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8/22/2019 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