Design of EHV Switchyard

JAYANTH KUMAR BOPPA

EXECUTIVE ENGINEER
ELECTRICAL DESIGN
NPCIL, MUMBAI
Agenda
Introduction
Design Considerations
Design Parameters
Switchyard Electrical Clearances
Transmission Line Clearances
Switchyard Design Calculations
Comparison of rigid and flexible buses
Point on wave switching
Porcelain vs Polymer Composite Insulators
Proposal Implementations For Future Project
 Introduction
400kV Switchyard
400kV Systems is designed to cater for evacuation of generated power
from 2x700 MWe units of KAPP-3&4.
The power generated at 21kV is stepped up to 400kV level by three single
phase 285MVA, 21kV/420/3kV GTs located adjacent to Electrical Bay
building and connected to 400kV switchyard through overhead lines.
400kV Systems also provide start-up power through GT-UT circuit by the
provision of GCB between the generator and GT.

Description KAPP-3&4 RAPP-5 to 8

Breaker Scheme One and half with I type One and half with I type
and configuration
Number of Bays 4 line + 2 GT + 1 BR + 1 future 4 line + 3 lines with line
bays reactor + 4 GT + 1 BR bays
Conductor size 4.5 Al. tube (EH) main bus, 4 / 4.5 Al. tube (EH) main
4 Al. tube (EH) / Triple AAAC bus, 4 Al. tube /4 Al. tube
/ Twin AAAC or ACSR (EH)/ Twin AAAC or ACSR
equipment connections. equipment connections.
 Introduction Contd..
220kV Switchyard
220kV System is common for both KAPS-1&2 and KAPP-3&4.
Two additional bays for SUT-3A & 3B and SUT-4A & 4B have been
added to the existing 220kV switchyard to provide off site power
supply to station auxiliaries through start-up transformers.
Description KAPP-1 to 4 RAPP-5 to 8
Breaker Scheme and Two main bus with by-pass Two main bus with by-pass
configuration isolators isolators
Number of Bays 8 line + 2 GT + 4 SUT + 1 BC 2 lines+1 line under
construction + 4 SUT +
2Colony T/F + 1BC

Conductor Size 4 Al. tube (EH) for Main, Triple Moose ACSR for Main,
Twin Moose ACSR / 2.5 Al. Twin Moose ACSR / 2.5 Al.
tube (EH) for equipment tube (EH) / 3 Al. tube for
connections. equipment connections.
 Design Considerations
Safety of personnel and equipment
Reliability and Security
Quality
o Manufacturing
o Construction
Adherence to
Statutory obligations
CEA rules
AERB regulation
Electrical design considerations
Structural design considerations
Ease of maintenance
Possibility to Expand
 Design Parameters
Based on CEA regulations on technical standard for construction of
electrical plants and electrical lines
Sr. Description 400kV 220kV
1 Nominal system voltage 400kV 220kV
2 Max. operating voltage 420kV 245kV
3 Rated frequency 50Hz 50Hz
4 Number of phases 3 3
5 System neutral earthing Effectively earthed
6 Maximum power transfer capacity of 2000 500
switchyard MVA
7 Switching scheme for air insulated One & half Two main
switchyard breaker with bypass
8 Circuit Breaker 1 auto reclo 1 auto reclo
Rating kA 50 or 63/1s 40/3s
Maximum break time 40msec 60msec
PIR >200km line --
 Design Parameters Contd..
Sr. Description 400kV 220kV
9 Corona Extinction voltage kVrms (ph 320kV 156kV
to earth)
10 Max. Radio interference voltage at 1000 V 1000 V
1MHz for phase to earth voltage @ 267kV @ 156kV
11 Min. Creepage distance
For heavy pollution area 25mm/kV 25mm/kV
For very heavy pollution area 31mm/kV 31mm/kV
12 i) Min. duration for computation of 3h for steady & continuous
capacity of battery (if stand by) 1h emergency light load
ii) Min. duration for computation of 6h for steady & continuous
capacity of battery (without stand by 2h emergency light load
battery)
 Design Parameters Contd..
Sr. Description 400kV 220kV Remarks
13 Rated insulation levels
i) Full wave impulse
withstand voltage (1.2/50s)
-- for other equipments 1425kVp 1050kVp
-- for reactor/ Xmer (Winding) 1300kVp 950kVp
-- for lines 1550kVp 1050kVp
ii) Switching impulse 1050kVp
withstand voltage (dry/wet)
iii) One min. power freq.
withstand voltage (dry/wet)
-- for lines 680kV 460kV
-- for other equipments 630kV 460kV
Outdoor Switchyard Electrical Clearances
Adopted Minimum Electrical Clearances for KAPP-3&4 and RAPP-7&8.
Based on CBIP Substation Manual

Sr. Description 400kV 220kV

1 Phase to Phase 4200 mm 2100 mm
2 Phase to Earth 3400 mm 2100 mm
3 Ground Clearance 8000 mm 5500 mm
4 Height of insulator bottom from 2440mm
ground
5 Safe working clearance 6400 mm 4300 mm
Safe working clearances
Safe working clearances
Transmission Line Electrical Clearances
CEA regulations on measures relating to safety and electric supply and
CBIP Manual on Transmission Lines.

Sr. Description 400kV 220kV

1 Transmission line Corridor 52 m 35 m
2 Vertical clearance from building 3.7 m+0.3m for every
additional 33kV
3 horizontal clearance from building 2 m+0.3m for every
additional 33kV
4 Ground clearance 5.2 m+0.3m for every
additional 33kV
5 Mid span clearance between 9m
conductor and earth wire
6 Spacing between sub conductors 450 mm 300 mm
 Bus Arrangements
Single Bus scheme
Single Bus with Sectionaliser scheme
Main and Transfer Bus scheme
Double Bus with Single Breaker scheme

Double Bus and Transfer bus scheme

Ring Bus scheme

Double Bus with Two Breaker scheme

 Design Calculations
Bus bar sizing (IEEE 605 & IEC 60865)
Sag Tension Calculations (IS: 802 (Part-1/section-1)
1995, IS: 5613, Generation, Transmission &
Utilisation of electrical power by A.T.STARR)
Short Circuit Force calculation as per IEC 60865
Earthing Design (FEM of ETAP / IEEE- 80)
Lightning Protection design (High Voltage
Engineering by Razveig)
Switchyard Lighting design as IS 6665/3646
Equipment sizing design and its cantilever strength
calculation
 Bus bar design
Calculate solar heat gain
Start (qs)=QsAKsin()
System parameters (V, f, IL, If, tf) From heat balance equation
I=sqrt( (qc+qr-qs)/(RF)
Ambient temperature (a), Solar
radiation (Qs), Wind speed, Short time with stand current
Emissivity constant (), Solar
absorption constant()

Layout details (h, phase spacing),

Conductor details (A, D,
Conductor temperature before No Check
fault (bf), after fault (af)), Skin IL<I &
effect coefficient, DC resistance If<Iswc
Yes
Calculate convection loss
(qc)=3.561D-0.4A(bf-a) No Corona
shall be
Calculate radiation loss checked
(qr)=5.6697*10-8A[(bf+273)4- Yes
(af+273)4] Stop
Comparison of Rigid and Flexible Bus
Rigid Bus Strain Bus

Conductor Extruded Structural or seam Stranded bundled

less tube conductors
Broken conductor Conductors are not under Conductors are under strain
faults strain
Seismic Less reliable More effective
Bus height Main Bus 8.8 m & Crossing Main Bus 15.8 m
of bus 13.8m Jack Bus 23.3m
Jack Bus 22.3m
Mounting structure 13 BPI+4 HPI = 2 X 15.8m ht towers
for 2 bays & one bus (13*0.3MT+4*0.86MT) = (2*4.8MT)+ 2 X 27m long
7.34 MT beam (2*4MT) =17.6 MT
Foundation More (13 nos) Less (2 nos)
Insulators 13 nos Post Insulators 6 nos String Insulators & its
hardware
Time Higher man hours Fewer man hours
Contd..
 Gantry Structure Design
Sag / Tension calculation :
Sr. Temp Wind Pressure Limits
1. Min. 36%

2. Every Day Temperature 100% T <= 70% of UTS

3. Every Day Temperature No wind T <= 22% of UTS for

conductor
T <= 20% of UTS for
ground wire
4. Max. No wind Clearances
(ACSR 750C/ AAAC 850C)
5. At every 50C (up to 500C) No wind
Contd..
Start
Calculate vertical sag and
Environmental details (wind,1, inclination sag
2), Min. clearances
Conductor data (n, A, w, E, UTS), No Check
Spacer data & insulator data clearances
within limits
Layout details (span length, Yes
height) & Initial tension Stop
Calculate equivalent weight of
conductor & force due to wind

Note: Repeat the above procedure

for achieving the conditions as
mentioned in previous slide.
No Check T2, T1 value
within as per IS-
802 (Previous
slide)
Yes
 Short Circuit Force Calculations
System data, Layout,
Conductor, Static
tensile force at Min. / Calculate Drop force (Fd)
Max. Temperature
No Calculate
Electromagnetic Force (Fm) per minimum air
unit length of conductor clearances
Yes
Calculate direction of force,
Number of No
resulting period, swing out angle
conductors>1
Tensile force during short circuit Yes
(Ft)
Calculate pinch force (Fpi)
Swing out angle Yes
<60 deg, Ratio of Max.(Ft, Fd & Fpi)
Fm & Gravitational
Force < 0.6
Stop
No
Earthing Design

Guiding standards IEEE 80, IS:3043, CBIP-302.

Switchyards are designed for the system fault level . However
for optimal earthing design actual fault current may be
considered.
Basic Objectives:
Step potential within tolerable
Touch Potential limit
Ground Resistance
Adequacy of Ground conductor for fault current (considering
corrosion)
Earthing Design
Description KAPP-3&4 RAPS-5&6

Area 352 m*160 m 107.5 m*254 m

Soil resistivity 41ohm-m @ 2m depth 1450 ohm-m
800 ohm-m
Gravel resistance 2500 ohm-m 5000 ohm-m
Conductor size 195.1 sqmm Cu 40mm dia MS rod
Total length of ground 9040 m 39746.5 m
conductor
Total length of ground rods 372 m 180 m
depth 0.6 m 1m
Touch potential 563.3 V < 583.9 V 1445.12 V < 1645.27 V
Step potential 748.1 V < 1886.2 V 1500.26 V < 5902.27 V
Ground resistance 0.99 ohm 1.91 ohm (Isolated)
Calculation methodology FEM - ETAP IEEE-80
FEM
Finite Element Method (FEM) solves partial differential equations by
discretizing the volume-space (usually with triangular vertices)
The analysis using FEM has four steps
Discretization of the geometry to sub-region or element (triangular ).
Attainment of the field equation as Governing equation in surface of element
Assembly of all the elements in the solution region by matrices.
Solve the matrices obtained
Touch and Step potential
 Lighting Design
Adequate lighting is necessary for safety of working personnel and O&M activities

Recommended value of Illumination level

Control desks - 400 Lux
Protection panel - 200 Lux
Battery room - 150 Lux
Cable gallery - 100 Lux
Other areas of control building - 200 Lux
Switchyard - 50 Lux (main equipment)
- 20 Lux (balance Area / road @
ground level)
20% light fixtures shall be provided as AC emergency lighting in switchyard and
control building
DC lighting in control building
 LED vs General Lighting Service
Description LED FTL
It made up with long glass tube with metal
LED is made up of a semiconductor fittings on each end by filling small amount
Principle of material. LED bulbs are grouped in of mercury and an inert gas and coated
operation clusters with diffuser lenses. inside phosphorous powder
Direction of light 110 deg. (Directional) 360 deg.
Initial Cost More Less
Running cost Up to 50000 hours 10000 hours
After significant amount of time FTL used
Noise Do not have this problem to make buzzing noise

Instant on Instantly Time required to flicker before staying on

It provides different colours (depends on
chip material and colour temperatures
for any purpose. It requires feedback Warm white (2700 K) for residential
loop systems with colour sensors, to lighting/ Neutral-white (3500 K) / Cool-
actively monitor and control the colour white (4100 K) for office lighting / Daylight
Colour output of multiple colour mixing LEDs (5000 K to 6500 K) which is bluish-white

Heat Generation Heat sink is required Small amount of heat produced

Sensitivity for Sensitive to excessive heat, like most
heat solid state electronic components No sensitivity
 LED vs General Lighting Service
Watts (LED) Watts Watts (CFL) Watts (FTL)
Description (Incandescent)
450 Lumen 4-5 40 9-13 --

800 Lumen 6-8 60 13-15 --

1,100 Lumen 9-13 75 18-25 --
1,600 Lumen 16-20 100 23-30 --
2600 Lumen 25-28 150 30-55 40W + 12W

Heat Emitted 3.4 btu's/hour 85 btu's/hour 30 btu's/hour

(1Btu = 0.55 deg.C) (6-8 watts) (60 watts) (13-15 watt)
Life Span 50000 hours 1200 hours 8000 hours 20000 hours
Contd..
Contd..
Lightning Protection Ground Wire

Zone of protection by
single ground wire

bx=1.2H(1-Hx/(0.8H)) for
Hx<2/3H
bx=0.6H(1-Hx/H) for
Hx>2/3H

Zone of protection by
two ground wire
FIG-4a FIG-4b H0=H-S/4
 Lightning Protection Lightning Mast
FIG-3.0

FIG-2a

FIG-2b

Zone of protection by single LM

rox=1.5h(1-hx/(0.8h)) for hx<2/3h
rox=0.75h(1-hx/h) for hx>2/3h
If h>30m, P=5.5/sqrt(h) shall be multiplied with above equations.
Distance bewteen two LM: S<=7(h-h0)
Maximum diameter of three LM: D<=8(h-h0)
220kV Cable Selection Process
LOAD, VOLTAGE LEVEL, CONDUCTOR CROSS
SCC, LAYING CONDITION SECTION

SELECTION OF CABLE
CABLE TYPE & DESIGN ACCESSORIES

CONDUCTOR MATERIAL
LAYING CONDITION

EARTHING METHOD OF
SHEATH
220kV Cable Manufacturing Process
CONDUCTOR RODS CURING

STRANDS DEGASFYING

SEMICONDUCTING & WATER

BETWEEN EACH LAYER WATER SWELLABLE TAPE OVER
SWEALLABLE TAPE IS PROVIDED INSULATION

COPPER WOVEN TAPE

COMPLETE COMPACTED
CONDUCTOR
METALLIC SHEATH

CONDUCTOR SCREEN (Semi

Conducting tape) BITUMINUS COMPOUND

OVER SHEATH (Extruded HDPE

TRIPLE EXTRUSION PROCESS (Type ST7)
Cross section view of single core 500sqmm 220kV
Cable used in RAPP-7&8 and KAPP-3&4
 220kV Cable Design Calculations
Reference standard IEC 62067 & IEEE 635
Heating of cables
Core loss (Wc=I2R)
Dielectric loss (Wd=CV2tan)
Sheath loss (Ws=Wc)
Charging current (Ic=V/Xc=CV)
Dielectric stress calculation at conductor and at insulation
Sheath Induced Voltage
Continuous and Short Circuit Current rating of cable
Effect of charging SUT with cable feeder.
 Earthing of 220kV Cable
Both end bonding Single end bonding

Cross bonding
 220kV Cable Accessories
Air termination
Link box without SVL
Link box with SVL
Bonding Cable
Earthing Continuity Cable (ECC)
 Point on Wave Switching
Reference standard IEC 62271-302
Principal
Alternative to PIR
It introduces a suitable time delay between the instant it receives an input command for operating
the switchgear.
Application
Shunt Reactor Switching
Transformer Switching
Capacitor banks switching
Transmission line switching
System Requirement
Individual pole operated CB
Mechanism of the CB
Bus voltage for reference
CT input
Temperature input
Point on Wave Switching
Point on Wave Switching
 Porcelain vs Polymer Composite Insulators
Description Porcelain Polymer Insulators
Material Clay, feld spar, quartz and Glass fiber reinforced epoxy resin rod shaped
alumina core (FRP rod) over seamless sheath of
silicone elastomeric or silicone alloy
compound.
Hydrophobic Forms water film on the Prevents the formation of conductive film on
surface making easy path its surface without the need of washing
leading to more flashovers
Strength Good Better due to crimping, but high crimping
force leads FRP rod damage
Resistance to High fragile Flexible hence high resistance to breakage
breakage
Leakage current Higher Lower
Tracking Poor tacking resistance Excellent tracking resistance avoids erosion or
tracking of the housing material
Draw backs Porosity Parrots, which loves to chew on polymeric
insulators.
Moisture may enter in the core if any
unwanted gaps b/w core & weather sheds
Standard IEC 60383 IEC 61109
Polymer Composite Insulator Cross Section
 Seismic Design
The switchyard and towers are be designed for earthquake as per IS: 1893 Part-4
with an importance factor of 1.75.
Horizontal seismic coefficient (Ah) for structure = (Zone factor(Z)/2)*(Importance
factor/Response reduction factor) *(Average response acceleration
coefficient(Sa/g)).
Shear force = Ah*(m*g) Newton
Seismic design force for higher floors shall be computed as per the provision of
clause 13.3 of ASCE 7-05
Future Implementations (proposed)

Lightning cum lighting mast

Point on wave switching for Circuit Breaker
Butterfly tower in Transformer yard
LED fixtures in switchyard control building
Bay Control Room
Switchyard Seismic Design - IEEE Std 693-2005
 Butterfly tower

Specially designed tower

for tapping connection
to GTs.
Avoid snapping of
conductor on GTs (MAPS
GT-2 incident).
Proposed for new
projects
Bay Control Rooms
THANKS for attention!