Gas Insulated Substations EXK-0

for installations up to 145 kV, 2500 A, 40 kA

PowerIT
IT
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Content

General nnn 4-5

Set-up of a substation nnn 6-7

The system and

its components nnn 8-19

Busbar with combined disconnector

and earthing switch
Circuit breaker with current transformer
Hydromechanical spring operating mechanism
Cross unit with combined disconnector
Space-saving design, low weight, and short delivery time
and earthing switch
characterize the Power IT GIS EXK-0
Make-safe earthing switch
Current and voltage transformer
Cable sealing end
SF6 outdoor bushing
Supplementary modules
Control cubicle

Transport, installation, nnn 20-21

and maintenance

Version examples nnn 22-30

Double busbar
Single busbar
H-circuit
Y-circuit

11⁄2-breaker method
Mesh substation

Technical data 31

■2
General

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Since the presentation of the Over 2,000 stations with more than
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first SF6-insulated 110-kV-switch- 10,000 switch bays demonstrate .
bay in the year 1965, ABB has their value every day in 70 countries. . .
Extensive experience in plant opera-.
been among the pioneers of this
technology .
tion in a wide variety of conditions
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and with many different requirements
forms the valuable basis.of the needs-
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oriented development and production
Nowadays the range of high-voltage
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of our gas-insulated substations,
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applications includes several series

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of modular PowerIT Gas Insulated with their recognized high quality.

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Substations (GIS) for rated voltages

Characteristic advantages
of between 52 kV and 800 kV.
of the PowerIT GIS EXK-0 are
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– Space saving, compact design

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– High availability
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– Low maintenance and repair

requirements
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– Short delivery and commissioning

period
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– Consistent modular technology

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Busbar with combined disconnector

and earthing switch
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Modular system for optimum

substation layout
Set-up of a substation

An ingenious modular system With PowerIT GIS all basic circuits

makes possible a variety used in classic substation construc-
of solutions tion can be realized. Substations with
single or multiple busbars – optionally
with transfer busbar also – can be
PowerIT Gas Insulated Substations
created with standard modules just
(GIS) EXK-0 are created by the com-
as well with disconnectable or switch-
bination of standardized function
able busbars and bus couplings.
modules such as circuit breakers,
disconnectors and earthing switches,
The circuits using the two-breaker
instrument transformers, supplemen-
and one-and-a-half-breaker methods
tary modules, etc. These 3-phase
and mesh substations usual outside
modules are connected together by
Europe can also be produced econo-
means of carefully machined flange
mically.
connections.

The dimensions of these flanges are

the same with all modules, so that
various components can be com-
bined very freely. This facilitates the
design of a substation and its plan-
ning.

The ingenious modular system offers

the planning and project engineer
great flexibility for optimization. He
can thus easily realize his concepts
of the optimum configuration for the
substations. Various criteria such
as basic circuit, routing of lines and
cables, building size, accessibility, and
provisions for extensions and rapid
fault rectification are evaluated indivi-
dually and taken into consideration
accordingly.

■6
 ➍

➑
➏

➌ ➎

➐
➋
➊

Bay with double busbar

and cable connection
➊ Busbar with combined
disconnector and
earthing switch
➋ Circuit breaker
➌ Current transformer
➍ Voltage transforme
➎ Line disconnector
with earthing switch
➏ Make-safe earthing switch
➐ Cable sealing end
➑ Control cubicle

7■
The system and its components

The functions of the individual com-

ponents, and thus also of the
substations, are dependent on the
increasingly strict system require-
ments for electrical networks and
their equipment, e.g. economy, safety,
and quality. Here, an appropriate
solution is: PowerIT GIS – compact
design, flexible application, extremely
reliable primary and secondary tech-
nology.

Uniform, standard modules, which

are type-tested and manufactured in
large numbers, are joined to form
individual systems. Structures with
great functional complexity are crea-
ted by the combination of clearly
defined elements. This concept is
a precondition for effective, compre-
hensive quality assurance.
Disconnector operating mechanism:
direct drive
Disconnector active part
Busbar with combined discon-
nector and earthing switch
The busbar is made by adjoining
busbar components. The length
of these elements corresponds to
the bay width of 800 or 1000 mm.
Gas-tight barrier insulators in every
switch bay avoid time consuming
gas filling and emptying of large gas
compartments. Telescopic transverse
assembly elements facilitate tasks
necessary for on-site assembly and
plant extensions or conversions.
The busbar phase conductors are
fastened bay by bay to gas-tight bar-
rier insulators. These insulators are
each combined with a telescopic
transverse assembly element, which
facilitates the work necessary in event
of station extensions or conversions.
Removable plug-in contacts in the
transverse assembly element connect
the busbar conductors. Alternations
in length caused by temperature
fluctuations are thereby flexibly com-
pensated. Mechanical strains on
the insulators due to differing heating
of the individual conductors and
the enclosures are thus completely
avoided.
A combination of busbar discon-
nector and maintenance earthing
switch is an integral part of each
busbar module. The operating
mechanism comprises, beside the
step-down gear a click-stop device,
which complements the electric
locking of the two switching devices
mechanically. Gears and gear racks
convert the rotary movement of the
insulating shafts to axial movement
of the contacts.

■8
 ➌
Position indicators and auxiliary swit-
➊
ches are positively connected to the ➎
operating mechanism. Furthermore, ➍
as the switching does not take place
until immediately before the contact
➋
end positions are reached, an
accurate overview of the contact
position is therefore always assured.

By means of a crank handle, manual

operation of the combined discon-
nector and earthing switch is also
possible.
Busbar with combined disconnector
and earthing switch

➊ Contact pin
➋ Disconnector contact
➌ Earthing switch contact
➍ Barrier insulator
➎ Transverse assembly
element
 Circuit breaker with
current transformer

The circuit breaker is equipped with

two or three connection flanges. Their
position and form is determined by
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the station layout. As all other mo-
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dules can be connected directly, by
means of appropriate project planning
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very compact and thus inexpensive
stations can be formed. Circuit breaker assembly . ..
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The circuit breaker works as a single- Long-life auxiliary contacts for arc ..
In the compression
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volume, the SF6
pressure breaker according to the
auto-puffer principle with one break
extinction and the absence of contact
erosion at the continuous-current .
off
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gas is compressed during the switch-
movement. The gas suppresses
per pole, and therefore requires very
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contacts make the need for inspec- . the operating currents and small
tion and maintenance rare and in .
little maintenance. The arcing cham-
ber used in this breaker arises from most cases even superfluous. .
. short-circuit currents. Compression
volume and contact geometry are
.
the outdoor circuit breaker, which . optimized with regard to low over-
The puffer piston connected . to the
is tested under the most stringent
. the SF6 voltage, soft extinction behavior.
conditions. It is characterized by the .
contact nozzle generates
consistent separation of the continu- gas flow necessary . for arc extinction In the heat-up volume, the energy
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ous-current contacts and the auxiliary during the switch-off movement. In present in the short-circuit arc is used
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contrast to the usual puffer piston to heat the SF6 gas. The pressure
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contacts for the arc extinction.

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breaker, the auto-puffer breaker is thus created serves to extinguish

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equipped with a two-stage blast short-circuit currents up to the rated

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volume. The partial volumes are breaking current. The compression

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separated from each other by means power to interrupt the short-circuit

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of a freely movable non-return flap. currents is thus not performed by

the breaker operating mechanism.
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The operating mechanism – a spring-

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assisted hydraulic mechanism is

used – can therefore be made es-
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pecially simple and reliable.

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➊ Breaker closed The majority of the switching opera-

➋ Interrupting
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operating current tions are normal-load operations;

➌ Interrupting
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most switching operations are thus

short-circuit current
performed with the lower mechanical
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load from the compression

● Heat-up volume
volume. Reaction forces and wear are
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● Compression volume accordingly low.

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➊ ➋ ➌
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Auto-puffer principle
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Circuit breaker with integrated

current transformer
➊ Arcing chamber
➋ Current transformer
➌ Barrier insulator
➍ Hydraulic operating
mechanism
Hydromechanical spring
operating mechanism

The hydromechanical spring operating The operating mechanism for three-

mechanism of the circuit breaker
forms an ideal connection for the
wear-free power transmission of the
hydraulics system, with the robust-
ness of a mechanical energy accu-
mulator. A Belleville spring assembly
serves as an energy accumulator.
Its excellent qualities include reliability,
long-term stability and independence
of temperature.
pole switch actuation comprises
four functional modules: recharging
module with hydraulic pump and low-
pressure tank, accumulator module
with Belleville spring assembly,
working module with drive piston
and integrated end-position damping
and a monitoring and control module
with open-close control coils. In the
version for single-pole actuation,
there are three working and control
modules respectively.

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Tripping and enabling of the drive . .
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➊ ➌ ➍ ➋ ➏ ..
energy is by means of tried and
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tested hydraulic drive technology

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components. In accordance with
the accepted. safety philosophy,
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the close-open changeover valve
is .equipped with two redundant open

. . .coils.
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. . The operating mechanism has no

. . pipe or screw connections. The num-

ber of sealed points to the outside
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is kept to a minimum. Pressurized

. sliding gaskets are arranged so that

. unavoidable leaks can only reach
.➎
. the low-pressure reservoir and never
reach the outside.
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Hydromechanical spring operating

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mechanism Basic diagram ➊ Low pressure oil

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➋ High pressure oil

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➌ Hydraulic pump
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➍ Drive piston
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➎ Changeover valve
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➏ Storage spring
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The high- and low-pressure reservoirs
are hermetically sealed, excluding the
possibility of long-term change to the
hydraulic fluid caused by oxidization.

Hydromechanical spring operatig mechanism

for three-pole actuation

Hydromechanical spring operatig mechanism

for single-pole actuation

13 ■
Cross unit with combined dis-
connector and earthing switch

The line disconnector is located in

a cross-shaped module. It is com-
posed of the same active elements
as the busbar disconnector. Integral
component of the disconnector
is a motor-driven earthing switch. Make-safe earthing switch assembly

➌
➊

➍ ➎
➋
Combined disconnector and earthing switch

In addition, this disconnector provides

the possibility of connecting a voltage
transformer. Here, the electrical con-
nection is made either before or after
the isolating distance, so that the vol-
tage is either displayed for the station
side or the line side. The connecting
flange for the voltage transformer also
➏
serves as a test flange for the high-
voltage test of the substation or the
cable.

In general this module is combined Line disconnector with

cable sealing end ➊ Contact pin
with a voltage transformer, a make- ➋ Disconnector contact
safe earthing switch, and a cable ➌ Earthing switch contact
sealing end or a pipe outlet line. ➍ Barrier insulator
➎ Transverse assembly element
➏ Plug-in cable connection

■ 14
Make-safe earthing switch
The make-safe earthing switch is
fitted with a spring operating mecha-
nism which makes contact switching
very fast. It is therefore particularly
suitable as a line earthing switch,
as any conceivable effects in the case
of incorrect switching are thus small.
Make-safe earthing switch
➍
➊ ➋
➌
Make-safe earthing switch
➊ Contact pin
➋ Female contact
The closed earthing switch can be ➌ Insulation
isolated from the operational earthed ➍ Earthing connection
enclosure during an inspection. There
is therefore the possibility of creating
an electrical connection from outside
via the housing of the earthing switch
and the movable contact pins, which
are insulated from each other, to the
main circuit. This considerably facili-
tates the adjustment and checking of
the protective relays, cable checking,
and locating cable faults. During
operation, the insulation is short-
circuited.
15 ■
 ➍

Current and voltage transformers

For measurement and protection

purposes inductive, single-phase ➌
current and voltage transformers are

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used. For both transformers the
primary insulation consists of SF6 ➋ .
➊
gas. The transformers are particularly
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operationally safe, as this insulation
material is not subject to any aging. .
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Feeder current transformers are
arranged in the junction flange of the . .
circuit breaker. The available core . .
volume was determined to allow
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installation of up to four cores.
➎ . .
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. Voltage transformer
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The voltage transformer. has a so-
➊ Primary winding
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called SF6 film insulation. Here, the ➋ Secondary winding

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individual layers of the winding are ➌ Transformer core

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➍ Terminal box
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insulated from each other by means

➎ Barrier insulator
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of plastic film and the intermediate

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spaces have been impregnated in a

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special process with SF6 gas. On the

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secondary side of the voltage trans-

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formers, two measurement windings

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and one open delta winding may

The current transformer is designed
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be provided for earth fault detection.

as a low-voltage transformer. The
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available transformation ratios, secon-

dary outputs, accuracy classes, etc.
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of the transformers correspond to the

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usual requirements of modern protec-

tion and measurement technology.
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Busbar-side voltage transformer

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Gas-tight compact cable sealing end

Cable sealing end

By means of the cable sealing end,

cables of any kind can be connected.
For the XLPE-insulated cables mostly
in use today, there is a cable sealing
end with a short installation length
and a completely dry solid insulation.

The main elements of the plug-in

sealing ends are the plug-in sockets
made of epoxy resin and the cable
connectors with the pre-manufactu-
red stress-cones made of silicone
rubber. An advantage is the con-
sistent separation of the substation
and cable system installations.

For other types of cable, a sealing

end is selected of which the main
component is the longer cable insu-
lator for liquid-filled sealing ends.
SF6 outdoor bushing
The outdoor bushing allows the tran-
sition from the enclosed substation to
overhead lines or the bare connection
of transformers.
Plastic compound bushings are pre-
ferably used. They are characterized
by a fiber-reinforced support pipe
made of epoxy resin with vulcanized
shields made of silicone rubber.
These bushings are fracture- and
explosion-proof, easy to handle and
have excellent pollution layer charac-
teristics on account of the hydro-
phobic insulation material. Upon
customer request, traditional capa-
citor bushings can also be provided
with porcelain insulation.
Direct transformer connection and
transverse assembly element
■ 18
Supplementary modules
With regard to station layout various
connection modules may be required
for combination of the equipment.
These are primarily:
Pipe connections
Overhead line connection
Angle pieces
T-pieces
The components are equipped with SF6 gas system
a support or barrier insulator. Plug-in
and tulip contacts serve for connec- In accordance with the dual function
ting the conducting paths. of the SF6 gas as arc extinction and
insulating medium we differentiate
Occasionally, station sections are
between the extinguishing gas com-
combined with a transverse assembly
partments, and the insulating gas
element in order to facilitate subse-
compartments of the busbars,
quent station modifications, exten-
disconnectors, instrument transfor-
sions or repairs.
mers, etc. The gas compartments are
segregated by gas barrier insulators
and the gas pressure is monitored by
temperature compensated pressure
relays (density related relays).
All gas compartments have their own
automatic vacuum coupling, so that
all maintenance jobs, like drawing
a gas sample or topping-up the
SF6 gas can be carried out without
difficulty.
Control cubicle

The auxiliary electrical units required

for command input, warning, locking,
etc. are accommodated in their own
individual control cubicles.

The units are connected to the con- Control cubicle

trol cubicles by means of control
cables with coded multiple connec-
tors. These connections are already
manufactured and tested in the fac-
tory. The electrical connections
between control cubicle and control
room are routed on terminal strips.
Located behind the glass door is the
mimic diagram with the position indi-
cators, associated control switches
and visual alarm indicators. By means
of key-switches, the units’ locks are
released or switched to local or re-
mote control.

19 ■
Transportation,
assembly, and maintenance

Factory-assembled and -tested

substations

Thanks to the low weight of the

EXK-0 components, transportation
and assembly of a substation is easy.
Preferably, EXK-0 substations are
supplied in completely assembled
and tested bays with the relevant
control cubicles.

Here, the following advantages may

be applicable:

– The assembly period at the instal-

lation site is very short and the
work for substation commissioning
is uncomplicated.

– The insulating property has been

proven in the factory by means
of unit tests of the complete bays.
As here a partial-discharge
measurement was also carried
out, impairment of the insulating
property due to material or manu-
Air-freight shortens the delivery time
facturing faults can be safely ruled
out.

– On account of the small bay
dimensions and weights, EXK-0
substations can also be delivered
by air freight without problem.
Complicated packaging and
preservation are not required,
so commercial use of the station
can start earlier.
After the station has been set up, the
gas compartments are filled with SF6
gas. For this purpose, special service
trolleys are available. As all gas com-
partments are provided with valve
couplings which can be opened
without gas or pressure loss, these
operations are very simple to per-
form. Gas losses and emissions are
therefore almost completely elimina-
ted. After the switchgear has been
checked for perfect mechanical
operations, the results of the commis-
sioning tests are recorded.

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. Operating mechanism and secundary technology
are well accessible

Maintenance

The operational safety of fully encap- Circuit-breakers and disconnectors

sulated SF6 insulated substations
is subject to no external influence
resulting from dirt, moisture or similar.
PowerIT Gas Insulated Substations
EXK-0 therefore require extremely low
maintenance.
In the case of inspections, the inside
of the switchgear is not interfered
with, so the substation can remain
in operation. The condition of the
gas and hydraulic oil is checked and
the actuators, auxiliary contact units,
density monitors are subjected to a
function test.
should be inspected only after 5,000
mechanical operating cycles. In addi-
tion, repair of the circuit-breaker is
scheduled after approx. 10-20 short-
circuit cut-outs at the earliest, depen-
ding on the switched-off short-circuit
current.
Experience shows that these limit
values are far in excess of the re-
quirements of practical operation.
With respect to network planning,
the usual precautionary measures
and redundancies can therefore be
considerably reduced.

21 ■
Version examples

Gas insulated EXK-0 substations are
always the right choices when the low
space requirements are an important
decision criterion: for supplying power
to cities and conurbations, industrial
complexes and when aggressive
environmental conditions necessitate
a sheltered location.
All the usual station circuits can be
optimally implemented on account of
the modular component system. At
the same time, it is possible to take
into consideration the various require-
ments regarding building dimensions,
subsequent station extensions, secu-
rity of supply, comprehensive station
overview, access to equipment,
protection concept etc. on the basis
of a solution tailored to the individual
case in accordance with its value.
The following examples prove the
flexibility of the system and are in-
tended to provide stimulus for the
conception and planning of new
substations.
The bay width is basically 1 m,
or 0.8 m with the most compact
design. The required building depth
is generally 6 m, the ceiling height
less than 5 m. No crane is neces-
sary for assembling the factory-
assembled and -tested switch bays
and maintenance of the equipment;
however, installation of a crane is
recommended to facilitate the work
and to save time.

1000

500

Substation with double busbar

and cable connections
3580

6000

E01 E02 E03 E04 E05 E06 E07

Reserve Reserve
8265

13300

Feeder E02, E06

E02 E03 E04 E05 E06

3600
2825

1000
8265
3580 500

■ 22
 Substation with double busbar and
cable connections

Double busbar

This circuit is the most common cir-

cuit version for important key-point
substations, power plant supply etc.

If both busbars are operated with The possible coupling versions

equal priority – instead of the opera-
ting method with main and reserve
busbars – the principle of busbar se-
paration can be applied to reduce the
short-circuit current. The two busbars
and their feeders belong to separate
sub-networks. If required, individual
feeders can be allocated to the other
sub-network. This concept relieves
the networks and their equipment
as a result of low short-circuit loading,
longer maintenance intervals and
offers greater supply security.
are particularly varied: The simple
bus coupling or the combined bus
sectionalization and coupling with
six or eight disconnectors are two
examples. Double disconnectors even
allow subsequent high-voltage tests
after station extensions or mainte-
nance measures during partially
normal operation.

E02 E03 E04 E05 E06

23 ■
Single busbar

Smaller stations or single- or double-

feed stations are frequently designed
with single busbars. Here, in the in-
terest of adaptable system manage-
ment, bus section couplings and bus
3-bay substation with single busbar
couplings are provided. This means,
for example, that part of the station
can remain in operation during station
extension work.
Feeder E01

The layout of a station with simple

busbar is similar to that of double
busbar stations, as only the lower
or upper busbar is eliminated. If the

5660
appropriate connection flanges are
already provided on the circuit-brea-
kers on the initial version, it is easy
subsequently to upgrade to a double
500

3580
busbar.

Feeder E02 3600

2825

E01 E02 E03 E04 E05

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8000

1500
500

3576

6000
E01 E02 E03 E04 E05

10300

E01 E02 E03 E04 E05

25 ■
H-circuit

The H-circuit is often used to supply

industrial companies or smaller
regions. Two feed lines and two step-
down transformers are optimal with
regard to supply reliability and net-
work reserves. The station can be
E01 E04
operated as a double-feed station,
E03
with closed cross connection also
as a ring substation. Frequently, ring-
stations with H-arrangement are E02 E05
carried out without circuit breakers
in the line feeders.

If a subsequent station extension is

under consideration, the single bus-
bar with section coupling is selected
as basic layout. There is even subse-
Q1 Q1 Q9 Q1
quently the possibility of converting Q51 Q51 T1 T2 Q53 Q51
this to a station with double busbar
and bus coupling. If subsequent
possibilities for extension are not
required, the especially compact
E01 E03 E04
version without busbar is selected.

E01 E04

E03
E01 E02
(E04) (E05)
5585

4736

E02 E05

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 4500 500
1000

3580

E01 E02 E03 E04 E05 6000

1000 4500

E01 E02 E03 E04 E05

7000

E01 E02 E03 E04 E05

2350

27 ■
 Y-circuit

In subtransmission networks the

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open-loop or closed-loop operations
prevail upon star operation owing
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to the better supply reliability. From Ring station .
terminal stations – usually with double
or multiple busbars – the energy, fed . ..
in from the superposed transport . .
networks or from directly connected 500
. .
power plants, will be distributed via
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..
line or cable rings to some or several

3580
step-down stations close to the
.
customers. .
.

6000
.
Often the step-down stations have .
only one single transformer. Such
.
1080 3375
.

configuration with two line feeders

.

and one transformer bay is also called

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ring station. These stations usually

.

7000
have no circuit breaker in the trans-
.
.

former bay. The transformer pro-

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tection then is done by the circuit

..

E0 E02 E03
breakers in the line feeders. If the
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interruption of the line ring in the

event of a transformer failure is not
..

2375

accepted, a third circuit breaker

..

must be provided.
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3400
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E01 E02 E03

..
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3600
..

2355
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3580
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11⁄2 -breaker method

14000 Feeder E04, E07, (E01)
9400
1000
The 11⁄2-breaker method is a traditio-
nal circuit with which the non-availa-
bility of the circuit-breaker during
3600

maintenance is taken into particular

2355
5000
8000

500
consideration. It is used primarily with
maintenance-intensive breakers, and
where the secondary medium-voltage E01 E02 E03 E04 E05 E05 E07 E08 E09
8000
network does not take even a brief
additional load, or a primary transmis-
sion network is not provided.

Such networks or stations are usually

operated in such a way that all
switches are closed. Each feeder
is then fed from two sides, so that
even a faulty busbar can be switched
off without reducing the supply. E01 E02 E03 E04 E05 E05 E07 E08 E09

29 ■
Mesh substation

Similarly to the 11⁄2 breaker method,

the ring bus allows uninterrupted
operation of all cable and line feeders
even in the event of switchgear main-
tenance work. With this circuit, the
number of breakers and the cable Feeder E03, E05
and line feeders is equal, so the
station is in general more inexpensive
than a corresponding version with
11⁄2 breakers per bay.
. ..
3600
. .
Preferentially small substations with
2355
.
for instance four bays are built-up
with this layout. Switching of one fee-
..
der implies at least short-time inter-

500
rupting the ring-busbar. This is inap- 7000
propriate for big substations, because
in the case of a short-circuit failure
the unplanned opening of the ring
busbar causes considerable load-flow
variations or supply interruptions.

12000
8320
500

1000
3750

7000

„X“

E01 E02 E03 E04 E05 E06 E07

E01 E02 E03 E04 E05 E06 E07

■ 30
 Technical data
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Rated values*

Operating voltage kV 72.5 123 (126) 145

Operating frequency Hz 50/60

Lightning impulse withstand voltage kV 325 550 650

to ground
Lightning impulse withstand voltage kV 375 630 750
over isolating distance

Power frequency withstand voltage kV 140 230 275

to ground
Power frequency withstand voltage kV 160 265 315
over isolating distance

Operating current A 800-2500

Peak withstand current kA 82/104
Short time withstand current 31.5/40

Breaking current kA 31.5/40

Making current kA 82/104

Min. insulating gas pressure at 20 °C kPa 520

Min. quenching gas pressure at 20 °C kPa 600

*Higher data on request

31 ■
 Note:
We reserve the right to make technical changes
or modify the contents of this document without
prior notice. With regard to purchase orders, the
agreed particulars shall prevail. ABB does not
accept any responsibility whatsoever for poten-
tial errors or possible lack of information in this

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document.

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We reserve all rights in this document and in the

.
subject matter and illustrations contained therein.
Any reproduction – in whole or in parts – is for-
.
bidden without ABB’s prior written consent.
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Copyright© 2003 ABB
All rights reserved . ..
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10.03· 2000 ·
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Publication Nr. 1HDX580053 · Printed in Germany

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ABB Calor Emag Hochspannung GmbH

. . . .

Brown-Boveri-Strasse 30 Information on power technology products

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