SF6-free primary GIS | BGP-40.5
BGP-40.5, a versatile switchboard
BGP-40.5 is a medium voltage dry air insulated switchboard up to 40.5kV, used in primary distribution applications. It can be fitted with the
following protection devices:
- Transformer protection
- Line protection
Its compactness, wide range of functions and ease of installation and extensibility, make it a versatile switchboard to fit many transmission and distribution applications such as: utilities, industry, infrastructure or renewables.
Electrically insulated using dry air
The high voltage conductive parts of the BGP-40.5 switchboard are placed in green insulating air (clean dry air). The dry air is confined in a hermetically sealed stainless steel tank. BGP-40.5 is insensitive to the outside environment and to any possible aggressions such as:
- Humidity
- Dust
- Pollution
- Dirt
- Harmful rodents
The use of dry air as an insulating gas, and the design of BGP-40.5, makes it one of the most compact switchgear available.
Simple operation and maintenance
With a service life of 30 years for the main circuit without maintenance, the overall design of Brunstock’s range of BGP-40.5 switchboards guarantees simple and reliable use:
- Simplified maintenance of the functional units and with continuity of service for the other units (LSC2 class)
- No air filling is required on site at installation nor during the service life of BGP-40.5 under normal operating conditions
- It has a long service life
- It features interlocking to ensure the correct sequences of operations
- Can be used in substations with or without walk-in operation corridors
- Voltage presence indicator light
- Wide cable compartment to allow the installation of various types of cable, etc.
Safety and innovation
BGP-40.5 has been designed for maximum safety of the operators and equipment, with special attention given to the remote possibility of internal arcing in the equipment:
- Safety valves at the rear yield and thus avoid gas overpressure
- Each functional compartment is independent completely
- The overall structure is inside a tank with good sealing performance and strong compressive strength
A major asset
Brunstock integrates with a manufacturing partner to produce BGP40.5 and their role includes monitoring quality, environmental impact and employee safety to ensure compliance with standards. They utilise management systems to help achieve this. As an extra layer of scrutiny, Brunstock’s representatives apply local knowledge to verify design and quality manufacturing, and may use their own management systems.
The manufacture of BGP-40.5 is certified under the following
management systems:
- ISO 9001: 2015 quality
- ISO 45001: 2018 workplace health and safety
- ISO 14001: 2015 environment
Quality system certified
During manufacture, each BGP-40.5 functional unit is subject to systematic routine testing with the aim of checking the quality and conformity of the following features:
- Measuring of opening and closing speeds
- Dielectric test
- Testing of safety systems and interlocks
- Testing of low voltage components
- Conformity with drawings and diagrams
The results obtained are recorded and approved by the quality control department on each device’s test certificate. This therefore guarantees product traceability.
Environment system certified
As part of the manufacturer’s environmental policy, Brunstock equipment is managed under an environmental management system.
BGP-40.5 has been designed with environmental protection in mind:
- All materials used, for instance gas tank and conductors, are
identified, and easily separable for recycling - Our production sites are certified to ISO 14001
Health and safety system certified
Workplace Health and Safety (WHS) bears the highest importance at Brunstock. The manufacture of BGP-40.5 includes controlling risks and making improvements in performance in compliance to ISO 45001: 2018. Brunstock supports the system’s focus on eliminating or minimising risks to personnel and other interested parties who could be exposed to WHS hazards associated with the manufacture of BGP40.5.
Operating conditions
- Ambient temperature: from –5°C to +40°C (*)
- Average value over 24 hours (max.): +35°C
- Typical maximum altitude for installation above sea level is 1,000 m However, much higher altitudes are possible on request
- Type of insulating gas: Clean dry air
- Rated pressure at +20°C: 0.32 MPa
(*) Lower/higher ambient temperature on request.
Protection index (IP)
- Main electrical circuits (gas tank): IP67
- Enclosure: IP4X
- Between compartments: IP2X
- Switchgear: IK10
Partition class and loss of service continuity category
- Partition Class: PM (1)
- Loss of Service Continuity Category: LSC2B for single functional unit (2)
Internal Arc Classification
BGP-40.5 is a pressurised sealed-unit system that complies with IEC 62271-1. Its tank is filled with dry air that is used as an insulating and breaking medium. BGP-40.5 internal arc classification as per IEC 62271 200 is detailed in the table below. In the unlikely event of air overpressure, the dry air is discharged via safety valves away from the operator.
- PM class according to IEC 62271-200 edition 2: metallic partitioning between
compartments; - Based on IEC62271-200 edition 2, BGP-40.5 is classified as LSC2B
IEC standards
Our BGP-40.5 switchboards comply with the standards shown below:
General introduction
- BGP-40.5 is a dry air insulated, metal shell, fixed switchgear, and is an indoor complete set of three-phase AC 50Hz single bus and bus segments. Mainly used in power distribution systems such as power plants, small and medium generators, substations, high-rise buildings, industrial and mining enterprises, subways and electrified railways, to implement the control, protection and detection of power supply systems and loads. It is especially suitable for underground, high altitude, frozen soil, coastal, humid and other challenging environments. It is equally delightful at fitting into densely populated areas as it is at saving construction costs in rural and remote locations.
- The key technologies of product development and design, such as insulation, temperature rise, mechanical strength, sealing and arcing are all calculated by computer simulation to ensure the quality and reliability of product development.
- In order to ensure the stability and reliability of product manufacturing quality, our manufacturing partners use three-dimensional fiveaxis robot welding equipment, a helium quality general leak detector, lightning impact, X-ray detection, partial discharge tester, temperature rise, high and low temperature testing and other equipment.
- The high-voltage primary components of BGP-40.5 are enclosed in aluminum alloy gas chamber, and the main circuit is fully enclosed, fully insulated and maintenance-free.
- BGP-40.5 uses dry air insulation and vacuum arc extinguishing breaking technology, and the service life of the vacuum circuit breaker is up to 10,000 times.
- The product is designed with an independent arcing channel, and the arcing capacity of the whole cabinet: IAC-AFLR 31.5kA/1s
Advantages
Diversified solutions
- This SF6-free switchgear is an integral part of a green GIS solution
- Bus and line VT solution
- Disconnector solution
- Bus riser
Capability of development
- Self-developed the core components (CB and TPS)
Compact size
- The height with standard LV box: 2350mm
- Width: 600mm/800mm
- Depth: 1840mm/1980mm
Positioning
Technically
- 40.5kV dry air gas insulated switchgear series
Market
- Utility, railway, photovoltaics, oil & gas, mining, etc.
- Africa, Asia Pacific, Middle East, Switzerland
Quality & cost
- IEC compliant and cost effective
High-end
- Safe and highly reliable, maintenance-free
Features
- Dry air insulation, vacuum interruption, environmentally friendly
- No need to fill with dry air when on-site installation takes place
- Rated pressure for air filled is lower to 0.32MPA
- With unique natural air cooling duct
- Modular design, removeable gas tank and compartment
- The main circuit is fully enclosed and insulated with IP67
- The circuit breaker is up to 2500A, main busbar up to 2500A and the rated breaking current is 31.5kA
- Independent centralised pressure relief channel
- Main bus VT and arrester with isolation switch is easy for operation and maintenance
- Compact size
BGP-40.5
| Rated voltage kV | 40.5 |
| 1min power frequency insulation kV | 95/118 |
| Lightning impulse withstand voltage (peak) kV | 185/215 |
| Rated frequency Hz | 50/60 |
| Rated short-circuit breaking current (RMS) kA | 25/31.5 |
| Rated peak withstand current kA | 63/80 |
| Rated short-time withstand current (RMS) kA | 25/31.5 |
| Duration of rated short-time withstand current s | 4 |
| Rated current of main busbar A | 1250/2500 |
| Rated current of branch busbar A | 630/1250/1600/2000/2500 |
| Internal arc classification kA/s | IACA FLR 31.5/1 |
| Mechanical endurance of VCB times | 10,000 |
| Mechanical endurance of three-position disconnector times | 5,000 |
| Rated ex-factory filling pressure (relative) MPa | 0.32 |
| Alarm pressure (relative) MPa | 0.29 |
| Blasting pressure of explosion-proof membrane (relative) MPa | 0.26 |
| Type of insulating gas | Dry Air |
| Moisture content (20°C) ppm | ≤300 |
| Annual leakage rate % | ≤0.05 |
| 1min power frequency insulation at zero gauge pressure kV | 85 |
| Volume (WXDXH) mm | 1250A: 600X1840X2350, 2500A: 800X1980X2350 |
| IP class Gas tank (the primary circuit) | IP67 |
| IP class Enclosure | IP4X |
| IP class Between compartments | IP2X |
* Note: 1. The standard height of the LV box is 600mm. If more instruments, the height of the secondary room can be increased appropriately through technical clarification.
BGP-40.5 Vacuum circuit breaker
| Rated voltage kV | 40.5 |
| 1min power frequency insulation kV | 95/118 |
| Lightning impulse withstand voltage (peak) kV | 185/215 |
| Rated frequency Hz | 50 |
| Rated short-circuit breaking current (RMS) kA | 25/31.5 |
| Rated peak withstand current kA | 63/80 |
| Rated short-time withstand current (RMS) kA | 25/31.5 |
| Duration of rated short-time withstand current s | 3 |
| CB electrical endurance / | E2 |
| 100% short-circuit breaking times times | 30 |
| Rated cable-charging current A | 50 |
| CB mechanical endurance times | 10,000 |
| Closing time ms | 30-70 @ Rated voltage |
| Opening time ms | 18-45 @ Rated voltage |
| Contact opening distance mm | 19±1 |
| Over travel mm | 4±1 |
| Rated operating sequence / | O-0.3s-CO-180s-CO |
BGP-40.5 Three position switch
| Rated voltage kV | 40.5 |
| 1min power frequency insulation kV | 95/118 |
| Lightning impulse withstand voltage (peak) kV | 185/215 |
| Rated frequency Hz | 50 |
| Rated short-time withstand current (RMS) kA | DS/ES: 31.5 ES circuit: 27.4 |
| Rated peak withstand current kA | DS/ES: 80 ES circuit: 69.6 |
| Duration of rated short-time withstand current s | 4 |
| Three-phase closing asynchrony mm | ≤3 |
| Three-phase opening asynchrony mm | ≤3 |
| The circuit resistance between the dynamic and static contacts of the main circuit μΩ | ≤30 |
| Manual operating torque N. M | ≤200 |
| Mechanical endurance times | 5,000 |
LV cubicle
It is modular and withdrawable, the height is 750mm, 800mm (optional), plug-in control busbars (through 6-10 pin plug-in terminals), equipped with traditional and digital relays. The secondary equipment is designed according to customer requirements.
Three-position switch
The three-position disconnector on the BGP-40.5 combines the functions of an isolating switch and a grounding switch. It does not have the ability to make and break, and the maximum rated circuit is 2500A. It can only perform ‘close and open’ operations when there is no current. The specific structure can be shown as below.
- Main busbar
- Disconnector closed position
- Disconnector open position
- Earthed position
Bus connector
A basin-insulated bus connector is used between the cabinet of BGP40.5 and the main busbar inside a dry air tank. Its operation is not involved in the assembly of the switch cabinet, so it is not affected by dust and condensation. This makes the installation of BGP-40.5 more convenient and it has less of a requirement for flat foundations. The partial discharge of each solid bus can be controlled within the range of 5pC under 45kV experimental voltage. The maximum rated current of the bus of BGP-40.5kV is 2500A, however, we do have an optional solution for 3150A. Please discuss with your Brunstock rep.
- Basin-type insulator
- Solid busbar
Vacuum circuit breaker
Our circuit breaker uses vacuum breaking technology in BGP-40.5. The maximum rated current is 2500A. The rated short-time withstand current is 31.5kA (3s). The electrical life is E2 (30 times) and the mechanical life is M2 (10,000 times). The three phases of A/B/C are horizontally arranged from left to right. After the installation and commissioning of the cabinet, it is fixed in the cabinet. The specific structure is shown below.
- Vacuum interrupter
- Circuit breaker pole
- Sealing plate
- Operating mechanism
Function
- Rated opening and closing current
- Short-circuit breaking and making operations
- Incorporates a three-position switch to achieve the grounding function
The three-position switch can only be operated when there is no current in the circuit. The earthing switch can only be closed once the circuit breaker is opened.
The three-phase pole of the circuit breaker is horizontally placed in the circuit breaker gas tank. The operating mechanism is located outside for easy maintenance. The mechanism and the pole are connected by movable sealing bellows.
Operating mechanism (three-position switch and circuit breaker)
The operation buttons and position indicator of the circuit breaker, three-position switch and air pressure manometer of BGP-40.5 are embodied on the front panel. The operation and indication are user friendly. The specific structure is shown as below.
- Opened/Closed indication for ES
- Opened/Closed indication of DS
- CB operation counter
- CB opening button
- CB opened indication
- CB energy charging
- Unlock button for DS manual operating
- Selection knob for DS/ES operation hole
- Gas manometer of TPS tank
- Handle insertion aperture for manual operation of ES
- Handle insertion aperture for manual operation of DS
- Gas manometer of CB tank
- CB closing button
- CB energy storage indication
Current transformer
BGP-40.5 has straight-through type CTs, which can go through incoming/outgoing single or multiple cables and the main busbar. The external cone cable is used to connect the CT on BGP-40.5. The threephase integrated CT can be directly fixed on the outer cone sleeve. The primary current of the current transformer is 100 to 2500A, and the secondary current is 1A or 5A. The specific secondary coil quantity, accuracy and capacity of the CT is determined when ordering.
CT installation in the cable side
The cable-side circuit transformer passes through the incoming/ outgoing cable and is fixed on the beam on the cable compartment, as shown as below.
Voltage transformer
The voltage transformer (VT) in BGP-40.5 is designed with an insulated medium voltage terminal with a plug-in connector, and the VT is directly plugged into the special socket on the bottom side of the product’s gas tank. The VT core and the winding are integrated, and can be protected by a fuse. The fuse is installed inside the transformer and its current matches the short-circuit current withstand capacity of the transformer. This effectively protects the VT when the power grid has problems, such as harmonics. Please see the figure below for a depiction of the VT with or without a fuse. The VT secondary voltage is 100V, and the secondary coil can provide a measurement level and a protection level. For example: 35/√3/0.1 √3/0.1√3/0.1/3. VT specific secondary coil quantity, accuracy, capacity and other characteristics are determined when ordering.
The VTs are physically arranged at the bottom of the cabinet, and can be directly plugged in and fixed on the base of the cubicle’s cable room or outside through a cable connection.
Bushings
The primary main circuit of BGP-40.5 is fully enclosed and fully insulated. All incoming and outgoing cables are equipped with plug-in cable terminals. The connection between the connector and the product cabinet is coordinated and fixed by bushings. There are two catogories of bushings in BGP-40.5: inner cone bushings and outer cone bushings. Refer to the below table for relevant information of cable types, rated current and applicable BGP-40.5 cubicle types.
Connectors
The connection between the cable and cabinet of BGP-40.5 is fully enclosed and fully insulated, which is mainly realised by cable terminal. According to the structure, the connectors are divided into inner cone connectors and outer cone connectors. The connectors’ structure and applicable cabinet type involved in BGP-40.5 are shown below.
Surge arrester
The BGP-40.5 surge arrester can be divided into two types according to the cable sockets: one with an outer cone sleeve and the other with an inner cone cable socket. These have a plug-in connection with the cubicle and match with the 2# inner cone sockets. The surge arresters of the main busbar and the line side are placed on the bottom of the cubicle.
The specific technical parameters of arresters is determined when ordering.
Electrical interlock
- Electrical interlock can be achieved by the intelligent control and protection unit’s contact detection and logic programming for the position state of the TPS and CB, and it can be achieved by microswitch as well
- The electrical interlock works only when the secondary power supply is energised
- Electromagetic lock is optional for ES
Mechanical interlock
- Mechanical interlock can only be achieved by operating the main shaft with TPS manually under certain conditions
- When circuit breaker is closing, the manual operation cover of DS is interlocked. Only after the CB is opened, can the cover be freely opened. Then the handle can be inserted into the hole for DS operation. Whenever someone has opened the cover manually, the CB cannot be operated electrically or mechanically
- Key lock and padlocks are optional for CB/DS/ES upon request
Installation
Engineered with outer cone solid busbar connectors, the system streamlines on-site installation by removing the need for vacuumfilling, dry-air testing, and other complex procedures — ensuring faster, more efficient deployment.
Extension
Easy extension: Low requirements on the foundation flatness (2mm/m)
Maintenance
Efficient maintenance: When an ‘unrecoverable fault’ occurs in any compartment, the switchgear can be replaced. Please refer to BGP40.5 maintenance manual for details. The process of replacement is shown below.
Storage
BGP-40.5 must be packaged depending on the requirements for its planned storage duration. BGP-40.5 must be preserved intact in its original factory packaging.
The storage area must not have any sharp significant changes in temperature. Consult your Brunstock representative about the particular storage conditions you are planning to use.
Packaging and transport
Packaging
For road and rail transport:
BGP-40.5 switchboards are packaged under protective sheeting. It will be delivered fixed onto a wooden pallet by two plastic tapes.
For maritime transport:
BGP-40.5 is packaged in a heat-sealed cover with bags of desiccant, then enclosed in a wooden case with a solid leak tight bottom (including transport by container).
For air transport:
BGP-40.5 switchboards are packaged in wooden boxes (crates) with solid walls and protective covers (dust covers).
Handling
The BGP-40.5 must be transported vertically.
When moving using a forklift:
Only move the device on a pallet.
When moving without a pallet:
A lifting sling must be hooked onto the switchgear’s lifting rings. The angle with the lifting sling must be at least 45°.
When transporting on a pallet:
Don’t tilt the switchgear. Respect the centre of gravity markings.
When transporting with slings:
Use the two lifting rings
Maintenance
Brunstock representatives help you to plan the full design and execution of your solution, to secure your process and optimise your time. With training provided by Brunstock, our reps usually offer the following:
- Technical feasibility studies: Accompany you to design a solution specifically for the given environment
- Preliminary design: Accelerate turn-around time to come to a final solution design
Install
Brunstock representatives will help you to install efficient, reliable and safe solutions based on your plans.
- Project Management: Designed to help you complete your projects on time and within budget
- Commissioning: Ensures your actual performance versus design, through on-site testing, commissioning tools and procedures.
Optimise
Brunstock reps propose recommendations for improved safety, availability, reliability and quality.
- Electrical Assessment: Define improvement and risk management program.
Frequency of maintenance intervention
Brunstock equipment manufacturers recommend a schedule for maintenance activities to extend Electrical Distribution equipment performance over time. Further information is available in the product manual and can be discussed with your Brunstock representative.
At the end of the BGP-40.5 service life
The dismantling and disassembly of BGP-40.5 is possible at the end of its service life. The separation of the elements making up the switchgear will be made:
- By disconnecting the mechanical connections
- By dismantling, breaking or shearing the connections.
To guarantee efficient and ecological sorting and destruction of the materials, all plastic components have been identified. Your Brunstock representative will provide a description of the materials to you, their customer, along with information on the best valorisation process that recylcing companies in your local area may need.
End of service life processing
Brunstock can support you in your BGP-40.5 end of service life processing approach.
Eliminate hazardous gas recovery
Due to the use of dry air, BGP-40.5 has no need for a process of SF6 gas recovery
Composition of materials and valorisation at end of service life
After disassembly or dismantling, the recovered elements must be forwarded for treatment in the following manner:
Waste processing
