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© PTHVP - Page 1
Training Course Level 1
Integrated Switchgear Solutions
General Theory Technical Design
ABB PTHVP – 2, 2002-01-18, MT, Level1
Sales Arguments Applications Standards
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
ABB PTHVP – 3, 2002-01-18, MT, Level1
To be familiar with the web based tools for design … and quotation
The basic Compact modular concept Integrate standard & well proven ABB switchgear apparatus to a type-tested and pre-engineered module. LTB & HPL standard breaker
ABB PTHVP – 4, 2002-01-18, MT, Level1
IMB, A & B standard IT PEXLIM standard SA Modular structure and bus bar
Type tested and pre-engineered modular building block
A modular step-by-step Concept 72-300 kV
ABB PTHVP – 5, 2002-01-18, MT, Level1
Identically the same standard and well proven LTB/HPL Circuit Breaker is used in all application
Indoor applications Compact in-door with-drawable breakers
ABB PTHVP – 6, 2002-01-18, MT, Level1
72 – 170 kV
General Theory Technical Design
ABB PTHVP – 7, 2002-01-18, MT, Level1
Sales Arguments Applications Standards
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)
ABB PTHVP – 8, 2002-01-18, MT, Level1
To measure voltage and current (e.g. for relay protection and SCADA) To limit high voltage surges (e.g. from lightning strokes) Transformers
What are the real requirements Maximum availability = Minimized interruptions
Lowest possible maintenace need
ABB PTHVP – 9, 2002-01-18, MT, Level1
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
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.
Comparing old and new technology
Failure and maintenance rate
© ABB PTHVP – 11, 2002-01-18, MT, Level1
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
Substation Availability How to achieve increased availability?
© ABB PTHVP – 12, 2002-01-18, MT, Level1
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
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
© ABB PTHVP – 13, 2002-01-18, MT, Level1
busbar
Mean unavailability (hours/year) busbar bay
2
COMPACT switching module:
6
Mean unavailability (hours/year) busbar bay
~0
0,2 - 2
COMBINED disconn breaker:
disconn circuit breaker
busbar
Mean unavailability (hours/year) busbar bay
2
2
Substation Availability Mean unavailability due to maintenance Apparatus and modules For 145 kV Circuit Breakerd Circuit Breakera
SF6 Oil
Disconnecting Circuit Breaker
© ABB PTHVP – 14, 2002-01-18, MT, Level1
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
Substation Availability Mean unavailability due to failure Apparatus and modules For 145 kV Circuit Breaker d Circuit Breaker a
SF6 Oil
Disconnecting Circuit Breaker
© ABB PTHVP – 15, 2002-01-18, MT, Level1
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
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
© ABB PTHVP – 16, 2002-01-18, MT, Level1
L1
T1
T2
L2
T1
L3
L4
T2
Substation Availability “The disconnector Paradox” The more disconnectors installed, the higher unavailability rate
Traditional Single Bus
Traditional Double Bus with by-
X
X
© ABB PTHVP – 17, 2002-01-18, MT, Level1
Possible Compact
X X
Disconnectors to maintain that can fail
X
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
© ABB PTHVP – 18, 2002-01-18, MT, Level1
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
General Theory Technical Design
© ABB PTHVP – 19, 2002-01-18, MT, Level1
Sales Arguments Applications Standards
© ABB PTHVP – 20, 2002-01-18, MT, Level1
Conventional Circuit Breaker
LTB 170 D 3 pole
HPL 550B2 1 of 3poles
Conventional outdoor design • Busbar • Disconnector 1 • Circuit Breaker • Disconnector 2
Bus bar
• Current Transformer
© ABB PTHVP – 21, 2002-01-18, MT, Level1
• 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!
How can Compact improve substation availability?
© ABB PTHVP – 22, 2002-01-18, MT, Level1
• 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
Compact Switching Module 72 – 300 kV
© ABB PTHVP – 23, 2002-01-18, MT, Level1
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
Compact Switching Module 360 – 550 kV
© ABB PTHVP – 24, 2002-01-18, MT, Level1
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
Compact Switching Module Conventional
Compact Module
• Busbar • Disconnector 1 • Circuit Breaker • Disconnector 2
© ABB PTHVP – 25, 2002-01-18, MT, Level1
• Current Transformer • Voltage Transformer • Earthing Switch • Surge Arrestor
Compact with maintenance free s Corona protection
© ABB PTHVP – 26, 2002-01-18, MT, Level1
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.
Maintenance free s Fixed maintenance free towards bus and line/transformer (Self cleaning)
Moving s with flexible fingers (+/- 20 mm)
© ABB PTHVP – 27, 2002-01-18, MT, Level1
Open
Closed
How can Combined improve substation availability?
© ABB PTHVP – 28, 2002-01-18, MT, Level1
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
Combined Switching Module Combined Disconnecting Circuit Breaker LTB or HPL., 72 – 420 kV Integrated Earthing Switch Safe Interlocking System
© ABB PTHVP – 29, 2002-01-18, MT, Level1
Options Busbar CT type IMB Separate Line Entrance Module
Combined Switching Modules
© ABB PTHVP – 30, 2002-01-18, MT, Level1
Visual Indication, On/Off
Combined Switching Modules Key interlocking of Disconnecting Circuit Breaker and Earthing Switch with manual operating mechanism
© ABB PTHVP – 31, 2002-01-18, MT, Level1
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
Combined Switching Modules
© ABB PTHVP – 32, 2002-01-18, MT, Level1
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
Combined Switching Module
© ABB PTHVP – 33, 2002-01-18, MT, Level1
Visual Indication, Earthing Switch Position
On-Closed/Off-Open and live
Off-Open and earthed
Combined Switching Module Conventional
Combined Module
• Busbar • Disconnector 1 • Circuit Breaker • Disconnector 2
© ABB PTHVP – 34, 2002-01-18, MT, Level1
• Current Transformer • Voltage Transformer • Earthing Switch • Surge Arrestor
© ABB PTHVP – 35, 2002-01-18, MT, Level1
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 – 36, 2002-01-18, MT, Level1
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
The Compact Modular Family
© ABB PTHVP – 37, 2002-01-18, MT, Level1
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).
The Combined Modular Family kV
Type of operation (Single/Three Phase)
© ABB PTHVP – 38, 2002-01-18, MT, Level1
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
General Theory Technical Design
© ABB PTHVP – 39, 2002-01-18, MT, Level1
Sales Arguments Applications Standards
Sales Arguments Life cycle cost Availability Space saving Minimum maintenance
© ABB PTHVP – 40, 2002-01-18, MT, Level1
Fast installation
Sales Arguments Space requirement Conventional 145 kV station
© ABB PTHVP – 41, 2002-01-18, MT, Level1
1000 m2
Integrated Switchgear Modules 120 m2
30 m
40 m
25 m
4m
Sales Arguments
© ABB PTHVP – 42, 2002-01-18, MT, Level1
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
Sales Arguments Cost comparison Installation
Conventional
© ABB PTHVP – 43, 2002-01-18, MT, Level1
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
Sales Arguments
© ABB PTHVP – 44, 2002-01-18, MT, Level1
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
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
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
Sales Arguments
© ABB PTHVP – 46, 2002-01-18, MT, Level1
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
XXX
Compact
Evaluation sheet
Combined
Importance
Evaluation
Conventional
Sales Arguments
Low Value 1-10 High Rate Tot Rate Tot Rate Tot Rate Tot
Distribution
© ABB PTHVP – 47, 2002-01-18, MT, Level1
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
General Theory Technical Design
© ABB PTHVP – 48, 2002-01-18, MT, Level1
Sales Arguments Applications Standards
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.
© ABB PTHVP – 49, 2002-01-18, MT, Level1
Combined modules Cost optimised solution for distribution S/S Shortest erection time Minimum of space
Applications Pitfalls New concept not known by customer Diverge from specification Limited competition Concept backbited by competitors
© ABB PTHVP – 50, 2002-01-18, MT, Level1
Possibilities Extensive Reference List Limited competition Top-down sales using LCC as argument Increased business opportunities for all HV-apparatus
Applications Swedish Power Grid
© ABB PTHVP – 51, 2002-01-18, MT, Level1
Hemsjö 420 kV Sustation
Line
Transf
Line
Cap.
Line
Line
Cap.
Cap.
14 HPL Combined Switching modules 420 kV, 4000 A, 31,5 kA
Applications ESBI Alberta Canada 260 kV Substation 12 HPL Compact Switching Modules
© ABB PTHVP – 52, 2002-01-18, MT, Level1
300 kV, 4000 A, 40 kA Breaker-and-a-half system
Applications Norsk Hydro, Norway
© ABB PTHVP – 53, 2002-01-18, MT, Level1
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
Applications PS-1 Standard for Productified Substations
© ABB PTHVP – 54, 2002-01-18, MT, Level1
145 kV Distribution Substation
LTB Combined Switchgear modules 145 kV, 3150 A, 40 kA
General Theory Technical Design
© ABB PTHVP – 55, 2002-01-18, MT, Level1
Sales Arguments Applications Standards
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
© ABB PTHVP – 56, 2002-01-18, MT, Level1
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
Standards Combined Disconnecting circuit-breaker Complies with IEC requirements Isolating distance requirements - IEC
© ABB PTHVP – 57, 2002-01-18, MT, Level1
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
Standards Additional Type Testing of Combined
© ABB PTHVP – 58, 2002-01-18, MT, Level1
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
Training Course Level 1
Integrated Switchgear Solutions
General Theory Technical Design
ABB PTHVP – 2, 2002-01-18, MT, Level1
Sales Arguments Applications Standards
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
ABB PTHVP – 3, 2002-01-18, MT, Level1
To be familiar with the web based tools for design … and quotation
The basic Compact modular concept Integrate standard & well proven ABB switchgear apparatus to a type-tested and pre-engineered module. LTB & HPL standard breaker
ABB PTHVP – 4, 2002-01-18, MT, Level1
IMB, A & B standard IT PEXLIM standard SA Modular structure and bus bar
Type tested and pre-engineered modular building block
A modular step-by-step Concept 72-300 kV
ABB PTHVP – 5, 2002-01-18, MT, Level1
Identically the same standard and well proven LTB/HPL Circuit Breaker is used in all application
Indoor applications Compact in-door with-drawable breakers
ABB PTHVP – 6, 2002-01-18, MT, Level1
72 – 170 kV
General Theory Technical Design
ABB PTHVP – 7, 2002-01-18, MT, Level1
Sales Arguments Applications Standards
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)
ABB PTHVP – 8, 2002-01-18, MT, Level1
To measure voltage and current (e.g. for relay protection and SCADA) To limit high voltage surges (e.g. from lightning strokes) Transformers
What are the real requirements Maximum availability = Minimized interruptions
Lowest possible maintenace need
ABB PTHVP – 9, 2002-01-18, MT, Level1
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
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.
Comparing old and new technology
Failure and maintenance rate
© ABB PTHVP – 11, 2002-01-18, MT, Level1
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
Substation Availability How to achieve increased availability?
© ABB PTHVP – 12, 2002-01-18, MT, Level1
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
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
© ABB PTHVP – 13, 2002-01-18, MT, Level1
busbar
Mean unavailability (hours/year) busbar bay
2
COMPACT switching module:
6
Mean unavailability (hours/year) busbar bay
~0
0,2 - 2
COMBINED disconn breaker:
disconn circuit breaker
busbar
Mean unavailability (hours/year) busbar bay
2
2
Substation Availability Mean unavailability due to maintenance Apparatus and modules For 145 kV Circuit Breakerd Circuit Breakera
SF6 Oil
Disconnecting Circuit Breaker
© ABB PTHVP – 14, 2002-01-18, MT, Level1
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
Substation Availability Mean unavailability due to failure Apparatus and modules For 145 kV Circuit Breaker d Circuit Breaker a
SF6 Oil
Disconnecting Circuit Breaker
© ABB PTHVP – 15, 2002-01-18, MT, Level1
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
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
© ABB PTHVP – 16, 2002-01-18, MT, Level1
L1
T1
T2
L2
T1
L3
L4
T2
Substation Availability “The disconnector Paradox” The more disconnectors installed, the higher unavailability rate
Traditional Single Bus
Traditional Double Bus with by-
X
X
© ABB PTHVP – 17, 2002-01-18, MT, Level1
Possible Compact
X X
Disconnectors to maintain that can fail
X
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
© ABB PTHVP – 18, 2002-01-18, MT, Level1
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
General Theory Technical Design
© ABB PTHVP – 19, 2002-01-18, MT, Level1
Sales Arguments Applications Standards
© ABB PTHVP – 20, 2002-01-18, MT, Level1
Conventional Circuit Breaker
LTB 170 D 3 pole
HPL 550B2 1 of 3poles
Conventional outdoor design • Busbar • Disconnector 1 • Circuit Breaker • Disconnector 2
Bus bar
• Current Transformer
© ABB PTHVP – 21, 2002-01-18, MT, Level1
• 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!
How can Compact improve substation availability?
© ABB PTHVP – 22, 2002-01-18, MT, Level1
• 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
Compact Switching Module 72 – 300 kV
© ABB PTHVP – 23, 2002-01-18, MT, Level1
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
Compact Switching Module 360 – 550 kV
© ABB PTHVP – 24, 2002-01-18, MT, Level1
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
Compact Switching Module Conventional
Compact Module
• Busbar • Disconnector 1 • Circuit Breaker • Disconnector 2
© ABB PTHVP – 25, 2002-01-18, MT, Level1
• Current Transformer • Voltage Transformer • Earthing Switch • Surge Arrestor
Compact with maintenance free s Corona protection
© ABB PTHVP – 26, 2002-01-18, MT, Level1
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.
Maintenance free s Fixed maintenance free towards bus and line/transformer (Self cleaning)
Moving s with flexible fingers (+/- 20 mm)
© ABB PTHVP – 27, 2002-01-18, MT, Level1
Open
Closed
How can Combined improve substation availability?
© ABB PTHVP – 28, 2002-01-18, MT, Level1
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
Combined Switching Module Combined Disconnecting Circuit Breaker LTB or HPL., 72 – 420 kV Integrated Earthing Switch Safe Interlocking System
© ABB PTHVP – 29, 2002-01-18, MT, Level1
Options Busbar CT type IMB Separate Line Entrance Module
Combined Switching Modules
© ABB PTHVP – 30, 2002-01-18, MT, Level1
Visual Indication, On/Off
Combined Switching Modules Key interlocking of Disconnecting Circuit Breaker and Earthing Switch with manual operating mechanism
© ABB PTHVP – 31, 2002-01-18, MT, Level1
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
Combined Switching Modules
© ABB PTHVP – 32, 2002-01-18, MT, Level1
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
Combined Switching Module
© ABB PTHVP – 33, 2002-01-18, MT, Level1
Visual Indication, Earthing Switch Position
On-Closed/Off-Open and live
Off-Open and earthed
Combined Switching Module Conventional
Combined Module
• Busbar • Disconnector 1 • Circuit Breaker • Disconnector 2
© ABB PTHVP – 34, 2002-01-18, MT, Level1
• Current Transformer • Voltage Transformer • Earthing Switch • Surge Arrestor
© ABB PTHVP – 35, 2002-01-18, MT, Level1
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 – 36, 2002-01-18, MT, Level1
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
The Compact Modular Family
© ABB PTHVP – 37, 2002-01-18, MT, Level1
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).
The Combined Modular Family kV
Type of operation (Single/Three Phase)
© ABB PTHVP – 38, 2002-01-18, MT, Level1
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
General Theory Technical Design
© ABB PTHVP – 39, 2002-01-18, MT, Level1
Sales Arguments Applications Standards
Sales Arguments Life cycle cost Availability Space saving Minimum maintenance
© ABB PTHVP – 40, 2002-01-18, MT, Level1
Fast installation
Sales Arguments Space requirement Conventional 145 kV station
© ABB PTHVP – 41, 2002-01-18, MT, Level1
1000 m2
Integrated Switchgear Modules 120 m2
30 m
40 m
25 m
4m
Sales Arguments
© ABB PTHVP – 42, 2002-01-18, MT, Level1
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
Sales Arguments Cost comparison Installation
Conventional
© ABB PTHVP – 43, 2002-01-18, MT, Level1
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
Sales Arguments
© ABB PTHVP – 44, 2002-01-18, MT, Level1
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
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
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
Sales Arguments
© ABB PTHVP – 46, 2002-01-18, MT, Level1
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
XXX
Compact
Evaluation sheet
Combined
Importance
Evaluation
Conventional
Sales Arguments
Low Value 1-10 High Rate Tot Rate Tot Rate Tot Rate Tot
Distribution
© ABB PTHVP – 47, 2002-01-18, MT, Level1
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
General Theory Technical Design
© ABB PTHVP – 48, 2002-01-18, MT, Level1
Sales Arguments Applications Standards
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.
© ABB PTHVP – 49, 2002-01-18, MT, Level1
Combined modules Cost optimised solution for distribution S/S Shortest erection time Minimum of space
Applications Pitfalls New concept not known by customer Diverge from specification Limited competition Concept backbited by competitors
© ABB PTHVP – 50, 2002-01-18, MT, Level1
Possibilities Extensive Reference List Limited competition Top-down sales using LCC as argument Increased business opportunities for all HV-apparatus
Applications Swedish Power Grid
© ABB PTHVP – 51, 2002-01-18, MT, Level1
Hemsjö 420 kV Sustation
Line
Transf
Line
Cap.
Line
Line
Cap.
Cap.
14 HPL Combined Switching modules 420 kV, 4000 A, 31,5 kA
Applications ESBI Alberta Canada 260 kV Substation 12 HPL Compact Switching Modules
© ABB PTHVP – 52, 2002-01-18, MT, Level1
300 kV, 4000 A, 40 kA Breaker-and-a-half system
Applications Norsk Hydro, Norway
© ABB PTHVP – 53, 2002-01-18, MT, Level1
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
Applications PS-1 Standard for Productified Substations
© ABB PTHVP – 54, 2002-01-18, MT, Level1
145 kV Distribution Substation
LTB Combined Switchgear modules 145 kV, 3150 A, 40 kA
General Theory Technical Design
© ABB PTHVP – 55, 2002-01-18, MT, Level1
Sales Arguments Applications Standards
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
© ABB PTHVP – 56, 2002-01-18, MT, Level1
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
Standards Combined Disconnecting circuit-breaker Complies with IEC requirements Isolating distance requirements - IEC
© ABB PTHVP – 57, 2002-01-18, MT, Level1
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
Standards Additional Type Testing of Combined
© ABB PTHVP – 58, 2002-01-18, MT, Level1
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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