See discussions, stats, and author profiles for this publication at: https://www.researchgate.net/publication/322675479 Thermal Performance of The Contacts in Circuit Breakers Conference Paper · January 2018 CITATIONS READS 0 317 5 authors, including: Mohammad Jazini Tehran Regional Electric Company,Iran,Tehran 1 PUBLICATION 0 CITATIONS SEE PROFILE Some of the authors of this publication are also working on these related projects: ARC AT CIRCUIT BREAKER View project All content following this page was uploaded by Mohammad Jazini on 24 January 2018. The user has requested enhancement of the downloaded file. No. E-15-AAA-0000 Thermal Performance of The Contacts in Circuit Breakers Mohammad Jazini S. M. Mousavi G. Department of Planning and Research, Tehran Regional Electricity Company (T.R.E.C), Ministry of Energy, Tehran, Iran mohammadjazini@gmail.com Centre of Excellence for Railway, Iran University of Science and Technology Tehran, Iran Gevork B. Gharehpetian Department of Electrical Engineering, Amirkabir University of Technology. Department of Planning and Research, Tehran Regional Electricity Company (T.R.E.C), Ministry of Energy, Tehran, Iran Mahdi Jazini Tehran, Iran Grptian@aut.ac.ir Mohsen Jazini Department of Planning and Research, TAVANIR Company, Ministry of Energy, Tehran, Iran basis of contacts materials in Circuit Breakers factories, refineries, power plants, super distribution and transmission Whereas the conventional alloys with large mesh are not the characteristics required for such contacts, the various substations as well as gas and oil installations are mostly metallurgical methods should be provided the desired alloy equipped with high tension power. However, charge .Costs of production, a broad survey of the alloy was increase and grid development bring some difficulties to the performed. The results show that the use of Nano scale metal use of these equipments which in turn make high tension powders, all the properties required for high power switches to power designers face more complicated challenges. [9]. provide an incredible boost. In order to achieve this study are examples of alloys W-Cu is made under various metallurgical and electrical tests were high and the results showed the correctness of the theory Tungsten-copper has unique material properties. A high level of temperature resistance is one of the most important advantages of tungsten, while the copper content increases the electrical and thermal conductivity. Show the relationship between geometric characteristics of the melt bead and the optical-acoustic emissions from arc flash during melting in the switching process. The paper summarizes results of measurements of remelting area geometry, thermal efficiency and melting efficiency. keywords Circuit breaker; breakdown; Nano-contact; I. plasma; Arc; electrical INTRODUCTION The Nano structures generally are worked longer and very stronger in electrical devices[1], [2].The nano sructures was built with the aim of providing Strength electrical connections are used[3], [4]. The electrical contacts Play an important role in Circuit Breakers and is very important in power electirc and electronic[5], [6].The contacts in power electric mainly affect circuit breaker. If the surface temperature on electrical contact, exceeds the tolerate is contacts would melt and eventually led to the explosion is circuit breaker[7],[8].In order to increase the stability of the Due to its wide spread, power grid is exposed to numerous events, the worst of which is short-circuits and error currents. The closest breaker to error has the responsibility of error removal by cutting off the faulty part of the grid immediately. A shorter cut-off time results in protection and improvement of stability in grid electrical installations and users power quality. As of yet, this problem has received different solutions, each of which involves some certain faults such as: cost increase in construction and exploitation, increase in equipment amounts, increase in place of installation, and so on. The fact that smart grids establishment intensifies the requirement of industries particularly electricity, oil and energy industries to faster breakers, adds to the difficulty. II. THE IMPORTANCE OF REDUCING THE EFFECTS OF ARC FLASH ON THE POWER CIRCUIT BREAKER The negative effect of the electrical arc between the circuit breaker power posts, the breaker substations are close to error. Because the closer circuit breaker to the fault location becomes more intense. Therefore, it should be tougher to short circuit breaker remote substations and provide relief in a shorter time. Therefore, should the necessary calculations to determine the critical time and time to fix the error by short-circuiting circuit breaker is that in most cases, be carried out. Paper Title 30th Power System Conference - 2015 Tehran, Iran Therefore, taking into account the delay of the circuit breaker off the arc flash, to be reached faster than the time error handling is critical. According to Table I if the generator is going to remain stable, the error should be removed in an angle less than critical one; otherwise, the generator will lose its stability. Thus, as to jitter, the breaker function time should be less than critical time for error removal so that system does not lose its opportunity to reach stability. Generally, breaker function time is the span between receive time of telecommunication command to cut off and electrical extinguishing. Moreover, this time should not be more than two or three cycle (less than 60 seconds in 50(HZ) frequency). The review of the research team, on the events of recent decades that cells containing circuit breakers for electricity distribution and transmission posts, within the Tehran Regional Electricity Company, did, it was found that 93% of the events leading up to the arc flash and hit It had been due to severe mechanical. Of this number, 72% in the arc electrical due to an explosion just as circuit breakers and is not suitable conductivity breaker blades, and increases the critical time breaker performance resulting in the possibility of problems and even explosion. The critical time is increased because of the rise of the electrical arc. It is essential to remember that critical time when to remain stable power grid and global uncertainty it is necessary. The circuit breaker is the only tool for switching electric power supply networks can be used. Another important task circuit breaker, cut area has a short circuit. Short circuit of the electrical network in the area is said to electrical energy in a way inappropriate, flow and if the circuit breaker is not cut short. Electric energy in path, destroy electrical equipment. III. THE FUNCTION OF HIGH VOLTAGE BREAKERS In comparison to remote substation breakers, plant substation breakers are more affected since they should remove more intense short-circuits during a shorter time. Therefore, it is necessary to calculate the enough critical time to remove the error which is mostly a short-circuit one[8]. Fig. 1 . The relationship between Arcing Gap (mm) and The length of Arc(ms) About temperature arc flash in Fiders1 of Substation. In all this time and heat tolerance electrical connection should be enough so that the dough does not start and will not end up melting. Power plant breaker should operate within allowed delay range Fig.1 at the error occurrence moment and breaker function time should be less than tcr. TABLE I. THE TIMING OF BREAKER FUNCTION AT ERROR MOMENT tcr = receive + tarc Sequence of events tcr: critical time of error removal. receive: receive time of telecommunication command to cut off from DCS and PMU devices . tarc: time delay from electric are extinguishing or breaker function time. 1. error time 2. relay recognition 3. sending cut-off command to breaker 4. start and end of electrical arc flash 5. breaker function 6. allowed delay 7. critical time 8. generator instability Thus, considering delay from electrical arc extinguishing, breaker function should be faster than critical time for error removal [9]. 1 Fider is a kind of cell for feeding power grid that contains the circuit breaker in the substation. 2 Paper Title 30th Power System Conference - 2015 Tehran, Iran IV. heat, for although Nano metals are small, they have more stability [10]. ELECTRICAL ARC FLASH FEATURES Electrical arc features are classified according to breaker type and extinguishers inside the arc flash suffocating chamber, shown at Table II. 4. If conductivity of breaker s contacts is increased, the electrical arc is more quickly established and finished. On the other hand, since in Nano materials the contact area of material is enhanced, the cross section to transfer power is added, too. And it is known that because of skin effect, electric current tends to flow on conductive areas. TABLE II..ELECTRICAL ARC FEATURES IN KINDS OF CIRCUIT BREAKER Electrical arc Feature Arc Speed Arc Time Period 6000 (m/s) Oil circuit breaker with quenching the arc flash by oil 10 ( s) Gas circuit breaker (GIS) with quenching the arc flash by SF6 gas and vacuum 0.4 ( s) Air circuit breaker (AIS) without quenching device some seconds Arc flashTemperature 20000 Nano Silver Alloys in circuit Breaker s Contacts Since silver has the highest electrical and thermal conductivity of all elements, it is the most common metal used in construction of relay contacts, power circuit breakers and conductorsz. Meantime, its high malleability as well as its severe tendency to show reaction with Sulfur and then production of Sulfide layer has made it the most suitable cover for other metals and alloys[11].. Applying silver in construction of gas circuit circuit breakers (GIS) with arc flash extinguishing by SF6 gas is very productive, for this gas is a combination of sulfur and fluorine, is 6 times heavier than air and its isolation property is 3 times more than that of air [12], [13] . In comparison between silver-copper alloy (Ag-Cu) and silver-palladium alloy (Ag-Pd), copper is the most resistant metal against corrosion. Moreover, cadmium in silvercadmium alloy (Ag-Cd) is an environmental pollutant for which environmental limitations have been regarded. Instead, silver-lithium-lanthanum alloy (Ag-Li-La) can be replaced which has more properties, as well. However, the usage of Nano silver would have positive effects on improvement of following items: 1. The increase of cross section to transmit power with faster pass of electrical arc because of higher conductivity of Nano silver. °C Electrical arc suppressing is crucial for grid and industrial installations; therefore, numerous technical techniques have been suggested. Electrical Arc Extinguishing Methods These methods include [9]: 1. Lengthening the distance between two contacts. 2. Quenching the electrical arc by oil, gas and vacuum. 3. Adding multiple electrical arc extinguishing chambers. 4. Employing Nano metal alloys in breakers blades . V. USAGE OF NANO METALS IN IMPROVING THE FUNCTION OF HIGH VOLTAGE BREAKERS. Usage of Nano Metals duo to Improve the Function of High Voltage Breakers.there are several solousion for this. 1. Reducing the extinguishing time of electrical arc: 2. The increase of electrical arc heat transmission and the decrease of arc flash period by cooling it faster [14], [15]. Cooling of equipments is of great importance, especially in crucial places and underground spaces in urban, like: common tunnel of energy installations and gas lines (GIL) [16]. Decreasing the distance between two contacts: The distance between breakers blades (breakers which cut off the grid and error current) and sectionners (breakers which separate the grid without charge and error) can be decreased by lessening the electrical arc length using Nano alloys. Nevertheless, regarding the usage of Nano metals the attention should not be given to investment on cooling methods of electric installations but it ought to be drawn to not producing heat and electrical arc which is the sthece of heat production [17], [18]. 2. Quenching the electrialc arc without any loss of oil, gas and vacuum in breaker: Each time an electrical arc is produced, the amount of oil, gas or vacuum of the breaker is reduced, too. Decreasing the electrical arc slows this process which in turn decreases the reduction of electrical arc extinguishing materials[9]. VI. EVALUATION OF THE EFFECT OF TEMPERATURE ON THE ELECTRICAL ARC Plasma conducts electricity. The arc creation cycle is continuous as long as there is energy in the contact and plasma maintain contact with the material being cut to establish an electric circuit[19], [20]. 3. Preventing from contact corrosion: Each on-and-off in breaker makes the contacts corrosive, burns breaker s particles and increases its heat which finally result in longer-period arc. Nano alloys applied in breaker s contacts prevent from corrosion and In general, arc contacts exhibit significantly less stability than do filament lamps because the gas plasma is inherently 3 Paper Title 30th Power System Conference - 2015 Tehran, Iran unstable and can be affected both by magnetic fields and erosion of the contact tips[21]. Tungsten-copper has unique material properties. A high level of temperature resistance is one of the most important advantages of tungsten, while the copper content increases the electrical and thermal conductivity. Tungsten copper composites have been used in manufacture of electric contact .The manufacturing method of the W-Cu composite material thin board characterized by mixing the end of copper powder, and tungsten powder, and having the first process for thermal spraying of carrying out powder production, and the second process of carrying out plasma spray coating of the above-mentioned powder for thermal spraying to a substrate, and forming a thin board in the manufacturing method of a metal base composite material[26].. During plasma arcing, tungsten-copper powder is melted in a plasma arc and then propelled at high speed against the workpiece that is to be coated. In this way, it is possible to deposit impermeable, adherent layers on tools and various equipment components. When switching occurs, the Arcing contacts and contacts have to withstand temporary ° temperatures of more than 10,000 C. Fig .2. That is a challenge that the tungsten-copper contacts can easily rise to. Using back-casting techniques, we are able to achieve particularly reliable tungsten-copper bonds. The contacts ensure optimum heat transfer and are able to withstand even the most extreme mechanical stresses[22].. Considerable knowledge exists on processing tungsten powders over a broad particle size range. Published data and processing models have been combined for tungsten powders ranging from 100 nm to 100 m to build a response model for press-sinter processing. The model predicts apparent density, green density, green strength, sintered density, sintered grain size, and product properties such as strength, hardness, and wear resistance. Green strength is a term used to describe a molded or cast products ability to withstand handling, mold ejection, and machining before it is completely cured or hardened. This physical characteristic is a critical criterion in the productivity levels processes such as injection molding and powder metallurgy[27]. The quicker cast or molded products can be removed or ejected from the mold and handled the higher the process turnover becomes. This process must not, of course, damage or alter the finished product so a high green strength rating in any product is a desirable characteristic. The mechanical strength which a compacted powder must have in order to withstand mechanical operations to which it is subjected after pressing and before sintering, without damaging its fine details and sharp edges [28]. Good green strength values play a vital role in many areas including the ceramics, thermoplastic, and metal powder molding industries. Further, the model isolates several problems as particle size decreases that will require changes in how tungsten powders are handled, compacted, and sintered. Maps of strength versus processing conditions are generated from the model to direct future efforts toward improved properties using Nanoscale tungsten powders. From these findings, new opportunities become evident for press-sinter consolidation of Nanoscale powders. Fig.2.Temperature of Plasma Arcing Between Contacts in Circuit Breaker VII. EVALUATION OF THE EFFECT OFTHE ARC FLASH PROCESS IN THE CIRCUIT BREAKER In the arc flash process in the circuit breaker, the melt is produced by the extreme heat of an electrical arc drawn between an contact and the workpiece, or in some cases, between two contact s. Melts are made with or without the application of pressure and with or without filler metals. The plasma is a state of matter consisting of free electrons and ionized atomsinteracting with each other with a high electromagnetic conduction and high energy density, normally maintained by elevated temperatures over ° 30,000 C. In the center of this channel, there is a negatively charged contact[23].. When applying electricity to the negative contact and touch the tip of the metal, the connection creates a circuit. A powerful arc is generated between the contact and the metal. Fig.2. Composite tungsten-copper mainly as electrical contact materials in harsh working conditions such as currents and high voltages in electrical arcs severe mechanical wear, surface melting, and so locate Therefore, optimization of physical properties - mechanical and longevity of these composites in this study process powder metallurgy is used for the preparation of Nano-contacts. Powder metallurgy (PM) is a term covering a wide range of ways in which materials or components are made from metal powders. PM processes can avoid, or greatly reduce, the need to use metal removal processes, thereby drastically reducing yield losses in manufacture and often resulting in lower costs [29]. The SF6 gas that passes through the electrical arc at high speeds, will ionize conforming a very hot plasma flow ° directly at 6 km per second with over 16,000 C [24]. In plasma, the energy begins to break down the gas molecules and the atoms which begin to separate from their electrons, which move quickly and causing the 4 Paper Title 30th Power System Conference - 2015 Tehran, Iran collision with other electrons and ions, releasing a vast amounts of energy[25]. VIII. TABLE III. THE APPLICATION OF ELECTRICAL CONTACTS ON THE APPLICATION AND THE LEVEL OF HEAT TOLERANCE Energy of Arcing Arcing Flash Mechanical Ultrasonic Friction Explosion Chemical Radiant Gas Thermit Laser beam Electron beam Electro slag Resistance Resistance spot Fig. 3 shows the Position of the 400 (kV) Moving Contact in Circuit Breaker. Resistance butt Gas tungsten arc Plasma arc Electrical Arc Gas metal arc Shielded metal arc Submerged arc Detailed descriptions of the various processes may be found in, we like to have good images to show the difference between the main contacts and the arcing contacts. When a circuit breaker opens, the main contacts should open partially first before the arcing contacts start to open. There should be no arcing damage to the main contacts because the arc interruption takes place between the arcing contacts. Table III. Fig . 4. The Arc position & Nano-contact This protects the current carrying surfaces of the main contacts so there is minimum contact resistance at the main contacts. Good contact surface means no overheating. For the same reason, when the circuit breaker closes, the arcing contacts close first, suffering any arcing damage. After the arcing contacts are closed, the main contacts close. All this keeps the main contacts in good condition. At the heart of the switching chamber, W-Cu arcing contacts are exposed to extreme mechanical and thermal ° stresses, with (temperatures 20,000 K) being reached during arcing. The attached image shows the damage to the stationary and movable arcing contacts and to the arc runner that extends into the arc chutes to extend and divide the arc until it is extinguished. The main contacts, the 16 curved segments across the middle of the image, are in good shape. No arcing damage what so ever. This image is from a medium voltage air circuit breaker. Contact the extreme mechanical and thermal stress during switching voltage by the power circuit breaker. For a fraction of a second, the temperature is Several thousand degrees resulting from the arc, increases. Temperature of electrical arc, will rise several thousand. Fig. 3. IX. FABRICATION OF W 20WT% CU COMPOSITE NANOPOWDER Fabrication of W Cu 20wt% composite Nanopowder and sintered alloy with high thermal conductivity. Fig. 4. Tungsten-copper (W-Cu) materials are used for arcing contacts in circuit breakers for high and medium voltage applications: 5 1. The mechanical energy is used for producing metallic bond in friction, ultrasonic and explosion switching. 2. The highest heat generation is at the positive pole: The heat of the arc in the first place leads Paper Title 30th Power System Conference - 2015 Tehran, Iran to the melting of the metal. At the same time the heat makes the gas better ionized; conductivity is improved. In case of gas metal arc switching and submerged arc switching the arc starts with a simple short circuit. Some momentary short-circuits lead to arcing. These results in ionization of the gas that becomes conductive and a switching arc can be formed. Fig. 4. In this regard, heat and mechanical damage due to abrasion possible profile and localized high density arc simulation and simulation point-to-point movement of the movable contacts to the fixed contact, the contact resistance variation is calculated. 3. X. The estimates also makes a major contribution to faster and cheaper access to the arc contacts, and an estimated remaining life of the power circuit breaker can also make Fig. 5 shows the effect of an electrical Contact point on the electrical arc and heat distribution. Whatever the angle of the contact tip increases, the level of contacts increases and Surface contact with electrical arc reduces and .in Fig.6, the greater angle has level 1 that And causes the electrical arc is focused on the tip of contacts then is eroding faster tip contacts on small part of tip. and more heat-tolerant material will eventually be processed. As a result, about level 7 to design the electrical connection is more suitable because it is the minimum angle. EVALUATION OF THE EFFECT OF THE ANGLE OF THE TIP OF THE ELECTRICAL CONNECTION sample A, well-known geometric deviation is the out of line positioning of the pieces. It's commonly called highlow. The deviation is usually caused by the skills of the melter. In addition, In Fig. 5 to demonstrate graphically how the conical selection will affect the size of the melt bead and the amount of penetration, below is a drawing that shows typical representations of the electrical arc shape and resultant melt profile for different conical. Table IV. In case of gas metal. the electrical arc switching and submerged arc switching the electrical arc starts with a simple short circuit. Some momentary short-circuits lead to electrical arcing. These results in ionization of the gas that becomes conductive and a switching arc can be formed. Table IV Sharper Contacts Nano-contacts Easy electrical arc starting Usually harder to start the electrical arc Handle less amperage Handle more amperage electrical arc shape Narrower electrical arc shape Good electrical arc stability Potential for more electrical arc wander Less melt penetration Better melt penetration Shorter contact life Longer contact life Wider In Fig7 you see differences between angle of contacts 0 ( ) in the melt also the effect of current intensity and electrical arc scanning velocity on geometrical parameters of remelting. The Nanostructured W-20wt%Cu electrical contact materials was prepared by mechanical alloying and hot press sintering process.The hardness of Nanostructured WCu contact materials is higher than that of conventional WCu alloy, but the electric conductivity is similar. a) The electrical breakdown voltage of Nanostructured W-Cu material does not depend on breakdown numbers, showing an excellent electrical arc stability. c) Nanostructured W-Cu material shows the characteristic of spreading electrical arcs, which is of benefit to electrical arc erosion. d) Whatever The smaller the particle size of the metal powder used in the electrical connection of electrical contacts uniform heat distribution and faster and negative effects of electrical arc is reduced. 6 Paper Title 30th Power System Conference - 2015 Tehran, Iran XI. [7] Nano Today Journal. Map points to stable nanostructured metals. Nano Today, Volume 7, Issue 6, December 2012, Pages 482-483. [8] Longhua Guo, Joshua A. Jackman, Huang-Hao Yang, Peng Chen, Nam-Joon Cho, Dong-Hwan Kim. Solvothermal synthesis of metal nanocrystals and their applications. Nano Today, Volume 10, Issue 2, April 2015, Pages 213-239. [9] Chunli Bai, Minghua Liu.Implantation of nanomaterials and nanostructures on surface and their applications. Nano Today, Volume 7, Issue 4, August 2012, Pages 258-281. [1] Mohammad Jazini, S. M. Mousavi G., G. B. Gharehpetian and Mohssen Rafie.Increasing of Contact Strength with Nano-materials in Electrical Breakdown. 2nd Regional CIRED Conference and Exhibition on Electricity Distribution, Tehran, Iran, CONCLUSION Power equipment design with technological approach towards Nano materials and their application in power industry remove many problems in the area of power and energy. One of these equipments is circuit breaker, the very cut-off circuit breakers in short-circuits and circuit breakers of error currents. Nanotechnology is very productive regarding oil and the contacts between two sides of the breakers. Following items are improvements which can be reached through this process: 1. Considerable reduction in circuit breakers size. 2. The increase of lifetime and the decrease of protection and repair service (P.M.). 3. Considerable saving in amount of power substation installations. 4. Considerable saving in place of power substation construction. [2] [3] [4] Reaching reliability is of great significance for which measurement should be carried out through simulators and accuracy should be evaluated by experimental tests. Of course, these two factors have to be accompanied by considering the sensitivity of substations and passive defense. Afterwards, these equipments can be utilized in development of substations. [5] Applications of Nano metals improve the performance of high voltage circuit breakers: [8] [6] [7] [19] 1. Reduce the destruction of circuit breaker contacts and fixed by the electrical arc. 2. Homogeneous distribution of heat in surface contact. [20] 3. Decentralization electrical arc on the tip of the electrical contact. In general, Nano thecnology is very useful for power electric. XII. [21] REFERENCES [1] Kui-Qing Penga, Xin Wanga, Li Lia, Ya Hua, Shuit-Tong Leeb. Silicon nanowires for advanced energy conversion and storage. Nano Today, Volume 8, Issue 1, February 2013, Pages 75 97 [2] Nano Today Journal .Heating up at the point of contact. Nano Today, [22] [23] Volume 2, Issue 3, June 2007, Page 55. [3] Longhua Guo, Joshua A. Jackman, Huang-Hao Yang, Peng Chen, Nam-Joon Cho, Dong-Hwan Kim. Solvothermal synthesis of metal nanocrystals and their applications. Nano Today, Volume 10, Issue 2, April 2015, Pages 213-239. [4] Wei Wang, Wentao Duan, Suzanne Ahmed, Thomas E. Mallouk, Ayusman Sen. Small power: Autonomous nano- and micromotors propelled by self-generated gradients. 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