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Within a project for a foundry in Poland, it was necessary to design a medium-voltage switchgear capable of handling high currents at a voltage level of 36 kV while simultaneously adapting to the limited installation space of the facility. The solution had to be clear in layout, service-accessible, and operationally safe in a demanding industrial environment.

The power plant, owned by the Ministry of Energy, consists of a steam unit and six gas turbines. As a result of military conflicts in past decades, some generating units were damaged or completely dismantled. Following the end of the conflicts, a gradual rehabilitation and modernization program was initiated, including the restoration of the high-voltage distribution systems.

IVEP participated in the project by delivering two key high-voltage solutions, each addressing a different technical challenge.

The customer required a compact and clearly arranged solution for the medium-voltage generator power output that would:

• combine multiple functions into a single device,
• minimize space requirements within the generator block,
• ensure safe and reliable connection of the generator to the downstream equipment.

The specification also emphasized long-term operation, clear wiring layout, and ease of maintenance.

The customer operated a disconnector with an earthing switch in the vicinity of a transformer, where:

• the equipment performed approximately 500 switching operations per month,
• the ambient temperature long-term reached up to 70 °C,
• the environment was moderately dusty.

The customer operates a testing laboratory for medium-voltage asynchronous motors, which are supplied without their own cable terminations. For repeated testing of various machines, a universal and safe solution was required for:

• quick connection of power cables,
• handling in a laboratory environment,
• easy operation without the need for complex procedures.

Emphasis was placed on:

• operator safety,
• minimum possible equipment dimensions,
• simple design without measuring or protective devices,
• the ability to handle the equipment using a crane,
• a freestanding design with an open bottom section for cable entries.

Zařízení bylo navrženo jako funkční pokračování svorkové skříně generátoru TG3 a tvoří součást širšího celku vyvedení výkonu generátoru včetně vazby na generátorový vypínač (GCB) a uzemňovací systém. Projekt neřešil pouze dodávku samotné skříně, ale kompletní inženýrské a konstrukční řešení včetně návazností na další technologie.

The GSI-CB switchgear was supplied as the main power output from the generator to the primary power distribution system of the power plant. The equipment is installed indoors and forms a key link between the generator and the downstream distribution technology. The customer required a solution with high operational reliability, capable of meeting the demanding conditions of power generation while also allowing customization to specific project requirements.

The customer required a solution that respected the specific generator arrangement, where:

• both the power and neutral terminals are located on one side of the machine,
• a common terminal box for power and neutral must be installed on a single foundation,
• the interconnection between the power and neutral sections has a very limited length of approximately 750 mm,
• the connection of customer cables must be implemented via drilled cable glands and busbars with pre-drilled holes.

Emphasis was placed on precise mechanical execution, low contact resistance, and a clear arrangement of current paths.

The customer in Vietnam operated an indoor high-voltage switchgear with a generator that had been in service for only two years. Despite this relatively short period of operation, the equipment was already in very poor technical condition and contained components from suppliers that the customer could no longer accept for political and strategic reasons. The existing solution posed a risk to safe and stable operation and did not meet the requirements for long-term reliability.

Zákazník realizující projekt přečerpávací elektrárny požadoval dodávku středněnapěťového rozváděče tvořícího uzel (starpoint) generátoru. Zařízení muselo splňovat vysoké nároky na bezpečnost, spolehlivost a provozní stabilitu, včetně integrace měřicích prvků a přesně definovaných zkoušek. Součástí zadání byla také kompletní odpovědnost dodavatele za návrh, výrobu, kontrolu a tovární zkoušky zařízení.

The operator of a coal-fired power plant in the Czech Republic required a reliable solution for interconnecting medium-voltage equipment within a technological system. Due to the outdoor installation, emphasis was placed on resistance to weather conditions, safe operation, and long-term reliability of the equipment under both normal and fault conditions.

At a district heating plant in the Czech Republic, it was necessary to provide a safe and reliable disconnection of the electric boiler technology directly at the generator output. The solution had to operate in an outdoor environment, withstand high currents and short-circuit stresses, and at the same time allow manual operator intervention in emergency conditions.

In a petrochemical industry facility in the Czech Republic, there arose a need to simplify and clarify the disconnection of incoming cables within the medium-voltage distribution system. The existing solution was not optimal from a maintenance perspective, and interventions in the cabling were time-consuming and operationally complex.

The customer required a solution that would enable fast, safe, and unambiguous separation of cable routes, with an emphasis on operator safety and access control.

Within a project in the petrochemical industry in the Czech Republic, a solution was required for the transition and interconnection of different types of medium-voltage cables. The key requirements were a clear cable arrangement, sufficient space for handling large-diameter cables, and the maintenance of operational safety.

At a cement plant in the Czech Republic, eight cement mills equipped with medium-voltage motors are installed and must be shut down approximately five times per month for cleaning of technological components. These interventions do not involve electrical equipment; however, without an appropriate technical solution they would require the presence of an electrician during every service operation.

The customer’s objective was to create a system that would allow safe disconnection of the MV motor directly at the point of the technology, enabling maintenance technicians to work independently, without risk and without intervention in the electrical system beyond a clearly defined procedure.

For a pumping station project in Russia, the customer required a medium-voltage bypass switching solution that would allow safe switching between the grid and the converter output. The key requirement was to completely eliminate any possibility of feeding grid voltage into the converter output, even in the event of operator error.

In the initial phase, two technically feasible solutions were discussed in detail:

• a solution using a simple disconnector,
• a solution using a changeover disconnector.

Within a railway infrastructure project in the Russian Federation, the customer requested the supply of six outdoor transition cable cabinets intended to serve as the power supply points for a stacking machine. The cabinets were designed not only for the transmission of medium-voltage power, but also for the combined routing of power and fiber-optic cables.

The project was particularly specific due to the combination of climatic, environmental, and certification requirements.

As part of the Istanbul WTE project in Turkey, a standalone high-voltage generator terminal box with an output of 100.96 MVA was supplied. The unit is designed for the safe power output connection and grounding of the generator neutral point. The terminal box ensures a stable connection to the high-voltage generator and supports measurement and testing of power parameters in the industrial environment of a waste-to-energy plant.

In the foundry project in Poland, it was necessary to design a high-voltage switchgear capable of handling high currents at 36 kV while also adapting to the limited installation space of the facility. The solution had to be clear in layout, easily serviceable, and operationally safe in a demanding industrial environment.