P2.
Internal Arc Fault Simulation in Medium Voltage
Panel for Thermal and Structural Withstand
Parkash Kumar, Amol Kale, Abhimanyu Kumar Singh, Mahesh Ranade
Switchgear Design & Development centre
Electrical & Automation, Larsen & Toubro Ltd., Mumbai, India
mahesh.ranade@Lntebg.com
$EVWUDFW²'XULQJDQHYHQWRILQWHUQDODUFIDXOWLQ09VZLWFKJHDUV collapse. Thermal radiations due to internal arc have been a
HOHFWULFDO HQHUJ\ RI WKH RUGHU RI VHYHUDO 0- LV UHOHDVHG PDMRU cause of serious burn injuries to a person working in
SRUWLRQRIZKLFKLVXWLOL]HGLQKHDWLQJWKHHQFORVXUHJDVHVUHVXOWLQJ surrounding. Hence, large concerns especially about the public
LQVLJQLILFDQWWHPSHUDWXUHDQGSUHVVXUHULVHLQVLGHWKHFKDPEHU and construction safety of electrical installations arise [1] [2].
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Internal Arc Classification (IAC) of medium voltage switchgear
YDULRXV DUF SDUDPHWHUV VXFK DV SUHVVXUH ULVH LQ FRPSDUWPHQWV
H[KDXVWJDVWHPSHUDWXUHWHPSHUDWXUHDWLQGLFDWRUSODQHSUHVVXUH according to IEC and IEEE standards is one of the most
RQ SDQHO ZDOOV DQG VWUXFWXUDO ZLWKVWDQG 7KLV VLPXODWLRQ PRGHO important requirements to guarantee personal safety in case of
KDV EHHQ GHYHORSHG WR LPSURYH GHVLJQ HIILFLHQF\ VDIHW\ DQG internal arc events. Some crucial test criteria according to IEC
VSHFLDOO\ WR PLQLPL]H WKH QHHG IRU SK\VLFDO WHVWLQJ $ 62271-200 [3]:
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VZLWFKJHDU SDQHO LV FDUULHG RXW WDNLQJ LQWR DFFRXQW WKH FRXSOHG Correctly secured doors and covers do not open.
LQWHUDFWLRQVEHWZHHQIORZWHPSHUDWXUHWXUEXOHQFHDQGUDGLDWLRQ Deformations are accepted up to a clearly defined
ILHOGV 7HPSHUDWXUH DQG SUHVVXUH ULVH GXH WR LQWHUQDO DUF DW degree.
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FRPSDUHG 7HPSHUDWXUH ULVH DW GLIIHUHQW ORFDWLRQV RQ LQGLFDWRU 60g are accepted.
ZDOOVDUHREWDLQHGIURP&)' Arcing does not cause holes in the accessible areas up
to a height of 2 m.
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Cotton indicators, simulating the clothes of persons in
KLJKSUHVVXUHDQGWHPSHUDWXUHFDXVHGE\DUFIDXOW2YHUSUHVVXUH
GXHWRDUFIDXOWFDQFUHDWHVLJQLILFDQWPHFKDQLFDOVWUHVVHVRQWKH the vicinity of the switchgear, shall not ignite from the
HQFORVXUH VWUXFWXUH FDXVLQJ GHIRUPDWLRQ RI ZDOOV GRRUV JHWWLQJ effect of hot gases.
EORZQRXWIDLOXUHDWIDVWHQHUORFDWLRQHWF3UHVVXUHGDWDREWDLQHG The personal safety and service continuity of equipment in
IURP&)'LV XVHG DVDQLQSXW WRFDUU\RXWVWUHVVDQDO\VLVRIWKH case of internal arc fault is one of the most challenging design
HQFORVXUHVWUXFWXUHXVLQJ)($7UDQVLHQWVWUXFWXUDOVLPXODWLRQLV
criteria in switchgear. There are few methods developed by
SHUIRUPHG FRQVLGHULQJ JHRPHWULF DQG PDWHULDO QRQOLQHDULW\ WR
researchers to estimate pressure rise and structural effects in the
REWDLQGHIRUPDWLRQDQG PHFKDQLFDOVWUHVVHVRQDOOZDOOV5HVXOWV
IURP)($FDQEHXVHGIRUGHVLJQTXDOLILFDWLRQDVZHOODVIRUWKH
arc fault event like standard calculation method (SCM) &
RSWLPDO GHVLJQLQJ RI VWUXFWXUH DQG LWV FRPSRQHQWV 6LPXODWLRQ Advanced SCM (ASCM) [4]. Computational fluid dynamics
PRGHORIDW\SLFDO09SDQHODUUDQJHPHQWLVGLVFXVVHGKHUH (CFD) approach is a more detailed method used in recent days,
for which the conservation equations are solved based on
.H\ZRUGVLQWHUQDODUFVZLWFKJHDU&)')($ Navier Stokes formulation. CFD is based on finite volume
methodology which gives spatial description of pressure and
I. INTRODUCTION gas flow in complex and large shape geometries [5].
The design of a Medium voltage (MV) switchgear must The paper describes the simulation of an internal arc fault in
provide the maximum safety to operating personnel and should MV switchgear panel conforming to IEC using CFD as
be able to limit the consequences of an arc fault to the simulation platform. The pressure developments and
compartment in which it occurs. Incidence of an internal arc temperature distribution at different locations within the
fault is very rare in modern switchgears but when it happens it different compartments are calculated & these results are
may seriously damage the equipment, building and may even further used for the structural response analysis of the MV
endanger human life. If the electric arc occurs inside switchgear panel.
it generates internal overpressures and results in local Panel enclosure structure should be designed so that it
overheating which may cause high mechanical and thermal withstands the high temperature and pressure generated from
stresses in the equipment. The involved materials can generate internal arc fault. FEA is used to obtain the overall response of
hot decomposition products, gases or fumes, which due to the the structure to a given loading environment and also help in
overpressure are always ejected to outside of the enclosure thus arriving at an optimal design. Time varying temperature and
jeopardizing the operator safety. Buildings may be stressed by pressure data obtained from CFD is used as an input to transient
overpressure resulting in damages, cracks in walls or even structural analysis which estimate the stresses and deformation
978-1-5386-6315-8/18/$31.00 ©2018 IEEE 405 IEEE Holm Conference on Electrical Contacts
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in the enclosure structure members. These are then compared Time step size controls the accuracy of capturing the
with the allowable strength of material under consideration. dynamic response. Hence the information obtained from modal
analysis is used to arrive at the time step size to be used for
II. MODEL ARCHITECTURE transient structural analysis. It is given by,
$ &)'DQDO\VLV ଵ
οݐ௧ ൌ ଶ (1)
During internal arcing, the arc energy is transferred to the ೝೞೞ
surroundings by different mechanisms like conduction, where οݐ௧ is the initial time step and ݂௦௦ is the
convection and radiation. Fraction of energy is used for
electrode melting, evaporation as well as enclosure walls frequency of the highest mode of interest.
heating due to radiations and remaining energy is absorbed by Damping is an energy dissipation mechanism that causes
the surrounding gas causing temperature and pressure rise. The vibration to diminish over time and plays an important role in
ratio between the energy leading to the pressure rise and the the structure’s response to time varying load. In this work only
total electrical energy, well known in literature as thermal beta damping, also known as structural/stiffness damping, is
transfer coefficient “NS”, is considered and implemented in the used to damp out the high frequency oscillations. E (stiffness
numerical simulation. In general, NS is not a constant and is coefficient multiplier) can be calculated from a known value of
known to depend on gas density, arc current, and electrode [ (damping ratio) and a known frequency Z.
material [6], whereas in this simulation it is considered as
constant. Arc energy is an input to CFD, calculated based on ଶక
ߚൌ ఠ
(2)
empirical relations defined by IEEE 1584 and validated with
the power graph. Arc energy from calculations is multiplied by where Z is the most dominant frequency selected from modal
factor NS and applied as a source to the arc fault region using analysis.
User Defined Functions (UDF) [7] [8].
& $VVXPSWLRQV
The 3-D domain of calculation is discretised into small cells
with a structured/unstructured mesh. The coupled partial To reduce the complexity of the simulation, few
differential equations are solved using the finite volume assumptions and simplifications are adopted as follows,
method. The standard Nİ model is used in order to describe
turbulence. Radiation is modelled using Discrete Ordinate (DO) x Arc plasma is considered to be in local thermodynamic
method which is more accurate for a wide range of optical equilibrium (LTE)
thicknesses. DO also consider re-absorption phenomenon x The arc–electrode interaction is not taken into account
which leads to the pressure rise inside the enclosure. x Vapors due to evaporation of surrounding material are not
Thermodynamic and transport properties of air arc plasma like considered in the model
specific heat, thermal conductivity, density, and viscosity etc x A coupled interaction among the electromagnetic and flow
are used considering non-linear variation with temperature and fields generated from the arc is not considered in order to
pressure and referred from the work of A. D’Angola [9] and S. reduce computation cost
Ghorui [10]. x Bilinear isotropic material model is considered
% 6WUXFWXUDODQDO\VLV x Effect of strain rate is not considered
x Effect of temperature on mechanical properties is not
For thin walled structure such as this, dynamic effect considered
becomes significant and hence full transient structural analysis
is required to obtain the overall response of structure. It III. NUMERICAL MODEL
involves a two-step procedure.
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L 0RGDODQDO\VLV
Basic hydrodynamic equations of mass, momentum and
This is a linear and most basic of all the dynamic analysis. energy conservation are solved to get the temperature and gas-
Modal analysis is a technique used to obtain the dynamic flow field of arcing plasma using Navier-stokes equation which
characteristics of the system by calculating its natural is presented as a general transport equation [11] as below,
frequencies, modal participation factors, and mode shapes of ப
ሺɏሻ ή ሺɏɋሻ ൌ ή ሺȞሻ (3)
the structure. This also gives information on effective mass of ப୲
the structure for each mode as well as the dominant frequencies where, ø represents the conserved variables under
in each direction. consideration, ρ is the gas density, ν is the gas velocity, Γ is the
transport coefficient of ø and S is the source term for ø..
LL 7UDQVLHQWVWUXFWXUDODQDO\VLV
% ,(((±(TXDWLRQVIRU,QFLGHQW(QHUJ\>@
This analysis is used when inertial forces and damping of
the structure play an important role. Transient structural IEEE-1584 defines an empirical method to calculate the
analysis is used to calculate a structure’s response to time incident energy from the arc, derived based upon test results,
varying loads. statistical analysis and curve fitting programs.For bolted fault
current in the range from 700 A to 106 kA and system voltage
Non-linear effect, such as geometry, contacts, and material, from 208V to 15kV the arcing current can be calculated as
are included by updating the stiffness matrix in general equation follows,
of motion given by Eq (9).
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Arc Current - metal-clad AIS panel at 12kV and 40kA rms current for 1s.
Medium voltage panel has three compartments namely Breaker
For systems between 0.208kV to 1 kV: (VCB) compartment, Cable compartment and Busbar
compartment as shown in Fig.1. As per the standards
݈݃ሺܫ ሻ ൌ ܭ ͲǤʹ ቀ݈݃൫ܫ ൯ቁ ͲǤͲͻሺܸሻ ͲǤͲͲͲͷʹሺܩሻ requirement internal arc test has to be carried out in all the
ͲǤͷͷͺͺሺܸሻሺሺܫ ሻሻ െ ͲǤͲͲ͵ͲͶሺܩሻ݃ܫሺܫ ሻ compartments independently by generating the arc in respective
compartment. Simulation geometry for CFD analysis of the
For systems between 1kV to 15 kV: panel is also shown in Fig.1.
݈݃ሺܫ ሻ ൌ ͲǤͲͲͶͲʹ ͲǤͻͺ͵ሺ݈݃൫ܫ ൯ሻ (5)
Incident Energy –
݈݃ሺܧ ሻ ൌ ܭଵ ܭଶ ͳǤͲͺͳሺ݈݃ሺܫ ሻሻ (6)
௧ ଵೣ
ܧൌ ͶǤͳͺͶሺܥ ሻሺܧ ሻሺ ሻሺ ሻ (7)
Ǥଶ ೣ
Flash Boundary –
௧ ଵೣ
ܦ ൌ ሾͶǤͳͺͶ൫ܥ ൯ሺܧ ሻ ቀ ቁ ቀ ቁሿଵȀ௫ (8)
Ǥଶ ாಳ
Where,
(B = Desired incident energy at the boundary
( = Incident energy in joules/cm2
,a = Arc fault current in kA;
,bf = 3-phase bolted fault current in kA;
9 = Voltage in kV
* = Conductor gap in mm
. = -0.153 (open-air arcs)
= -0.097 (enclosed arcs)
(n = Energy normalized for distance of 610 mm and
arc duration of 0.2 seconds, in joules/cm2;
.1 = -0.792 (open-air arcs) & Fig.1 MV Panel and CFD Simulation geometry
= -0.555 (enclosed arcs)
.2 = 0 (ungrounded/high-Z systems) &
= -0.113 (grounded systems)
&f = Calculation factor, 1.0 (voltages above 1 kV)
= 1.5 (for voltages below 1 kV)
W = Arc duration in seconds
' = Distance from arc in mm
[ = Distance exponent
& *HQHUDO(TXDWLRQRI0RWLRQ
In a transient structural analysis, general equation of motion
is solved:
ሾܯሿሼݔሷ ሽ ሾܥሿሼݔሶ ሽ ሾܭሺݔሻሿሼݔሽ ൌ ሼܨሺݐሻሽ (9)
Where ሾܯሿ = structural mass matrix, ሾܥሿ = structural damping
matrix, ሾܭሺݔሻሿ = structural stiffness matrix, ሼݔሷ ሽ = acceleration
vector, ሼݔሶ ሽ = velocity vector, ሼݔሽ= displacement vector, ሼܨሺݐሻሽ Fig.2 Arc Power graph
= force vector. This is also the force balance equation where in
first term, second term and third term on the LHS represents Arc is simulated as a hot gas region above 5000K initialized
inertial force, damping force, and stiffness force respectively with zero (gauge) pressure and fed with a power input as per the
and on the RHS is the applied force which is a function of time. power graph shown in Fig.2. This graph is derived from test
specifications and energy release (47MJ in 1s) which is
obtained from test data. The energy data from test is validated
IV. CFD & STRUCTURAL SETUP with energy derived using the equations (4) to (8) as defined by
IEEE 1584-2002 standard [12].
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Fig.1 shows the CAD model of a double busbar MV panel A no-slip boundary condition is applied at the solid walls.
highlighting various chambers in which arc fault is to be Chamber walls are defined as adiabatic as the phenomena
investigated. The internal arc fault test is carried out on the happens within fraction of second. Thickness is assigned to
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each wall as per design specifications to simulate temperature
rise of walls. Emissivity is applied to each wall as per material
of wall to simulate radiative heat dissipation. Walls which are
open to atmosphere are assigned pressure outlet boundary
condition.
% 6WUXFWXUDOVHWXS
Enclosure structure’s door and walls are analyzed for the
overpressure created due to the internal arc fault at various
locations. Spatially averaged time varying pressure data,
obtained from CFD, is applied to the enclosure structure walls
and door. Simply supported boundary conditions are used at all
the bolt and rivet locations on walls and door. For a thin walled
structure geometric non linearity becomes significant and
therefore is accounted here and for material non linearity a
bilinear isotropic hardening model with yield strength of 250
MPa is considered for the simulation.
V. RESULTS & DISCUSSION
This section discusses the results obtained from CFD and
FEA simulations.
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Maximum Temperature in various compartments of the MV
panel are compared with respect to time as shown in Fig.3. Arc
temperature reaches nearly 12,000K in first few milliseconds
irrespective of the chamber and then drops to different
temperatures depending upon the chamber volume and its
distance from the exhaust duct. Temperature in all the chambers
varies from 6000 to 10000K after 20ms, as can be seen from
Fig.3.
Fig.4 Temperature distribution & flow of hot gases in VCB chamber
Fig.3 Temperature vs time
Fig.4 shows flow of hot gases and temperature distribution
for internal arc fault in VCB chamber at different time interval.
Pressure relief flap of VCB chamber opens at pressure of 0.11
bar between 3-4 ms. Maximum temperature in the
compartment rises upto 12,200K at around 3-4 ms. Maximum
(gauge) pressure in the chamber reaches to 1.45 bar at 16ms.
Fig.5 Temperature at indicator planes
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Temperature at indicator planes is also estimated from the
simulation. Fig.5 shows temperature at indicator planes located
at the three sides of the panel i.e. front, left (or right) and rear
side. It can be observed from the graph that temperature at the
indicator planes remains below 320K which is well below
cotton burning temperature.
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Pressure rise in various compartments of the MV panel are
compared from simulation results. As soon as arcing starts,
pressure increases rapidly till 15 to 20ms and then it starts
decreasing and reaches to atmospheric within 25ms to 60ms
depending on arcing in various compartments. All the
compartments subjects to different pressure based on flap Fig.6(b) Pressure at Cable chamber walls – Test & Simulation
opening time, location of flap and volume of the chamber.
% 6WUXFWXUDOUHVXOWV
Average pressure on walls of the various chambers is
plotted w.r.t. time as shown in Fig.6(a). Busbar lower chamber Transient structural analysis of all the chambers of MV
walls subjects to highest pressure around 2.1 bar whereas VCB panel is conducted independently using pressure data obtained
& Busbar upper chamber subjects lower pressure on walls from CFD simulation. Only those walls/door having higher
around 0.4 bar & 0.6 bar respectively. Negative pressure seen stresses and deformation for a particular fault are discussed
in the graph is due to shock wave effect. Shock front of highly here.
increased pressure is followed by a negative pressure which can
9&%&KDPEHU:DOOV
be explained by Friedlander waveform theory. This pressure
data is used for the transient structural analysis of the panel As it can be seen from Fig 6 above, the average pressure
walls to investigate structural withstand of the same. values are lowest for VCB fault location due to the large volume
available at the fault location. Pressure flaps are located near
fault location resulting in efficient dissipation of high
temperature gases and pressure waves associated with it.
Deformation of the wall are within acceptable limit [3]. Stresses
are high only near the rivet location on front door, thus require
support plates for reinforcement. Stresses on other walls are
well within acceptable limits. Max. deformation of VCB door
is 25mm as shown in Fig.7 & Fig.8.
Fig.6(a) Avg. Pressure on Side walls of MV panel - Simulation
9DOLGDWLRQ
Maximum Pressure on Cable chamber walls obtained from
simulation is upto 1.25 bar whereas from measured test data it
is observed as 1.1 bar at the walls as shown below in Fig.6(b).
Difference in peak pressure timing could be attributed to the
assumptions taken in simulation; no electromagnetic and metal
vapor effect, and constant NS during the entire simulation run.
Every chamber is fitted with pressure relief flap which operates
Fig.7 Stresses & deformation at VCB chamber (front door)
when pressure inside chamber increases more than the
clamping pressure of flap which is designed to operate at 0.13
bar. It is observed from simulation that time of pressure relief
flap operation is closer to the test data.
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Fig.10 Stresses & deformation at bus-bar chamber (rear wall)
Pressure peak of 2.1 bar, is obtained for lower busbar chamber
fault as shown in Fig. 6(a) above. It was difficult to ensure
convergence with implicit scheme and the results were non-
physical, hence not discussed here.
Fig.8 Stresses & deformation at VCB chamber (side wall)
VI. CONCLUSION
&DEOH&KDPEHU:DOOV
An internal arc simulation methodology is established
$verage pressure with a peak of 1.25 bar is observed at cable conforming to IEC Standard using CFD and FEM platforms.
fault location due to the narrow passage available for gas Simulation helps in visualization of spatial distribution of
discharge. Stresses are high only near rivet locations as can be pressure, temperature and gas flow field inside the arcing
seen in Fig.9. Deformation observed from simulation is well chamber as well as it minimizes experiments and development
within the acceptable limit. cycle.
%XVEDU&KDPEHU:DOOV Peak pressure varying from 0.75 bar to 2.1 bar in various
Average peak pressure on walls for upper busbar fault are compartments of MV panel were observed based on the given
considerably lower at 0.6 bar inspite of low volume at arc fault energy inputs. Maximum temperature of hot gases inside the
location. This is due to the presence of multiple pressure flaps compartments reaches upto 12200K. Temperature at all
which facilitates gas discharge resulting in efficient discharge indicator planes was found to be in safe limits. The variation of
of hot gases. Fig.10 shows the stresses and deformation for average pressure w.r.t. time on the walls of the VCB, Cable &
Busbar chambers are of major interest for design with respect
upper busbar chamber fault. Weld plates, as expected, gives the
to structural integrity of the switchgear panel.
needed stiffness to the doors resulting in reduced deformation.
Stresses and deformation are within safe limits as can be seen Design qualification of panel enclosure structure was done
from Fig.10. using transient structural analysis. This study helps in
optimizing the design of panel enclosure structure and in
material selection for a desired withstand capability.
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[1] Kittipong Anantavanich, "Calculation of Pressure Rise in
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Communications Ltd, London (2010)
[3] IEC 62271-200 & IEC 61641 Standard
[4] Yi Wu, Mei Li, Mingzhe Rong, Fei Yang, A B Murphy, Yifei Wu
and Duanlei Yuan, "Experimental and theoretical study of
internal fault arc in a closed container",J. Phys.,IOP, Nov 2014.
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arcing faults", IEEE Trans. Power Deliv. 14 365–70, 1999
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in low voltage circuit breakers”,59th IEEE holm conf. on
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