© PTHVP -Page 1 Integrated Switchgear Solutions Training Course Level 1
© P
TH
VP
-P
age
1
Integrated SwitchgearSolutionsTraining Course Level 1
© A
BB
PT
HV
P –
2, 2
002-
01-1
8, M
T, L
evel
1
General
Theory
Technical Design
Sales Arguments
Applications
Standards
© A
BB
PT
HV
P –
3, 2
002-
01-1
8, M
T, L
evel
1
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
© A
BB
PT
HV
P –
4, 2
002-
01-1
8, M
T, L
evel
1
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
© A
BB
PT
HV
P –
5, 2
002-
01-1
8, M
T, L
evel
1
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
© A
BB
PT
HV
P –
6, 2
002-
01-1
8, M
T, L
evel
1
Indoor applications
Compact in-door with-drawable breakers
72 – 170 kV
© A
BB
PT
HV
P –
7, 2
002-
01-1
8, M
T, L
evel
1
General
Theory
Technical Design
Sales Arguments
Applications
Standards
© A
BB
PT
HV
P –
8, 2
002-
01-1
8, M
T, L
evel
1
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
© A
BB
PT
HV
P –
9, 2
002-
01-1
8, M
T, L
evel
1
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.
© A
BB
PT
HV
P –
10,
200
2-01
-18,
MT
, Lev
el1
Substation Availability
© A
BB
PT
HV
P –
11,
200
2-01
-18,
MT
, Lev
el1
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
nten
ance
rat
e
© A
BB
PT
HV
P –
12,
200
2-01
-18,
MT
, Lev
el1
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
© A
BB
PT
HV
P –
13,
200
2-01
-18,
MT
, Lev
el1
Substation Availability
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
© A
BB
PT
HV
P –
14,
200
2-01
-18,
MT
, Lev
el1
Substation Availability
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
© A
BB
PT
HV
P –
15,
200
2-01
-18,
MT
, Lev
el1
Substation Availability
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
© A
BB
PT
HV
P –
16,
200
2-01
-18,
MT
, Lev
el1
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
© A
BB
PT
HV
P –
17,
200
2-01
-18,
MT
, Lev
el1
Substation Availability
TraditionalSingle Bus
Traditional Double Bus with by-pass
X
X
Disconnectors to maintain that can fail
X
X X
Possible Compact
© A
BB
PT
HV
P –
18,
200
2-01
-18,
MT
, Lev
el1
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
© A
BB
PT
HV
P –
19,
200
2-01
-18,
MT
, Lev
el1
General
Theory
Technical Design
Sales Arguments
Applications
Standards
© A
BB
PT
HV
P –
20,
200
2-01
-18,
MT
, Lev
el1
Conventional Circuit Breaker
LTB 170 D3 pole
HPL 550B21 of 3poles
© A
BB
PT
HV
P –
21,
200
2-01
-18,
MT
, Lev
el1
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
© A
BB
PT
HV
P –
22,
200
2-01
-18,
MT
, Lev
el1
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
© A
BB
PT
HV
P –
23,
200
2-01
-18,
MT
, Lev
el1
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
© A
BB
PT
HV
P –
24,
200
2-01
-18,
MT
, Lev
el1
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
© A
BB
PT
HV
P –
25,
200
2-01
-18,
MT
, Lev
el1
Compact Switching Module
• Busbar
• Disconnector 1
• Circuit Breaker
• Disconnector 2
• Current Transformer
• Voltage Transformer
• Earthing Switch
• Surge Arrestor
ConventionalCompact Module
© A
BB
PT
HV
P –
26,
200
2-01
-18,
MT
, Lev
el1
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
© A
BB
PT
HV
P –
27,
200
2-01
-18,
MT
, Lev
el1
Maintenance free contacts
Closed
Open
Fixed maintenance free contacttowards bus and line/transformer (Self cleaning)
Moving contacts with flexible fingers(+/- 20 mm)
© A
BB
PT
HV
P –
28,
200
2-01
-18,
MT
, Lev
el1
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
© A
BB
PT
HV
P –
29,
200
2-01
-18,
MT
, Lev
el1
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
© A
BB
PT
HV
P –
30,
200
2-01
-18,
MT
, Lev
el1
Combined Switching Modules
Visual Indication, On/Off
© A
BB
PT
HV
P –
31,
200
2-01
-18,
MT
, Lev
el1
Combined Switching Modules
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
© A
BB
PT
HV
P –
32,
200
2-01
-18,
MT
, Lev
el1
Combined Switching Modules
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
© A
BB
PT
HV
P –
33,
200
2-01
-18,
MT
, Lev
el1
Combined Switching Module
Off-Open and earthedOn-Closed/Off-Open and live
Visual Indication, Earthing Switch Position
© A
BB
PT
HV
P –
34,
200
2-01
-18,
MT
, Lev
el1
Combined Switching Module
• Busbar
• Disconnector 1
• Circuit Breaker
• Disconnector 2
• Current Transformer
• Voltage Transformer
• Earthing Switch
• Surge Arrestor
ConventionalCombined Module
© A
BB
PT
HV
P –
35,
200
2-01
-18,
MT
, Lev
el1
Combined Switching Modules
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
© A
BB
PT
HV
P –
36,
200
2-01
-18,
MT
, Lev
el1
Combined Switching Modules
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
© A
BB
PT
HV
P –
37,
200
2-01
-18,
MT
, Lev
el1
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:
© A
BB
PT
HV
P –
38,
200
2-01
-18,
MT
, Lev
el1
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:
© A
BB
PT
HV
P –
39,
200
2-01
-18,
MT
, Lev
el1
General
Theory
Technical Design
Sales Arguments
Applications
Standards
© A
BB
PT
HV
P –
40,
200
2-01
-18,
MT
, Lev
el1
Sales Arguments
Life cycle cost
Availability
Space saving
Minimum maintenance
Fast installation
© A
BB
PT
HV
P –
41,
200
2-01
-18,
MT
, Lev
el1
Sales Arguments
25 m
40 m
1000 m2
4 m
30 m
120 m2
Conventional 145 kV stationIntegrated Switchgear Modules
Space requirement
© A
BB
PT
HV
P –
42,
200
2-01
-18,
MT
, Lev
el1
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
© A
BB
PT
HV
P –
43,
200
2-01
-18,
MT
, Lev
el1
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
© A
BB
PT
HV
P –
44,
200
2-01
-18,
MT
, Lev
el1
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
© A
BB
PT
HV
P –
45,
200
2-01
-18,
MT
, Lev
el1
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
© A
BB
PT
HV
P –
46,
200
2-01
-18,
MT
, Lev
el1
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
© A
BB
PT
HV
P –
47,
200
2-01
-18,
MT
, Lev
el1
Sales Arguments
Evaluation sheet Imp
ort
an
ce
Co
nv
en
tio
na
l
Co
mb
ine
d
Co
mp
ac
t
XX
X
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
© A
BB
PT
HV
P –
48,
200
2-01
-18,
MT
, Lev
el1
General
Theory
Technical Design
Sales Arguments
Applications
Standards
© A
BB
PT
HV
P –
49,
200
2-01
-18,
MT
, Lev
el1
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
© A
BB
PT
HV
P –
50,
200
2-01
-18,
MT
, Lev
el1
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
© A
BB
PT
HV
P –
51,
200
2-01
-18,
MT
, Lev
el1
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.
© A
BB
PT
HV
P –
52,
200
2-01
-18,
MT
, Lev
el1
Applications
ESBI Alberta Canada
260 kV Substation
12 HPL Compact SwitchingModules
300 kV, 4000 A, 40 kA
Breaker-and-a-half system
© A
BB
PT
HV
P –
53,
200
2-01
-18,
MT
, Lev
el1
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
© A
BB
PT
HV
P –
54,
200
2-01
-18,
MT
, Lev
el1
Applications
PS-1 Standard for Productified Substations
145 kV Distribution Substation
LTB Combined Switchgear modules 145 kV, 3150 A, 40 kA
© A
BB
PT
HV
P –
55,
200
2-01
-18,
MT
, Lev
el1
General
Theory
Technical Design
Sales Arguments
Applications
Standards
© A
BB
PT
HV
P –
56,
200
2-01
-18,
MT
, Lev
el1
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
© A
BB
PT
HV
P –
57,
200
2-01
-18,
MT
, Lev
el1
StandardsCombined Disconnecting circuit-breaker Complies with IEC requirements
Isolating distance requirements - IEC
© A
BB
PT
HV
P –
58,
200
2-01
-18,
MT
, Lev
el1
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