DC Switchgear

PowerBond™

BRUSH PowerBond™ DC Switchgear is an innovative solution designed to meet the demands of the world’s busiest transit systems. Utilising our award-winning magnetic actuator technology, PowerBond™ is an all-in-one solution, combining the functionality of a line circuit breaker with that of a bonding switch.

Overview

Developed for today’s modern rail network, PowerBond™ is an air-insulated, air-break, high-speed direct current circuit breaker which allows direct current contact line systems to be fed from the traction power supply, or alternatively to be bonded to negative or earth.

Designed for 750V DC and 1500V traction power systems, both overhead line and conductor (3rd and 4th) rail, PowerBond™ is compatible with a wide range of protection relays, including BRUSH Switchgear Mitre+.

With all this functionality in one unit, PowerBond™ offers a smaller footprint, convenience of installation, safe maintenance and superior performance.

Key benefits

Lower cost of ownership
Proven design
Custom solutions
Award-winning magnetic actuator technology

Technical specifications

Ratings to EN 50123-1/2/6 and IEC 61992-1/2/6Symbol900 V Version1800 V Version
Nominal VoltageUn750V 1500V
Rated VoltageUNe900V1800V
Rated insulation voltageUNm1800V3000V
Rated impulse withstand voltageUNi18kV18kV
Power Frequency WithstandUa6.9kA / 8.3kV6.9kA / 8.3kV
OvervoltageOV43
Pollution degreePD44
Rated Auxiliary Voltage48V, 50V, 110V or 125V dc
Circuit Breaker Rated Service CurrentINe4000A (L),
6000A (R),
8000A (R; L),
4000A (L),
6000A (R),
Busbar Selector Rated Service CurrentINe4000A (*ve),
500A (-ve),
4000A (*ve),
500A (-ve),
Positive Busbar Rated Service CurrentINe6000A or 8000A
Negative Busbar Rated Service CurrentINe500A
Rated Short Circuit CurrentINss125kA / 180kAp100kA / 142kAp
Rated Short Time Withstand (Circuit Busbar)INcw63kA / 90kAp for 250ms
Rated Short Time Withstand (Positive Busbar)INcw125kA / 180kAp for 250ms
Rated Short Time Withstand (Negative Busbar)INcw70kA / 100kAp for 250ms
Rated Short Time Withstand (Earth Bar)INcwe10kA / 14.2kAp for 1s
Rated Track Time ConstantINc100ms63ms
Duty – Line (Feeder) Breakersf, e, d, i -duty cycle 1
Duty – Rectifier Breakersr, s, lr
Duty – Interconnectorsff, fr, lr
Critical Current 50A Bi-Directional
Service Life40 Years
Mechanical endurance – Circuit Breaker20000
Mechanical endurance – Busbar Selector10000

Switchgear services

From initial system analysis, to design, engineering, supply, installation, commissioning and upgrades of equipment through to repurposing or decommissioning. We provide lifecycle management and support.

POWERSUB

Expertly engineered solutions

Virtually maintenance free, PowerSub is pre-assembled, pre-tested
and ready for site installation

Overview

Combining our extensive knowledge of engineered solutions with our engineering expertise, we’ve developed PowerSub, a bespoke, adaptable and tailored solution that enables critical power to where it is needed most.

Suitable for a range of sectors, including healthcare, EV charging, renewables, industrial and commercial settings, PowerSub offers a range of key benefits including a reduced build cycle and minimal civils work, helping to save time, resources and materials.

Technical specifications

Power:A range of power options are available
Switchgear:Tailored to customer specification
Transformer:Oil or ester filled to customer specification
Container:Prefabricated
Other:Protection, control, condition monitoring panel

Key benefits

Plug & play
System decarbonisation
Lifecycle support
Minimal maintenance
Ideal for areas with limited space
Low-risk solution
Interruption of supply back-up
Reversed powerflow
Award-winning switchgear

A sustainable solution

Helping to deliver critical energy needs, PowerSub can also support sustainability goals:

Reduced build cycle minimises impact to local environment

Less raw materials, such as concrete, required for install

Low maintenance option

SF6 free in line with EU regulations

Suitable for renewables

Supports system decarbonisation

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Transformers

Power Transformers

BRUSH transformers are in service all over the world, providing power to millions of homes and businesses.

Overview

We have built a solid reputation for reliability and longevity amongst our many satisfied clients.

Our standard range covers power transformers with:

  • Power ratings between 5MVA and 120MVA
  • Voltages up to and including 145kV systems

Options

Our transformers can be designed to customer specific needs  as well as many national and international specifications, amongst these:

  • ENATS
  • IEC
  • ANSI
  • Shell DEP
  • Aramco
  • Rail

Key benefits

Low carbon technologies & supply chain
Reversed powerflow
High efficiency
Smaller equipment footprint
Lower cost of ownership

Key Features

Compact transformer design
Reduces overall substation footprint enabling significant savings in civil costs
High efficiency
Transformers based on EU EcoDesign Directive EU 548 and Tier 2 efficiencies
UK manufacture
Full assembly and testing at our Loughborough factory

Features and benefits

  1. High efficiency transformers based on EU EcoDesign Directive EU 548 and Tier 2 efficiencies
  2. Alternative cooling fluids including Midel and FR3 for environmentally sensitive or urban sites
  3. Low noise level transformers with advanced core build technology and variable speed fan options
  4. Designs are calculated for minimal Partial Discharge values through an optimised insulation structure that extends operational lifespan
  5. Condition Monitoring options via fibre optic temperature sensors & gas detection systems
  6. Compact transformer design reduces overall substation footprint enabling significant savings in civil costs
  7. Cooling methods ranging from naturally cooled to directed-oil via pumps and forced-air via fans
  8. Tapchanging by On-Load (bolt-on or in-tank) or Off-Circuit switching devices. Remote Tapchanger Control Panels can also be supplied
  9. Full range of accessories and protection devices available including digitally enabled options as well as condition monitoring equipment

Applications

Whether your requirements call for a DNO approved transformer or a bespoke solution, BRUSH covers the vast majority of applications.

Transformer services

We provide lifecycle management and support from initial system analysis, to design, engineering, supply, installation, commissioning and upgrades of equipment through to repurposing or decommissioning.

Generators & Motor

2 Pole Air Cooled Generators

A leading industry authority in synchronous rotating machines, BRUSH has been providing generator expertise for over a century. From standard applications to highly customised solutions that meet the most demanding environments and operation conditions in the world.

Overview

The 2-Pole DAX generator range is driven by steam or gas turbine outputs from 10 MVA to 350 MVA. With over 3,500 active installations, the time-proven DAX range of generators built in a European ISO accredited site are specified by leading industrialists, EPCs and facility operators.

BRUSH generators are compatible with any turbine up to 350MVA including aero-derivative gas turbines, heavy frame gas turbines, steam turbines and turbo-expanders. 

BRUSH’s engineering team are recognised, world-leading experts in synchronous rotating machines and provide optimised generator selections to meet customers’ unique operating conditions.

Key benefits

Custom solutions
Lower total cost of ownership (TCO)
Hazardous area certified – IECEx /ATEX
Proven design

Resources

Product Innovation

World’s First 2-Pole 13.8KV Non-Sparking Generator

This application-led solution reduces procurement, operation and maintenance costs on generators and associated equipment installed in explosive environments.

A White Paper by Roy Beardshaw, BRUSH’s Head of Application Engineering, details how this development has changed the use of power generation equipment in hazardous areas.

To read the full story please download the document below.

Technical Specifications

SpecificationValue
VoltageUp to 20 kV
ExcitationBrushless or static
InsulationClass F
Frequency50 or 60 Hz
Output10 to 350 MVA
DriveSingle or Double End Drive
DriverSteam Turbine / Aeroderivative Gas Turbine / Heavy Frame Gas Turbine
Design StandardsIEC, IEEE, CSA, ATEX, IECEx, ABS, DNV and Lloyds compliant

Key Features

High Efficiency
Up to 98.8% efficiency in service
High Availability
Proven high availability for all operating regimes – baseload, peak power (frequent start-stop on daily basis as peak units)
HIR Options
High Initial Response (HIR) options available for brushless excitation systems
International Standards Compliance
Designed to meet in-country standards (eg CSA and specific grid code compliance)
Fast start-up
Machines do not need to be held at defined speeds for certain timeframes, Ex ec removing need for purge and pressurisation cycle
PARTS

Strategic Parts Management

To protect against loss of revenue through unscheduled outages and ensure the reliable operation of capital equipment, we recommend a combination of OEM certified Operational Spares, Maintenance Spares, Strategic Spares and Commissioning Spares based on site configuration and site specific operational conditions.

Man holding a ball of energy symbolising connections
CONTACT US

Speak to our team

BRUSH has a global reputation for service excellence and dedicated customer support. With a wealth of experience spanning almost 150 years and significant in-house knowledge and expertise, our commitment to excellence is backed by experience and knowledge.

Whether it’s the provision of parts, the delivery of service support in the field, at the customer’s premises or at our network of service workshops, our team of highly experienced engineers are on hand to support.

DC Switchgear

Lightning DC

Combining innovation with 50 years of DC circuit breaker design and manufacturing experience, the Lightning offers optimal safety, reliability and high speed performance, the ideal solution to your DC requirements.

Overview

Incorporating The NDC Circuit Breaker

The BRUSH Switchgear Lightning product, incorporating the high-speed NDC Circuit Breaker, utilises award winning magnetic actuator technology and provides an innovative DC switchgear solution for a variety of markets and demanding applications.

Combining innovation with 50 years of DC circuit breaker design and manufacturing experience, lightening offers optimal safety, reliability and high speed performance, the ideal solution to your DC requirements.

Key benefits

Asset life extension
Custom solutions
Lower total cost of ownership (TCO)
Proven design
ENGINEERING FOCUS

NDC circuit breaker at the heart of Lightning DC

The patented arc transfer system prevents internal contamination of the circuit breaker compartment and cubicle.

The cold cathode arc chute assembly dissipates all arcs whilst the transfer coil provides additional magnetic flux across the contact gap, assisting with the interruption of low currents that would otherwise lead to long arcing times.

The magnetic actuator is based on a solenoid plunger, and provides the motion required to close the main contacts and to reset the latch device on tripping.

Technical specifications

PropertyRating
Nominal Voltage750-1500V dc
Rated Voltage900-1800V dc
Rated Service Current4000/6000/8000A
Power-Frequency Withstand Level9 kV (ac)
Rated Short-Time Withstand Current100kAp / 71kA 250ms
Rated Track Time-Constant100ms
Rated Short-Circuit Current180kAP/125kA – 142kAP/100kA
Bi-directional Critical Current25-26A
Mechanical Endurance50,000 operations
Breaking CharacteristicHigh Speed
Rated Impulse Withstand20kVp
Insulation CategoryOV4
Auxiliary Operating Supply50V dc (other options available)

Switchgear services

From initial system analysis, to design, engineering, supply, installation, commissioning and upgrades of equipment through to repurposing or decommissioning. We provide lifecycle management and support.

Man holding a ball of energy symbolising connections
CONTACT US

Speak to our team

BRUSH has a global reputation for service excellence and dedicated customer support. With a wealth of experience spanning almost 150 years and significant in-house knowledge and expertise, our commitment to excellence is backed by experience and knowledge.

Whether it’s the provision of parts, the delivery of service support in the field, at the customer’s premises or at our network of service workshops, our team of highly experienced engineers are on hand to support.

DC Switchgear

SafeBond

SafeBond integrates the feeder circuit breaker function and the remote bonding function into one standard Lightning panel footprint, a big advantage in floor space saving, civil engineering, cabling and operational consistency and safety.

Overview

SafeBond incorporates the NDC high speed, unidirectional circuit breaker, featuring the award-winning magnetic actuator, to carry out the making and breaking of all load and fault currents, whilst an ‘off-load’ motorised two position disconnector selects the circuit.

With the disconnector in the positive position and the NDC circuit breaker closed, the positive busbar is connected to the track feeder cable thereby functioning as a standard feeder circuit breaker. 

Key benefits

Asset life extension
Custom solutions
Lower total cost of ownership (TCO)
Proven design

Key features

Enhanced Functionality
Feeder circuit breaker and bonding functions integral to one panel
Ease of Operation
Proven ‘off-load’ two position disconnector selects the circuit
Improved Operator Safety
Electrical control/interlocking schemes to suit customer requirements
Ease of Installation
No additional civil engineering/cabling or outdoor housing costs
Automation Ready
SCADA remote control of complete unit as standard
ENGINEERING FOCUS

NDC circuit breaker at the heart of SafeBond

The patented arc transfer system prevents internal contamination of the circuit breaker compartment and cubicle.

The cold cathode arc chute assembly dissipates all arcs whilst the transfer coil provides additional magnetic flux across the contact gap, assisting with the interruption of low currents that would otherwise lead to long arcing times.

The magnetic actuator is based on a solenoid plunger, and provides the motion required to close the main contacts and to reset the latch device on tripping.

Technical specifications

PropertyRating
Nominal Voltage750-1500V dc
Rated Voltage900-1800V dc
Rated Insulation Voltage1800-3000kV
Power-Frequency Withstand Level9 kV (ac)
Rated Impulse Withstand Level20 kV (ac)
Rated Short-Time Withstand Current100kAp / 71kA 250ms
Rated Short-Circuit Current180kAP/125kA – 142kAP/100kA
Auxiliary Operating Supply48 / 110 / 220V dc
Specified Service Life30 Years
StandardsBS EN 50123
Environmental ConditionsAs EN 50123-1 clause 4.1, normal
Max and Min Operating Temperature40 / -5 Deg C
Degree of PollutionEN50124-1 PD4

Switchgear services

From initial system analysis, to design, engineering, supply, installation, commissioning and upgrades of equipment through to repurposing or decommissioning. We provide lifecycle management and support.

AC Switchgear (Outdoor)

GVR Recloser

BRUSH Switchgear’s world renowned GVR Recloser was the first in a range of equipment utilising one of the most advanced operating mechanisms available on the market, featuring the award-winning magnetic actuator technology.

Overview

The GVR provides intelligent control and protection on power distribution networks, whilst offering a lifetime of trouble-free service.

The GVR automatic recloser is now available as a tank only option for customers wishing to connect their own protection and control cubicles.

Alternatively, customers looking for a ground-mounted solution can select our epoxy separable bushings for cable connected networks.

Key benefits

Custom solutions
Asset life extension
Lower total cost of ownership (TCO)
Proven design

Key Features

Inbuilt Power Supply
Magnetic actuator operation independent of MV supply
Environmentally friendly
Vacuum interruption produces no by-products
Lightweight
Aluminium tank makes transport and installation easier
Durable
Mechanical endurance – 10,000 operations
Flexible
Pole mounted or substation mounted
3-in-1 Solution
Can be configured to function as a switch, sectionaliser or recloser
ENGINEERING FOCUS

Featured protection options:

Polarr

The Polarr is the standard relay package for the GVR, offering full auto-reclose protection and control functionality.

Beckwith

The Beckwith M-7679 relay offers optimum levels of advanced control and protection for distribution networks. Functions include directional protection, voltage synchronisation, load encroachment supervision and under-frequency load shedding.

Technical specification

PropertyGVR15GVR27GVR38
Maximum System Voltage15.5kVrms27kVrms38kVrms
Continuous Current630A630A630A
Interrupting Current12.5/16kA12.5kA10kA
Impulse Voltage Withstand110kV peak125/150kV peak150/170kV peak
Power Frequency Withstand Dry50 kVrms for 60s60 kVrms for 60s70 kVrms for 60s
Power Frequency Withstand Wet50 kVrms for 60s50 kVrms for 60s60 kVrms for 60s
Rated Gas Pressure for aboveAtmospheric/0.3 barAtmospheric/0.3 barAtmospheric/0.3 bar
Number of Operations with no Maintenance10,00010,00010,000
Weight145kg145/155kg155kg

Switchgear services

From initial system analysis, to design, engineering, supply, installation, commissioning and upgrades of equipment through to repurposing or decommissioning. We provide lifecycle management and support.

AC Switchgear (Outdoor)

Horizon & Horizon Compact

The Horizon fills the market need for outdoor, ground-mounted circuit breakers and features the award-winning magnetic actuator.

Overview

Featuring the most advanced operating mechanism available on the market today, the Horizon offers unrivalled reliability, protection and environmental endurance for outdoor circuit breakers.

Designed for 15.5kV, 27kV or 38kV applications, the Horizon can be used with other products from BRUSH Switchgear to provide cost-effective and compact substations or breathe new life into existing substations by replacing old and obsolete equipment.

Key benefits

Custom solutions
Asset life extension
Lower total cost of ownership (TCO)
Proven design
Improved operator safety

Key Features

Safety Without Compromise
Vacuum interruption in an SF6 filled, controlled environment and internal arc containment
Dead tank construction
Suitable for live or dead tank applications
Versatile
Generous accommodation for current transformers and optional adjustable legs
Lightweight
Aluminium tank makes transport and installation easier
Damage Resistant
The silicone rubber bushings have an extended creepage of 1550mm
ENGINEERING FOCUS

Unique features

Current transformers are located within the bushing design, external to the gas enclosure, to allow for easy changing/addition.

Mechanical ON/OFF position indication visible through clear viewing window from ground level.

The magnetic actuator is based on a solenoid plunger, held in the tripped or closed position by a permanent magnet.

Technical specification

PropertyRatingRatingRating
Maximum System Voltage15.5kV27kV38kV
Continuous Current1250A1250A1250A/2000A
Interrupting Current25kA25kA25kA/31.5kA
Rated Operating SequenceO – 0.3sec – CO – 15sec – COO – 0.3sec – CO – 15sec – COO – 0.3sec – CO – 15sec – CO
Impulse Voltage Withstand95kV125kV170kV/200kV
Power Frequency Withstand Dry1min 28kV1min 50kV1min 80kV
Power Frequency Withstand Wet10secs 80kV10secs 80kV10secs 80kV
Control Voltage110V dc110V dc110/125V dc (48 & 220 Optional)
Rated Frequency50/60Hz50/60Hz50/60Hz
Rated 3 sec Short-Time Current25kA25kA25kA/31.5kA
Rated Peak Making Current65kA65kA65kA/82kA
Ambient Air Temperature-50˚C to +50˚C-50˚C to +50˚C-50˚C to +50˚C
Weight294kg294kg800kg

Switchgear services

From initial system analysis, to design, engineering, supply, installation, commissioning and upgrades of equipment through to repurposing or decommissioning. We provide lifecycle management and support.

Man holding a ball of energy symbolising connections
CONTACT US

Speak to our team

BRUSH has a global reputation for service excellence and dedicated customer support. With a wealth of experience spanning almost 150 years and significant in-house knowledge and expertise, our commitment to excellence is backed by experience and knowledge.

Whether it’s the provision of parts, the delivery of service support in the field, at the customer’s premises or at our network of service workshops, our team of highly experienced engineers are on hand to support.

AC Switchgear (Indoor)

SWR Retrofit

This effective retrofit solution provides a new lease of life to existing switchgear. Employing magnetic actuator technology with vacuum interrupters, the SWR12 is designed for 10,000 operations and a life expectancy of 30 years.

Overview

The SWR12 is an OEM designed retrofit circuit breaker for both the South Wales Switchgear C & D range oil circuit breaker and the HG12 gas circuit breaker, to IEC 62271-100.

BRUSH Switchgear is proud of its heritage in the C and D range of switchgear which continue to work at the highest standards. Technological advances have allowed us to improve further and offer our customers a circuit breaker that boasts the award-winning magnetic actuator along with removing the need for SF6 gas.

The SWR12 circuit breaker is an effective retrofit solution – offering a new lease of life for existing switchgear. Utilising magnetic actuator technology with vacuum interrupters, the SWR12 is designed for 10,000 operations and a life expectancy of 30 years.

It is designed for retrofitting into existing switchboards without the need for panel modification.

Key benefits

Custom solutions
Asset life extension
Lower total cost of ownership (TCO)
Proven design

Key Features

Easy Installation
No civil works required and existing HV cabling remains undisturbed
Enhanced Safety
Removes oil or SF6 gas from the system
Longevity
Considerable life extension of the existing switchgear
Low Cost of Ownership
Virtually no maintenance and increased asset life
ENA Compliant
Improved panel interlocking to latest requirements
ENGINEERING FOCUS

Upgrading obsolete designs to modern standards

Retrofit solutions for:

1: D4X circuit breaker (designed in 1970)

2: Hawkgas12 circuit breaker
SF6 filled switchgear with vertical isolation (designed in 1990)

Ratings

PropertyRating
Rated Voltage12 kV
Normal Rated Currents400/630A, 800A, 1250A
Lightning Impulse Withstand Voltage75kVP
Short Duration Power Frequency Withstand Voltage28kV
Rated Frequency50Hz
Rated Short-Time Withstand Current25kA for 3 seconds
Rated Peak Withstand Current62.5kA Peak
Rated Duration of Short Circuit3 seconds
Making Current (peak)62.5kA
Symmetrical Breaking Current25kA
Rated Auxiliary Voltages30, 48/50, 110/125V dc
Minimum opening time/closing time33/76ms
Normal Operations10,000
Weight211Kg
Rated Operating SequenceO-0.3s-CO-15s-Co
Operating Mechanism Type Dependent power closingStored energy opening
(Springs, charging for closing)

(Magnetic actuator)

Switchgear services

From initial system analysis, to design, engineering, supply, installation, commissioning and upgrades of equipment through to repurposing or decommissioning. We provide lifecycle management and support.

AC Switchgear (Indoor)

BSR Retrofit

An OEM designed retrofit circuit breaker for both the BRUSH Switchgear VSI range of oil circuit breakers and the VMV vacuum circuit breaker, to IEC 62271-100.

Overview

The BSR is an OEM designed retrofit circuit breaker for both the BRUSH Switchgear VSI range of oil circuit breakers and the VMV vacuum circuit breaker, to IEC 62271-100.

BRUSH Switchgear is proud of its heritage in the VSI, VTD and VMV range of switchgear, which continue to work at the highest standards today. Technological advances have allowed us to improve further and offer our customers a circuit breaker that boasts the award-winning magnetic actuator technology with vacuum interrupters.

The BSR circuit breaker offers a new lease of life to existing switchgear with this effective retrofit solution. The BSR is designed for 10,000 operations and a life expectancy of 30 years. It is designed for retrofitting into existing switchboards without the need for panel modification.

Key benefits

Custom solutions
Asset life extension
Lower total cost of ownership (TCO)
Proven design

Key Features

Easy Installation
No civil works required and existing HV cabling remains undisturbed
Enhanced Safety
Removes requirement for oil in the system
Longevity
Considerable life extension of the existing switchgear
Low Cost of Ownership
Virtually no maintenance and increased asset life
Hassle Free
Uses existing design of primary and automatic secondary contacts
ENA Compliant
Improved panel interlocking to latest requirements
ENGINEERING FOCUS

Upgrading obsolete designs to modern standards

Retrofit solutions for:

1: VSI/VTD circuit breaker (designed in 1963)

2: VMV circuit breaker (designed in 1990)

Technical specifications

PropertyRating
Rated Normal Current630A/1250A/2000A
Rated Voltage12kV
Lightning Impulse Withstand Voltage75/95kVP
Short Duration Power Frequency Withstand Voltage28kV
Rated Frequency50Hz
Rated Short-Time Withstand Current25kA for 3 secs
Rated Peak Withstand Current62.5kA Peak
Making Current (peak)62.5kA
Symmetrical Breaking Current25kA
Rated Short-Time Current25kA (3 sec)
Rated Auxiliary Voltages30, 48/50, 110/125 V dc
Minimum opening time/closing time33/76ms
Normal Operations10,000
Weight211Kg

Switchgear services

From initial system analysis, to design, engineering, supply, installation, commissioning and upgrades of equipment through to repurposing or decommissioning. We provide lifecycle management and support.