Electrical Review August-2010

8/9/2019 Electrical Review August-2010

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Inside this issue:

I Technology improves cable fire safetyI SIMply the best for fault location

I SuperCap UPS fast response, long lifeIMethodical risk identification

MINISTER ANNOUNCES 8.4MPLASTIC ELECTRONICS INVESTMENTA range of specialist plastic

electronics businesses are to

benefit from a total of 8.4m

investment in research and

development into new technologythat will lead to the creation of a

range of new products such as

conformable and rollable electronic

displays, ultra-efficient lighting and

low-cost, long-life solar cells.

The investment was announced

by the universities and science

minister, David Willetts, during a

speech to the Tomorrows Giants

conference in London. Thirteen

projects, involving more than 30

industrial and academic partners, will

benefit from the funding allocated as

a result of two competitions run by

the government-backed Technology

Strategy Board.

Minister for universities and

science David Willetts said: It is

early days for this emerging field,

but plastic electronics will give rise

to a range of new excitingproducts, such as ultra-efficient

lighting and cheaper, longer-lasting

solar cells. Looking ahead, this

technology offers enormous

potential to help our local

environment, improve our everyday

standard of living and support the

nations economy.

The global market for plastic

electronics is now worth almost

$2bn (1.337bn) and is forecasted

to grow to as much as $120bn

(80.19bn) by 2020. The funding

Ive announced today is important

in supporting UK businesses to be

world leaders in one of the key

industries of the future.

Commercially exploiting the

outputs of the UKs world-leading

science and research base has a

vital role to play in helping oureconomy to grow.

7.4m has been offered to eight

projects to help build the supply

chain and to overcome the barriers

to UK exploitation of plastic

electronics technology, including

over 800,000 from the

Engineering and Physical Sciences

Research Council (EPSRC). A further

1m has been offered by the

Technology Strategy Board to five

projects to encourage UK

businesses to use plastic electronics

in their product development by

producing demonstrators with

potential for real commercial value.

News Page 3 Power cables Page 10 UPS Page 20 Building services Page 24

August 2010 Volume 243 No 8

KNX UK Association member

Andromeda Telematics (ATL)

was shortlisted in the KNXInternational Awards, presented

at the 2010 Light+Building

Exhibition in Frankfurt, for the

company's O2 project in Dublin.

The project is a showcase of

progressive design and building

services providing an integrated

control solution for the

renovation, delivering KNX/DALI

colour change functionality as

well as an emergency lighting

test system.

The KNX/DALI solution

includes lighting scene control

for public areas, controllable via

local touch screens and a central

headend. There is also local

scene set control and dimming

in the private bar areas, as well

as local control in all back-of-

house areas for override of

lighting condition. The external

lighting controls feature lux

sensors which activate lighting at

dusk. An override function isavailable for periods where the

building is unoccupied.

For the latest news, products and event information visit www.electricalreview.co.uk

ELECTRICAL

REVIEW

TUV ACQUIRES LAIDLER GROUP SHARESTV Product Service, a UK subsidiary

of the TV SD group, has acquired

the shares of the Laidler group of

companies, the UK machinery safety

compliance organisation. Operatingfrom offices in Cleveland and

Yorkshire, the Laidler group has

consolidated sales of 2.6m and 30

employees.

The acquisition of Laidler brings a

wealth of experience in machinery

safety to our UK organisation and aposition in the UK that is second to

none, said Jean-Louis Evans,

managing director of TV Product

Service. We feel there are

considerable synergies between our

organisations and bringing the two

organisations together will establish amuch stronger Machinery Safety

business for TV SD in the UK.


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3/36www.electricalreview.co.uk 03

Nexans has signed a draft agreement for the

creation of the trans-Mediterranean super-grid

Transgreen with 12 other industry partners, in

the presence of the French minister of ecology,

energy, sustainable development and sea, Jean-

Louis Borloo, the French Republic presidents

special advisor, Henri Guaino and the French

secretary of state for european affairs Pierre

Lellouche.

Transgreen is an unprecedented industry

initiative aimed at studying the feasibility of a

power transmission grid between the northern

and southern shores of the Mediterranean and

at developing interconnections around the

Mediterranean Basin. It is part of theMediterranean Solar Plan (MSP), which provides

for the building of renewable mainly solar

power generation facilities in the southern and

eastern areas of the Mediterranean, with a total

output of 20 GW by 2020.

The 13 signing companies will collaborate

within a common legal entity, especially in

order to propose the technical and economical

master plan for a trans-Mediterranean super-

grid with 5GW export capacity to Europe by

2020.

Nexans generates about half of its sales inthe infrastructure market and has recognised

expertise in the design and installation of high

voltage submarine power links, therefore it was

obvious for us to participate in Transgreen. As

access to electricity remains a vital need for

human beings, it is more essential than ever to

get involved in responsible projects which make

it possible not only to build and interconnect

new grids but also to develop renewable

energy resources, said Frdric Vincent.

Power grid performance is central to Nexans

strategy. In fact, Nexans offers a complete

portfolio of terrestrial and submarine high-

voltage AC and DC cables and cabling systems,

with products and services which enable

integration of alternative energy sources into

the grid, real time monitoring of infrastructure

for increased reliability and installation of newmaterials including superconductorsfor

improved performance.

Leveraging its expertise in high-voltage

submarine power transmission, Nexans has

many references in this field, such as the link

between Morocco and Spain, the NorNed link

between the Netherlands and Norway and,

more recently, the COMETA link between the

Spanish mainland and the Balearic Islands. In

recent years, Nexans has also demonstrated its

skills in connecting renewable energy resources

by participating in numerous offshore windfarmprojects worldwide, including Barrow (England),

Horns Rev (Denmark), Lynn & Inner Dowsing

(England) and Wolfe Island (Canada).

Siemens is to supply 68 wind turbinesfor the Griffin onshore wind farm inScotland. The wind power farm willhave a capacity of 156 MW upon itscompletion in 2012, and is expected togenerate enough power to supplyover 80,000 homes. The scope ofsupply for the Griffin wind farmincludes the delivery, installation, andcommissioning of 68 of Siemens 2.3-MW turbines. Of the 68 turbines, 61will have a 101m rotor and 7 will havea 93m rotor. This is the first time aSWT-2.3-101 will be deployed in the

UK. Siemens will also provide servicesfor turbine operation andmaintenance for an initial period offive years.

TRANS-MEDITERRANEAN GRID

SIEMENS WINSWIND CONTRACT

CONTENTS

03 | NEWS06 | OPINION08 | GOSSAGE12 | POWER CABLES

16 | ARC FLASH22 | UPS

25 | PRODUCT WATCH26 | BUILDING SERVICES32 | CLASSIFIED35 | BLOWN FUSE

When a power service

engineer is called out to

deal with a loss of

supply on a customers

HV distribution

network, the chances

are it will be traced to a

faulty undergroundcable that has caused a

device such a circuit

breaker to operate

and cut off the power

With IT central to the

successful operations

of most modern

organisations, the

UPS system has a

central position in the

critical physical

infrastructure which

supports servers,

storage and

communications

equipment, and

ensures continuity ofservices during all

local mains conditions

Recolight, the specialist WEEE compliance

scheme for the lighting industry, has

announced a partnership with recycling

scheme, CoBRA (Community Bulb Recycling

Alliance) to increase consumer access to

collection facilities for low-energy light-bulbs.

Founded by Mark David Hatwood in 2007,

CoBRA was initially established to provide

community recycling for waste batteries. The

scheme works by recruiting volunteers to place

collection containers in community locations

and then take responsibility for collecting the

waste and taking it to a central collection

facility. Through this partnership with

Recolight, the CoBRA scheme will be adaptedto provide community collection of low-energy

light-bulbs, using Recolights new in-door

light-bulb collection container.

SCHEME TO INCREASE

LAMP RECYCLING


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EDITORElinore Mackay 020 8319 [email protected]

ADVERTISEMENT MANAGERNeil Coshan 020 7933 [email protected]

PRODUCTION MANAGERTania King 020 7933 [email protected]

CLASSIFIED SALES EXECUTIVEJohn Steward 020 7933 [email protected]

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Laurence Pountney HillLondon EC4R 0BL020 7933 8999

PUBLISHING DIRECTORChris Cooke

PRINTING BYWilliam Gibbons

Any article in this journal represents the opinionsof the author. This does not necessarily reflect theviews of Electrical Review or its publisher StJohn Patrick Publishers

ISSN 0013-4384

All editorial contents Saint John Patrick

Publishers Ltd 2010. Jan-Dec 2009 6,484

NEWS

The new ABB swappage scheme is supported by

a recycling programme that this year recycled 13

tonnes of waste variable speed drives, recover-

ing over 90% of their component materials by

weight. The ABB swappage scheme offers at

least 17.5% off the list price of a new ABB drive

and will swap out incumbent drives from any

manufacturer.

The ABB recycling programme, now in its

eighth year, takes these scrapped drives and re-

cycles them according to the WEEE Directive, even

though drives are not covered by the legislation.

Once the drive has been removed for recy-

cling, ABB issues a certificate that can be used

for environmental audits by end users complying

with ISO 14001.

PROGRAMME RECYCLES13 TONNES OF WASTE VSDS

David Pollock, group chiefexecutive officer of theElectrical ContractorsAssociation ECA, will retireat the end of September2010. His successor will beSteve Bratt, C Dir, MBA, theECAs Deputy CEO.Following his retirement,Pollock will continue as anadviser to the association; hewill represent ECAs interestsin Europe and in lobbyingand representational work.Pollock said: I have spent anexciting and fulfiling 13 yearswith ECA. I am very gladthat Council has agreed thatmy successor should be SteveBratt. I wish him, ourPresident, Diane, the otherOfficers and all the Membersand staff the greatestpossible success. I amlooking forward to a very

active retirement and I am glad I shall becontinuing to represent the ECA in someimportant areas.

Balfour Beatty Engineering Services BBEShas announced a key business developmentappointment. Henry Mayes has joined thecompany as business development manager forLondon and the South East. Mayes will reportto business development director Bill Merry,and will assume responsibility for new businessdevelopment. He joins from M&E designconsultant Maleon and will be based in theRedhill office.

Hochiki Europe has announced a series ofsenior level appointments that will drive thecompany forward and strengthen its marketposition. Tomoki Ikeda pictured is now themanaging director of Hochiki Europe, while hispredecessor, Minako Adachi, stays within theHochiki organisation as its executive officer ofoverseas division based at HochikiCorporations Headquarters in Tokyo, Japan.Meanwhile, Kevin Restell has been promoted asHochiki Europes operations director and joinsthe board of directors.

PEOPLE

HenryMayes

TomokiIkeda

DavidPollock


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OPINION

HOW MANY electrical contractors does it take to

change a light bulb? It doesnt really matter,

because, with the double focus nowadays on

health and safety and sustainability, the real

question should be: Do they know whats

being done with the old one?

As efficient electrical waste disposal gets

both more complex and more necessary for

financial, operational and legal reasons - those

nvolved in electrical engineering and building

services would be unwise not to pay heed to

the answer, a fact that one recent prosecutionhas shed some revealing light on.

The sustainability lobbys continued success

n promoting the balancing of successful

business with effective environmental

protection (not to mention the wellbeing of the

mmediate workforce) has ever greater

ramifications for the industries responsible for

creating and managing the built environment.

Sustainability, above all, is an area where

electrical contracting, now worth some 8bn

per year, has a key role to play, with the

opportunity to propose low or no CO2 options.

But to play its role successfully the industry

must also pay close attention to the matter of

the waste the alternative option creates, and

how it is disposed of. Developments such as

the WEEE regulations (Waste Electrical and

Electronic Equipment Directive) impose legal

obligations on contractors over the

management of waste streams onsite, and in

their subsequent disposal. It aims to improve

the environmental performance of businesses

that manufacture, supply, use, recycle and

recover electrical and electronic equipment

and has put the practical management ofsustainability centre stage. For the electrical

contractor its implications are unavoidable.

Energy efficient light bulbs (end-of-life gas

discharge lamps) are covered by the WEEE

regulations and present a particular challenge,

because they contain mercury and are classified

as hazardous waste. When these lamps are

recycled the potential release of mercury into

the air at the lamp crushing stage is a threat to

both the wider environment and those in the

vicinity if the right protective equipment is not

in place. Each time a fluorescent bulb is

crushed or broken, mercury vapour is released.

If the gas is not effectively captured, that

vapour will find its way into the atmosphere,

the staff and others in the area.

The challenges of lamp recycling made

headlines earlier this year when a Glasgow-

registered company, Electrical Waste Recycling

Group, and one of its directors, were fined a

total of 145,000 plus costs after recycling

processes being used for gas discharge lamps

exposed workers to toxic fumes for a period of

up to ten months.

If an electrical contractor is going to proposethe likes of optimal lighting configurations or

energy efficient lighting units, and if they are

tempted to employ energy efficiency as a sales

tool, they should be confident that the

principles and practice that underpin

sustainability and safety are being applied all

the way through the supply chain, including

what happens to the waste.

Bulb crushing on an industrial scale is a

serious undertaking that comes with huge

levels of environmental responsibility.

Nevertheless, electrical contractors may face the

prospect, perhaps even at the tendering stage,

ELECTRICAL CONTRACTORS

CAN NOT AND MUST NOT

TAKE THE RECYCLING OF

FLUORESCENT BULBS LIGHTLY

SAYS TERRY ADBY Shedding lightRESPONSIBLY


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of client pressure to commit to deliver such a

service. Contractors need to be completely

confident of the ability of the suppliers they

choose to meet their commitments. They also

need to know what is being done in their

name further down the supply chain.

In the case of Electrical Waste RecyclingGroup, it was the failure to ensure the safety

of the lamp crushing phase of the recycling

process at its Huddersfield plant that let

down the company, their workforce and the

local environment. EWRG, which runs

easyWEEE, WERCS (Waste Electrical Recycling

Compliance Scheme) and other recycling

schemes, were contracted to handle

commercial waste for several Local

Authorities, which included light bulbs. While

none of these clients were in any way

implicated along with their supplier, thejudgment in the case suggests others in the

chain such as electrical contractors - could

be more vulnerable. It has already been

indicated in court that putting a service out to

a third party does not absolve an organisation

of key responsibilities and, in respect of

health & safety, the HSE - which brought the

successful prosecution in the EWRG case - has

said that The client must ensure whoever

carries out the work is able to do so in a way

that controls risks. As this case suggests,

sustainability and health and safety

responsibilities often go hand in hand.

Some of the details of the EWRG judgment

highlight the type of issues any business,

including electrical contracting businesses,

should take into account to ensure they and

their suppliers comply with statutory

requirements when dealing with waste. The

promises of suppliers, the judge made clear,are no defence in the eyes of the law. They

must be effectively monitored.

One of the judges major criticisms was the

lack of an effective risk assessment process at

the EWRG recycling centre, not least because

issues highlighted such as excessively high

mercury levels for no apparent reason - could

have been rectified much earlier had risk

assessment been in place. It is, in any case, a

legal requirement for an employer in

discharging their obligations to keep workers

and the public safe as far as "reasonablypracticable".

The HSE recommends five steps for effective

risk assessment: identification of hazards;

establishing who might be harmed and how;

evaluation of risk and deciding on precautions;

recording and implementing findings and

regular review. Suppliers in a business as

hazardous and regulated as lamp recycling

should certainly be implementing all five.

Those employing them to do the work should

be equally concerned that they are.

The judge in the EWRG case also stressed the

need for competent staff to be involved in the

process monitoring, who understand the

regulations and have the knowledge and

experience to spot a breach or issue. Most

successful organisations, he said, have

employees who understand why risk

assessment and vigilance is important for the

company, staff and other groups with aninterest, such as the local community.

However, all responsibility cannot be

delegated to one individual or team, he added.

Senior managers need to put themselves in the

position of being able to interpret and

understand the implications of the results of

any monitoring which is undertaken. If they do

not understand the implications of results, they

cannot just ignore them. In the case of a

prosecution it will be the senior managers and

directors who will be held responsible. It is

clear, above all, when things go awry, buckpassing between organisations or individuals is

not an option.

EWRG paid a heavy price because it did not

read nor heed the warning signs. Those looking

for lessons from its prosecution certainly

should however. The safe recycling of energy

efficient lamps may represent a beacon for a

better future but, viewed from both an

environmental or health and safety perspective,

the message for electrical contractors is clear:

the responsibility for a safe and sustainable

approach to lighting may not end with the life

of the low-energy bulb.

OPINION

When things go awry, buck passing between

organisations or individuals is not an option


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OPINION

CHALLENGE TO YOUNG RIVALGOSSIP!

GOSSAGE!

HEBRIDES RAINDANCE

LEARNING TIMES TABLES

08 Electrical Review August 2010

The Climate Change Committee is a frightfully important entity. Formed as a

result of the Climate Change Act 2008 to ensure the UK remains on track to be

the worlds most eco-friendly nation, it consists of a set of Commissioners

drawn from the Great and Good. Led by the former head of the CBI, Adair

(now Lord) Turner. Who also heads the Financial Services Authority in his

spare time.

Periodically the Committee issues large reports. Which consistently seem to

conclude that, whilst the UKs aspirations to reduce carbon dioxide emissions

are splendid, we must do better regarding progress on the ground. These

reports are littered with serious statistical recommendations for how best

progress should be made. Each of which the government is supposed to act

upon immediately.

However, dig a little deeper. And you do begin to wonder just how reliable

some of the figures are. For instance, when launching the latest progress

report, mLord Turner thundered that to keep the eco-trajectory going - the

number of homes where insulation is placed within the external cavity walls

should be running at 1.2m each year. This means doubling the number

currently being insulated.

His Lordship did not misread his script. The accompanying press release

contained precisely the same demands. The number of homes each year

having cavity wall insulation installed must be doubled. No less than 1.2m

should be improved each year. But if you consult the official agency that

issues guarantees after every such installation, they will tell you that this year

the total number of homes benefitting is around 400,000. Getting the rate up

to 1.2m a year wouldnt be doubling. It would be tripling the size of themarket. If Lord Turner really cannot tell the difference between times two

and times three, it is probably a relief to know his spare time job chairing

the Financial Services Authority is coming to an end.

I have in the past chronicled the woes of the previously highly successful

Renewable Energy Association. Not least when in 2008 a lowly book-keeper

in the finance department absconded with 247,000 of its members cash.

Which on a turnover of 604,000, left rather a large hole in its finances.

Membership fees were immediately hiked, some by over 20%. Several

companies opted out. Its founder and CEO Philip Wolfe took early

retirement. And one long-established rival association suddenly woke up to

the opportunities offered.

The British Wind Energy Association (BWEA) had been around since 1978.

Despite windpower being far and away the largest renewable power option,

it remained unconcerned about its younger rival the Renewable Energy

Association covering not just all the other non-fossil fuel options. But also

bringing into membership many of the big players, especially in the

burgeoning off shore windpower field.

This year the BWEA has had a complete shake-up. It has re-examined its

objectives. It has brought into membership new companies (some 600 now).

And most significantly it has changed its name. To become RenewableUK. A

direct challenge to the wounded upstart, the REA.

No question where Whitehalls sympathies lie. Whilst chief executive Maria

McCaffrey MBE remains in post, despite the name change, ministers and top

civil servants queue up to appear on her public platforms, meet with her

privately, all signs of official approval. I was going to say let battle

commence. But actually I rather think the battle is already over.

They are praying for rain in the Hebrides. Most especially on the

picturesque island of Eigg. Because the 70 people who live there

would like to go back to having toast for breakfast.

Normally practically all the islands electricity is provided by

hydro-power. But as there have been three months with almost

no precipitation, the islanders are having to forgo using any of

their optional electrical appliances. Like toasters.

This is not the first time there has been insufficient rain to

power the island. Which is precisely why they have retained

diesel generators for back-up. However there is a distinct

reluctance to bring these back into use.

Why? Because just last January, the community took up a

challenge of a 300,000 prize (amongst 700 people!) to becomeone of Europes lowest carbon communities. And that could be

forfeited if they succumb to cranking those old diesel generators

back into action.

THE NEW ASBESTOSCheerleaders for the Great God Atom like to promote its virtues by

emphasising how nuclear can substitute for energy imports. And

particularly energy imports from unreliable countries. Whilst that is

certainly not true for most of the components nor of their suppliers, most

of which are definitely neither UK owned nor domiciled, there is one key

component which everyone accepts simply can never be found on these

shores.

There are only a handful of counties around the world where uranium

is to be found. According to that impeccably neutral source, the World

Nuclear Association, the total amount of recoverable uranium supplies

worldwide is some 5.469,000 tonnes. Concentrated in a very few places.

By far the biggest of these is Australia, with 1,243,000 tonnes. Where

curiously enough no nuclear power is permitted.

Australia has been the most reliable past supplier. But will it be in

future? Not if the powerful Australian Electrical Trades Union has its way.

It is banning its members from working in uranium mines because and I

quote uranium is the new asbestos in the workplace. Australian

unions, particularly as now under a Labor government, are not to be

trifled with. If they wont mine the stuff for health reasons, chances are it

wont get mined.

But whilst it is the biggest potential source of uranium, Australia is notthe only one. There are other countries with substantial reserves. The next

two biggest are Kazakhstan (with 817,000 tonnes). And Russia (546,000

tonnes). Obviously it is perfectly possible to trade with both countries. If

the promised expansion of nuclear ever goes ahead, we may well have to

do so. But do remember. These are precisely the kind of unreliable

suppliers which those in the nuclear lobby who scare us about the

dangers of energy imports endlessly warn us about.


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10/36

POWER CABLES

The microstructure of the

Infit insulation after a fire

(magnified 5000 X in an

electron microscope)

On the left, the Infitinsulation after a fire and

on the right, conventional

insulation


FIRE-RESISTANT cables play a crucial role in applications

where it is essential to ensure the integrity and continuity

of vital safety circuits during the critical building

evacuation and fire fighting periods required by stringent

national and international standards. In many cases, the

need for cables that can deliver the required levels of

performance, reliability and safety has forced designers

and installers of electrical systems to compromise on

other desirable properties regarding ease of handling andinstallation.

Now though, a major advance in the materials science

related to the properties of the cable insulation called

Infit is making it possible to produce new families of

electrical power and data cables with outstanding fire

resistance using classical extrusion methods. The result is

a user friendly cable that offers the best of both worlds.

Eliminating the need to chose between insulationtechnologiesUntil now, the cable industry has mainly relied on two

major technologies to insure the integrity of flexible cableinsulation during a fire: XLPE/Mica taping and ceramic

forming silicone rubbers.

Each of these technologies presents a number of

advantages. The classical insulation taping based on Mica,

and largely used since the 80s, can easily be implemented

on an industrial scale to provide a tough, effective

electrical insulation when overlaid with a cross-linked

polyethylene (XLPE) coating. It is strong but stiff to handle,

so can present some installation difficulties.

On the other hand, silicone rubber insulation can be

extruded directly on to the conductors, and offers a good

compromise between fire performance and ease of

installation thanks to its flexibility. It is, however,

vulnerable to cuts and tears.

Increasing customer demands for improved fire

performance, together with strippability, ease of

installation and connection prompted Nexans to searchfor a new insulation technology that could offer all these

benefits.

Infit transforms into a tough insulating ceramiclayerInfit is a unique, proprietary innovative technology that

combines, in a polymeric material, the advantages offered

by both the tough mica tapes layer and the extruded

silicone insulation layer. This now enables the manufacture

of fire-performance cables that are both tough and easy to

handle as well as being easy to strip and install.

Infit technology offers enhanced fire-performancebecause when the insulation is exposed to fire, it

transforms from a flexible, plastic covering to a tough

insulating ceramic layer, hardening like clay in a potters

oven to form a protective shield. The key to the success of

the new insulation has been in using advanced materials

and polymer science to optimize the nanostructure of the

primary insulation materials. A combination has been

found that reduces the occurrence of cracks or breaks in

the insulation to preserve the operational integrity of the

circuit i.e. preventing short-circuits.

Extensive laboratory tests have shown that cables with

Infit insulation will to continue to deliver power in the

event of a fire, long after the plastic sheath and insulation

have burnt away. This means, for example, exit lighting,

smoke and heat exhaust ventilators, fans or pumps will

still function reliably, even in areas directly affected by fire,

ensuring safe evacuation.

The science partThe new technology is the result of some ten years of

development by the Nexans International Research Centre

based in Lyon, France, working in close partnership with

the Australian Nexans R&D Centre. The successful

outcome of the project has been based on fundamental

studies that especially highlight the synergy betweenceramic science and the latest polymer science.

In classic ceramic science, a well defined curing process

is followed to form a high performance ceramic. Yet, in

BY ARNAUDPIECHACZYK,R&D GROUP

LEADER, NEXANSINTERNATIONAL

RESEARCHCENTER

Infit technology improves



the case of accidental fire, the temperature increase is

sudden and unmanaged. So the first challenge was to

develop a ceramic forming system able to react and form

an electrical insulating shield in a very short time across a

wide range of temperature increases, while also exhibiting a

high level of electrical insulation.

The second parallel challenge was to achieve this

performance using an extrudable formulated polymeric

material, rather than a powder, that was also suitable for thevery demanding standards of the cable industry. As a result,

Infit technology is principally based on filled copolymers of

polyolefins (like polyethylene). This kind of polymeric matrix

is well adapted to the extrusion process, and well known in

the cable industry - but it is also intrinsically highly

combustible. However, Infit uses the synergy between this

combustible matrix and a mixture of inorganic fillers to

create a new insulating material that offers superior fire-

performance.

Infit applicationsDepending on the specific cable application, the new

insulation material can be offered in either a cross-linked or

thermoplastic version. This will enable cables to offer the

ideal combination of fire, mechanical, electrical or thermal

properties optimized for each application.

Infit is a proprietary Nexans technology, and can be

implemented in compliance with many worldwide cable

standards, and according to the most rigorous productquality and safety criteria. Nexans cables insulated with Infit

can, for example, resist fires reaching temperatures of

around 1,000C, at voltages up to 1kV, exhibiting a high

level of char cohesion and electrical insulation.

Infit is gradually being deployed across the Nexans fire

resistant product ranges. This will include power,

communications, control and LAN cables for use in public

building and industrial applications and it is expected to be

of particular interest to the marine sector.

electrical

cable FIRE SAFETY

POWER CABLES


12/3612 Electrical Review August 2010

POWER CABLES

A CABLE in good condition and installed correctly can last

a lifetime well over 30 years. However, cables can beeasily damaged by incorrect installation or poorly

executed jointing, while subsequent third party damage

by civils works such as trenching or curb edging is also

another main cause of damage.

Service engineers are usually equipped with a suite of

test equipment that enables them to perform an

immediate on site check on the

key network elements of

switchgear, transformers and

cables. If the fault is identified

in a cable, as it often is, and the

network is interconnected, theyare then able to sectionalise the

problem circuit to restore

power to as much of the

network as possible, bringing in

additional generation if

necessary. The next task is to

locate the position of the

underground cable fault as

accurately as possible, since this

makes it easier to find and repair so that the full network

can be restored quickly.

ABB has developed a fault location regime that has

proved very accurate in locating underground cable

faults in both modern XLPE type cables and older

PILCSWA (paper insulated lead covered steel wire

armoured) designs. Fault location is usually carried out

on cable networks up to 11 kV, however the techniques

can be applied on cables up to 33 kV.

The main technique employed is the SIM (secondary

impulse method) that combines the use of classic high

voltage surge generator thumping with low voltage TDR

(time domain reflectometry). To see how this works, it is

useful to consider the merits of the individual techniques.

Cable thumpingThe high voltage surge generator, or thumper, is a

portable device that is used to inject a high voltage DC

pulse (typically up to 30 kV) at the surface termination of

the cable to be tested. If the voltage is high enough to

cause the underground fault to break down it creates anarc, resulting in a characteristic thumping sound at the

exact location of the fault.

Historically, fault location was carried out by various

measuring techniques and by setting the surge generator

to thump repeatedly, and then walking the cable route

until the thump could be heard. At which point x would

mark the spot to start digging. Naturally, the higher the

DC voltage applied the louder the resulting thump and

the easier it becomes to find the fault. If the cable is long

it could take days to locate a fault by this method. During

which time the cable is exposed to potentially damaging

high voltage thumping. So while the existing fault mightbe located, other areas of the cable could have been

weakened in the process. Statistically, cables that have

been thumped tend to fail sooner than would otherwise

have been expected.

TDRTDR (time domain reflectometry) uses a pulse echo range

finding technique, similar to that used by sonar systems,

to measure the distance to changes in the cable structure.

It works by transmitting short duration low voltage (up to

50 V) pulses at a high repetition rate into the cable and

measuring the time taken for them to reflect back from

areas where the cable has low impedance, such as at a

fault. The reflections are traced on a graphical display

with amplitude on the y-axis and elapsed time, which

can be related to the distance to the position of the fault,

on the x-axis.

A cable in perfect condition will not cause any

reflections until the very end, when the pulse encounters

an open circuit (high impedance) that results in a high

amplitude upward deflection on the trace. If the cable

end is grounded ie a short circuit, the trace will show a

high amplitude negative deflection.

Low voltage TDR works very well for the location of

open circuit faults and conductor-to conductor shorts.However, for shielded power cables, it becomes very

difficult to distinguish faults with a resistance higher than

20 ohms. Unfortunately, the majority of faults in

WHEN A POWER SERVICE ENGINEER IS CALLED OUT TO DEAL WITH A LOSS OF SUPPLY ON A

CUSTOMERS HV DISTRIBUTION NETWORK, THE CHANCES ARE IT WILL BE TRACED TO A FAULTY

UNDERGROUND CABLE THAT HAS CAUSED A DEVICE SUCH AS A CIRCUIT BREAKER TO

OPERATE AND CUT-OFF THE POWER. DANNY OTOOLE, ABB POWER SERVICE, EXPLAINS

SIMply the best for locatingUNDERGROUND cable faults

The higher the DC

voltage applied

the louder the

resulting thump,

and the easier it

becomes to findthe fault

The surge

generator used as

part of the SIM

fault location

technique


13/36


14/36

POWER CABLES

underground distribution cables are high resistance

faults in the area of thousands of ohms or even

megaohms.

SIMThe SIM (secondary impulse method) technique

combines low voltage TDR and a thumper in an

integrated system that makes the trace easier to

interpret, with a clear indication of the fault location on

a handheld display.

The process starts by running a TDR test on a healthy

core, this is then stored in the SIM system memory. The

thumper is then triggered to send a single HV pulse, and

while the arc is forming at the fault the TDR sends a

further low voltage pulse. The arc acts as a very low

impedance point that

causes the pulse to

reflect in exactly the

same way that it would

from a short circuit. Thehandheld display

combines the two traces

and the fault location is

shown as a large

negative dip, with its

distance easily read off

on the x-axis.

SIM enables a fault to

be located to within a

few metres, even over

very long cable runs of several kilometres. Of course,

underground cables do not always take the shortest ormost direct route between two points, so it is important

to have access to the site cable records. In cases where a

map of the cable route is not available a radio-detection

system can be used to find the cable, but this could add

a considerable amount of time to the exercise. ABB

would always advise customers to make a detailed

record of their underground cable circuits a priority in

their maintenance planning.

Once the target area above ground has been

identified, the surge generator is turned on to start

thumping the cable. The operator then listens for the

thump to home in on the precise location of the fault

this approach minimises the amount of time that the

cable is thumped, eliminating the risk of further damage.

The next step is to bring in the repair team to dig up the

cable, make a visual confirmation of the problem and

then effect a repair.

The time taken to locate a fault by SIM varies

according to each case, but will typically take around

half a day.

Fast track fault location for Silverstone CircuitSilverstone Circuit, located on the border between

Northants and Buckinghamshire, has its own high

voltage power network comprising 17 11kV/433V

substations that provide local power supplies at key

points around the three-mile track. ABB has a long-

standing service contract for the network to provideongoing maintenance and repair services including a

fast call-out response in the event of a fault.

At 6am on 1 July 2008 the ABB duty stand-by

engineer fielded an emergency call saying that there

was a major outage, with a total loss of power to half

the site. In normal circumstances this would be a cause

for concern. With the British Grand Prix taking place on

the Sunday and hospitality organisers and traders

already setting up on site, the loss of power threatened

to cause significant disruption.

Within an hour, an engineer was on site. After

establishing the fault was on Silverstones own networkthey opened discussions with Central Networks, the local

DNO (distribution network operator) to organise

reinstatement of supply. A thorough test and inspection

showed the problem was not due to faulty switchgear,

but was cable related. So ABBs specialised cable fault

location vehicle was called to the site together with

spare cable and joints.

While waiting for the fault location vehicle, the fault

was successfully sectionalised so that it was isolated

from the rest of the network, ensuring it couldnt cause

any further loss of power. This step enabled Central

Networks to restore full power to the rest of the site at

around 9.00am.

The fault location vehicle arrived at 10am, and in less

than two hours the cable fault was located to an area

beneath the tarmac base under a hospitality marquee

erected for the F1 Paddock Club.

The next stage was to expose the identified section of

cable for a visual verification of the damage. A further

10m of trench was then exposed to enable a new

section of cable to be jointed into place. By 10pm, the

jointing operation was finished, pressure tested,

energised and phasing proved so that power could be

restored to this local section of the network. All that

remained was for the trench to be backfilled andrecovered by tarmac. So what might have caused very

severe disruption in Silverstones busiest week of the

year effectively became a minor incident.


Top: Listening equipment is used tolocate the thump that indicates theprecise position of the cable faultafter the SIM technique has guidedthe service engineer to the generalarea

Bottom: Silverstone Circuit wherecable fault location helped find andrepair a major outage in the run upto the British Grand Prix

The graph shows a typical SIM trace. The dip indicates the location of the fault that can be read off

on the x-axis as the distance from the end of the cable


15/36


16/3616 Electrical Review August 2010

ARC FLASH

AN ARC FLASH can be hotter than the surface of thesun. Typically, the arc flash is triggered, for example,

when a short circuit occurs in electrical switch gear,

often during maintenance work. An arc flash can

only occur if the fault

current is very high

several tens of

thousands amps. The

massive energy

released in the fault

instantly vaporises the

metal conductors

involved, blastingmolten metal and

expanding plasma

outward with extreme

force. In addition to

the explosive blasts of

such a fault, much of

the deconstruction

arises from the intense

radiant heat produced

by the arc.

Everybody

knows artificial

electrical arcs

from arc welding

physically seen

an arc flash isthe same but with magnitudes of higher intensity.

The metal plasma arc produces tremendous amounts

of light energy from far infrared to ultraviolet.

Surfaces of nearby people and objects absorb thisenergy and are instantly heated to vaporising

temperatures. The effects of this can be seen on

adjacent walls and equipment; they are often

ablated and eroded from the radiant effects.

Globally accepted studies with regard to the

distribution of thermal injuries have shown apart

from the hands, the head and face are top of the list

of this concerning ranking.

Plastic shields manufactured from polycarbonate,

propionate or acetate providing sufficient thickness

can protect against:

LConventional heat (the plasma heat ball)

L Fragments (primarily or secondarily released by

the explosion)

L Molten particles (e.g. from electrodes, arc feet)

However they are designed to let electromagnetic

radiation pass through. With ultra-violet filters (UV

blocker) a part of this tremendous energy can be

absorbed but scientific findings have proved that this

is by far not enough. The intensity of visible light is

high enough too irreversibly injure human eyes and

the infra-red (IR) radiation can burn eyes and skin.

For optimal protection we need an intelligent face

protection providing:

L Contrast enhancement

L High visible light transmission (up to VLT 70%)

L True colour impression for a broad range of visi-

ble light. Under normal circumstances the highest

possible absorption of radiation from UV to IR.

By using the innovative process of ablation the

proprietary ablative materials absorb the arc flashs

energy layer by layer through a controlled

dissociation process and make the Arc Shield give

up its surface. Subsequently, Paulson improved this

protection mechanism by using nanotechnology; a

further significant milestone following years of

intensive research and testing.

For further information visit

www.arcflashprotect ion.co.uk

AN ARC FLASH OR ARC BLAST INCIDENT IS A KIND OF LIGHTNING IN AN ELECTRICAL CIRCUIT

THAT RESULTS FROM A FAULT IN A HIGH CURRENT ELECTRICAL SYSTEM, REGARDLESS

WHETHER THIS IS A LOW, MEDIUM, OR HIGH VOLTAGE SYSTEM. THE LIGHTNING COMES

FROM IONIZED DAS, SO CALLED PLASMA, EXPLAINS CHRIS ROSS OF J&K ROSS

Protection of eyes and facefrom ARC FLASH injury

Do we really understand this?

CaptionCaption


17/36


18/36

ARC FLASH

It is not sufficient to

decide to work live

and then devise

preventative or

protection measures

Note the relationship between

assessment and decisions is

interdependent


FROM MY EXPERIENCE, I believe Regulation 14 from the

Electricity at Work Regulations 1989, referring to live

working, is often misunderstood and sometimes

overlooked. The duty holder is asked to apply a rigorous

test of reasonableness in allowing live work to proceed in

the first place, and to prevent injury by taking suitable

precautions. It must be stressed that Regulation 14

requirements are absolute which means it must be met

regardless of cost or any other consideration. With this in

mind it makes it very important that any live operation

must be subject to a suitable and sufficient risk

assessment.

Regulation 14 - Work on or near live conductorsA person shall not be engaged in any work activity on or

so near any live conductor (other than one suitably

covered with insulating material so as to prevent danger)

that danger may arise unless

(a) it is unreasonable in all circumstances for it to be dead;

and

(b) it is reasonable in all circumstances for him to be at

work on or near it while it is live; and

(c) suitable precautions (including where necessary the

provision of suitable protective equipment) are taken

to prevent injury.

Before we move on, let me highlight a few of the

important words from Regulation 14.

Near. This word debunks the myth live working onlymeans those activities that require the manipulation or the

removal/replacement of live conductors and components.

Live work can also mean live testing and testing for dead.

It can also mean the opening of control panel doors to

undertake visual examinations or undertake non electrical

work near energised equipment. I find that most live

working in industrial and commercial facilities is confined

to testing, inspections and running adjustments.

Suitably. This word completely changes the meaning ofthe opening sentence. I often hear when conductors are

insulated through finger safe shrouding or cable

insulation then live work can proceed with no further

precautions necessary. I can name several examples of

incidents in switchgear which was finger safe or of Form

4 construction. It is the task or activity near live conductors

which will determine whether the insulation is suitable or

not. An armoured and insulated underground cable may

be suitably covered with insulation where its presence is

known and careful location and hand dig techniques are

adopted but would not be suitable using a jack hammer

without safe dig techniques. Finger safe shrouding,

providing it hasnt been removed, may be suitable

insulation for routine testing but may not be suitable for

the task of drawing in of cables into switchgear

enclosures or other similar invasive tasks.

And. Parts a) b) and c) are separated by the word andwhich means there is a legal requirement for all parts of

the regulation to be satisfied before live work can be

permitted.

Danger and Injury. Danger and injury are highlighted inbold and are specifically defined in the guidance

documents referred to in this article. Briefly, danger means

risk of injury, and injury means death or personal injury

from electrical shock, burns or explosion and arcing. Forlive working, danger may be present but injury must be

prevented.

As an electrical duty holder who may be vexed by the

MIKE FRAIN OF ELECTRICAL SAFETY UK, EXAMINES LIVEWORKING ON LOW VOLTAGE SYSTEMS IN INDUSTRIAL ANDCOMMERCIAL FACILITIES; DETAILING A METHODICAL PROCESSFOR IDENTIFYING THE RISKS ASSOCIATED WITH LIVEWORKING AND THE METHODS FOR CONTROLLING THEM.

Methodical process for risk

IDENTIFICATION



questions posed in regulation 14 where do you look for

help? Firstly there is the Memorandum of Guidance (HSR

25) published by the HSE. This is usually purchased

instead of a separate copy of the actual regulations, to

assist with the interpretation of each of the regulations in

turn. In addition there is the guidance booklet HSG85

Electricity at Work Safe Working Practices, also available

from HSE Books. Further guidance can be obtained from

the HSE website www.hse.gov.uk.I find HSG85 Electricity at Work Safe Working

Practices is particularly helpful in the decision making

process for working live or dead. Simple flowcharts are a

feature of this document and one such flowchart is

shown below.

It is not my intention to repeat verbatim the advice

given in the existing guidance notes but to further expand

on this decision making process and to emphasise a

methodical process for identifying the risks and the

methods for controlling them. I have used the following

model many times with duty holders to explain the

relationship between the live/dead working decision, task,identification and quantification of the hazard and

preventative measures to be taken. As can be seen, this

relationship is an interdependent one. It is not sufficient

to decide firstly to work live and then devise preventative

or protection measures.

To further clarify this relationship, a decision for work to

proceed cannot be taken in isolation to other factors. The

level of hazard and also the availability and effectiveness

of preventative or protective measures will also need to

be considered. This is all directly affected by the work

task.

Steps to Identify and Assess the Risks and Methodsfor Controlling them.The live working decision flow chart Figure 1 illustrates that

a critical part of decision making is the identification of risks

and the methods for controlling them. I find it useful to

break this down into a four step process as follows.

STEP 1: Equipment and shock hazard

STEP 2: Electrical flashover

STEP 3: People and safe systems of work

STEP 4: Environment

Fig 1. Diagram reproduced

from HSG85 Electricity at

Work - Safe Working

Practices under PSI license

no C2010000923


20/36

ARC FLASH

STEP 1 Equipment and shock hazardHas the equipment been checked and is it in a safecondition? Check whether the equipment to be workedupon has been examined and in a safe condition for

work. Live work should never be permitted where there

are any doubts about the safety of cables and electrical

equipment being worked upon or even adjacent to those

being worked upon. The examination can be visual but

also using other senses such as smell and hearing to

detect burning or electrical discharge.

Signs of vermin or birds inside switchgear or water

ingress is a definite prompt to stop and investigate only

when the switchgear is dead and isolated. Approaches

should never be made to cables damaged by site traffic or

excavation.

Is the equipment finger safe? If the equipment is in asafe condition the next step is to consider whether the

equipment is finger safe. If the equipment is not finger

safe, can measures such as temporary shrouding be used

to prevent contact with live parts? The term finger safe isdefined as no exposed live parts that can be accessed by

solid objects greater than 12.5mm as given by IP rating

IP2X.

Do not rely purely on the original specification of the

equipment. Insulation is often removed and not replaced.

If it is not finger safe, or other measures cannot be

introduced to prevent contact with live parts then carry

out the work dead.

Are tools, instruments and leads checked fit forpurpose? If measures to prevent contact with live partscan be implemented, are tools, instruments and leads

checked fit for purpose? Tools and instruments must beof the correct duty rating and their condition must be

checked especially test leads. It is important correct

instruments and leads should be selected and in

particular the correct over voltage installation category in

accordance with EN61010-1. The wrong meter and leads

can increase the chances of electric shock or the initiation

of an electrical flashover due to transient over voltage.

Most instrument manufacturers publish guidance about

overvoltage on their websites.

Are you sure the equipment is designed for live

operation? There seems to be some opinion that because

electrical components plug in then this operation can be

carried out live. Examples of such components are plug in

circuit breakers or bus bar trunking tap off units. Always

contact the equipment manufacturer if such a live

operation is contemplated. You may find the equipment

has been designed for flexibility rather than for live

operation and the manufacturer may discourage such

activities.

STEP 2 Electrical flashover or arc flashIs there a significant risk of burns from electricalflashover? I have authored several articles on the subjectof electrical flashover in Electrical Reviewand they can be

accessed at www.electricalreview.co.uk. In brief, theseverity of the thermal effects of an electrical arcing event

is usually expressed in units of calories per square

centimetre at the working distance from a potential arc

source and the head and torso of the worker. This is called

incident energy and a level of 1.2 cal/cm2 is sufficient to

predict a 50% chance of the onset of a second degree

burn.

Incident energy has an approximate linear relationship

firstly; to the amount of current that can flow in the arc

and secondly to the time that it can flow before the

upstream protective device clears the fault. Note that

arcing current does not equal prospective fault current

(PFC) and at 400 volts is likely to be less than 50% of PFC.

It follows the upstream device may take longer to operate

with resulting higher levels of incident energy. Keep in

mind also, protective devices need to be maintained to

ensure they will operate according to their time current

characteristic.

When undertaking arc flash studies for industrial and

commercial facilities, I have found, where the upstream

protective device is a conventional fuse or fast acting

fixed pattern circuit breaker at a rating less than 100

amperes and the voltage is at 400 volts 3 phase andbelow, then the incident energy levels will be limited. A

rule of thumb is to use the good old BS88 Industrial

fuse as a model. If the entire time/current characteristic

curve of the upstream device can sit below a BS88 100

ampere characteristic curve, the incident energy at a

working distance of 450mm is unlikely to exceed

1.2cal/cm2. This does not mean flash burn injury can be

totally discounted and severe burns can still be

experienced particularly at the hands which will usually

be closer any arc initiated when testing live circuits. For

comparison, a BS88 400 ampere fuse could present a

predicted *20 cal/cm2 at certain fault levels and an 800ampere fuse could be in excess of *60cal/cm2.

*Note these figures are for indicative purposes only, not

to be used in a risk assessment.

Suitable risk control measures must be employed and

as a last resort PPE should always be used. In the case

of the 800 ampere fuse, PPE is unlikely to fully protect

the worker because of the possible ballistic and other

effects of a flashover. Regardless of tasks, I recommend

electrical workers should not carry out work in high

power environments in clothing that can ignite or melt.

If the incident energy at the equipment to be worked

on is over 1.2 cal/cm2, then can it be reduced to below

1.2 cal/cm2? As an alternative, can risk controls be put

in place to prevent or mitigate arc flash effects and are

they adequate? Please refer to my recent articles,

available on the Electrical Review web site. If the

answer is no to both questions then proceed no further

until advice is sought or carry out the work dead.

STEP 3 People and safe systems of workAre the workers competent for the task? Regulation 16from the EAW Regulations 1989 states: A person shall not

be engaged in any work activity where technical

knowledge or experience is necessary to prevent danger

or, where appropriate, injury, unless he possesses suchknowledge or experience, or is under such degree of

supervision as may be appropriate for that purpose

having regard to the nature of the work.

Do not rely purely on

the original

specification of the

equipment. Insulation

is often removed andnot replaced



21/36

In the context of live work, technical knowledge or

experience means the person should be properly trained

and assessed in the techniques being employed but the

person must also understand the hazards from the

electrical system and be able to recognise whether it is

safe for the work to continue at all times including whilst

the work is being carried out.

Is the work to be carried out at height? Working on liveequipment at height is always a special case for

consideration for two reasons:

1. Electric shock or arc flash to a worker at height can

bring about a fall with obvious consequences.

2. An arc flash incident whilst working at height may

mean that the worker cannot move out of the way

because of the limited working space on access

equipment. This may be the work platform of a scaffold

or a mobile elevated work platform.

If the work has to be carried out at height, can risk

control measures to prevent shock, burns and falls be put

in place?Is Accompaniment Required? Anyone undertakingwork on or near energised electrical conductors will nearly

always require some form of accompaniment by someone

who can give assistance in an emergency. This implies a

degree of competence such that the accompanying

person can assist without danger to themselves or others.

A requirement for a second person is to ensure safe

working procedures e.g. preventing encroachment of non-

authorised personnel into the working area.

STEP 4 Environment

Is access and space adequate? Establish whether theaccess and space in front of the equipment is adequate to

allow the worker to pull back from the conductors without

hazard. HSG85 mentions a minimum 915mm measured

from a live part or 1375mm when there are live parts

exposed on both sides of the worker. The working space

may need to be greater than these minimum distances as

a result of the electrical flashover assessment in Step 2.

The work area should be clearly defined, with no

tripping and slipping hazards and with good means of

escape and illumination. Simple barriers and signs can

often be erected for the demarcation of work areas to

keep non-authorised staff away and also to protect

electrical workers from interruptions at times when they

need concentration.

Is lighting adequate? It is also important to checkwhether lighting levels are adequate for work as well as

another requirement in Regulation 15. Use of additional

lighting is essential where ambient lighting levels are

poor.

Are hazardous conditionspresent? Check to ensure theimmediate environment is free

from water or dust. A hostile or

wet environment will

significantly increase the risk and

severity of electric shock and

should therefore be subject of

special consideration to controlthe risks. Ensuring there is no

possibility of an ignition hazard

due to sparks is crucial. If there is

a possibility of an ignition

hazard, take precautions to

remove the hazard before

proceeding. There may other

local environmental hazards that

may need to be taken into

account such as automatic fire

fighting equipment.

Proceeding with workAfter all 4 steps are satisfied, then revisit the flowchart in

Figure 1 and confirm the work is justified relative to the

precautions, implement safe working and ensure

adequate monitoring and supervision. Make sure any

special equipment and PPE is properly used and

maintained and always keep the duration of any live work

to a minimum.

www.electricalreview.co.uk 21

Recommended Further Reading

HSR25 Memorandum of Guidance on the Electricityat Work Regulations 1989 (HSE books)

HSG85 Electricity at Work - Safe Working Practices(HSE books)

INDG163REV2 Five Steps to Risk Assessment (HSEbooks)

INDG 354 Safety in Electrical Testing at Work (HSEbooks)

GS38 Electrical Test Equipment for use by Electri-cians (HSE books)

Guidance on Safe Isolation Procedures for LowVoltage Installations (Electrical Safety Council)

HSG230 Keeping Electrical Switchgear Safe (HSEBooks)

ARC FLASH


22/36


23/36


24/36

UPSsolution for bridge power.

The very high cycle life of a SuperCaps UPS means

unlike lead acid batteries, there will likely be little or no

need for constant replacement. The facility to repeatedly

charge and discharge for up to a million cycles without

disintegrating, means the lifetime cost of the SuperCap is

expected to break even with lead acid batteries.

Longevity is helped by the fact their high power density

results in reduced strain on the battery in times of need.

Another major consideration is the fact the SuperCap also

has the ability to recharge instantaneously, in a few seconds.

This is really useful in data centres, to help cut power costs

associated with keeping batteries charged.

Another important factor is the ability of SuperCaps to

offer versatile functioning in a wide temperature range,

dramatically reducing cooling costs. This is because the

function of a SuperCap does not require a chemical

reaction, and therefore, does not involve an optimal

temperature range for best performance or longevity.

It has been estimated the supercap can be used from -

40C to +70C, without degradation in its performancecharacteristics. This is in stark contrast to the lead-acid

battery, which when used in industrial applications, almost

always requires a mechanically cooled environment.

Pros and ConsThe SuperCap is green in two ways. Firstly, it reduces waste

because it has a very high cycle life, and therefore decreases

disposal issues. Secondly, the materials and substances used

in the SuperCap UPS are toxin free and biodegradable, e.g.,

nano carbon particles are commonly used. They can operate

in a wide temperature range without any degradation of

performance characteristics, and it also has the ability torecharge instantaneously in a few seconds.

SuperCaps are ideal energy storage devices for fast and

short-term peak power delivery, which is why they are so

suited for UPS systems. They are also more efficient than

conventional batteries as they do not release any thermal

heat during discharge, and various figures have shown that

they operate at around 80% - 95% efficiency in most

applications.

SuperCaps also take up much less room compared to

lead-acid batteries, and indeed weigh less as well, which

can be an important factor in certain situations or locations.

The table below contrasts the pros and cons of SuperCaps

with traditional UPS technology.

ConclusionThere is no doubt the industrial market needs an energy

storage solution that is both reliable, and can offer a quality

service. SuperCaps offer high power density, cycle life, and

thermal susceptibility, and the increasing adoption of

renewable energy expands the possibilities of using

SuperCap-based technology.

Frost and Sullivan points out the total world

ultracapacitor (SuperCap) market had generated revenues

of $113.1m (75m) in 2008 and is likely to reach $381.9(250m) by 2015. It feels this market has witnessed growth

(despite the economic situation) due to the great interest in

propelling alternative energy storage mechanisms by

governments. Indeed, Europe has given the highest priority

to any environmentally friendly technology and has a

proud tradition of being one of the first global markets to

accept new technology and consider its applicability in

various solutions.

The high price of oil, coupled with high electricity costs,

the need for devices that can reduce the power burden of

a data centre represents a significant opportunity. The

increasing use of supercap technology within thetransportation industry will also serve to spur new

developments and help drive down the initial cost of

ownership.


Pro

A SuperCaps UPS is green and does not contain toxic materials

Can operate in a wide temperature range, without a degradation in its

performance characteristics

Do not release any thermal heat during discharge

A SuperCaps UPS is much more efficient than a conventional battery

Ideal energy storage device for fast and short-term peak power delivery, for

indefinite cycles.

Up to 20 years lifespan

Reduced footprint compared to lead-acid batteries, and also weighs less

Scalable-modular nature that make it well suited for many applications

A SuperCaps UPS, used strictly as a bridge, has high power density that is well

suited to supply high power for short periods of say around 30-100 seconds

Flexible voltage range

A SuperCaps UPS is inherently reliable because of its composition and construction.

There are no mechanical moving parts, eliminating maintenance

Capable of sitting on a charge voltage for extended periods without any loss of

capacity, unlike a batteryDevelopment of the technology is being pushed by massive industry heavyweights

in the transportation sector. Honda for example has developed its own supercaps

for its vehicles

Con

Despite their indefinite life cycle, SuperCaps have the ability to provide only very

short-term power

High initial cost of ownership. Supercaps are more expensive than flywheel, as it is

still in its nascent stage of commercialisation

End users are unable to perceive or experience the true advantages of this

technology due to early stages of take-up and lack of awareness

Lack of industry standards to regulate and stimulate full commercialisation of thetechnology. Design time is longer, which results in a longer lead time to get a

product ready for the end user

The SuperCaps UPS is unable currently to store as much energy as a battery

because there are no chemical reactions taking place that can sustain the slow

discharge of current to power equipment

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Pros and Cons of the Supercap UPS(Maxwell Technologies)

The very high life cycle life of aSuperCaps UPS means, unlike leadacid batteries, there will likely beittle or no need for constant

replacement


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PRODUCT WATCH

PROVING UNIT LAUNCHIt is a recommendation of the HSE given in guidance note GS38 that voltage indicators should be proved

before use and after use.The Portable battery powered proving unit PU260 has been introduced by Di-Log to carry out this vital

check function for all makes of two pole voltage testers up to 690 V.In addition to proving the correct functioning and voltage output a voltage tester the PU260 ha a number

of unique features which have not been previously found on this type of unit. Continuity test for testing: fuses, test leads etc

Additional touch electrode for quick testing of fuse leads Optical and acoustic continuity indication Low battery indication LED indication of current output in excess of 3.5 mA Protective rubber holster Supplied with batteries

Di Log Test Equipment0161 877 0322www.dilog.co.uk

TINY DRIVES TAKE VERSATILITY TO THE MAXAdditional EMC filtering options, configurable analogue inputs and enhanced fieldbus connectivity are

among the many new features that have been added to the latest M-Max variable speed drives from Eatonselectrical sector, which are available with ratings up to 7.5kW.

Featuring compact book-style construction and very competitively priced, M-Max drives can be configuredby the user for either V/f or sensorless vector control. This makes them an ideal and cost-effective choice forenergy-saving fan and pump applications, and also for generalindustrial applications where accurate speed control is needed.

A large built-in display and operating unit makes it easy toconfigure the drives and to monitor their performance, while anelectronic setpoint potentiometer facilitates accurate speed setting.

Eaton0161 655 8900

www.eaton.com

POWER SUPPLY AND LINE DIAGNOSTICS ON THE BUSR. Stahl's new Advanced Fieldbus Power Supply (A-FPS) is said to be the first and only power supply

module for Foundation fieldbus H1 segments to addi-tionally provide a wide range of physical layerdiagnosis functions. At a 10% premium over the standard supply module from the same series, theintegrated devices enable complete and continuous plant monitoring.

In the past, the integration into asset management systems requiredseparate, cost-intensive diagnosis modules and software tools. EachAdvanced Fieldbus Power Supply (A-FPS) not only detects overload andshort circuits on its seg-ments, but also continuously registers the physicalparameters of the fieldbus, such as voltage and current on the trunk,

communication level, noise level, asymmetries and jitter.

R Stahl0121 767 6400www.rstahl.co.uk

PROTECT MISSION CRITICAL APPLICATIONSThe PowerGem Pro Series has been upgraded with the latest DSP technology to

provide a new Online Double Conversion range from the British Power ConversionCompany. Available in both tower and rackmount configurations from 1kVA up to10kVA is an advanced True Sinewave design combined with our unique isolationtechnology to give you a UPS with all the flexibility and dependability you need.

These modern, compact UPS have an enviable reputation in providing theultimate in no-break power protection making them ideal for sophisticated

computer networks, as well as telecommunications, industrial, defence, medical and process control equipment.

This new range achieves higher reliability and greater immunity from mains power problems to the connectedload by using a Digital Signal Processor (DSP). The front LCD panel display provides real time status andparameter readings allowing simple operation and a full diagnosis for easy servicing.

BPC EMEA01794 521200www.bpc-ups.com

PRE-TERMINATED MULTI-FIBRE TRUNK CABLEASSEMBLIES

Now available from the Amp Netconnectbusiness unit of Tyco Electronics is a range ofmulti-fibre trunk cable assemblies in avariety of configurations.

The new cables are factory terminatedand tested in custom length options up to500 m initially available with 12 fibres asOM3 multi-mode and OS2 single-modeversions and a choice of LC-LC or SC-SCconnectors. They can be used as pre-

terminated links for quick deployment or cutin half to create fibre harness links.

Each cable ends in a staggered fan-outassembly with 2 mm buffered tubes withprotective tube over the connectors. Cable

jacket features internal and external ULSZH(Universal Low Smoke Zero Halogen)construction.

Tyco Electronics UK020 8420 8130www.tycoelectronics.com

SUPPORT FOR SAFETY- RELATEDMACHINE CONTROL

Designed to provide developers and testers ofsafety-related machine controls with comprehensivesupport in the evaluation of safety in the context of ENISO 13849-1, Sistema software is available fordownload on www.wielandsafety.net. Sistema standsfor safety integrity software tool for the evaluation ofmachine applications and enables users to model thestructure of the safety-related control componentsbased upon the designated architectures. This, in turn,allows automated calculation of the reliability valueswith various levels of detail, including that of theattained performance level (PL).

Relevant parameters such as the risk parameters fordetermining the required performance level (PLr), thecategory, measures against common-cause failures(CCFs) on multi-channel systems, the averagecomponent quality (MTTFd) and the average faultdetection level (DCavg) of components and blocks, areentered step by step in forms. Once the required datahave been entered into Sistema, the results arecalculated and displayed instantly.

Wieland01483 531213www.wieland-electric.com

Products continued on p28


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BUILDING SERVICES


THE SECTOR faces the twin challenges of riding out the

toughest recession in living memory, and delivering new or

refurbished buildings which consume less energy and emit

less carbon. Much of that carbon is emitted by electrical

systems, so the electrical services sector is at the forefront

of the drive to improve our building stock.

With the latest revisions to Part L of the Building

Regulations coming into force in October 2010, and with

the recently introduced Carbon Reduction Commitment in

place, developers and building owners will have to allocate

more resources to adapting their buildings for future

climate changes.

The current cost of adaptation, using some technologies

that are not 100% tested and proven, is not considered to

offer a fast enough payback, and in many cases is seen as

relatively expensive in offsetting the short-term cost of

carbon emissions. Several adaptation technologies such as

photovoltaic, on-shore wind farms, hydro and wave power,

demand large open spaces, or require planning

permissions, or both, which can be hard to obtain. There is

a growing conflict between the desire of government to

cut carbon emissions and invest in renewable, and the

willingness of planners to sanction them.Whilst some building integrated low or zero carbon

technologies are well established, such as solar thermal

water heating, photovoltaics, or heat pumps, they may

require substantial upfront capital investments. There are

only a handful of exemplar projects provided by the

Carbon Trust and Energy Saving Trust to demonstrate real

life energy and carbon emissions reduction. The

Technology Strategy Board is funding a number of further

projects in this area to demonstrate how buildings can be

adapted to meet the requirements of our anticipated

future climate, but these will take time to influence and to

stimulate investments by the private sector.

The introduction of the Feed in Tariff provides some

incentives to install renewable technology, with the

prospect of ongoing revenue to encourage initial capital

outlay. The tariff came in in April, and it is too early to see

how much of an impact it is having on demand. There are

therefore a number of measures which can be expected to

stimulate demand for electrical services, but not in the

immediate future. Whether this demand will materialise intime to support the sector through the current period of

reduced workload remains to be seen.

What we ought to see at this time, with the prospect of

IN MARCH 2010, THE TIMESREPORTED UK CONTRACTORSGROUPS OUTLOOK FOR THENEXT FEW YEARS IS DEEP PUBLICSPENDING CUTS WILL LEAD TO

SOARING UNEMPLOYMENT INTHE CONSTRUCTION INDUSTRY.AT THE SAME TIME, THE UKFACES CHALLENGING CARBONEMISSIONS REDUCTION TARGETSBETWEEN NOW AND 2050,WHICH COULD BE JEOPARDISEDBY THE LOSS OF KEY SKILLS

FROM THE SECTOR EXPLAINSTONY SUNG, CHAIRMAN OFCIBSE GROUP AND TECHNICALDIRECTOR AT HYWEL DAVIES

New skills for new

OPPORTUNITIES?

Tony Sung



steadily increasing demand for energy efficient

refurbishment and renewable technologies, is increasing

training to meet the emerging demand for these skills. But at

present training in the sector is falling, as firms, many of

them SMEs, cut back on all non essential spending to

conserve cash and protect the business.

One of the measures introduced in response to the

Climate Change Act is the Carbon Reduction Commitment

Energy Efficiency Scheme, or CRC. This started in April 2010,

with the primary objective of helping medium to large size

organizations whose total half hourly electricity consumption

exceeds 6,000MWh, to cut their energy use and carbon

emissions. To enable the For CRC to be a success, Britain

needs to up-skill the current M&E workforce (electricians,

design and installation engineers) competently to apply,

install, test and commission the low zero carbon and smart

metering technologies in tens of thousands of existing

buildings rather than just for new buildings.

Again, looking at the figures for compliance with the

requirement for Energy Performance Certificates, Display

Energy Certificates and Air Conditioning Inspections, we should

be cautious about the prospects of CRC stimulating a wholenew wave of activity in the current economic conditions.

Another area of development is the new amended

BS7671:2010, currently issued in draft for public comments.

This includes vital changes necessary to maintain technical

alignment with Cenelec harmonisation documents. One of

the perceived advantages of the technical alignment is it

should help British companies to win work in the EU.

Cibse, through its Electrical Services Group, provides

electrical services engineers with a network of like minded

professionals who are active in all of these areas. Through

Group events and through the website, http://www.cibse-

electricalservicesgroup.co.uk members can access the

collective knowledge and expertise of the group.

Additionally, Cibse runs a number of events and training

courses for electrical services engineers, and recently

launched a new web based learning initiative, to provide

training in electrical services (and other building services

disciplines) that is flexible and adaptable to user needs. Cibse

and the Electrical Contractors Association recently signed a

Memorandum of Understanding, which commits both

bodies to work together more closely to help develop and

deliver electrical skills and services, to better meet the

challenges of climate change.

If we are to meet the carbon emissions reduction targets

for 2030 and 2050, we will need to see greater investment,both in new technologies and in skills. Cibse will be looking

to work with engineers and employers in the sector to

deliver both.

BUILDING SERVICES

Image courtesy of Shutterstock


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PRODUCT WATCH

AC DRIVE CONTROLLEDSCROLL COMPRESSORIMPROVES EFFICIENCY

A chiller unit utilising a scroll compressor is setto generate 15% lower energy consumption thanmodels with a traditional compressor design.

The unit has been produced by air conditioningmanufacturer Rhoss, using an ABB standard drive.

Scroll compressors pressurise the refrigerant between two interleaved spirals or scrolls,resulting in a design with fewer moving parts, less noise and reduced vibrations comparedto other compressor types. Variation of output is traditionally provided by mechanicalmeans, for instance by splitting the cooling capacity of the chiller into several circuits.However, by using the ABB standard drive, Rhoss has achieved better performance whileusing a simple design with a single circuit.

ABB01925 741 111www.abb.co.uk/energy

ETHERNET SWITCH WITH FAST TACK

SWITCHING TECHNOLOGYThe Ha-VIS FTS 3100s-A is the first switch in the HARTING

family of industrial Ethernet switches to offer the companysinnovative Fast Track Switching technology: a solution thatsatisfies the majority of perf

Documents

Electrical Review August-2010