PHOENICS Based Arc Models as a Test Tool for New Design Ideas in Switching Device

J D Yan, T M Wong, *X. Ye, *M. Claessens and M T C Fang

Department of Electrical Engineering and Electronics, The University of Liverpool, Liverpool, L69 3GJ, UK * ABB Ltd, High Voltage Products, Fabrikstr. 13a, 5400 Baden, Switzerland CHAM USER MEETING 2006

BACKGROUND OF WORK

  Liverpool group has long been engaged in atmospheric plasma research in industrial devices such as high voltage switchgear, welding and cutting, material processing and nano-materials production.

PHOENICS has been used in Liverpool for 14 years. Currently we are using version 3.4 and 3.6.1

Microwave Plasma Auto-expansion C.B.

Welding arc

Nozzle

Rotary arc C.B.

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Nozzle Cathode Probe Temperature (K) Anode 5.0E+2 2.4E+3 4.3E+3 6.2E+3 8.2E+3 1.0E+4 1.2E+4 1.4E+4 1.6E+4 1.8E+4 2.0E+4 2.2E+4 2.3E+4 2.5E+4 2.7E+4

 

AN EXAMPLE OF CIRCUIT BREAKER

At high current, vapour from nozzle surface pumped into storage volume to form a high pressure reservoir (fig. on right). At current zero, fast gas flow into nozzle quenches the arc, thus interrupt the current .

2000 1500 1000 500 0 -500 -1000

Current

-1500 -2000 0.020

0.022

0.024

0.026

0.028

0.030

0.032

0.034

80000 60000 40000 20000 0 -20000 -40000 -60000 -80000

Vapour flows towards storage Ablating surface CHAM USER MEETING 2006

    

UNDERSTANDING THE KEY MECHANISMS

Capability of PHOENICS to handle the implementation.

Surface ablation represented by mass, momentum and energy surface sources.

Arc current interact with its magnetic field (Magnetic pinch effect) is represented by momentum source.

Ohmic heating and radiation are treated as volumetric energy sources.

Numeric implementation of moving contact (fig. below) and operation of valves.

A A A

1 2 Mass, momentum and energy taken away at Time 2 and returned to the evacuated cells at Time 3. 3 1 2 3

Mass, momentum and energy added to the cells is equal to the amount that disappears when the cells become solid at time 3. CHAM USER MEETING 2006

DIFFICULTIES WITH ARC MODELLING

    Temperature in the range from 300K to 35000K and with steep gradient (upper fig.). Material properties are highly nonlinear. Pressure ranges from 0.2bar to 100bar. Density changed by order of magnitude.

Radiation is operating. Very strong emission and absorption in thin layer.

Flow field is very complex (lower fig.). Shock waves exist in part of the domain. Implications on convergence and relaxation.

 (  )  t    (   V )    (     )  S   

Equation

Mass of mixture  -momentum (azimuthal) z-momentum r-momentum Enthalpy PTFE concentration 1 u w v h c m 0  l +  t  l +  t  l +  t (k l +k t )/c p  (D l +D t )

S

 0  

vu r

+ (J  B)  + viscous terms  P/  z + (J  B) z + viscous terms  P/  r  

u r

2 - (J  B) r + viscous terms  E 2 -q +dP/dt + viscous dissipation 0

SPECIAL SCHEMES

 To improve and maintain convergence, we used a multi zone false time step for relaxation of momentum and energy equations. The division of the zones is mainly based on density and energy source term For heat source: Zone one: 300 ~10000K Zone two: >10000K or volume energy source higher than 10 8 J/(s.m

3 ).

 Arc – electrode interaction. Difficulty was that arc did not following the movement of the electrode. Special coding was introduced in ground to tackle this problem.

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WHAT WE HAVE ACHIEVED

 An arc model that applies to a range of industrial plasma devices which produce realistic, reasonable results within acceptable time.

 Can simulate the operation of the arcing process and the movement of the mechanical parts.

 Implementation of all important physical mechanisms.

 Use of Liverpool’s arc model for optimization of design and test of new ideas.

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Current (A)

VERIFICATION OF RESULTS

Pressure (Pa)

4.5E+06 4.0E+06 Current (A) 3.5E+06 3.0E+06 2.5E+06 2.0E+06 1.5E+06 1.0E+06 5.0E+05 0.0E+00 0.000

0.010

0.020

Current (A)

80000

Test result

60000

Simulation

40000 0.030

0.040

0.050

0.060

20000 0 -20000 -40000 0.070

-60000

Comparison with test results for an auto-expansion circuit breaker.

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INFLUENCE OF DESIGN PARAMETERS

 Circuit breaker design is expensive.

 To produce results matching measurement is only the first step.

 Complicated phenomenon, such as fast pressure transient, was observed and identified as an important aspect of circuit breaker design. Reasons for pressure transient are to be identified.

 Aim is to answer the whys and hows in circuit breaker design. For example if we change a design parameter how the arc behaves differently? Beneficial or adverse effects on circuit breaker performance.

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INFLUENCE OF DESIGN PARAMETERS

For Case FG holes For Case FG holes high f For Case FG holes low f Heating chamber Results are compared for pressure at point D which is an important location.

Heating channel Moving contact CHAM USER MEETING 2006

Pressure (Pa)

INFLUENCE OF DESIGN PARAMETERS

Current (A) 4.5E+06 4.0E+06 3.5E+06 3.0E+06 2.5E+06 2.0E+06 0.030

Reference case 0.031

60000 40000 20000 0 -20000 0.032

reference Length2, constant V Series6 current 0.033

-40000 -60000 Time (s) 0.034

Arc column shrinks rapidly near current zero, thus creating low pressure region. This process races with gas from high pressure reservoir.

Influence of length of heating channel CHAM USER MEETING 2006

INFLUENCE OF DESIGN PARAMETERS

Pressure (Pa) Current (A) 4.50E+06 6.00E+04 Reference case 4.00E+04 4.00E+06 2.00E+04 3.50E+06 0.00E+00 3.00E+06 -2.00E+04 2.50E+06 reference FG holes high f current 2.00E+06 0.030

0.031

0.031

0.032

FG holes FG holes, low f 0.032

0.033

0.033

Time (s) 0.034

-4.00E+04 -6.00E+04 0.034

For Case FG holes For Case FG holes high f For Case FG holes low f Influence of internal structure CHAM USER MEETING 2006

TO TEST NEW DESIGN IDEAS

Link channel Pressure recording Inlet A Pressure recording GOOD OR BAD IDEAS? CHAM USER MEETING 2006

4.50E+06 4.00E+06 3.50E+06

TO TEST NEW DESIGN IDEAS

3.00E+06 2.50E+06 2.00E+06 0.0280

Buffer-DV-B1 Reference Buffer-EV-B2 Linked buffer-EV-Blocked Linked buffer-EV-Valve Current 0.0290

0.0300

0.0310

Tim e (s) 0.0320

GOOD IDEAS? CHAM USER MEETING 2006

0.0330

6.00E+04 4.00E+04 2.00E+04 0.00E+00 -2.00E+04 -4.00E+04 -6.00E+04 0.0340

WHAT CAN BE DONE FURTHER

 On fundamental level, we need a more accurate radiation model for gas mixture of SF6 and PTFE.

 Convergence problem is not fully solved, especially with skewed grids (BFC).

 On PHOENICS side, parallel computation for speedy simulation, unstructured grids for 3D simulation.  Associated issues such as calculation of electric field and radiation transfer etc in unstructured grid system.

 Post-processing. CHAM USER MEETING 2006