test circuit shall be earthed through the terminal of the earthing switch which is normally connected to earth.

4.3 Test frequency

Earthing switches shall preferably be tested at rated frequency; however, for convenience of testing, tests may be
performed at either 50Hz or 60Hz and are considered to be equivalent.

4.4 Test voltages and Test currents

The test voltages shall be selected such as to yield the appropriate power frequency voltage across the earthing
switch terminals before making and after breaking as shown in table.
The test current shall be equal to the rated induced current as shown in table. During the 40kA current passing
through earthing switch, copper contacts shall not be separated for 3sec. during breaking test and for making test
contacts should be open within 3sec.

4.5 Test circuit

The following fig 6(a). Show the actual G.A. drawing for the test. It gives the clear picture to electric engineer
that how to make the set up for STC test. Single line diagram for electromagnetically induced current making and
breaking tests shown in fig 6(c)
FIG.6 (a) G.A.drawing (AutoCAD) for test

Source : Autocad drawing by author

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Fig .6(b) Actual set up for STC Insulator

support

Moving
contacts

Bus bar system

Source-Siemens factory
(input to ES)
Fix contacts

Fig. 6(b)-single line diagram

Source-Auto Cad drawing by Author

(UL-supply voltage-12 kV, VT-voltage transformer to sense the voltage passing through the system, CT-current
transformer to sense current passing through the system, GRD-ground/Earth)

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4.6 Table-Test details:

12kV, 40kA, 3s Earthing Switch: A Three Phase earthing Switch in an air-insulated metal enclosed switchgear and
control gear assembly.

Designation: Rated Normal Current: 1250 A

Earthing Switch: M0 E1 class
Table 1: Panel test details
Sr.
Details Specification
No.
1 Rated Voltage 12 kV

2 Rated Power Frequency withstand Voltage 28kV – 1min

3 Rated Lightning Impulse withstand Voltage 75 kV

4 Number of Phase 3

5 Frequency 50 Hz

6 Short time withstand Current 40 kA

7 Peak withstand Current : 100 kA

8 Duration of Short Circuit 3s

9 Short Circuit Making Current 100 kA

10 Class E1
Source-12kv switchgear manuals

4.7 Mechanism: Spring Assisted Manual Closing/Manual Opening. For test purposes-operated by pneumatically as
shown in picture (fig. 7). It uses the lever type handle for ON/OFF operation. Manually it requires 50N-150N force
for closing the switch. During on operation it uses the compression spring force to return to its original positions.

Fig. 7 operating mechanism

Pneumatic cylinder for ON/OFF of ES

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5. Results and discussion

The test should be carried out as per IEC 62271-102 standard. Main objective of the test is to see the earthing
switch performance during large current flowing through the system. It gives the satisfactory effect as we expected.
Test shows that copper current carrying parts can sustain 40kA current which makes Short Circuit Bridge for 3 sec.
and able to ground the high current. During making test all the copper contacts made successfully and makes the
circuit complete. We have to see that when current flow through the earthing switch, we apply the force through
pneumatic cylinder i.e. 100N to close the earth switch, which makes successful closing of earth switch. When the
current flow through the system, there is large heat generated for 3sec, during this short time of period, copper
contacts made should not be weld. These contacts must be capable of 40kA current carrying capacity. So that we use
all the copper contacts 50x5 cross sectional area with respective lengths as per design.
During breaking test we have to see that 40kA current flow through the system, and our system is capable of
breaking this large current and making earth switch open and break the circuit by manually operation or for test, we
can use pneumatic cylinder.

5.1 Behavior of earthing switch during tests

The earthing switch shall perform successfully without undue mechanical or electrical distress. Outward emission
of flame or metallic particles from the switch during operation is permitted, if this does not impair the insulation
level of earthing switch or prove to be harmful to an operator. But during the test it goes under some vibrations
during closing operations because of moving contacts engage with fix contacts. But it does not affect the further
operations.

5.2 condition of earthing switch after tests

The mechanical functions and the insulation of the earthing switch shall be essentially in the same conditions as
before the test. The earthing switch shall be capable of carrying its rated peak withstands current and its rated short-
time withstands current.
Results show that earth switch is capable of carrying such type large currents i.e. 40kA for 3sec and 100kA for 0.1
sec. as shown in graphs for all three phases (R-Y-B).

Fig.8 R-Y-B phase oscillographic reports (40kA-rated current, 100kA-rated peak current)

Source-Oscillograph report at Test site

5.3 STC calculations

Force calculations:
Force exertion during 40kA current passing through the system is calculated as per given formula.

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F= 2.04 (Is) ² x (L/R) x 10 ² kgf

Is – peak current kA

L- Span between insulator supports

R- Spacing between neighboring conductors in three phase bus system

Putting values,

F= 2.04 (2.5 x Isp) ² x (266/420) x 10 ²

Isp = 40kA

F= 2.04 x (100)² x 0.6333 x 10 ²

F= 129 kgf.

Clearance table to indicate the distance between live part and earth part which is related to arcing during short-
circuit test.

Table 2: Clearance table

Clearance To earth Between phase

3.3 51 51
11 77 128
36 223 351

6. Conclusion

In these paper, we are successfully developed the 40kA earthing switch which is type tested as per IEC 62271-102
standard of M0-E1 class. Theories required for new adaptive design implemented successfully, which gives easy
guideline to new product design and development described in detail. Development of 40kA earthing switch with
the reference and utilization of 31.5kA earthing switch design is successful attempt by applying French model
theory.
Experiments and tests carried out on earth switch gives satisfactory results that it is capable of withstanding at 40kA
current for 3sec with the 50x5 cross sectional area of current carrying parts made of copper. It is also sustain at the
rated peak value i.e.100kA for 0.1sec which fulfills the customer requirement. Experimental results show the
performance of the developed earth switch is satisfactory.

8. References
[1] T Ulrich, S.D. Eppinger, “Product design and development”.
[2] ABB power distribution manuals-“earthing switch with fault making capacity”, IEC (129) publication-1984, pp
(1-20)
[3] Instruction manuals-“EK6-series”, pp (3-12)
[4] Microelectrica scintifica-m.s. Resistances-“Three pole indoor earth switch”, pp (1-4)
[5] Meibner M., Blessing L., “Defining an adaptive product development methodology”.
[6] IEC standard 62271-102, “Alternate disconnectors and earthing switches”, pp(34-84)
[7] IEC standard 62271-200-, “High voltage switchgear and controlgear”.
[8] http://www.worldcopperdevelopementassociation.com
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[9] Michigan technical university, Department of electrical engg. -USA-“A 40kV high power earthing switch”, pp
(1-5)
[10] United Arab Emirates-federal electricity and water authority, “Technical specification of 11kV switchgear”, pp
(12-15)
[11] Catalog: Siemens HG, “3D Disconnectors and Earthing switches”, 11.31.2008.
[12] Schneider Electric, “Earthing switch up to 17.5kV-installation guide 2008”.
[13] Gemini communication, “Earth resistance measurement”.
[14]EG0- power system earthing guide-DRAFT-August 2009.
[15] Sunil s. rao, second edition, “Switchgear and protection “, pp-1230-1258.

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