MOD switches and Disconnects

Disconnect switches
 Allow disconnection of major substation equipment
o Transformers
o Circuit breakers
o Lines & Busses
 Allow for maintenance and testing
 Provide a physical and visual disconnect to ensure separation of energized equipment
from de-energized equipment

Switch types
 Single phase – switch connected to bus by insulators, connection broken by pulling on
ring at the top connection with an insulated hook stick.

 Three phase – Gang or group operated switch, three switches simultaneously operated
by a single mechanism (handle or crank)
  Motor operated switch – 3 phase simultaneous disconnect powered by the operation of
a motor.

Disconnect Switch Applications

 Isolating – Disconnect used to isolate back-to-back bank positions.
 Bus – Disconnect attaching a line or equipment to an operating bus.
 Line – Disconnect located between a line and a circuit breaker.
 Bank – Disconnect located between a bank circuit breaker and a transformer.
 Transfer bus – Disconnect that links a line or equipment to a transfer bus.
 Ground – Utilized for linking a de-energized line or piece of equipment to ground
potential.
 Position – Located between a bus disconnect and bus tie circuit breaker.
 Station – Disconnect that allows disconnection of circuit from station.
 Fuse – Protection asset that de-energizes circuit in overcurrent situations.
 Section – Used when two banks feed a single bus that is not running in parallel.
 Bypass – Used to bypass a piece of equipment to keep the feed energized.
Ratings
 Switches are constructed to meet certain industry standards and requirements. Those
standards will dictate the rated:
o Maximum voltage, continuous and short duration impulse
o Continuous or nominal current
o Short-time and peak current
o Ice-breaking operations
o Mechanical operation
o Interruption capability

Voltage Rating
  Nominal rated voltage
o The voltage value that the system will typically operate at. The switch will be
able to withstand this voltage level continuously.
 Preferred Ratings
o IEEE standard C37.32 specifies the preferred voltages levels for switch
construction.
o These KV ratings are as follows; 8.3, 15.5, 27, 38, 48.3, 72.5, 123, 145, 170, 245,
362, 550, 800.
o A switch constructed at a specific rating will withstand all operating voltages
below that rating. This allows utilities that have unique operating voltages to
select a switch from an existing standard selection as opposed to having a costly
custom switch constructed.
 Impulse voltage
o This is the rating of the switches capability to withstand a voltage much higher
than the nominal voltage. Referred to as BIL, basic impulse level or basic
insulation level.
o 3-10 times the rated nominal voltage, duration is very small in the order of
milliseconds.
o Can be caused by lightning, switching or fault.
o Opening and closing of switches develops a large voltage stress across the switch
and its insulators.
o The BIL indicates the strength of the insulation during voltage surges caused
from high voltage events.
o As the nominal voltage increases the insulation level, BIL, should be increased as
well. A higher nominal voltage will also have higher voltage surges.
o Higher insulation levels will increase the reliability of the equipment while also
increasing cost. This is a trade-off that engineers must contend with when sizing
equipment.
o Inside of the substation, all equipment operating at the same nominal voltage
will need to have the same BIL, this is an intuitive concept as a specific nominal
voltage will necessitate a certain BIL.
o BIL requirements can also be found in IEEE C37.32. In this standard BIL is
referred to as “Lightning Impulse”.
o When referencing the high voltage levels on IEEE C37.32, you can see there is
more than one BIL. This is due to cost differences in insulation and
improvements in surge arrestor technologies that have developed over time.

Current Ratings
 Continuous
o Load current rating
 o Standard ratings; 600, 1200, 1600, 2000, 3000, 4000, 5000, 6000. These values
pulled from IEEE standard
 Short time (1 to 3 seconds)
o Fault current rating
o Required so that contacts do not heat up weld themselves closed during high
current faults
 Peak (10 cycles)
o Fault current rating
o Required so that magnetic forces do not cause the switch to mis-operate.
o Most important rating, required so the switch does not open unintentionally
during fault conditions as this can cause another fault that may switch the entire
substation out of service.
o Design features that address mis-operation.

 Spring loaded contacts: springs load the contact with a constant force dis-
allowing unwanted contact movement.

 Contact rotation: switch blade enters stationary contacts and rotates to

increase spring compression and contact pressure.
 Magnetic force effects: current flows up the contact fingers and then
back down in near proximity to the initial current flow. This reverse loop
contact design causes the opposing magnetic fields to push away from
each other and onto the switch blade. Increases in current also increase
magnetic forces, this will further restrict unwanted blade movement.

Ice Breaking & Mechanical Operations

 Ice coating thickness rating for breaking (if applicable): 3/8-inch, 3/4-inch for switches
with ice breaking capabilities.
  Mechanical ratings - 1000 operations, 900 close-open cycles, 900 with no loading and
100 with loading. This ensures the switch maintains proper alignment.
 Interlocks – mechanical interlocks are mechanisms that exist to restrict physical switch
operation. A switch can be interlocked so that it can be blocked from either opening or
closing. An example would be if testing needs to be performed on a motor operator but
you do not have clearance to operate the switch. The interlock can be engaged so that
the switch stays closed but the motor operator can still be activated.

Current Interruption
 A switch must have additional hardware for it to be able to safely break load current.
 They are used to prevent arching damage to the main contacts of the switch during
current interruption.
 These types of hardware include;
o Arching Horns – this is the simplest form of current interruption on a disconnect
switch. It consists of a horn on the stationary contacts of the switch that makes
contact to the horn attached to the blade as the switch opens. Load is carried by
the contacts of the switch during typical operation, once the switch commences
an open cycle the horns then make contact as the switch contacts separate. At
that time, load is transferred to the horns. This type of interruption can break
the magnetizing current of small transformers, as well as charging current on
small transmission lines and substation busses.

o Aching whips – A tapered this rod that has a high elasticity attached to the blade
fits into a latch on the stationary contact of the switch. As the switch opens the
rod/whip is latched to the stationary contact until the blade clear the contact.
Then the latch releases and the whip will deflect back toward the blade causing
an arc that will dissipate as distance between the whip and the contact
increases. These can break magnetizing current on medium sized transformers,
as well as bus and medium distance line charging currents.
 o Vacuum and SF6 interrupters – as the switch opens, the blade swings away from
the stationary contacts and creates a circuit through contact with the actuating
arm of the interrupter. This circuit is maintained until the blade is clear of the
stationary contacts. As the actuating arm is lifted it sends a trip to the contacts
inside of the interrupter bottle. This will break the circuit and the arc is
established inside of the bottle that is either under vacuum or contains SF6 gas,
both of which assist in arc extinguishing. As the blade fully opens the actuating
arm is reset allowing the contacts inside of the interruption bottle to reset.
Interrupter applications include load dropping capabilities.

Switch Movement
 Vertical breaking switches – Allows closer horizontal spacing between each phase
switch. They also require greater vertical clearance because of the direction of the
switch blade.
 Side breaking switches – Requires less vertical clearance, making it great for low-profile
substations. This set-up will require a greater horizontal spacing between phase
switches.

 Double side breaking switches – The switch blade rotates on the center insulator of the
switch. This has the advantage of both of the previous switch designs discussed with the
draw back of greater complexity because you are doubling the amount of contacts that
must be aligned.

 Center break switches – The device has two blades that disconnect at the center of the
switch. These require a smaller profile vertically and horizontally between phase but
come with more complexity being that the blades must be aligned properly to connect
at the center.
Grounding Switches
 Used to ground live parts of substation equipment, lines, and busses.
 They are required for safety during maintenance when conventional grounding cables
can not be used.
 They can be single pole or gang operated switches depending on design constraints.

Motor Operated Switches

 A motor that is connected through a cam to the switch operating mechanism. Motor
actuates cam that directly opens or closes the switch blades.
 Utilized for remote operations of the switch.
 Gears can be de-coupled from the switch mechanism, so that motor can be operated
independently of switch. This is useful in testing and maintenance.
 Auxiliary contacts in the motor operator allow for indication of switch position for
remote verification.
Circuit Switchers
 Circuit switchers, similar to disconnect switches, can de-energize equipment in the
substation for safety during maintenance. They have the added benefit of protection of
equipment like transformers and capacitor banks when used with protective relays.
 It is a combination of a circuit breaker and a disconnect switch; it has an interrupting
section as well as a visible blade disconnection.
 They are utilized for a variety of application, from interrupting small transformer
magnetizing currents to breaking kiloampere fault currents.
 They are often used with three phase gang-operated circuit disconnects.
 They have the benefit of providing protection to the system similar to circuit breakers at
a reduced cost.

 Circuit switcher operation

 o When the switcher is in the closed position, the interrupting section carries the
continuous current and withstands short-time fault currents, like a breaker.
o As the switcher starts to open, the brain, with its built-in sequence control and
stored energy, trips the interrupting section to open the circuit like a breaker.
o Next, the disconnect blade moves toward the open position to establish a visible
air gap.
o As the disconnect blade approaches the fully open position, the brain recloses
and re-cocks the interrupting section.
o When the blade closes, the jaw picks up in-rush or fault current, not the
interrupting section. Unlike the interrupter switch, the blade closes at high
speed, unimpeded by the need to reclose and re-cock the interrupting unit.
o The switcher is completely closed and ready for the next opening cycle.

 Shunt Tripping
o Circuit switchers can come with a shunt tripping device
o The shunt trip is a high-speed current breaking device that acts more quickly
than traditional tripping of the motor operator.
o Maximum interruption time is 8 cycles.
o Shunt tripping operated independently of the motor operator. It is achieved
through the shunt trip solenoid which trips the contacts in the interrupter.
 S&C Series 2000 Circuit Switcher
o Can be used for transformer protection.
o Can be sized up to 25 kA current interruption.
o Utilizes SF6 interrupter.
  S&C Mark V Circuit Switcher
o Versatile application (transformer, line, capacitor bank protection).
o Up to 80 kA current interruption.
o Utilizes SF6 interrupter.
o Can include shunt tripping for very fast isolation.

Metal-Clad Switchgear

 Metal-clad switchgear is a subset of metal enclosed switchgear, which is essentially

defined by its name, switchgear enclosed in a metal case. All components inside the
case are uncovered and accessible. Metal-clad switchgear is differentiated in that each
of the internal components are also covered in their own individual metal cases, and
they are easily removed from the circuit.
 The IEEE Metal-clad switchgear definition can be found in the IEEE standard C37.20.2
section 3.1.5.
a) The main switching and interrupting device is of the removable (drawout) type
arranged with a mechanism for moving it physically between connected and
disconnected positions and equipped with self-aligning and self-coupling primary
disconnecting devices and disconnectable control wiring connections.
b) Major parts of the primary circuit, that is, the circuit switching or interrupting
devices, buses, voltage transformers, and control power transformers, are
completely enclosed by grounded metal barriers that have no intentional
 openings between compartments. Specifically included is a metal barrier in front
of, or a part of, the circuit interrupting device to ensure that, when in the
connected position, no primary circuit components are exposed by the opening
of a door.
c) All live parts are enclosed within grounded metal compartments.
d) Automatic shutters that cover primary circuit elements when the removable
element is in the disconnected, test, or removed position.
e) Primary bus conductors and connections are covered with insulating material
throughout.
f) Mechanical interlocks are provided for proper operating sequence under normal
operating conditions.
g) Instruments, meters, relays, secondary control devices, and their wiring are
isolated by grounded metal barriers from all primary circuit elements with the
exception of short lengths of wire such as at instrument transformer terminals.
h) The door through which the circuit-interrupting device is inserted into the
housing may serve as an instrument or relay panel and may provide access to a
secondary or control compartment within the housing.
 Metal-clad switchgear is advantageous in that it allows for a much smaller equipment
footprint than traditional external switchgear.
 Pieces of equipment are compartmentalized in such a way that they can be
disconnected from the larger system for testing and maintenance, with minimal effect.
 Due to compartmentalization of the equipment within the enclosure, individual pieces
of equipment can be accessed without having to access more dangerous parts of the
equipment. Also, an advantage of this is that the individual compartments of each
equipment protect that equipment during a fault. Without the compartmentalization,
for example a metal enclosed switchgear set-up, a fault on one piece of internal
equipment could destroy the whole unit.
 Arc flashing is a situation that can arise when using metal-clad switchgear. An arc flash is
when an uncontrolled electrical arc forms at very high voltages through the air between
electrical conductors. They are incredibly violent and extremely dangerous, even deadly.

 When working with switchgear that can potentially expose workers to arc flashing, extra
precautions must be adhered to for safe working conditions to be established. These are
the boundary definitions of each zone of an arc flash as described by OSHA;
o Flash Protection Boundary (outer boundary): The flash boundary is the farthest
established boundary from the energy source. If an arc flash occurred, this
boundary is where an employee would be exposed to a curable second-degree
burn (1.2 calories/cm2). The issue here is the heat generated from a flash that
results in burns. Personnel are required to wear protective equipment if working
within this zone.
o Limited Approach: An approach limit at a distance from an exposed live part
where a shock hazard exists. This zone requires all personnel must be specially
trained or escorted by a specially trained person to perform work in this area, in
addition to having all required PPE.
o Restricted Approach: An approach limit at a distance from an exposed live part
which there is an increased risk of shock. Only specially trained individuals
should enter this zone with all required PPE.
o Prohibited Approach (inner boundary): A distance from an exposed part which is
considered the same as making contact with the live part. This zone should not
be occupied at all when the equipment is energized.
o This distance is not common between equipment. Some equipment will have a
greater flash protection boundary while other equipment will have a lesser
boundary.