25kv konnx coupler.pdf

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Worry Free High Voltage Couplers

WMEA Conference, San AntonioNovember 19, 2009Presented by Nick Turner of KonNx Inc.


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KONNX

AUSPROOFHeadquarters, Factory, and

Global Distribution in

Gladstone, Queensland, Australia

KonNx IncOffice, Warehouse and North American

Distribution

Denver, Colorado


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Computer Network from

Design to Manufacture

CNC Equipped Machine Workshop

Non-Ferrous Foundry

KONNX


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Final product totally

manufactured andready for use

Basic raw materialsreceived


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The Development

Of The

Cable Coupler Systems

KONNX


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PERFORMANCE RECORD OF COUPLERS IN SERVIC

PERFORMANCE RECORD OF COUPLERS IN SERVICPERFORMANCE RECORD OF COUPLERS IN SERVIC

1

2 3

45

6


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What made them fail?

Goal: Engineer out all the ways a

high voltage coupler can fail.


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RESEARCHING COUPLERS GLOBELYRESEARCHING COUPLERS GLOBELYRESEARCHING COUPLERS GLOBELY

Designs

around the World


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Initial FindingsInitial Findings

Quick Fix Solutions i.e. Teflon

Electrical Type Tests For Connector

Lower Than Requirement For Cable

makin cou ler weak link

Low voltage High voltage


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THE ULTIMATE TESTTHE ULTIMATE TESTTHE ULTIMATE TEST

SHORTSHORT


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Air Trapped Inside Coupler Enclosure

Phase To Phase Flashover

AIR AND PARTIAL DISCHARGEAIR AND PARTIAL DISCHARGEAIR AND PARTIAL DISCHARGE

AIR

PARTIAL DISCHARGE

Existing couplers tested with results exceeding

20,000 pico-coulombs (pC).

Extruded mining cable specifications call for

an average 5 pico-coulombs.


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SOLUTIONSSOLUTIONSSOLUTIONS

Remove Air with Silicon Rubber Insert Insulating Material Developed to ExtinguishInsulating Material Developed to Extinguish

TrackingTracking

SiliconSiliconInsertInsert

InsulatingInsulating

MaterialMaterial


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NO TRIPS OR ANY SIGNS OF FAULTNO TRIPS OR ANY SIGNS OF FAULTNO TRIPS OR ANY SIGNS OF FAULT


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ANALYSISANALYSISANALYSIS

Silicon Rubber Insulating Material

Stepping Stone


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PHASE SEGREGATION BY EARTHPHASE SEGREGATION BY EARTHPHASE SEGREGATION BY EARTH

PHASE

PHASE

PHASE

Mining Industry Standard

EARTH

EARTH

EARTH

EARTH


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A Phase to GroundFault was created

with conductive

paint

Earth Star Placed

Between Phases

A Through Fault Test was then performed on this solution

to see how it would perform in the field

FIRST SOLUTIONFIRST SOLUTIONFIRST SOLUTION


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REASON FOR FAILUREREASON FOR FAILUREREASON FOR FAILURE

PHASE 1

EARTH

PHASE 2

PHASE 3


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FINDING A SUCCESSFUL SOLUTIONFINDING A SUCCESSFUL SOLUTIONFINDING A SUCCESSFUL SOLUTION

.

Equipotential

Lines Good

Earth StarEarth Star

Equipotential LinesEquipotential Lines

Crushed UpCrushed Up

Individually ScreenedIndividually Screened

CableCable

EquipotentialEquipotential

Lines GoodLines Good


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ALL TYPE TESTS PERFORMED WEREALL TYPE TESTS PERFORMED WERE

WITHIN CABLE SPECIFICATIONSWITHIN CABLE SPECIFICATIONS

COUPLERS HOMOGENEOUS

WITH CABLE

COUPLERS HOMOGENEOUSCOUPLERS HOMOGENEOUS

WITH CABLEWITH CABLE

EARTHEARTHCROSS SECTION


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CurrentCurrent

Contacts are of an eight fingerdesign.

Heat treated locking ring to

maintain contact pressure.

Continuous rating of 800A

TYPE TESTS PERFORMED ON NEW DESIGN

Temperature Rise at 800A Passed

Through Fault Test:20kA for 0.3 sec Passed

20kA for 0.3 sec Passed

20kA for 1.0 sec Passed


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Voltage Type Tests PassedVoltage Type Tests Passed

50kV for 1 min

35kV for 6 hours

125kV 10 Pos. Shots and 10 Neg. Shots

Impulse Voltage

A/C High Voltage Withstand

Partial Discharge

10pC Prior to 6 hour high voltage withstand

0.6pC After 6 hour high voltage withstand


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ComparisonComparison

Coupler Now As Good As The CableCoupler Now As Good As The Cable


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From Partial Solution to theFrom Partial Solution to the

Complete SolutionComplete Solution


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Water IngressionWater Ingression

Cable GlandsCable Glands

Existing round O-ring seal

Square section silicon face

seals with a life of 30 yrs

Tested to IP 68 Standard

KonNx gland incorporates adjustments to

maintain tension on cable over time.

Design will tighten on cable if tension on

cable is applied.

Glands are design specifically for cable sizes.

IEC 60529


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Special Cold Pour Developedwith 3M


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BiBi--Sexual DesignSexual Design

All male couplers.

Guide pins assist alignment.

All Silicon 800amp

female/female Phase

connectors w/Rockwell

hardened lock rings

MSHA Compliance.


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Tools & CouplingTools & Coupling

Enclosed slide hammers.

Earth pilot attachment.

Coupling tool.

After together use four bolts to

secure


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Integrated Handling System ForIntegrated Handling System For

Surface Mining ApplicationsSurface Mining ApplicationsAssists with opening and closing couplers

One man operation

Able to relocate couplers while energized.

Protection for the joint.

Roll-over.

Skid wear pads.

Cable clamp at each end.

No tools required


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Eliminating risk of phase to phase faults. Reducing the risk of phase to ground faults

Fully integrated handling systems.

Couplers do not limit the power supply to machines

(All couplers cont inuously rated at 800 amps)

Eliminates need for male/female cable orientation

We listen to our customers and keep improving our products Increase in expected life of coupler.

Over 1000 of our couplers in service since 1992 with no problems

Research & DevelopmentResearch & Development

5% of annual incomeLatest Development is integrated Fiber Optics

Benefits to the Mining Industry


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Track RecordTrack Record 25kV couplers operating in Australian mines since 1992.

In excess of 2000 couplers in Australia, South Africa,

South America, North America and Asia

Specified 25kV coupler byBHP Bill iton.

Rio Tinto.

Xstrata Coal.

Anglo American Coal

Arch MineralsCline Resources

Signal Peak Energy


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Specified 15kv Couplers by:

GCC Energy

Prairie States Energy Project

ICG

Consol Energy

Specified 8kV Couplers by:

BHP San Juan Mine

Arch Minerals

Signal Peak Energy

Patriot Coal

FMC Chemicals

Track RecordTrack Record


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KonNx

25kv konnx coupler.pdf

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