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
