SubStation Types

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Integrated SwitchgearSolutionsTraining Course Level 1

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General

Theory

Technical Design

Sales Arguments

Applications

Standards

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Goal for this part of Training Course

To be familiar with the Integrated Switchgear Modules …and to be able to offer them

To be able to use the presentation material from the …CD

To be familiar with the web based tools for design …and quotation

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The basic Compact modular concept

Integrate standard & well proven ABB switchgear apparatus to a type-tested and pre-engineered module.

LTB & HPLstandard breaker

IMB, CPA & CPBstandard IT

PEXLIMstandard SA

Modular structureand bus bar

Type tested and pre-engineeredmodular building block

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A modular step-by-step Concept 72-300 kV

Identically the same standard and well proven LTB/HPL Circuit Breaker is used in all application

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Indoor applications

Compact in-door with-drawable breakers

72 – 170 kV

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General

Theory

Technical Design

Sales Arguments

Applications

Standards

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Why do we have switchgear

To connect transmission lines,cables and transformers witheach other in a substation

To disconnect and isolate ifrequired (e.g. a short-circuit)

To measure voltage and current(e.g. for relay protection and SCADA)

To limit high voltage surges(e.g. from lightning strokes)

Lines

Transformers

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What are the real requirements

Maximum availability = Minimized interruptions

Maximum safety = Minimized risk for personnel equipment and environment

Maximum economy = Minimized costs for design, construction, operation, maintenance and outages

Lowest possible maintenace need

Reduced nos. of entrances

Lowest LCA

The probability that power is available at a certain

point in the substation, e.g. at the MV bus or an outgoing line.

Factors influing substation availability- Equipment failure rate and repair time.- Need and time for maintenance of equipment. - Availability of incoming power to the substation.- Substation configuration, i.e., busbar schemes.

Most critical components to the availability- Equipment connected directly to the busbar such as disconnectors.

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Substation Availability

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Comparing old and new technology

Bulk Oil Breakers

Minimum Oil breakers

SF6 Breakers

Disconnectors with open contacts

1950 2000

Air blast Breakers

Air blast with 10 breaking units

Oil minimum with 4 breaking units

HPL B1 for 300 kV with one breaking unit

Fai

lure

and

mai

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rat

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How to achieve increased availability?

Conventional AIS Multiple bus bars Many disconnectors Large separation distances provide easy access for maintenance work

Compact and Combined Conventional disconnectors are eliminated Maintenance-free bus bar connections with low failure rate Minimised maintenance requirements for remaining parts Simplified bus bar schemes are possible

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ConventionalAIS equipment:

circuit breaker

disconnector

disconnector

Mean unavailability (hours/year)busbar bay

2 6

busbar

COMPACTswitching module:

withdrawablecircuit breaker

fixed contact

fixed contact

~ 0 0,2 - 2

busbar

busbar bay

Mean unavailability(hours/year)

COMBINEDdisconn breaker:

disconn circuit breaker

busbar

Mean unavailability (hours/year)busbar bay

2 2

Example: Unavailability of busbar and bay - caused by maintenance

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Mean unavailability due to maintenance

Apparatus and modules Duration Period UnavailabilityFor 145 kV hours years hours/year

Circuit Breakerd SF6 10 15 0,7Circuit Breakera Oil 20 6 3,3

Disconnecting Circuit Breaker 10 15 0,7

Disconnectord 4 5 0,8

Switching Module - withdrawable partd 1 ; 10 15 0,07b ; 0,7c

- fixed contactsd - - ~0

a utility statisticsb replacement modulec maintenance on sited ABB standard

CombinedModule

CompactModule

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Mean unavailability due to failure

Apparatus and modules Duration FrequencyFor 145 kV hours 1/100 years

Circuit Breakerd SF6 72 0,09Circuit Breakera Oil 72 0,3

Disconnecting Circuit Breaker 72 0,09

Disconnectord 8 0,12

Switching Module - withdrawable partd 1 ; 24 0,2 - fixed contactsd 8 0,012

a utility statisticsb replacement modulec maintenance on sited ABB standard

CombinedModule

CompactModule

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New equipment allows simplified arrangements

T2

L3 L4

T1

L1 L2

L1

T2T1

L2 L3 L4

Example: Traditional doublebusbar layout may be replacedby sectionalized single busbarUsed together, LTB Compactand LTB Combinedgive the optimal solution

Compact switchingmodule LTB Compact

Disconnecting circuit-breaker LTB Combined

“The disconnector Paradox”The more disconnectors installed, the higher unavailability rate

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TraditionalSingle Bus

Traditional Double Bus with by-pass

X

X

Disconnectors to maintain that can fail

X

X X

Possible Compact

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Conclusion

Unavailability = MTTR/MTBF + MTTM/MTBM

The lowest unavailability (and the highest availability) is achieved when the failure frequency, maintenance frequency, time to repair and time to maintain all are minimized

Modern SF6 circuit breakers has improved tenfold compared to old oil/airblast breakers…but the disconnectors are basically the same as 40 years ago!

Replacing conventional disconnectors with a maintenance free and none exposed disconnecting function will improve reliability

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General

Theory

Technical Design

Sales Arguments

Applications

Standards

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Conventional Circuit Breaker

LTB 170 D3 pole

HPL 550B21 of 3poles

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Conventional outdoor design

• Busbar

• Disconnector 1

• Circuit Breaker

• Disconnector 2

• Current Transformer

• Voltage Transformer

• Earthing Switch

• Surge Arrestor

Disconnectors , especially directly connected to the bus are the most critical primary component for the availability!

The auxiliary contacts from the disconnectors which are required for the interlocking system are the most critical secondary components for the reliability!

Bus bar

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How can Compact improve substation availability?

• Conventional disconnectors are eliminated• Busbar connections require no maintenance work• All maintenance is carried out on withdrawn modules Hence:• The busbars need not be de-energized for maintenance

No regular maintenance of stationary disconnector contacts:- no moving parts- silver plated copper- separate contact zones for making/breaking and for stationary closed position

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LTB or HPL Circuit Breaker 72 - 300 kV Plug-in/Draw-out motorised truck tested

for 2000 disconnection operations Self-cleaning and maintenance free fixed

contacts (tested for 10 000 operations)

Options Busbar CT Type IMB, CVT, SA and Earthing Switch

integrated or separate Line Entrance Module

Compact Switching Module 72 – 300 kV

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HPL Circuit Breaker 360 - 550 kV Pantograph Disconnector on one or

both sides Self-cleaning and maintenance free

fixed contacts

Options CT Type IMB, CVT, SA and Earthing Switch

integrated or separate Line Entrance Module

Digital Optical CT and VT

Compact Switching Module 360 – 550 kV

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Compact Switching Module

• Busbar

• Disconnector 1

• Circuit Breaker

• Disconnector 2



• Earthing Switch

• Surge Arrestor

ConventionalCompact Module

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Compact with maintenance free contacts

Fixed contact (toward bus and line) is maintenance free with extremely low failure probability. It is type tested aspart of module for 2000 operation and mechanicallytested for 10 000 operations.

Corona protection

Moving contact isflexible allowing+/- 20 mm

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Maintenance free contacts

Closed

Open

Fixed maintenance free contacttowards bus and line/transformer (Self cleaning)

Moving contacts with flexible fingers(+/- 20 mm)

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How can Combined improve substation availability?

COMBINED disconnecting circuit-breaker, DCB:

-The DCB permits simple S/S solutions- The DCB is directly connected to the busbar. This affectsthe availability during maintenance or repair

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Combined Switching Module

Combined Disconnecting Circuit Breaker LTB or HPL., 72 – 420 kV Integrated Earthing Switch Safe Interlocking System

Options Busbar CT type IMB Separate Line Entrance Module

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Combined Switching Modules

Visual Indication, On/Off

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Key interlocking of Disconnecting Circuit Breaker and Earthing Switch withmanual operating mechanism

2a. Insert key A2b. Mechanical interlockingof disconnecting breaker2c. Remove key B

3a. Insert key B3b. Close ES

0. Open Breaker1a. Electrical and mechanical interlocking of closing latch1b. Remove key A

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Key interlocking of Disconnecting Circuit Breaker and Earthing Switch withmotor operated mechanism

0. Open Breaker1a. Electrical and mechanical interlocking of closing latch1b. Remove key A

2a. Close ES which automatically gives mechanical interlocking of breaker pull roadin all three phases2b. Insert key A and electrically interlock ES

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Off-Open and earthedOn-Closed/Off-Open and live

Visual Indication, Earthing Switch Position

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• Busbar

• Disconnector 1

• Circuit Breaker

• Disconnector 2



• Earthing Switch

• Surge Arrestor

ConventionalCombined Module

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Utilising the well proven LTB or HPL SF6 circuit breaker in composite insulation and with integrated earthing switch

Designed and tested as both circuit breaker and disconnector according to IEC and ANSI standards

Designed with safe interlocking system and clear indications

Optional conventional current transformers

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To simplify the design and improve the availability of substations using pre-tested & multi-functional modules without conventional disconnectors

To optimise the life cycle economy by reducing the installation, operation and maintenance time & cost

To enhance personnel and equipment safety by minimizing exposed connections and replacing porcelain with composite insulation

To reduce environmental impact with minimum use of space and material

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The Compact Modular FamilykV Type of operation Insulation Level Breaking Current Rated Current

(Single/Three Phase) (kV) (kA) (A)

LTB 145 D1 (123) 245 E1

HPL 245B1

300 B1 420 B2 550 B2

3

1

1

1

1

1

650

1050

1050

1050 (+170)

1425

1550

40

50

50

50

63

63

3150

4000

4000

4000

4000

4000

i) SWITCHSYNC RELAY FOR SYNCHRONIZING CIRCUIT BREAKER OPERATION DURING SWITCHING OF CAPACITOR BANKS, SHUNT REACTORS, POWER TRANSFORMERS AND LONG LINES.

ii) POLYMERIC INSULATORS

iii) OPERATION DOWN TO -40 AND -50°C WITH MIXED GAS (WHICH REDUCE THE SHORT CIRCUIT CURRENT RATING).

*FREQ. 50/60 Hz TEMP. +40°C / -30°COptions:

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The Combined Modular FamilykV Type of operation Insulation level Breaking Current Rated Current

(Single/Three Phase) (kV) (kA) (A)

LTB 145 D1/B

HPL 145 B1

170 B1

245 B1 300 B1 420 B2

3

1/3

1/3

1/3

1/3

1

650

650

750

1050

1050 (+170)

1425

40

50

50

50

50

50

3150

4000

4000

5000

5000

4000

i) SWITCHSYNC RELAY FOR SYNCHRONIZING CIRCUIT BREAKER OPERATION DURING SWITCHING OF CAPACITOR BANKS, SHUNT REACTORS, POWER TRANSFORMERS AND LONG LINES.

ii) OPERATION DOWN TO -40 AND -50°C WITH MIXED GAS (WHICH REDUCE THE SHORT CIRCUIT CURRENT RATING).

iii) CT BRACKETS UP TO 170 kV

*FREQ. 50/60 Hz TEMP. +40°C / -30°COptions:

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General

Theory

Technical Design

Sales Arguments

Applications

Standards

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Sales Arguments

Life cycle cost

Availability

Space saving

Minimum maintenance

Fast installation

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Sales Arguments

25 m

40 m

1000 m2

4 m

30 m

120 m2

Conventional 145 kV stationIntegrated Switchgear Modules

Space requirement

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Sales Arguments

Cost comparisonInstallation

Summary of cost in kUSD Conventional Combined CompactEquipment 400 328,0 445Project management 60 22,0 17Primary engineering 17,6 6,8 2Secondary engineering 11,6 2,4 2,4Land & preparation 89,1 40,5 32,4Foundations 36 13,2 10,2Erection 42 17,6 22,1Installation 44 15,0 11Cabling to control room 0 0,0 0,0Other (Bus structures etc.) 30 0,0 0,0Total estimated installed cost 730,3 445,5 542,1

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Sales Arguments

Cost comparisonInstallation

Conventional Combined Compact

Number of foundations 72 18 17Approximate cost kUSD 33 11 11

Foundation costs are not included in previous slideThe numbers and costs above include the complete nos. of foundations for the station. I.e. Foundations for CT, VT, SA and ES are included

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Sales Arguments

Cost comparisonUnavailability

Summary of unavailability cost, 10 years in kUSD Conventional Combined CompactLoss of 1 through going load 134,7 62,9 13,2Loss of 2 through going load 70,4 62,9 0,2Total unavailability cost 205,1 125,8 13,4

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Sales Arguments

Cost comparisonService

Summary of service cost, 10 years Conventional Combined CompactMaintenance cost 90,7 26,7 10,7Repair cost 38,4 19,2 9,8Total service cost 129,1 45,9 20,5

Grand Total Life Cycle Cost (10 years) 1065 617 576

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Sales Arguments

Integrated Switchgear Modules Features and Benefits

Pre-manufactured multi-function module

Integrated SF6 breaker and disconnector function

Pollution & explosion resistant composite (polymer) insulation(Standard for Combined)

Simplified station layout with no disconnectors

Indoor version Available

Fast and simple installation at minimum area

Reduced operating andmaintenance cost

Maximum personnel and equipment safety

Maintained or improvedavailability with lower cost

An alternative in Urban applications

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Sales Arguments

Evaluation sheet Imp

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Value 1-10Low - High Rate Tot Rate Tot Rate Tot Rate Tot

1. Cost1.1 Equipment Cost 2 4 8 4 8 2 4 0 01.2 Installed Cost 4 2 8 5 20 3 12 0 01.3 Life Cycle Cost 4 1 4 4 16 5 20 0 0Sub Total Cost Rating 20 44 36 02. Availability2.1 At Distribution 0 1 0 3 0 6 0 0 02.2 At Transmission 0 1 0 3 0 6 0 0 02.3 Both T&D 10 1 10 3 30 6 60 0 0Sub Total Availability Rating 10 30 603 Environment3.1Space 4 1 4 3 12 6 24 0 03.2 Material 3 1 3 6 18 3 9 0 03.3 Safety 3 3 9 3 9 4 12 0 0Sub Total Environment Rating 16 39 45 04 Flexibility4.1 Operation & Maintenance 4 2 8 3 12 5 20 0 04.2 Retrofit 3 4 12 4 12 2 6 0 04.3 Extension 3 2 6 4 12 4 12 0 0Sub Total Flexibility Rating 26 36 38 0Grand Total 72 149 179 0

Evaluation

Distribution

Transmission

Both

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General

Theory

Technical Design

Sales Arguments

Applications

Standards

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Applications

Switchgear modules can be used in any substation application

Compact modules

Gives the highest availability

Suitable for applications with high operating frequency

(Capacitor and reactor)

Excellent for extension of existing S/S.

Combined modules

Cost optimised solution for distribution S/S

Shortest erection time

Minimum of space

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Applications

Pitfalls

New concept not known by customer

Diverge from specification

Limited competition

Concept backbited by competitors

Possibilities

Extensive Reference List

Limited competition

Top-down sales using LCC as argument

Increased business opportunities for all HV-apparatus

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Applications

Swedish Power Grid

Hemsjö 420 kV Sustation

14 HPL Combined Switching modules 420 kV, 4000 A, 31,5 kA

Line Transf LineLine LineCap. Cap. Cap.

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Applications

ESBI Alberta Canada

260 kV Substation

12 HPL Compact SwitchingModules

300 kV, 4000 A, 40 kA

Breaker-and-a-half system

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Applications

Norsk Hydro, Norway

145 kV Industrial substation for an aluminium smelting plant

LTB Combined Switchgear modules 145 kV, 3150 A, 40 kA

9 objects 7 objectsSectionaliser

In total 34 Combined in a double busbar system

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Applications

PS-1 Standard for Productified Substations

145 kV Distribution Substation

LTB Combined Switchgear modules 145 kV, 3150 A, 40 kA

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General

Theory

Technical Design

Sales Arguments

Applications

Standards

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Standards

Apparatus included in the Switchgear Modules are designed and tested according to their specific standards

The Compact module withdrawing function fulfils the Disconnector standard IEC 62271-102 and ANSI C37.32

The Disconnecting Circuit Breaker Combined fulfils the Circuit Breaker standard IEC 62271-100 and ANSI C37.09 and the Disconnector standard IEC 62271-102 and ANSI C37.32

IEC 62271-102, Clause 5.102:“For reasons of safety, disconnectors shall be designed in a way that no dangerous leakage current can pass from the terminals of one side to any of the terminals of the other side of the disconnector.This safety requirement is met when any leakage current is led away to earth by a reliable earth connection or when the insulation involved is effectively protected against pollution in service.”

Design solution, disconnecting circuit-breaker

1. Leakage current minimised by means of polymeric insulators

2. Any leakage current is lead away to earth when earthed with the integrated earthing switch

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StandardsCombined Disconnecting circuit-breaker Complies with IEC requirements

Isolating distance requirements - IEC

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Standards

Additional Type Testing of Combined

ABB Test Series on one unit, e.g. HPL 245B1 (50kA)

1. 10,000 operation mechanical endurance

2. No-load test prior to fault-breaking tests

3. 74 x T10 (10%=5kA) breaking tests

4. No-load test

5. 18 x T30 (30%=15kA) breaking tests

6. No-load test

7. 3 x L75 (75%=37.5kA) SLF breaking tests (high RRRV)

8. Dielectric Impulse Withstand Tests

Reliability, Safety & Performance of COMBINED supported by EXHAUSTIVE Accelerated Ageing Tests

Documents

SubStation Types