for &

By Sergio Feitoza Costa e ywords: #iecstandards #stl #ci gre #bu sbar #testinglaboratory #internalarc #overpressure #temp eraturerise # electrodynamic #stresses #shorttimecurrent # emc #ma gneticfields # ele ctricfield #certification #qualitysystem #newtechnologies #design #costsreduction #validation #calculation #busway #sergiofeitoza #switchge ardesign #hi ghpower #r&d #simulation #highpowertest #testing #shortcircuit #cpri #jstc #pehla #sats #stlna zku #intertek #s gs #bureauv eritas #switchgear #switchboards #asefa #paineis #barras # esef #tablero #consultant #iec62271 #veiki #i ec61439 #substation #lowcost #kema #k eri # lactec #c esi #stl #cepe l #powertech #sgs #sergio feitozacosta # aelp # chptl #icmet #fg #sabsnetf.

1. SAVING EARTH RESOURCES VIA ELECTRIC POWER INDUSTRY ACTORS

Imagine if the titans of the world's electrical industry—ABB, Schneider, Hitachi, Siemens, and Eaton — joined
forces to enhance their reputation for protecting the planet's resources. They would host a competition to
showcase concepts and goods that may reduce the use of materials in the electrical industry and increase
efficiency. The focus would be to create more efficient alternatives to the designs that all of them commercialize
all over the world for decades_
///////////////////////////////////////////////
First of all, equipment developers and researcher needs to be aware that people and companies who are comfortable
with less efficient technologies, where they have gained money, will put up obstacles in the way of pursuing better
technical solutions. This can be done subtly, even preventing international technical standards like IEC and IEEE from
mentioning that equipment that passes tests but also uses less materials and the planet's resources are better.

Basically, it is a fact of the same nature as to why, in today's world, much more is invested in selling weapons of war
than in creating better conditions for the almost impossible salvation of the Planet. These today wars have caused
immense loss of credibility to the good “green” efforts of the last decade. Credibility is the key word.

Large global manufacturers like ABB, Eaton, GE, Hitachi, Schneider, and Siemens were the catalysts of the evolution of
the electric industry from some 60 years ago. They invested in knowledge, R&D centers and in big testing laboratories.
It was due to their merits and the vision of countries close to them that the electrical industry grew with creative
solutions for the time, but which today could be much more efficient using less materials.

These big manufacturers are nowadays in the comfort zone of selling licenses to replicate that old less efficient product
in less developed countries. They already know how to create more efficient solutions. If nowadays even individuals
can easily create products with lower wight and resources (less kg/MVA), think how easy it would be for their
competent R&D teams. Furthermore, the main players in the IEC are large manufacturers. If they present more
efficient products, everyone will follow their good examples.

It is these manufacturers who dictate what will be included in the IEC and IEEE standards. It would be very easy and
quick for them to put statements in IEC and IEEE standards encouraging the use of fewer materials and resources.
This was done in the 80s in relation to EMC. All IEC product standards should include a statement about EMC. I saw
this happen up close because at that time I chaired IEC's Technical Committee 32..

///////////////////////////////////////////////

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"Failure to mitigate climate change" is one of the primary issues, according to the World Economic Forum 2022.
The "crisis of natural resources" is ranked in the top as well. Each has a connection to the Energy Transition
initiatives. Better sound examples to follow could be provided by the electric industry.

The two main global voices of the electric power sector are Cigrè and IEC. Their prominence makes it easier to
highlight sensible real-world examples that go toward protecting the environment. As of now, technical standards
do not promote or signal the use of aluminum, copper, and other materials in smaller quantities. Standards for
the creation and usage of products are still focused on approval through rigorous testing, as 50 years ago. Climate
change was not a top concern at the time. Positive statements on climate change these days must be supported
by activities that are visible and seen as models to follow.

The electric industry is well organized and can provide visible demonstrations of good long-term intentions.
Changing the emphasis of international technical standards (IEC, ANSI, IEEE, and others) is an example. Substations
equipment design and manufacturing, still use the approaches of the times of fat cows when doing a stronger than
necessary equipment that passes in the expensive tests was sufficient.

Nowadays, rather than concentrating solely on costly testing, the technical standards should promote
the development of more effective products that use less Earth resources (lower kg/MVA). Entities
like Cigrè have many experts who are great opinion makers and can go beyond promoting
technological advances. They have the strength to disseminate ideas that contribute objectively to
reducing climate change and the use of the Planet's resources. Historically, sensible changes to
technical standards must always go through these experts first.

Large global manufacturers can be the catalysts of the change, but they must leave their comfort zone of selling
licenses to replicate less efficient products in less developed countries. They already know how to create more
efficient products. If nowadays even individuals can easily create products with less kg/MVA, think how easy it
would be for their competent R&D teams. Furthermore, the main players in the IEC are large manufacturers. If
they present more efficient products, everyone will follow them.

As idea for a fast implementation is to support the creation, around the world, of some small research
centers like “kG /MVA: Research Centre on Environmental Efficiency of T&D Products”

Some initiatives, such as the development of a few like 7 demonstration projects with short-term visible results,
could demonstrate that when developing equipment with higher efficiency and less material consumption,
intelligent design, and attitude matter more than financial investments. Undoubtedly, the majority of these
projects ought to be carried out in nations that are not yet developed.

2. A CATALYZER: INCLUDE A STATEMENT IN ALL IEC / IEEE PRODUCTS STANDARDS ABOUT SAVING MATERIALS

Something like this was done by IEC in the 80’s to promote the importance of EMC (electromagnetic
compatibility). All technical standards should have a clause telling about the susceptibility or not of that product
with EMC.

Our new statement should signalize that reducing the use of copper, aluminum, and insulators is beneficial for the
environment, and this is encouraged by IEC standards. I imagine something like:
"PRODUCTS COVERED BY THIS IEC STANDARD use significant amounts of copper, aluminum, insulators,
and metals. Material savings are desirable for the Climate Change and Energy Transition initiatives. IEC
promotes designs and methods that lower the kg/MVA”.

Regarding the activities of these non-profit small research centers, that mentioned “opinion – makers” could give
a great help from the beginning. We anticipate that some other main sponsors would be large companies that,
due to their activities potentially conflicting with environmental preservation issues, want to improve their
environmental image by supporting initiatives that contribute to the preservation of the planet's resources.

Many of these companies are in the fields of oil and gas, chemicals, mining, and large agribusiness. They have in
common that they are large users of electricity. The idea is to demonstrate that it is simple to improve electrical

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products on the world market to spend at least 30% less materials than today. To achieve verifiable results and
stay focused, we would use products that are widely used in transmission and distribution (T&D) systems.

In Table 1 we see examples of possible demonstration projects. The results obtained would be monitored by a
“Council of Sponsors”, which would guide the next steps to follow.

Follow

Table 1 – The 7 demonstration projects scope

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 Table 1 – Examples of demonstration projects scope

Demonstration project Name Scope and monitoring of results

(Details in the links)
Environmental efficiency certificate To disseminate the idea, to monitor the level of
#1 of electrical products (kG/MVA): interest through the number of Linkedin followers, to
http://www.cognitor.com.br/demo1certificate.pdf
technical standard & demo projects create the guidelines for the implementation and to
management act within major technical standards organizations to
discuss and prepare the standard.
High Power (small size): Testing Design and implementation of 3 units in ) in three
#2 Laboratory with R&D services regions like South America (possibly Brazil), Africa and
http://www.cognitor.com.br/demo2Lab.pdf
focused on lower kG/MVA Asia (possibly in Malaysia ou Singapore or Thailand).
products
Examples of more efficient Design, testing results & comparisons of kg/MVA
#3 switchgear (30% less kg/MVA) between traditional techniques and ( a ) using several
http://www.cognitor.com.br/demo3SwitchgearEfficiency.pdf
using thinner bars, small thin bars, per phase, ( b ) small (auto) ventilation
ventilation, and different materials resources , ( c ) different coatings of the busbar
Cu / Al profiles and coatings connections and ( d ) parts of components using metal
foam
Designing triaxial busways for high Design and testing comparing the traditional busways
#4 rise buildings (lower kg/MVA & with a triaxial busway with higher rated and short
http://www.cognitor.com.br/demo4HighRiseBuildings.pdf
impedance for IEC62271 – IEC circuit current ratings (lower kg/MVA) using proved
61439) concepts used in measuring coaxial cables

A Super Enclosure for high current To be disclosed soon

#5 switchgear and controlgear
http://www.cognitor.com.br/demo5SuperEnclosures.pdf
(IEC62271 – IEC 61439)

Decidix for kg/MVA – a tool to A tool for technical-economic evaluations easy to use
#6 assess the efficiency of high electric by equipment developers with little knowledge of
http://www.cognitor.com.br/demo6EconoCosts.pdf
power products cost calculations. Allows you to compare the
attractiveness of projects of different natures
MHD for a water transportation To be disclosed soon
#7 vessel based on electrodynamic
http://www.cognitor.com.br/demo7MHD.pdf
forces and coaxial structures

3. USING THE MARKET COMPETITION AS A CATALYZER TO REDUCE THE WASTE OF MATERIALS IN THE
FABRICATION OF ELECTRIC POWER PRODUCTS (the role of the market, manufacturers, and technical-
standards makers).

I witnessed, participating directly in IEC working groups, that most technical standards are made by engineers, without
any political or environmental vision. The only goal is to specify equipment that will pass for type tests. To be more
efficient and using less materials and resources of Earth is simply disregarded. The standards texts do not have
statements saying that this is a goal to be achieved or even that it is desirable

This thinking is well reflected in the technical standards marketed by IEC, ANSI/IEEE. The documents do not signalize
that the equipment will be more efficient having a lower weight/MVA. If we can't even do this, how can we convince
the world population that 10% energetic efficiency gains are very good?

This “Environmental Efficiency Certificate for Electrical Products” is an action to signalize that higher efficiency via a
lower kg/MVA is good for the environment. The rules to get the CERTIFICATE are explained in the next lines.

A typical marketing strategy is manufacturing products with lower kG/MVA and $/MVA and making the
market to know this. Big buyers that need to take care of the environmental image, would prefer to buy
products with lower values. The first ones to obtain the Certificate would possibly do campaigns to disclose
who buys and who does not buy more efficient products. Declarations about the relevancy of a lower kg/MVA
in product technical standards would accelerate the process.

4. THE FUNDAMENTS OF THE CERTIFICATE

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 This Certificate attests that the project was designed and constructed to meet the requirements of the tests
prescribed in the product standard but, much beyond this, was designed for the minimum necessary use of copper,
aluminum, insulating supports, materials etc. This is a measurable objective using indicators like the weight per
transmitted power (KG/MVA) or the order of magnitude of the production cost divided by the transmitted power
($/MVA) . An easy example is that, within a switchgear panel, with a 2x100x5mm copper bar you can transmit
19% more current, for the same temperature rise, than using a 1x100x10mm bar. The weight of copper is the
same in both cases. So, the indicators KG/MVA and $/MVA are lower in the first case. You used less materials and
this means higher use of materials efficiency better for the Planet.

Figure 1 – 19% more current with same weight of copper

The Certificate shall be issued by third parties and based in an international technical standard explaining the
concepts and rules. The results shall be transparent, auditable, reproducible and easy to understand by the
common public. It shall demonstrate that the minimum material usage requirements have been met or tried. This
is not difficult to do and to verify using the tables of the IEC TR 62271-307.

The assessment results to support the Certificate may be obtained by real tests or - much cheaper and faster -
using testing simulations plus the concepts of IEC TR 62271-307. In this important IEC document issued by the first
time in 2015, the basis is a “head of the family” product already tested in the testing laboratory. Suppose you test
a product and simulate that test already done getting the same results. Now, suppose that you have another
design of the same nature as the tested one, but with some differences. If you do the same simulations on the
untested piece, using the same tool and a qualified method, there is no reason to question that the new simulation
represents what would happen in a real test. Then you can avoid the higher cost of real laboratory tests.

Draft of a technical standard: A key aspect is that, for this to be accepted by people and buyers who are not
qualified or skilled in engineering, the rules must be written in an international technical standard. A complete
draft text prepared by me is presented below. Any help to make this article and ideas to arrive to reach ISO, IEC,
IEEE, ANSI and other national standards associations is very welcome and the Planet thanks you in advance.

Using these methods, it is possible to compare the KG/MVA and $/MVA of different design alternatives. After a certain
time and experience, the world values of these indicators will become well-known. Then, the electric industry will see
how the current old designs, marketed around the world, can become more efficient with simple existing techniques.
Universities and technical schools could give importance to this theme in their teaching programs.

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The test reports issued by the qualified laboratories or others actor qualified to issue the Certificates must explicitly
indicate whether the equipment has passed the tests or not and to write and demonstrate the $/MVA and KG/MVA
indicators.

This is a fantastic market because, in 2023, rare substations equipment meets these requirements. Most of them can
be improved to use less materials, considering - mainly - the performance for temperature rises tests, internal arc, and
short circuit tests (electrodynamic forces). From the commercial point of view, a good marketing strategy is building
electric power products with lower $/MVA & kG/MVA , and, to make the World to know this. The big companies that
need to take care of the environmental image, will prefer to buy products with lower KG/MVA.

5. FINAL COMMENTS AND DRAFT TEXT OF THE TECHNICAL STANDARD

Complete examples of what is to do a more efficient electric product, with lower $/MVA & kG/MVA are presented in
the articles related to the demo projects 3 and 4 (links in Table 1 above). You may find the fundaments for these
articles in previous articles freely downloadable in the link https://www.cognitor.com.br/Downloads1.html

In Section 5 the reader may find the draft text of a technical standard to support the issuance of the ENVIRONMENTAL
EFFICIENCY CERTIFICATE of electric products, more or less in the format of IEC and ISO documents. This text may be
used freely for any person or institution which want to use it. Opinion makers, research centers, the universities and
the academic World have here an opportunity to do something effective in the direction of preserving Earth resources.

6. THE BASE TEXT OF THE TECHNICAL STANDARD IN THE FORMAT OF ISO / IEC

See next page.

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 GUIDE (Edition 1.0):
Guidelines for the use of the “ENVIRONMENTAL EFFICIENCY CERTIFICATE
of electric products”
CONTENTS
1 Scope
2 Normative references
3 Definitions
4 Working procedures
5 An example of CERTIFICATE and the process to obtain it.

FOREWORD

This “Environmental Efficiency Certificate for Electrical Products” aims to induce the electric industry to produce
items that goes beyond the quality assured by prescribed type tests . The focus is on award and highlight design
and construction actions on electrical power products that lead to weight per transmitted power (KG/MVA) or
estimated lower cost per transmitted power ($/ MVA). These indicators are used to characterize higher efficiency
and lower use of materials. It is particularly relevant to users that take care of the environmental image.

To obtain the Certificate, it is necessary to pass design verifications that are specified to meet specific
requirements and tests. To evaluate these characteristics, real tests, and test calculations or simulations can be
used.

Laboratory type testing, as specified in product standards, is – currently - the most efficient way to verify if a
certain product attends the specifications. However, it is necessary to recognize that high power tests to verify
temperature rise (aging), internal arc (safety of persons and installations) and short circuit forces are expensive.
By this reason, other lower cost alternatives of verification are necessary.

The main alternative is the use of testing simulations associated with the principles of the Extension of Validity
of Test Reports presented in IEC TR 62271-307 . Testing simulation techniques are used to predict results of most
type tests. They enable to obtain more detailed information than the information which could be obtained in a
real laboratory testing.

Simulations can be applied in situations like: (a) to avoid switchgear tests in equipment with characteristics near
to another one already tested or (b) to facilitate the certification process of products that pass for design
modifications after type tested or (c) to replace SF6 by air in some tests.

The main concern related to the use of testing simulations methods is to be sure that their results, well represent
the results of a real laboratory, within an acceptable tolerance. This Guide show rules for achieving this,
exemplify tolerances values and give guidelines to validate the methods.

For analyzing if a certain design is more efficient than others, it is necessary to define reference values for the
comparisons. . The starting point are values practiced in current designs. To define initial reference values, world-
wide queries were made, initially only, for switchgear , switchboards, and busways (IEC 62271 and IEC 61439
series). The weight and the transmitted power of a product is an easy to obtain characteristic. This Guide present
some initial reference values of KG / MVA for typical commercial products

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GUIDELINES FOR THE USE OF THE
“ENVIRONMENTAL EFFICIENCY CERTIFICATE OF ELECTRIC PRODUCTS

1 Scope

This Guide presents guidelines for the systematization of the use of the environmental efficiency
Certificate of electric products. The use of this “Certificate” is an action to motivate the electric
industry to design and manufacture more efficient electric power products with lower $/MVA &
kG/MVA. The concept is that , as the Certificate become known in the world market, companies,
especially the ones that need to take care of the environmental image, will prefer to buy products
with lower USD / MVA and KG / MVA . This means less of use of materials.

This Certificate attests that the project was made to meet the requirements of the tests prescribed
in the product standard but, much beyond this, was designed with the minimum necessary use of
copper, aluminum, insulating supports, materials etc. This is a measurable objective using indicators
like the production cost divided by the transmitted power ($/MVA) or the weight per transmitted
power (KG/MVA) .

An easy example is that with a single copper bar 100x10 mm you may transmit a certain value of
current having a certain temperature rise (like in a test) . However, if you use 2x100x5mm (same
weight) , for the same temperature rise value, you can transmit quite more current. So, the indicators
$/MVA and KG/MVA are lower in the second case because less materials are used, and this is better
for the Planet.

The Certificate shall be issued by third parties following the concepts in these Guidelines. The tests,
verifications and results shall be transparent, auditable and reproducible. It shall demonstrate that
the minimum material usage requirements have been met.

Whenever applicable, the design parameters presented in the tables of IEC TR 62271-307 shall be
used.

IN GENERAL, THE SEQUENCE TO OBTAIN THE CERTIFICATE IS THE FOLLOWING:

• Test a head of family product using the related product technical standard

• After being approved the data of these tests may be used to extend the validity of that tests
reports to other products of similar characteristics but that have similarities within the
concepts of IEC 62271-307

• If it is necessary to use testing simulations to demonstrate any of the IEC62271-307 assertions

this can be provided by the manufacturer or be done by the entity issuing the Certificate.

• Search for a 3rd part testing laboratory or certification company that will analyze the data,
calculate the $/MVA and KG/MVA indicators.

• This entity will issue the CERTIFICATE explaining the details and , in the conclusions of the
report, make statements based on the values currently practiced and showed in Table 1 of
these guidelines

Considering this expected sequence, statements in the product standards related to recommend
informing , in the type test report, the values of the indicators $/MVA and KG/MVA are useful for
future Certificates. This is the same type of procedure that was implemented 30 years ago goe
Electromagnetic Compatibility (EMC).

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 The results of the assessment to support the Certificate can be obtained from test reports or from
testing simulations based on the use of the tables and concepts IEC TR 62271-307. In this IEC TR the
origin of the process is a “head of the family” product already tested in a testing laboratory. The
testing simulations are used in a comparative sense. The principle is that, if the testing simulations
done in the tested equipment give the same results as the real test, they are able to predict what
will be the performance of other non-tested samples.

In other words, suppose you test a product and simulate that test getting the same results. Suppose
you now have another design of the same nature as the tested one, but with some differences. If you
simulate the tests of the new equipment, using the same tool and a qualified method, there is no
reason to question that the new simulation represents what would happen in a real test. However,
for this to be accepted by people and buyers who are skilled in engineering, the rules must be
transparent. This is the aim of this Guide.

Using validated simulation tools and methods, it is quick and simple to compare the $/MVA and
KG/MVA of different projects. It is expected that, after some time of application of this Guide, the
world values of these indicators become known, unlike today. The consequence will be the economy
of materials and resources of the Planet.

To implement the process of certification is necessary to stablish sound references to validate the
testing simulation methods. This is explained in the definitions of Section 3. The principles follow the
same concepts and design parameters detailed in IEC 62271-307. Examples of input data and results
which can be used to demonstrate that a certain simulation model is acceptable are presented in
Section 3.

The verification reports issued by the qualified laboratories and certifiers shall indicate in clear words
whether the equipment has passed the tests or not and to write and demonstrate the $/MVA and
KG/MVA indicators. For this purpose, it is particularly relevant the performance in temperature rise
tests, internal arc and short circuit tests (electrodynamic forces).

The use of simulations to replace tests is possible only when certain specific measurements and
registers are specified in the relevant product standards and are presented in the laboratory test
report. In Section 3 are listed the minimum measurements and photographic registers that shall
be informed in test reports, specified in product standards. These measurements make the test to
be reproducible and usable for future simulations. This data also help users to identify if a
commercialized product is similar to the laboratory tested one.

It is not an objective of this Guide to present calculation methods for testing simulation. It is
considered that a model or method is acceptable when it produces validated simulation results
within acceptable tolerances if compared with the real test results and this can be demonstrated
in a transparent way. In principle, the key design factors are based only in the geometry and
materials properties of the conductors, insulation and fluids.

2 Normative references

The following referenced documents may be used for the application of this Guide, where relevant.
For dated references, only the edition cited applies. For undated references, the latest edition of
the referenced document (including any amendments) applies.

a) ISO/IEC Directives, Part 2:2004, Rules for the structure and drafting of International Standards
b) IEC TR 62271-307:2015 : High-voltage switchgear and controlgear - Part 307: Guidance for the
extension of validity of type tests of AC metal and solid-insulation enclosed switchgear and controlgear
for rated voltages above 1 kV and up to and including 52 kV

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 c) IEC TR 60943: Guidance concerning the permissible temperature rise for parts of electrical equipment,
in particular for terminals.
d) IEC TR 60890: A Method of Temperature-rise Verification Assessment by Extrapolation for Partially
Type-Tested Assemblies (PTTA) of Low-Voltage Switchgear and Controlgear Assemblies by calculation.
e) IEC 61117: Method for assessing the short-circuit withstand strength of partially type-tested
assemblies (PTTA)
f) IEC 60865-1: Short-circuit currents – calculation of effects – Part 1: Definitions and calculation
g) IEC 60865-2: Short-circuit currents – calculation of effects – Part 2: Examples of calculation
h) IEC 60112: Method for the determination of the proof and the comparative tracking indices of solid
insulating materials
i) IEC 60071 1: 2010 Insulation co-ordination - Part 1: Definitions, principles and rules
j) Brochure CIGRE 602 / 2014 Tools for the Simulation of The Effects of the Internal Arc in T&D Switchgear
k) Brochure CIGRE 740 (2018) Contemporary Solutions for Low-Cost Substations.
l) Brochure CIGRE 830 (2021):Application and Benchmark of Multiphysics Simulation Tools for
Temperature Rise Calculations

3 Definitions
For the purposes of this Guide, the following definitions apply.

3.1 – kG/MVA ( weight divided by transmitted power ) of an electric product

The aim of the Certificate is to attest that the product was made to meet the requirements of the tests prescribed
in the product standard but, much beyond this, was designed with the minimum necessary use of copper, aluminum,
insulating supports, materials etc. To measure this objective the indicator to be used is the weight per transmitted
power (KG/MVA) . For example, a single copper bar 100x10 mm can transmit 20% less current than using
2x100x5mm (same weight) , for the same temperature rise. So, the indicator KG/MVA is lower in the second case.
Less materials were used, and a higher efficiency was obtained. This is better for the Planet resources.

3.2 - Simulation or calculation to replace a test and acceptable tolerances

A calculation method used to predict, within a certain specified tolerance, the results which would occur in
a laboratory test as specified in the relevant product standard. Here are typical values of acceptable
tolerances of the results to be obtained in the simulations if compared to the real laboratory test results:
Table 1
Type of test Parameter to compare Typical values of
acceptable tolerance for
the calculated values
Temperature rise test Temperature rise in solid and fluid parts 1% to 5%
Internal arc test Overpressure in the enclosure above the 5% to 10%
atmospheric pressure (crest value and
integral of the pressure curve)
Short time withstand Electrodynamical forces and mechanical
current, and peak withstand stresses 5% to 15%
current tests
Other applicable tests The ones listed in IEC 62271-307. (*)
( * ): Values of tolerances to be defined

3.3 - Product publication

Publication covering a specific product or group of related products

34 - Reproducibility of a simulation or calculation method

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The capability of to obtain, for a specified set of input data the same test results or the same simulation
results in two or more different occasions or two different test laboratories.

3.5 - Validation of a simulation or calculation method or a laboratory test

A method of comparison between the results showed in a well-documented test report issued at a test
laboratory and the results of a simulation method. A simulation method is generally acceptable, from the
point of view of users, when it is reproducible and gives a difference between simulation and laboratory
results not higher than a certain acceptable tolerance.

3.6 - Minimum input data to be registered in a temperature rise laboratory test report.
Temperature rise is the main parameter which defines the kG/MVA of a product. Equipment is approved during a
test if the final measured temperature rises of the parts do not go beyond certain limits dictated by the properties
of the insulating and conductive parts. These limits are showed in the relevant product standard. IEC TR 60943 and
IEC 60890 explain the concepts involved.

The data affecting the test and the simulations results are the ones explained in the relevant table of IEC 62271-
307 . The main ones are:
•the circulating electric current,
•the total power dissipation inside the fluid compartment
•the materials used in the conductor and insulating parts
•the contact resistances and its coatings (total per phase and also the ones of the individual parts like circuit
breakers, fuses , isolators)
•the ambient gas or liquid fluid temperature (for example at the bottom , the top and at 50% of the height of
the enclosure),
•the fluid velocity
•the geometry and spatial position of the conductors
•the volume of fluid inside the compartments
•The input and output areas for ventilation
•The number of horizontal partitions inside the enclosure if applicable
•The relative position of the equipment in relation to walls, ceiling and neighbor equipment (as presented in
IEC 60890)

For the sake of reproducibility, the measurement of the total per phase and partial electrical contacts resistances,
before and after the test, shall be registered in laboratory test report.

The values of the data mentioned above shall be clearly registered in the test report trough drawings and photos,

3.7 - Minimum input data to be registered in internal arc tests laboratory test reports

Equipment is approved during a test if the effects of the overpressures arising during the arc do not cause potential
risks to persons in the neighborhood of the equipment. The relevant aspects to consider are showed in the relevant
product standard. IEC 62271-200 and IEC TR 61641 explain the concepts involved.

The curve overpressure x time is the main parameter to predict a good or bad test result.

The data affecting the test and the simulations results are the ones explained in the relevant table of IEC 62271-
307 . They are explained in the reference Brochure CIGRE 602 / 2014. The main ones are

•the circulating electric current,

•the materials used in the conductor and insulating parts
•the geometry and spatial position of the conductors
•the volume of fluid inside the compartments
•The input and output areas for ventilation and devices to close it during the arc
•The areas for pressure relief after the arc
•The relative position of the equipment in relation to walls and ceiling

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For the sake of reproducibility, the measurement of the internal overpressure along the test shall be registered in
the laboratory test report. The values of the data mentioned above shall be clearly registered in the test report
trough drawings and photos,

3.8 - Minimum input data to be registered in short-time withstand current and peak withstand current test report

The objective of the test is to verify the supportability to the effects of electrodynamical forces on insulators and
conductors occurring during a short circuit without arc. The verification is done by visual inspection and
measurement of the resistances per phase.

The data affecting the test and the simulations results are the ones explained in the relevant table of IEC 62271-
307 . They are explained in the references IEC 61117, IEC 60865-1 and IEC 60865-2. The main ones are:
•The circulating electric current,
•The materials used in the conductor and insulating parts.
•The mechanical resistances of the insulators to compression, traction and flexion
•The geometry and spatial position of the conductors

For the sake of reproducibility, the measurement of the total per phase and partial electrical contacts resistances,
before and after the test, shall be registered in laboratory test report.

The values of the data mentioned above shall be clearly registered in the test report trough drawings and photos,

If visible permanent deformations are identified after the test, they shall be registered by photos and an estimate
of the maximum permanent sag after the test.

4 Working procedures

4.1 General
When dealing with subjects relating to the use of simulations or calculations to replace real laboratory tests, in
product standards, committees shall follow the provisions of this Guide, which is to be used in conjunction with
the ISO/IEC Directives.
The status of the simulation or calculation methods, as well as the acceptable values of tolerances, shall be re-
evaluated during the maintenance process.

4.2 Product publications

Committees developing product publications, involving subjects covered by this Guide, shall incorporate this
Guide into their own publication by reference. If necessary, they may specify, in their own publications, additional
details relevant to their product area

5 QUALIFYING AND EXTENDING THE VALIDITY OF TESTS AND CERTIFICATES USING TESTING SIMULATIONS

5.1 Steps of the assessment

The initial procedure is to collect data and test reports results of an already (approved ) tested design. Using
transparent verifiable tools and methods the tests already done are to be simulated. The results of the simulations
are compared with the test results to verify if they are within the acceptable tolerances presented in section 3.2.

The same testing simulations will be done in the untested sample to verify if an expected approval would occur,
within the same requirements of the product standard.

The relevant design parameters considered in the simulations are the ones described in the relevant table of IEC TR
62271-307 . In addition to those parameters, data related to the weight of conductor materials, insulating materials
and enclosures will be registered. The final objective is to calculate an indicator KG/MVA as defined in section 3.1.

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The Certificate shall inform if the untested sample would be expected to be approved in the type tests and also the
KG/MVA indicator. The relevant data shall be presented in a single figure like in the example in Section 5.2.

5.2 An example of a typical assessment

This example intend to facilitate the understanding of the concepts and how to register and compare test
and test simulation results with the purposes of:

a) To validate a simulation model

b) To assess a specific design.
c) To register transparently the data supporting the emission of a Certificate

This example can be used as a reference for data to be included in test reports required by product
standards, useful to support the preparation of future Certificates. It relates to typical medium voltage
switchgear. The input data is showed in the Figure 2 and Table 2.

Typical comparisons between test and simulation results are presented for temperature rise tests (Table 3), internal
arc tests (table 4) and short time withstand current, and peak withstand current tests (table 5). The data marked
with (*) in Table 1 was intentionally omitted.

Table 2 – Input data for the simulation of temperature rise test, internal arc tests and short time
current peak withstand tests
Rating Value
Rated voltage (Ur) and number of phases 15,0 kV - 3Ф
Rated frequency (fr) 60 Hz
Rated normal current (Ir) (*) A rms
Rated short-time withstand current (Ik) and duration (s) 31,5 or 40,0 kA rms – 1s
Rated peak withstand current (Ip) 79 or 100 kA cr
IAC (Internal Arc Classification) IAC AFLR - 31,5 or 40,0 kA - 1,0s
Busbar dimensions and material XX copper bars (*) x (*) mm per phase
Circuit breaker contacts resistance <=45 Ohms E-6
Total resistance per phase <= 112 Ohms E-6
Inlet and outlet free ventilation area (cm2) (*) cm2 x (*) cm2
Forced ventilation rated if any (m3/h) No
Pressure relief free area (cm2) (*) cm2
Absorbers or parts like grids working as absorbers Yes with a free area (*) cm2
Weight of conductor materials (Kg)
Weight of insulating materials (Kg)
Weight of enclosure and others (Kg)

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Table 3 – Temperature rise test and simulation results (K).

Point of the measurement Test result (K) Simulation result (K)

Connection at conductor # 1 (short circuit point ) 47 42
Connection at the end of conductor # 3 (circuit breaker - low) 57 54
Connection at the end of conductor # 4 (circuit breaker-low) 64 66
Connection at the end of conductor # 5 (circuit breaker-high) 64 65
Connection at the end of conductor # 6 (circuit breaker-high) 52 53
Connection at end of conductor # 7 (top horizontal) 32 28
Enclosure door circuit breaker 5
Fluid 50% height - cables compartment not measured 13
Fluid 50% height - circuit breaker compartment not measured 9
Fluid 50% height – bus-bars compartment 15 15

Table 4 – Internal arc test and simulation results (K).

Parameters Test result Simulation result

Symmetric or Asymmetric current Asymmetric
Arc voltage (V rms) 530 567
Maximum overpressure above 1 bar ΔP ( % ) 52 52
Overpressure duration ( ms) 42 45
Integral Pressure curve along the time (bar*s*1000) (*) 13
Time to 100% of overpressure peak ΔP (ms) 18 21
Time to 50% of overpressure peak ΔP (ms) 24~26 36

Table 5 – Short-time withstand current, and peak withstand current test and simulation results

Test result Simulation result

Max. Mechanical stress σH (N/mm2) Not measured 94
Max. Mechanical stress σT (N/mm2) (*) 18
Max. mechanical stress σH + σT (N/mm2) (*) 111
Max. Force on the insulator in compression or tension (N) (*) 8918
Max. Force on the insulator in flexion (N) (*) 5711

Figure 2 in next page.

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Figure 2 – Input data to be used in the assessment of designs according to the parameters in the Tables of IEC
62271-307. The numbers of the conductors are the same used in Tables 2 to 5

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 IEC STANDARDS STATEMENT about SAVING MATERIALS (as was done with EMC
in 1980s): Reduced use of copper, aluminum & insulators is beneficial for

the environment. All product standards should add this clause:

"PRODUCTS COVERED BY THIS STANDARD use significant amounts of
copper, aluminum, insulators, and metals. Material savings are
desirable for the Climate Change and Energy Transition initiatives.
promotes designs and methods that lower the kg/MVA” designs.

REFERENCES
[1] IEC TR 60943:1998 - Guidance concerning the permissible temperature rise for parts of electrical
equipment, in particular for terminals. Issued by IEC Technical Committee TC 32.

[2] CIGRÈ BROCHURE 830 (2021) – “SIMULATIONS FOR TEMPERATURE RISE CALCULATION”. (Sergio Feitoza
Costa is co-author)

[3] Cigrè Brochure 740 (2018) Contemporary design of low-cost substations in developing countries.

[4] Article “TEMPERATURE RISE LIMITS OF IEC 61439-1 : unclear values distort the LV switchgear market.
(May,12, 2023) - http://www.cognitor.com.br/IEC614391Table6.pdf

[5] IEC62271-307 (2015) - High-voltage switchgear and controlgear - Part 307: Guidance for the extension of
validity of type tests of AC metal and solid-insulation enclosed switchgear and controlgear for rated voltages
above 1 kV and up to and including 52 kV.

OTHER USEFUL REFERENCES

[6] Article “METAL FOAM in SWITCHGEAR, switchboards & bus ducts
http://www.cognitor.com.br/switchgearmetalfoam.pdf

[7] ENVIRONMENTAL EFFICIENCY CERTIFICATE OF ELECTRICAL PRODUCTS (KG/MVA): TECHNICAL

STANDARD & DEMO PROJECTS MANAGEMENT)
http://www.cognitor.com.br/demo1certificate.pdf

[8] SUBSTATIONS & LINES INNOVATIVE PRODUCTS. SMALL R&D CENTRES + TESTING LABORATORY
https://www.cognitor.com.br/demo2Lab.pdf

[9] ENVIRONMENTAL EFFICIENCY CERTIFICATE of electrical products (kg/MVA) . Draft of a technical standard
http://www.cognitor.com.br/EnvironmentalEfficiencyCertificate.pdf

[10] CIGRÈ BROCHURE 602 (2014) Tools for Simulation of The Effects of the Internal Arc in T&D Switchgear,

[11] IMPROVEMENT OF QUALITY OF ELECTRIC SYSTEM INDEXES:

https://www.cognitor.com.br/IEC602822sugestionstosc32afrombrazil.pdf

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[12] Free book by Sergio "RENEWABLE ENERGY + ENVIRONMENTAL EDUCATION TO TRY TO SAVE THE
PLANET" https://www.cognitor.com.br/educationfortheplanet.pdf

[13] Free book by Sergio “SWITCHGEAR, BUSWAYS & ISOLATORS & SUBSTATIONS & LINES EQUIPMENT”
https://www.cognitor.com.br/Book_SE_SW_2013_ENG.pdf

[14] Free book by Sergio” PROJECT SAVE RIO IN 10 YEARS:

https://www.cognitor.com.br/saverioENG.pdf

[15] Visiting researcher training: https://www.cognitor.com.br/trainingENG.pdf

[16] Other reference articles free downloads https://www.cognitor.com.br/Downloads1.html

CV Sergio Feitoza Costa https://www.cognitor.com.br/Curriculum.html

Things Sergio helped to do http://www.cognitor.com.br/HelpedToDo.pdf

Site https://www.cognitor.com.br

Contact e-mail: write to [email protected]

Linkedin profile (30K followers) : linkedin.com/in/sergiofeitozacosta

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