Training Course Level 1

Integrated Switchgear Solutions

PTHVP - Page 1

ABB

General Theory Technical Design

Sales Arguments
ABB PTHVP 2, 2002-01-18, MT, Level1

Applications Standards

ABB

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
ABB PTHVP 3, 2002-01-18, MT, Level1

ABB

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, CPA & CPB standard IT
ABB PTHVP 4, 2002-01-18, MT, Level1

PEXLIM standard SA
Modular structure and bus bar Type tested and pre-engineered modular building block

ABB

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

ABB PTHVP 5, 2002-01-18, MT, Level1

ABB

Indoor applications
Compact in-door with-drawable breakers

72 170 kV

ABB PTHVP 6, 2002-01-18, MT, Level1

ABB

General

Theory
Technical Design

Sales Arguments
ABB PTHVP 7, 2002-01-18, MT, Level1

Applications Standards

ABB

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)
ABB PTHVP 8, 2002-01-18, MT, Level1

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

Transformers

ABB

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
ABB PTHVP 9, 2002-01-18, MT, Level1

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

Lowest LCA

ABB

Substation Availability
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.
ABB PTHVP 10, 2002-01-18, MT, Level1

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

ABB

Comparing old and new technology

Air blast with 10 breaking units Oil minimum with 4 breaking units HPL B1 for 300 kV with one breaking unit

Failure and maintenance rate

ABB PTHVP 11, 2002-01-18, MT, Level1

Bulk Oil Breakers Air blast Breakers Disconnectors with open contacts

Minimum Oil breakers SF6 Breakers 1950 2000

ABB

Substation Availability
How to achieve increased availability?
Conventional AIS Multiple bus bars Many disconnectors Large separation distances provide easy access for maintenance work

ABB PTHVP 12, 2002-01-18, MT, Level1

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

ABB

Substation Availability
Example: Unavailability of busbar and bay - caused by maintenance
Conventional AIS equipment:
disconnector circuit breaker disconnector
ABB PTHVP 13, 2002-01-18, MT, Level1

COMPACT switching module:

fixed contact withdrawable circuit breaker fixed contact busba r

COMBINED disconn breaker:

disconn circuit breaker

busbar

busbar

Mean unavailability (hours/year) busbar bay

Mean unavailability (hours/year) busbar bay

Mean unavailability (hours/year) busbar bay

~0

0,2 - 2

ABB

Substation Availability
Mean unavailability due to maintenance
Apparatus and modules For 145 kV Circuit Breakerd Circuit Breakera SF6 Oil Duration hours 10 20 10 Period years 15 6 15 Unavailability hours/year 0,7 3,3 0,7
Combined Module

Disconnecting Circuit Breaker

Disconnectord
ABB PTHVP 14, 2002-01-18, MT, Level1

0,8
Compact Module

Switching Module - withdrawable partd - fixed contactsd

a b

1 ; 10 -

15 -

0,07b ; 0,7c ~0

utility statistics replacement module c maintenance on site d ABB standard

ABB

Substation Availability
Mean unavailability due to failure
Apparatus and modules For 145 kV Circuit Breaker d Circuit Breaker a SF6 Oil Duration hours 72 72 72 8 Frequency 1/100 years 0,09 0,3 0,09 0,12
Compact Module Combined Module

Disconnecting Circuit Breaker

ABB PTHVP 15, 2002-01-18, MT, Level1

Disconnectord Switching Module - withdrawable partd - fixed contactsd

a b

1 ; 24 8

0,2 0,012

utility statistics replacement module c maintenance on site d ABB standard

ABB

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 L4

Compact switching module LTB Compact Disconnecting circuitbreaker LTB Combined

L1 L2 L3 L4

ABB PTHVP 16, 2002-01-18, MT, Level1

T1

T2

T1

T2

ABB

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

Traditional Single Bus

Traditional Double Bus with by-pass

Possible Compact

ABB PTHVP 17, 2002-01-18, MT, Level1

X
X X

Disconnectors to maintain that can fail

ABB

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 breakersbut the disconnectors are basically the same as 40 years ago!
ABB PTHVP 18, 2002-01-18, MT, Level1

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

ABB

General Theory Technical Design

Sales Arguments
ABB PTHVP 19, 2002-01-18, MT, Level1

Applications Standards

ABB

Conventional Circuit Breaker

ABB PTHVP 20, 2002-01-18, MT, Level1

LTB 170 D 3 pole

HPL 550B2 1 of 3poles

ABB

Conventional outdoor design

Busbar Disconnector 1 Circuit Breaker
Bus bar

Disconnector 2 Current Transformer Voltage Transformer

ABB PTHVP 21, 2002-01-18, MT, Level1

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!

ABB

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

ABB PTHVP 22, 2002-01-18, MT, Level1

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

ABB

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 contacts (tested for 10 000 operations)

ABB PTHVP 23, 2002-01-18, MT, Level1

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

ABB

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 contacts Options CT Type IMB, CVT, SA and Earthing Switch integrated or separate Line Entrance Module Digital Optical CT and VT

ABB PTHVP 24, 2002-01-18, MT, Level1

ABB

Compact Switching Module

Conventional
Busbar
Disconnector 1 Circuit Breaker Disconnector 2 Current Transformer
ABB PTHVP 25, 2002-01-18, MT, Level1

Compact Module

Voltage Transformer Earthing Switch Surge Arrestor

ABB

Compact with maintenance free contacts

Corona protection Moving contact is flexible allowing +/- 20 mm

ABB PTHVP 26, 2002-01-18, MT, Level1

Fixed contact (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.

ABB

Maintenance free contacts

Fixed maintenance free contact towards bus and line/transformer (Self cleaning) Moving contacts with flexible fingers (+/- 20 mm)

Open

ABB PTHVP 27, 2002-01-18, MT, Level1

Closed

ABB

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

ABB PTHVP 28, 2002-01-18, MT, Level1

ABB

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
ABB PTHVP 29, 2002-01-18, MT, Level1

ABB

Combined Switching Modules

Visual Indication, On/Off

ABB PTHVP 30, 2002-01-18, MT, Level1

ABB

Combined Switching Modules

Key interlocking of Disconnecting Circuit Breaker and Earthing Switch with manual operating mechanism 3a. Insert key B 3b. Close ES

ABB PTHVP 31, 2002-01-18, MT, Level1

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

ABB

Combined Switching Modules

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

ABB PTHVP 32, 2002-01-18, MT, Level1

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

ABB

Combined Switching Module

Visual Indication, Earthing Switch Position

ABB PTHVP 33, 2002-01-18, MT, Level1

On-Closed/Off-Open and live

Off-Open and earthed

ABB

Combined Switching Module

Conventional
Busbar
Disconnector 1 Circuit Breaker Disconnector 2 Current Transformer
ABB PTHVP 34, 2002-01-18, MT, Level1

Combined Module

Voltage Transformer Earthing Switch Surge Arrestor

ABB

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

ABB PTHVP 35, 2002-01-18, MT, Level1

ABB

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

ABB PTHVP 36, 2002-01-18, MT, Level1

ABB

The Compact Modular Family

kV Type of operation (Single/Three Phase) Insulation Level (kV) Breaking Current (kA) Rated Current (A)

LTB 145 D1 (123) 245 E1

3 1

650 1050

40 50

3150 4000

HPL 245B1 300 B1 420 B2 550 B2

ABB PTHVP 37, 2002-01-18, MT, Level1

1 1 1 1

1050 1050 (+170) 1425 1550

50 50 63 63
*FREQ. 50/60 Hz

4000 4000 4000 4000

TEMP. +40C / -30C

Options:
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 -50C WITH MIXED GAS (WHICH REDUCE THE SHORT CIRCUIT CURRENT RATING).

ABB

The Combined Modular Family

kV Type of operation (Single/Three Phase) Insulation level (kV) Breaking Current (kA) Rated Current (A)

LTB 145 D1/B HPL 145 B1 170 B1 245 B1 300 B1 420 B2

ABB PTHVP 38, 2002-01-18, MT, Level1

3 1/3 1/3 1/3 1/3 1

650 650 750 1050 1050 (+170) 1425

40 50 50 50 50 50
*FREQ. 50/60 Hz

3150 4000 4000 5000 5000 4000

TEMP. +40C / -30C

Options:
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 -50C WITH MIXED GAS (WHICH REDUCE THE SHORT CIRCUIT CURRENT RATING). iii) CT BRACKETS UP TO 170 kV

ABB

General Theory Technical Design

Sales Arguments
ABB PTHVP 39, 2002-01-18, MT, Level1

Applications Standards

ABB

Sales Arguments
Life cycle cost Availability

Space saving
Minimum maintenance Fast installation
ABB PTHVP 40, 2002-01-18, MT, Level1

ABB

Sales Arguments
Space requirement
Conventional 145 kV station Integrated Switchgear Modules

1000 m2

120 m2

ABB PTHVP 41, 2002-01-18, MT, Level1

40 m

30 m

25 m

4m

ABB

Sales Arguments
Cost comparison Installation

ABB PTHVP 42, 2002-01-18, MT, Level1

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

ABB

Sales Arguments
Cost comparison Installation

Conventional Number of foundations Approximate cost kUSD

ABB PTHVP 43, 2002-01-18, MT, Level1

Combined 18 11

Compact 17 11

72 33

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

ABB

Sales Arguments
Cost comparison Unavailability

ABB PTHVP 44, 2002-01-18, MT, Level1

Summary of unavailability cost, 10 years in kUSD Conventional Loss of 1 through going load 134,7 Loss of 2 through going load 70,4 Total unavailability cost 205,1

Combined 62,9 62,9 125,8

Compact 13,2 0,2 13,4

ABB

Sales Arguments
Cost comparison Service

ABB PTHVP 45, 2002-01-18, MT, Level1

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

Conventional 90,7 38,4 129,1

Combined 26,7 19,2 45,9

Compact 10,7 9,8 20,5

Grand Total Life Cycle Cost (10 years)

1065

617

576

ABB

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)
ABB PTHVP 46, 2002-01-18, MT, Level1

Fast and simple installation at minimum area Reduced operating and maintenance cost Maximum personnel and equipment safety

Simplified station layout with no disconnectors Indoor version Available

Maintained or improved availability with lower cost An alternative in Urban applications

ABB

Sales Arguments
Importance Combined

Evaluation
Evaluation sheet

Conventional

Compact

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

Distribution

Transmission
ABB PTHVP 47, 2002-01-18, MT, Level1

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 0 0 10 10 4 3 9 16 8 12 6 26 72

4 5 4

8 20 16 44 0 0 30 30 12 18 9 39 12 12 12 36 149

2 3 5

4 12 20 36 0 0 60 60 24 9 12 45 20 6 12 38 179

XXX

0 0 0

0 0 0 0 0 0 0

0 0 10

1 1 1

3 3 3

6 6 6

0 0 0

4 3 3

1 1 3

3 6 3

6 3 4

0 0 0

0 0 0 0 0 0 0 0 0

4 3 3

2 4 2

3 4 4

5 2 4

0 0 0

ABB

General Theory Technical Design

Sales Arguments
ABB PTHVP 48, 2002-01-18, MT, Level1

Applications Standards

ABB

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
ABB PTHVP 49, 2002-01-18, MT, Level1

Cost optimised solution for distribution S/S Shortest erection time Minimum of space

ABB

Applications
Pitfalls New concept not known by customer Diverge from specification Limited competition Concept backbited by competitors Possibilities
ABB PTHVP 50, 2002-01-18, MT, Level1

Extensive Reference List Limited competition Top-down sales using LCC as argument Increased business opportunities for all HV-apparatus

ABB

Applications
Swedish Power Grid
Hemsj 420 kV Sustation

ABB PTHVP 51, 2002-01-18, MT, Level1

Line

Transf

Line

Cap.

Line

Line

Cap.

Cap.

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

ABB

Applications
ESBI Alberta Canada
260 kV Substation

12 HPL Compact Switching Modules 300 kV, 4000 A, 40 kA

ABB PTHVP 52, 2002-01-18, MT, Level1

Breaker-and-a-half system

ABB

Applications
Norsk Hydro, Norway
145 kV Industrial substation for an aluminium smelting plant

ABB PTHVP 53, 2002-01-18, MT, Level1

9 objects

Sectionaliser

7 objects

In total 34 Combined in a double busbar system

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

ABB

Applications
PS-1 Standard for Productified Substations
145 kV Distribution Substation

ABB PTHVP 54, 2002-01-18, MT, Level1

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

ABB

General Theory Technical Design

Sales Arguments
ABB PTHVP 55, 2002-01-18, MT, Level1

Applications Standards

ABB

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

ABB PTHVP 56, 2002-01-18, MT, Level1

ABB

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 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.
ABB PTHVP 57, 2002-01-18, MT, Level1

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

ABB

Standards
Additional Type Testing of Combined
Reliability, Safety & Performance of COMBINED supported 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

ABB PTHVP 58, 2002-01-18, MT, Level1

ABB