Substation Types 2k4p3e

© PTHVP - Page 1

Training Course Level 1

Integrated Switchgear Solutions

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General Theory Technical Design

ABB PTHVP – 2, 2002-01-18, MT, Level1

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 & HPL standard breaker


IMB, A & B standard IT PEXLIM standard SA Modular structure and bus bar

Type tested and pre-engineered modular 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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Why do we have switchgear Lines

 To connect transmission lines, cables and transformers with each other in a substation  To disconnect and isolate if required (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) Transformers

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What are the real requirements  Maximum availability = Minimized interruptions

 Lowest possible maintenace need


 Maximum safety  Reduced nos. of = Minimized risk for personnel entrances equipment and environment  Maximum economy  Lowest LCA = Minimized costs for design, construction, operation, maintenance and outages

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Substation Availability  The probability that power is available at a certain

© ABB PTHVP – 10, 2002-01-18, MT, Level1

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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Comparing old and new technology

Failure and maintenance rate


Air blast with 10 breaking units

Oil minimum with 4 breaking units

HPL B1 for 300 kV with one breaking unit

Bulk Oil Breakers Air blast Breakers

Disconnectors with open s

Minimum Oil breakers SF6 Breakers 1950

2000

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Substation Availability 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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Substation Availability Example: Unavailability of busbar and bay - caused by maintenance Conventional AIS equipment: disconnector

fixed

circuit breaker

withdrawable circuit breaker fixed busba r

disconnector


busbar

Mean unavailability (hours/year) busbar bay

2

COMPACT switching module:

6


~0

0,2 - 2

COMBINED disconn breaker:

disconn circuit breaker

busbar


2

2

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Substation Availability Mean unavailability due to maintenance Apparatus and modules For 145 kV Circuit Breakerd Circuit Breakera

SF6 Oil

Disconnecting Circuit Breaker


Disconnectord Switching Module - withdrawable partd - fixed sd utility statistics replacement module c maintenance on site d ABB standard

Duration hours

Period years

10 20

15 6

Unavailability hours/year 0,7 3,3

10

15

0,7

4

5

0,8

Combined Module

Compact Module

1 ; 10 -

15 -

0,07b ; 0,7c ~0

a b

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Substation Availability Mean unavailability due to failure Apparatus and modules For 145 kV Circuit Breaker d Circuit Breaker a

SF6 Oil

Disconnecting Circuit Breaker


Disconnectord Switching Module - withdrawable partd - fixed sd utility statistics replacement module c maintenance on site d ABB standard

Duration hours 72 72

Frequency 1/100 years 0,09 0,3

72

0,09

8

0,12

1 ; 24 8

0,2 0,012

Combined Module

Compact Module

a b

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New equipment allows simplified arrangements Example: Traditional double busbar layout may be replaced by sectionalized single busbar Used together, LTB Compact and LTB Combined give the optimal solution L1

L2

L3

Compact switching module LTB Compact

L4

Disconnecting circuitbreaker LTB Combined


L1

T1

T2

L2

T1

L3

L4

T2

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

Traditional Single Bus

Traditional Double Bus with by-

X

X


Possible Compact

X X

Disconnectors to maintain that can fail

X

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Substation Availability 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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Conventional Circuit Breaker

LTB 170 D 3 pole

HPL 550B2 1 of 3poles

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Conventional outdoor design • Busbar • Disconnector 1 • Circuit Breaker • Disconnector 2

Bus bar

• 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 s from the disconnectors which are required for the interlocking system are the most critical secondary components for the reliability!

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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 s: - no moving parts - silver plated copper - separate zones for making/breaking and for stationary closed position

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Compact Switching Module 72 – 300 kV


 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 s (tested for 10 000 operations)

Options  Busbar  CT Type IMB,  CVT, SA and Earthing Switch integrated or separate Line Entrance Module

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Compact Switching Module 360 – 550 kV


 HPL Circuit Breaker 360 - 550 kV  Pantograph Disconnector on one or both sides  Self-cleaning and maintenance free fixed s Options  CT Type IMB,  CVT, SA and Earthing Switch integrated or separate Line Entrance Module  Digital Optical CT and VT

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Compact Switching Module Conventional

Compact Module

• Busbar • Disconnector 1 • Circuit Breaker • Disconnector 2


• Current Transformer • Voltage Transformer • Earthing Switch • Surge Arrestor

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Compact with maintenance free s Corona protection


Moving is flexible allowing +/- 20 mm

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

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Maintenance free s Fixed maintenance free towards bus and line/transformer (Self cleaning)

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


Open

Closed

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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 affects the 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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Combined Switching Modules Key interlocking of Disconnecting Circuit Breaker and Earthing Switch with manual operating mechanism


3a. Insert key B 3b. Close ES

0. Open Breaker 1a. Electrical and mechanical interlocking of closing latch 1b. Remove key A

2a. Insert key A 2b. Mechanical interlocking of disconnecting breaker 2c. Remove key B

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Combined Switching Modules


Key interlocking of Disconnecting Circuit Breaker and Earthing Switch with motor operated mechanism

0. Open Breaker 1a. Electrical and mechanical interlocking of closing latch 1b. Remove key A

2a. Close ES which automatically gives mechanical interlocking of breaker pull road in all three phases 2b. Insert key A and electrically interlock ES

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Combined Switching Module


Visual Indication, Earthing Switch Position

On-Closed/Off-Open and live

Off-Open and earthed

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Combined Switching Module Conventional

Combined Module

• Busbar • Disconnector 1 • Circuit Breaker • Disconnector 2


• Current Transformer • Voltage Transformer • Earthing Switch • Surge Arrestor

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Combined Switching Modules 

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

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

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Designed with safe interlocking system and clear indications

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Optional conventional current transformers

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Combined Switching Modules 

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

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

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

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To reduce environmental impact with minimum use of space and material

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The Compact Modular Family


kV

Type of operation

Insulation Level

(Single/Three Phase)

(kV)

Breaking Current

Rated Current

(kA)

(A)

LTB 145 D1 (123)

3

650

40

3150

245 E1

1

1050

50

4000

HPL 245B1

1

1050

50

4000

300 B1

1

1050 (+170)

50

4000

420 B2

1

1425

63

4000

550 B2

1

1550

63

4000

Options: i)

*FREQ. 50/60 Hz

TEMP. +40°C / -30°C

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).

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The Combined Modular Family kV

Type of operation (Single/Three Phase)


Breaking Current (kA)

Rated Current (A)

LTB 145 D1/B

3

650

40

3150

HPL 145 B1

1/3

650

50

4000

170 B1

1/3

750

50

4000

245 B1

1/3

1050

50

5000

300 B1

1/3

1050 (+170)

50

5000

420 B2

1

1425

50

4000

Options: i)

Insulation level (kV)

*FREQ. 50/60 Hz

TEMP. +40°C / -30°C

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

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Sales Arguments  Life cycle cost  Availability  Space saving  Minimum maintenance


 Fast installation

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Sales Arguments Space requirement Conventional 145 kV station


1000 m2

Integrated Switchgear Modules 120 m2

30 m

40 m

25 m

4m

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Sales Arguments


Cost comparison Installation

Summary of cost in kUSD Conventional Equipment 400 Project management 60 Primary engineering 17,6 Secondary engineering 11,6 Land & preparation 89,1 Foundations 36 Erection 42 Installation 44 Cabling to control room 0 Other (Bus structures etc.) 30 Total estimated installed cost 730,3

Combined 328,0 22,0 6,8 2,4 40,5 13,2 17,6 15,0 0,0 0,0 445,5

Compact 445 17 2 2,4 32,4 10,2 22,1 11 0,0 0,0 542,1

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Sales Arguments Cost comparison Installation

Conventional


Number of foundations Approximate cost kUSD

72 33

Combined

Compact

18 11

17 11

Foundation costs are not included in previous slide The 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 comparison Unavailability

S umm ary of unavailability cost, 10 years in kU S D C o nventional Loss of 1 through going load 134,7 Loss of 2 through going load 70,4 To tal un availability cost 205,1

C om bined 62,9 62,9 125,8

C om pact 13,2 0,2 13,4

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Sales Arguments Cost comparison Service


Summary of service cost, 10 years Maintenance cost Repair cost Total service cost

Grand Total Life Cycle Cost (10 years)

Conventional 90,7 38,4 129,1

Combined 26,7 19,2 45,9

Compact 10,7 9,8 20,5

1065

617

576

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Sales Arguments


Integrated Switchgear Modules Features and Benefits Pre-manufactured multi-function module

Fast and simple installation at minimum area

Integrated SF6 breaker and disconnector function

Reduced operating and maintenance cost

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

Maximum personnel and equipment safety

Simplified station layout with no disconnectors

Maintained or improved availability with lower cost

Indoor version Available

An alternative in Urban applications

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XXX

Compact

Evaluation sheet

Combined

Importance

Evaluation

Conventional

Sales Arguments

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

Distribution


Transmission

Both

1. Cost 1.1 Equipment Cost 1.2 Installed Cost 1.3 Life Cycle Cost Sub Total Cost Rating 2. Availability 2.1 At Distribution 2.2 At Transmission 2.3 Both T&D Sub Total Availability Rating 3 Environment 3.1Space 3.2 Material 3.3 Safety Sub Total Environment Rating 4 Flexibility 4.1 Operation & Maintenance 4.2 Retrofit 4.3 Extension Sub Total Flexibility Rating Grand Total

2 4 4

4 2 1

8 8 4 20

4 5 4

8 20 16 44

2 3 5

4 12 20 36

0 0 0

0 0 0 0

0 0 10

1 1 1

0 0 10 10

3 3 3

0 0 30 30

6 6 6

0 0 60 60

0 0 0

0 0 0

4 3 3

1 1 3

4 3 9 16

3 6 3

12 18 9 39

6 3 4

24 9 12 45

0 0 0

0 0 0 0

4 3 3

2 4 2

8 12 6 26 72

3 4 4

12 12 12 36 149

5 2 4

20 6 12 38 179

0 0 0

0 0 0 0 0

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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

Line

Transf

Line

Cap.

Line

Line

Cap.

Cap.

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

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Applications ESBI Alberta Canada 260 kV Substation 12 HPL Compact Switching Modules


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

9 objects

Sectionaliser

7 objects

In total 34 Combined in a double busbar system LTB Combined Switchgear modules 145 kV, 3150 A, 40 kA

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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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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

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Standards Combined Disconnecting circuit-breaker Complies with IEC requirements Isolating distance requirements - IEC


IEC 62271-102, Clause 5.102: “For reasons of safety, disconnectors shall be designed in a way that no dangerous leakage current can 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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Standards Additional Type Testing of Combined


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

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More details w3441

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