Inc., Power Technologies Division

Conceptual  Design for 145 Kv High Voltage Dead Tank Circuit Breaker Support Frame

The Problem

ABB Inc. is a world leader in the high voltage circuit breaker industry. The headquarters of ABB Inc. High Voltage Breaker division is based in Mount Pleasant , Pennsylvania . The company ships a wide range of dead tank breakers; ranging from 72Kv up to 800Kv.  The basic function of a high voltage dead tank breaker is to interrupt any current inconsistencies or a very high fault current.  Dead tank breakers consist of tanks with SF6 insulated interrupting units, bushings, drive, control cabinet and frame.  The purpose of the frame is to lift the energized parts above a certain secure height and to align the drive, linkage, and interrupting units.

ABB finds that their current frame design occupies a lot of empty space in overseas shipping containers.  As overseas shipping is based on volume and not by weight, ABB needed a frame that could be packed more densely.

Current 145 Kv Breaker and Frame

Specifications

In order for ABB Inc. to meet their customers needs effectively and efficiently the team has proposed a redesigning and improving of their existing frame.  Kevin Goldstein, Senior R&D Engineer from ABB has provided us with the following concerns:  

• Cost
• Weight
• Durable finish
• Shipping (domestic and overseas)
• Static withstand
• Assembly/disassembly

Design Concept

After brainstorming, the team came up with four frame designs.  The team used a decision making matrix to decide which two of the four ideas developed in the brainstorming process would be used.  The first design took the original frame incorporated four hinges to enable the frame to fold for transportation.  The second design involved a design that enable the original frame to be taken apart and separated into two halves for transportation.  Cost estimates were obtained for the construction of the frames.  Static analysis of the two frames was carried using finite element software.  After studying the finite element model, the team found that both frames did not have excessive stress on any areas.  The team decided, based on cost, weight, simplicity, and ease of manufacture, that the split frame design would be the best solution to the project.  A galvanized hot dip finish is also recommended for a durable long lasting product.

    Concept 145 Kv Frame Assembled                       Concept 145 Kv Frame Disassembled for Transportation

The halves could be oriented in such a way to take up less space in overseas shipping containers ultimately saving money on overseas shipping costs.  With this design ABB would be able to fit 9 frames in their 40' shipping container and 5 frame in their 20' containers.

                Frame Halves in 40' Shipping Container