Highly Reliable Safety-Oriented Air-Insulated Switchgear Voltage Transformer Solution
Industry Pain Point Analysis
Traditional voltage transformers face two major safety hazards under harsh conditions:
- Seismic Vulnerability: Porcelain insulators prone to brittle fracture under earthquake or short-circuit current impact, leading to secondary short-circuit explosions.
- Rupture Risk: Metal enclosures susceptible to rupture during internal arc faults, with SF₆ gas leakage exacerbating accident severity.
Innovative Solution Architecture
I. Triple Seismic Protection System
• Dynamic Decoupling Base: Patented hydraulic damping device + spring energy storage mechanism (IEC 61166:2025 certified for Seismic Intensity 9).
• Flexible Current-Carrying Connection: Bellows-type conductive circuit design (±15mm axial/±8mm radial displacement tolerance).
• Composite Insulation Support: Glass fiber-reinforced epoxy resin pillars (380MPa flexural strength, 3.2× higher than porcelain).
II. Active Defense Explosion-Proof Structure
Pressure Monitoring → Rapid Pressure Relief → Directed Emission → Mechanical Isolation
• Nano-Ceramic Matrix Composite Enclosure: ≥120MPa flexural strength, 400% higher impact toughness vs. traditional steel.
• Dual-Channel Pressure Release System: Rupture disc (0.15MPa activation) + labyrinthine gas flow channel (≥800mm arc flame decay length).
• Arc Energy Graded Dissipation: Copper-tungsten alloy arc chute plates + ZnO non-linear resistors for suppression.
III. Full-Range Environmental Adaptability Design
• Dry-Type Solid Insulation System:
o Vacuum-cast epoxy/silicone rubber composite dielectric (CTI ≥600V).
o Complete replacement of SF₆ gas (GWP=0, compliant with IEC 62271-1:2024 environmental requirements).
• IP6X Protection Level: Fully sealed structure resistant to mine dust/humidity.
• Wide-Range Temperature Compensation: Maintains 0.2 accuracy class from -40℃ to +85℃.
Extreme Condition Validation Data
|
Test Item |
Criteria |
Achievement |
Certification Level |
|
Short-circuit Withstand |
IEC 60044 |
63kA/3s |
Passed |
|
Mechanical Impact |
IEC 62271 |
20J Impact Energy |
IK10 |
|
Seismic Performance |
IEC 61166 |
0.5g Acceleration |
Intensity 9 |
|
Environmental Durability |
IEC 60068 |
1000 Thermal Cycles |
No Degradation |
Typical Application Scenarios
- High-Seismic Zones: Coastal nuclear facilities (≥ Seismic Intensity 8 requirements).
- Explosion-Hazardous Locations:
o Underground coal mine distribution systems (GB 3836 explosion-proof compliant).
o Chemical plant explosion-proof areas (ATEX Zone 1 certified). - Harsh Environment Applications:
o High-altitude substations (4,500m normal operation).
o Offshore wind platforms (C5-M salt spray corrosion resistance).
Value Proposition Framework
Equipment Explosion-Proofing → System Continuity → Personnel Safety → Zero Environmental Pollution
• 40% Lower Lifecycle Cost: Maintenance-free design (30-year oil-free/gas-sealed operation).
• 92% Reduced Failure Rate: Operational data analysis (vs. traditional oil-immersed VTs).
• Carbon Reduction Benefit: ≥12.6 tons CO₂ equivalent reduction per unit annually.
