In theory, constructing a substation according to established and tested protocols should proceed without any unexpected issues. However, real-world experience tells a different story. This article explores the common challenges faced by project managers in the energy sector, considers whether they can be avoided, and offers solutions for when problems do arise.

Despite meticulous planning, the reality of project execution often deviates from the ideal scenario. Managers with extensive experience will attest that encountering challenges during construction is inevitable. Larger projects tend to face more significant obstacles, but even the best-prepared plans can falter due to unforeseen issues.

Why do well-prepared plans sometimes fail?

Careful planning of every project detail is essential for smooth implementation. Yet, in practice, various unforeseen factors can derail even the most meticulously prepared plans. The energy sector is particularly demanding, requiring precise coordination among all specialists and rapid response to crises. Often, the most complex issues are due to human factors, not a lack of commitment.

Time pressure, poor communication, and random accidents can cause significant delays, even with thorough preparation.

At Protektel, we have successfully completed numerous substation projects, gaining extensive experience in addressing and overcoming these challenges. Here, we share our insights and solutions.

Time Pressure and Underestimating Needs

Winning a tender marks the beginning of a project, but it’s also where difficulties often arise. Underestimating a project’s needs is common and usually stems from the harsh realities of the situation. Initially, documentation may include assumptions and standards, but detailed technical documentation is often lacking.

Creating a detailed plan for the station reveals the first challenges. Discrepancies between tender assumptions and actual needs can lead to significant delays. Common reasons for changes include:

• Alterations in planned equipment.
• Investor requirements.
• Field conditions.
• Changes in design assumptions.

Time pressure exacerbates these issues. Corrections to the project extend the timeline, and inaccuracies caught before ordering elements can minimize this impact. Working with trusted partners ensures orders align with needs, reducing potential delays.

Delivery Accidents

Another challenge is the occurrence of delivery accidents. Delays or damaged parts can significantly impact the project timeline. Common contingencies include supply chain issues, transportation problems, and production capacity limitations of suppliers.

For example, producing high-voltage transformers can take up to six months. Ordering components well in advance and storing them in our warehouse can prevent costly delays.

Discrepancies Between Projects and Contractors

Coordination between specialists and ensuring components fit their intended purposes are critical. Discrepancies between design and contractor execution can cause issues, such as incorrect drilling or structural changes during construction.

These issues can arise when:

• A different equipment supplier is needed.
• Field conditions differ from design parameters.
• Incomplete data or assumptions in the design.

Solutions include using adapters or modifying fixtures to match components. We also offer technical advice beyond our products, ensuring optimal solutions for each situation.

Inconsistencies in Equipment Class and Power

Ready-to-install orders sometimes reveal discrepancies in class, accuracy, or power of transformers, often due to design condition mismatches or incorrect assumptions. Common difficulties include:

• Changing investor demands.
• Distribution company requirements.
• General project modifications.

Solving these issues may involve additional calculations or necessary modifications to the transformer’s secondary circuit.

Conclusion

Challenges in the power sector arise regardless of experience. While careful design is crucial, being prepared for random situations is essential. Protektel’s specialists offer support at every project stage, from planning to implementation and legal support.

Are you starting a new project and want to ensure smooth execution? Contact us for a consultation. With Protektel, you gain not only a reliable product but also expert support at every step.

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PROXAR® surge arresters, produced in Poland, are designed to meet the European IEC 60099-4:2014 standard but also comply with the IEEE C62.11-2020 standard. This article highlights the differences between these standards and how they apply to Protektel’s surge arresters.

Our PROXAR® surge arresters are exported to countries like Peru, Ecuador, and Brazil. This global reach is possible because our devices meet the stringent IEEE C62.11-2020 standard, often exceeding its requirements. Learn more about how these standards compare.

Differences Between IEC 60099-4:2014 and IEEE C62.11-2020

The IEC 60099-4:2014 and IEEE C62.11-2020 standards are about 80% harmonized. The remaining 20% of the differences are mainly in terminology and environmental conditions for surge arrester applications. The table below illustrates these differences:

Table 1: Differences Between IEC 60099-4:2014 and IEEE C62.11-2020

Why Do IEC and IEEE Standards Differ?

The main differences between IEC 60099-4:2014 and IEEE C62.11-2020 standards stem from their varied approaches to surge arrester installation conditions, influenced by power system characteristics and environmental factors.

In Europe, surge arresters are primarily designed for protecting substations and power line facilities, requiring robust mechanical structures and solid fixings, which add to their weight and cost.

In contrast, in the Americas, surge arresters mainly protect transmission line insulators and compact lines, necessitating different installation methods that do not require as robust a design. This results in devices with lower mechanical strength, reducing their cost. However, Jacek Turkowski, Director of Marketing and Sales at Protektel, highlights an important point:

“While our PROXAR® surge arresters meet both IEC 60099-4:2014 and IEEE C62.11-2020 standards and are used for substation and power line protection, strictly line arresters (TLA) often have mechanical strength suitable for mounting on supporting structures in substation applications or other system areas.”

PROXAR® Surge Arresters and IEEE C62.11-2020 Compliance

The primary components of PROXAR® surge arresters exceed the IEEE C62.11-2020 standard requirements, thanks to the use of high-quality varistors in their design. This compliance is verified by tests conducted according to the latest EN 60099-4 standard.

Protektel’s surge arresters are suitable for in-line protection, a common practice in the Americas, and their robust design makes them ideal for substation protection.

In Europe, we stand by the motto “PROXAR® Unlimited Trust.” Partnering with us ensures not only high-quality surge arresters but also expert advice and knowledge from our specialists.

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The second edition of the EN 60099-4 standard introduced changes that posed challenges not only for surge arrester manufacturers but also for their customers. Even today, we receive inquiries about the specifics of this revision and its impact on our products. Interestingly, these changes have highlighted the superior quality of Protektel® arresters. Read on to discover more about this topic and understand why our company is synonymous with unlimited confidence.

Navigating the Stricter Standards

All surge arresters must meet global standards, yet most manufacturers focus on minimizing production costs while ensuring their designs pass the required laboratory tests. But what happens when standards become more stringent? At Protektel, we have the best answer to this question, as detailed in the following article.

Key Changes in the EN 60099-4 Revision

To illustrate, let’s examine the specific changes in EN 60099-4. This standard addresses the classification of non-directional surge arresters based on non-linear metal oxide varistors supplied with AC voltage above 1 kV.

First published in 2004, with a subsequent revision in 2005, the latest edition came out in 2016. This most recent revision introduced significant changes in the classification and type testing of surge arresters, as outlined in the tables below.

Table 1: New Classification of Surge Arresters

Table 2: Changes in Type Tests of Surge Arresters

Reasons for Changes in Surge Arrester Classification

The EN 60099-4 changes aimed to standardize testing methodologies, including thermal models for surge arresters. The effectiveness of heat dissipation largely determines the operational longevity of a surge arrester.

The primary goal of these changes was to eliminate low-quality surge arresters from the market. The new, more stringent requirements particularly affected low-budget manufacturers.

Impact of the Standard Revision

Manufacturers were the most affected by the EN 60099-4 revision, as they had to ensure their arresters met the new requirements, often necessitating higher quality varistors. This change required recertification of the new devices, which was time-consuming and costly.

End users, on the other hand, benefited from the new requirements. The inclusion of thermal characteristics in the classification meant that higher quality arresters were now available, resulting in longer periods of trouble-free operation.

High Quality of Protektel® Arresters Confirmed

With an understanding of the EN 60099-4 revision, we can explain how these changes validated the quality of Protektel® arresters. During the design phase, we faced several dilemmas, especially regarding the quality of varistors: should we opt for components that met existing standards or higher quality ones? Choosing the latter allowed us to avoid risks associated with future standard changes.

The confidence you place in our surge arresters stems from their quality, which is rooted in both innovative design and premium components. From the beginning, we have selected only the best components. This is confirmed by the latest EN 60099-4 standard tests, which our arresters passed effortlessly, maintaining reserves of 20-30% in key performance areas. Such results are hard to surpass in our industry, wouldn’t you agree?

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The European Commission has introduced new guidelines increasing the maximum voltage for power generation systems. Following these updates, many Polish distribution companies have set their own regulations, making it challenging for designers to select appropriate arrester parameters. Here, we explain how to interpret the new guidelines accurately and meet specific requirements, including the significance of the 145 kV value in these designs.

Changes in Maximum System Voltage

The latest European Commission guidelines state that the maximum system voltage U_s can no longer be 123 kV but must be 126.5 kV (for one hour). This adjustment is outlined in Commission Regulation (EU) 2016/631, establishing a network code on the requirements for connecting generating units to the power grid (NC RfG).

Voltage Conditions from NC RfG Article 25(1):

• Voltage range: 1.118 pu – 1.15 pu – Operating time: 60 minutes;
• Voltage range: 1.05 pu – 1.10 pu – Operating time: 60 minutes.

This regulation reflects the characteristics of green energy generation in facilities such as hydropower plants, wind farms, photovoltaic farms, and other generating units. As a result, surge arresters must be selected accordingly.

Issues Arising from the New Guidelines

Designers faced confusion about which surge arrester parameters to adjust to comply with the new regulations, especially for 110 kV systems (nominal voltage, U_N). Previously, in Poland, the maximum voltage (U_M, now U_s) was 123 kV, and equipment, including surge arresters, was chosen to match this value for optimal operation, protection, and longevity.

Surge Arresters for Western European Projects

Most RES projects in Poland originate from Western Europe, where 110 kV systems are used but with different configurations. For example, Germany uses a U_n of 132 kV and a U_s of 145 kV, complicating the selection of arresters for Polish implementations.

Selecting Arresters for U_s = 126.5 k

To select an arrester for a system with a maximum voltage of 126.5 kV (for one hour), calculate as follows: 126.5 kV / √3 = 73.12 kV. Standard arresters with a U_c of not less than 77 kV are sufficient. Thus, no special selection is required for this condition.

Addressing the 145 kV Requirement

Standard arresters for 110 kV systems can safely handle a U_s of 126.5 kV for one hour. However, the 145 kV parameter seen in Western European projects does not apply to Polish networks but can be addressed by using an arrester with U_r = 96 kV / U_c = 77 kV in a higher sheath to meet the insulation strength condition for a network with U_s 145 kV. Many Proxar® surge arresters can be manufactured with this longer sheath at an acceptable cost.

Proxar®: Your Trusted Partner in Surge Arrester Selection

At Proxar®, we offer not only high-quality surge arresters but also expert advice and support in selecting the right arresters for your needs, ensuring compliance with both European and Polish standards. Unlimited trust in our products and services is our commitment to you.

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Engineers and designers often trust the quality of surge arresters from well-known industry leaders. However, not everyone is aware that a Polish company manufactures these devices to a higher standard than many global competitors. Design offices and project managers, in particular, should take note. Discover the key advantages of PROXAR arresters that make them exceptional in the market.

Understanding Surge Arresters and Their Role

Surge arresters are vital electrical devices designed to protect equipment from voltage surges, which can result from lightning strikes or power grid fluctuations. These overvoltages can cause significant damage if not properly managed. While commonly used in home and telecommunications installations, surge arresters are essential in industrial and power sectors for safeguarding critical infrastructure and high-value equipment. Only the top manufacturers produce surge arresters capable of providing such high-level protection.

Evolution and Benefits of Arrester Design

The earliest surge protection devices were spark arresters, designed to protect against atmospheric surges. Technological advancements led to the development of more sophisticated solutions using spark gaps and semiconductor elements like silicon carbide (SiC). These lightning arresters effectively mitigated various surges but had limitations. The introduction of varistors, semiconductor elements with highly non-linear voltage-current characteristics, marked a significant improvement. Modern surge arresters, especially those using high-quality ZnO varistors, offer superior overvoltage dissipation without adverse effects such as spark re-ignition.

Table 1 Comparison of parameters of PROXAR arresters with counterparts manufactured by competing companies.

Protektel: The Polish Manufacturer Behind PROXAR Arresters

Protektel, a company with roots in the 1990s ZWAR company, formally began operations in 2002. After years of development, they launched the PROXAR brand of surge arresters. Manufactured entirely in Przasnysz, Poland, PROXAR arresters feature components like varistors imported to ensure consistent quality. Their innovative internal construction enhances mechanical strength, setting them apart from competitors.

Unique Production Process of PROXAR Arresters

The manufacturing process for PROXAR arresters includes several stages, notably the patented polyamide fiber braiding technique that provides exceptional mechanical strength. This robust braid allows PROXAR arresters to be installed in various locations, including non-standard ones, and ensures reliable operation for decades.

What Sets PROXAR Arresters Apart?

Protektel’s innovations, such as the unique polyamide braiding, start from within the arrester. Mechanical strength is crucial for many applications, and PROXAR arresters excel in this aspect. Compared to industry leaders, PROXAR arresters boast superior parameters, particularly in energy withstand capability, translating to longer life and more reliable performance.

Customization to Meet Your Needs

Protektel offers extensive customization options for PROXAR surge arresters to match specific customer requirements. Adjustments can be made to:

• U_r/U_c parameters to suit network conditions or competitor equivalents.
• Insulating housing size based on environmental conditions.
• Mounting and shield sizes to meet client expectations.
• Operating point to align with network conditions.
• Language and description of nameplates.

Additionally, modifications can be made to accessories such as terminals, mounting bases, and adapters. Technical documentation is also customized, including guaranteed data sheets with drawings in PDF and DWG formats.

More Than Just a Surge Arrester

Choosing PROXAR means gaining more than a high-quality surge arrester. It includes professional advice, comprehensive after-sales support, and reliability critical for long-term investments. With over 750 clients in the energy sector, both in Poland and internationally, and more than 130,000 units produced by July 2023, PROXAR has earned the trust of designers and investors alike.

PROXAR®. Unlimited Trust.

For projects requiring reliable and effective surge protection, PROXAR surge arresters offer unmatched quality and performance. Trust PROXAR for your critical infrastructure needs.

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Surge arresters are indispensable for medium and high voltage power networks. These devices are utilized across various power and industrial sectors, including renewable energy sources (RES). However, selecting the right surge arresters for each project is crucial. Discover why this selection process is so vital.

Understanding Surge Arresters and Their Function

Surge arresters are electrical devices with non-linear properties designed to protect power systems from overvoltages, such as those caused by lightning strikes or power system switching. When properly selected and operating within their rated conditions, they do not disrupt the power grid. Their primary function activates during overvoltage events, diverting the excess voltage to the ground and reducing it to safe levels, ensuring smooth operation of the equipment and power systems they protect. Surge arresters are engineered for long-term reliability, capable of handling multiple short-duration overvoltage events over decades of service.

Operating Under Harsh Conditions

Surge arresters must perform reliably under harsh environmental conditions, including:

• Prolonged exposure to sunlight and UV radiation.
• Extreme temperature fluctuations.
• Various forms of precipitation.
• Mechanical stresses.

Despite these challenges, well-selected surge arresters provide broad protection. For instance, they can effectively dissipate surges up to 100 kV in a 15 kV nominal voltage network. Such high-potential surges can occur repeatedly, and surge arresters are expected to maintain their performance for up to 30 years.

Key Parameters for Selecting Surge Arresters

• Selecting the right surge arrester involves considering multiple factors:
• System’s highest voltage (U_s).
• Short-circuit current at the installation point.
• Ground fault coefficient.
• Maximum duration of ground faults.
• Power grid grounding and protected equipment connections.
• Cable section lengths.
• Distance between arresters and protected equipment.
• Continuous operating voltage (U_c) relative to the network’s U_s.
• Arrester’s rated voltage for TOV surges.
• Expected lightning discharge currents.
• Equipment’s rated insulation level.

After determining these parameters, the next steps include assessing the arrester’s protective characteristics against lightning and switching surges and selecting the optimal installation location, ideally as close to the protected equipment as possible. However, technical constraints of the project or facility can sometimes make this challenging, as experienced with one of our clients in Poland.

Consequences of Improper Arrester Selection

Choosing the correct surge arrester parameters is a collaborative effort among designers, operation supervision services, and companies like Protektel, which provide expert support. Relying solely on schematic diagrams or network design descriptions can lead to significant responsibility, as improper selection can have dire consequences. For example, failure of a 400 kV transmission network due to an incorrectly chosen arrester could disrupt power to critical infrastructure, including hospitals and industrial facilities. An example of the severe repercussions of improper selection is the Jaworzno power plant in Poland, which supplies 10% of the country’s electricity. A failure here could lead to widespread and difficult-to-repair outages, with catastrophic national consequences.

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Background

A reputable design office, with which we’ve maintained a decade-long collaboration, secured a tender to design a wind farm integrated with a 110 kV system. The project involved designing transformers and surge protection for the high-voltage cables connecting the farm to the overhead grid.

The Challenge

Connecting the wind farm to the electrical grid posed several challenges. The wind farm’s substation needed to link to the overhead grid to both distribute power generated by the farm and supply the substation itself during periods of no power production.

The substation’s integration required careful selection of transformers that balanced both power consumption and distribution. Additionally, selecting suitable surge arresters to protect the high-voltage cable on both ends was crucial. These arresters also needed to be compatible with the cable shield.

Our Solution

The design office sought our expertise in selecting transformers with appropriate parameters for both power consumption and distribution. This process was intricate, often necessitating measurements within protection and billing systems to account for power distribution from the farm to the substation and vice versa.

Implementing this project demanded the use of additional transformers. Concurrently, we selected surge arresters to safeguard the equipment, considering network parameters and distances between the substation components.

Outcomes

The high-capacity cable connecting the wind farm’s substation to the overhead grid notch acted as a source of surges. We selected surge arresters for both ends of this cable, ensuring safe discharge of electric charges during switching surges. Moreover, our proposed surge arresters protected the substation equipment from lightning-induced damage.

We conducted our collaboration with the design office at the expected pace, culminating in the comprehensive selection of six combination transformers, six high-voltage surge arresters with ProCounter F trip counters, and twelve surge arresters for return conductor protection.

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Background

The modernization of Warsaw’s tramway system brought new challenges related to protecting power lines from surges. The existing technology was inadequate for safeguarding the advanced electronics of the new streetcars, leading to operational issues. Failures in power mains equipment had cascading effects, causing malfunctions in safety-critical systems such as switches and track switches. Additionally, repairing surge-damaged components, including power converters, led to increased expenses.

The Challenge

Selecting the right surge arresters was difficult due to a lack of knowledge about the specific surge parameters. These surges resulted from both lightning strikes and the daily operations of the tramway fleet and equipment. Therefore, the initial task was to identify vulnerable zones within the power supply network and understand the disruptions occurring in these areas.

Our Solution

Our collaboration began with a comprehensive inspection of the tramway infrastructure. To analyze surge parameters, our expert conducted numerous diagnostic runs on a streetcar equipped with specialized monitoring devices. These runs recorded disturbances, enabling us to select surge arresters with the appropriate specifications and determine the best installation sites.

From the start of the project to the delivery of an effective solution, the process took less than six months. We installed the selected surge arresters and monitored their performance over a 12-month period, as outlined in the contract. During this time, we regularly collected data, observed phenomena, and incorporated the Partner’s feedback through phone and email exchanges.

The rapid resolution of surge-related issues in Warsaw’s tram network led the Partner to reduce the initial operational timeframe by one year and include our product in their technical documentation for future tram network applications.

Outcomes

Through extensive consultations, both remote and on-site, we provided Warsaw Trams with over 1,000 surge arresters of various types. Additionally, we recorded emerging surges, pinpointed their sources and locations, and measured the characteristic parameters of the disturbances. We also continuously coordinated the overvoltage protection of the traction power system. Our ongoing cooperation ensures we remain available for any surge protection consultations needed.

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Background

Our Partner, committed to sustainable development, is expanding its photovoltaic farms and upgrading its in-house power grid. This expansion required the addition of three new medium-voltage switchgears:

• A 30 kV switchgear to serve the photovoltaic farm, fed from the 110 kV GPZ and connected to the others via a 30 by 6 kV transformer.
• Two 6 kV rated switchgears for energy distribution and power supply to the plant.
• The Challenge

What challenges did our partner face?

Our Partner needed surge protectors for all three new medium-voltage switchgears. Our task was to select surge arresters to protect the following MV equipment:

• Switchboards.
• Cable lines.
• Transformers.

We identified two key hotspots specific to this project:

• Transitions between cable and overhead lines: These points can experience surges of multiplied value. Additionally, repairing damage to cable lines is labor-intensive and costly, necessitating careful design to secure these connections.
• Incoming connections to transformers: These connections, being overhead, required careful calculation of the appropriate set of surge arresters to protect the MV transformer effectively.

Additionally, the absence of an existing overvoltage protection design meant we had to create one from scratch. Moreover, some proposed installation locations did not meet the technical requirements, requiring adjustments to the surge arrester parameters.

Our Solution

We began by obtaining comprehensive technical documentation of the existing electrical network from our Partner, including facility photos. We also conducted two video conferences with the client’s technical team. Although we were ready to visit the implementation site, it was unnecessary in this case.

Our work included:

• Calculating the maximum operating voltage of the arresters.
• Selecting appropriate limiter models.
• Analyzing operating points around switches to determine the best locations.
• Defining protection zones to establish the extent of individual surge arrester sets.
• Determining installation locations based on technical conditions and the Partner’s requirements.
• Checking short-circuit conditions to ensure our solutions could withstand short-circuit currents according to standards.
• Manufacturing and delivering custom surge arresters with specific parameters.
• Providing technical documentation, including installation and operation instructions, and product data sheets.

We produced custom surge arresters specifically for our Partner’s needs. The process, from initial contact to the submission of a comprehensive offer, took approximately two weeks. From technical discussions to the delivery of surge arresters, the timeline spanned about six weeks, despite the Partner’s tender process.

Outcomes

The project was scheduled for completion by the end of April 2023, but by mid-March, some arresters were already installed and operational. Upon project completion, the Partner achieved reliable protection for the power supply installation to their industrial plants. The number of surge damages is expected to decrease. Additionally, our client gained a trusted partner, as evidenced by selecting Protektel for the supply of replacement transformers in their next project.

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