Low Carbon Ready

Powerful CB: Power Electronic Fault Limiting Circuit Breaker

Project Data

Start date:

01/01/2017

End date:

08/31/2022

Budget:

£6,188,740.46

Summary

UK Power Networks developed and trialled a new fault-limiting circuit breaker that was significantly smaller and more efficient than any similar device in use at the time. The project aimed to reduce the cost and time required for distributed generation, particularly Combined Heat & Power (CHP) units, to connect to the electricity network.

What is the project about?

Combined Heat and Power (CHP) generators offered a highly efficient way to heat buildings while simultaneously generating electricity.

They gained particular popularity in large urban areas, such as hospitals, and played an increasingly important role in district heating and community energy projects.

The Greater London Authority aspired to see rising demand for electricity from these highly efficient CHP units as part of the broader transition to a decarbonised energy system.

UK Power Networks aimed to ensure that this additional generation could connect safely to the electricity network—without requiring significant investment from customers to upgrade network capacity.

To support this, the company developed the Fault Limiting Circuit Breaker (FLCB), a solid-state device that operated 20 times faster than any comparable technology previously available. It was capable of blocking 100% of fault-level contribution while allowing normal load current to flow both before and after the fault was cleared.

This high-speed operation offered enhanced protection for the electricity network. Its compact design also made it well-suited for installation in space-constrained urban environments, enabling many more CHP units and other generators to connect before any major network upgrades were needed.

If deployed at scale, the device had the potential to save customers across the UK an estimated £225 million by 2025. By enabling faster, more cost-effective connections for low-carbon generators, this innovation from UK Power Networks supported the transition to a cleaner, more sustainable energy system.

How we’re doing it

We developed and trialled a Fault Limiting Circuit Breaker (FLCB), designed by ABB and installed at an 11kV substation in London.

The trial successfully demonstrated the FLCB’s ability to increase fault level headroom, enabling more generators to connect to the network. As part of the project, we also prepared a comprehensive safety case for the device to build the engineering knowledge required to safely and effectively deploy FLCB technology on Great Britain’s electricity networks.

What makes it innovative

The Fault Limiting Circuit Breaker (FLCB) developed through this project was significantly smaller and more efficient than any comparable fault-limiting device in use at the time. It was the first device of its kind globally to operate using a fast-commutating switch. At the time of the trial, no other Distribution Network Operator (DNO) had adopted fault-limiting devices of this nature as part of their business-as-usual operations.

What we’re learning

We verified the functionality and effectiveness of the Fault Limiting Circuit Breaker (FLCB) on our network, assessing its impact on both the engineering and operational aspects of the site. Throughout development and the project trial, we identified several potential issues that informed further improvements beyond the prototype stage and supported considerations for broader deployment.

Key lessons learned from the project included:
Device modifications during installation and commissioning improved safety, reliability, and robustness, such as:

  • Installing Uninterruptible Power Supply (UPS) modules within the FLCB to enhance reliability and ensure continuous operation.
  • Adding protection logic to automatically isolate the FLCB as a safety measure if a “FLCB Out of Service/Faulty” alarm was triggered due to an internal fault.
  • Ensuring proper latching of the FLCB trip alarm so it could be detected by the SCADA system, along with applying a software update to ensure accurate alarm recording.

The FLCB tripping threshold was set at 4kA, and performance analysis during the trial showed that for several fault events, once the fault current reached this threshold, the FLCB successfully limited the peak and forced the current to zero within three milliseconds.

Images & Videos

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