Product brochure

Gas-insulated switchgear ELK-3 compact,

420 kV
High performance in a smaller footprint
ABB and 45 years of GIS innovation

ABB is a leader in power and automation technologies that enable utility and indus-
try customers to improve their performance while lowering environmental impact.
The ABB Group of companies operates in around 100 countries and employs about
145,000 people.

ABB offers a wide range of high-voltage products up to 1200 kV that help enhance
the reliability, efficiency and quality of power in transmission and distribution grids,
power plants and industries while minimizing environmental impact. The wide prod-
uct range is complemented by a comprehensive service offering.

ABB is the global leader in high-voltage GIS technology with more than 20,000 bays
installed around the world. In 2009, ABB commissioned a GIS rated to handle more
than one million volts (1200 kV), with a transmission capability of 6,900 megawatts,
reaching new heights in terms of global voltage levels. We pioneered high-voltage
GIS in the mid-1960s and with the introduction of the compact 420 kV, we continue
to drive technology and innovation. Our product portfolio comprises a full range of
advanced GIS for voltages from 72.5 kV to 1200 kV.

2 GIS ELK-3 compact, 420 kV | ABB

Table of contents

ABB and 45 years of GIS innovation 2

The ELK-3 compact, 420 kV 4

Applications 4
Benefits 4
High performance ratings in a compact design 4
Low space requirements 4
Shortest transportation, installation and commissioning time 4
Low environmental impact 4
Highest product quality 4
Convenient operation and serviceability 4
Maximum flexibility 5
Reliable, well proven technology 5
Advanced features for smart substations 5
Technology 5
The ELK-3 gas-insulated switchgear from ABB 5

ABB’s high-voltage circuit-breaker 6

The circuit-breaker 6
The circuit-breaker operating mechanism 7
How it works 7

ABB’s disconnectors and earthing switches 8

The disconnector 8
The earthing switch 9

ABB’s voltage and current transformers 10

The voltage transformer 10
The current transformer 11
Advanced features for smart substations 11

ABB’s terminals and connecting elements 12

The connecting elements 12
Surge arresters 12
The terminal connections 13
Transformer connections 13
Cable terminations 13
SF6-air bushings 13

ABB’s local control cubicle 14

The local control cubicle (LCC) 14
Advanced features for smart substations 14

ABB’s commitment to total quality control 15

Enhancing eco-efficiency over the life cycle 16

The life cycle phases 16
Manufacturing phase 16
Use phase 16
End of life phase 16

Worldwide success 17

Main technical data 18

ABB | GIS ELK-3 compact, 420 kV 3

The ELK-3 compact, 420 kV
Performance that addresses today’s power challenges
Applications
Benefits
High performance ratings
in a compact design
Low space requirements
Shortest transportation,
installation and commis-
sioning time
Low environmental impact
Highest product quality
Convenient operation and
serviceability
4 GIS ELK-3 compact, 420 kV | ABB
ABB holds a distinguished record of innovations in gas-insulated switchgear (GIS)
technology and our latest ELK-3 series for 420 kV is designed to break several
performance barriers.
In a power system, switchgear is used to control, protect and isolate electrical
equipment thereby enhancing the reliability of electrical supply. With GIS technology,
key components including contacts and conductors are protected with insulating
gas. Compactness, reliability and robustness make this a preferred solution where
space is a constraint such as in mega cities or in harsh environmental conditions.
The compactness of this GIS, which has a dimension of 8100 mm (length) x
2160 mm (width) x 3800 (height including voltage transformer), makes it ideal for
installations with constrained space and fast installation requirements where a tradi-
tional GIS with the 420 kV, 5000 A and 63 kA ratings does not fit.
The new design reduces product volume by up to 33 percent compared to its
predecessor resulting in a considerably smaller footprint and reducing infrastructure
such as land and building costs by 40 percent.
Due to the 420 kV’s compact and advanced design, it can be factory assembled
and fully tested, and shipped as one bay with all secondary cabling and local con-
trol cubicle in a container and on low bed trailers instead of many assembly units
delivering a remarkable 40 percent reduction in installation and commissioning time
compared to competing switchgears.
In addition to time and cost efficiencies, the compact ELK-3 is also very environ-
mentally friendly. Because of its smaller size, the amount of SF6 insulating gas
required is about 40 percent less than competing switchgears.
The reduced amount of sealing, flange connections and support structures makes
efficient use of resources by reducing thermal losses and infrastructure investments.
The use of less packing material and streamlined transportation improves your
carbon footprint.
The latest ELK-3 is fully assembled and tested in a manufacturing facility that
uses an advance flow production system that adheres to ABB internal quality and
manufacturing excellence procedures. All bays are produced and tested in excellent
conditions under the strict supervision of ABB’s engineers and GIS experts.
Together with the integrated local control cubicle front panel, the drive cubicle for
all drives for disconnector and earthing switches provides easy access for opera-
tion of the equipment. The drives carry position indicators, hand crank access and
padlocks at the operator corridor.
Gas density information can be supplied with combined density sensor/monitor and
indicated on the front panel. All instrument transformers are wired to the control
cubicle and have no additional interfaces in-between. A service platform above the
bays gives convenient access to viewports and gas handling equipment.
Full sets of standardized connection elements allows for all possible configurations Maximum flexibility
and building optimization, including integration into existing buildings, giving you ut-
most flexibility in the shortest possible delivery time. We offer standardized solutions
for the switchgear as well as for the control cubicle. With fewer parts to connect
and specific flange protection against environmental elements, you are assured of a
highly reliable SF6 insulation.

ABB believes that innovation is key to ABB’s competitive advantage and it has Reliable, well proven tech-
consistently invested in research and development to become a market leader. The nology
ELK-3 is based on pioneering GIS technology since the 1960s and installation in
over 100 countries. It complies with or exceeds the latest international standards
(IEC/ANSI) and has been type tested in independent laboratories.

To ensure an interoperable and future-proof substation, the ELK-3 has been de- Advanced features for
signed to incorporate the core values of the IEC 61850 standard. The standard smart substations
defines strict rules for realizing interoperability between functions and devices used
for protection, monitoring, control and automation in substations independent of
the manufacturer which means investing in the latest 420 kV GIS is safe and the life
cycle of your equipment is long-term.

Technology
The ELK-3 GIS from ABB is built on 45 years of pioneering research and develop- The ELK-3 gas-insulated
ment and experience delivering over 20,000 switchgears in over 100 countries. Our switchgear from ABB
switchgears are crafted using standardized and modular components that enable
the construction of common layouts and bus schemes.

ELK-3 switchgear components

Circuit-breakers
Disconnector and earthing switches
Voltage and current transformers
Connecting elements
Control & protection

ABB | GIS ELK-3 compact, 420 kV 5

ABB’s high-voltage circuit-breaker
Reliable, well proven technology

The circuit-breaker At the core of our switchgear system is the advanced double-motion puffer™
circuit-breaker with one chamber and an optimized and compact layout that mini-
mizes the volume of SF6 insulating gas required by 20 percent. The PEHLA-certified
circuit-breaker is designed to provide optimal performance and low maintenance.

Each circuit-breaker comprises three single-phase breaker poles. Each pole con-
sists of the spring operating mechanism, the interrupter column with one interrupt-
ing chamber and the enclosure with the basic support structure. During overhauls,
the interrupter unit can be removed easily from the enclosure and replaced by a
new unit.

The circuit-breaker uses the double-motion puffer™ operating principle. At high

currents, the pressure inside the puffer increases rapidly due to rising tempera-
tures. This closes the puffer valve. The energy needed now to extinguish the arc is
produced by the arc itself. At low currents, the puffer valve remains open and the
circuit-breaker acts as a puffer breaker.

Double-motion puffer™ interrupters require far less operating energy than single-
motion puffer interrupters. Arcing contacts on both sides of the breaker are coupled
by a gear and move in opposite directions (double-motion), which minimizes me-
chanical reaction forces and further reduces the necessary drive energy.

Circuit-breaker with operating mechanism

6 GIS ELK-3 compact, 420 kV | ABB

The circuit-breaker uses a spring operating mechanism for single- and three-pole The circuit-breaker operat-
operation. The mechanism combines the non-wearing properties of a hydraulic sys- ing mechanism
tem with the robustness of mechanical spring operating mechanisms. We use the
spring operating mechanism in our entire GIS portfolio from 72.5 kV to 1200 kV, and
we have supplied more than 65,000 spring operating mechanisms of this type.

Our spring operating mechanism is composed of a charging system, an energy

storage with disk spring stack, an independent actuator piston and control valves,
and auxiliary switches and position indicators. A hydraulic energy control system
is integrated within a compact and sealed block that does not require any external
piping. All components are easily accessible for maintenance and repair.

Charging How it works

A pump moves oil from the low-pressure oil reservoir to the high-pressure side of
the energy storage piston and compresses the disk spring stack. A micro switch
stops the pump when the disk spring stack is fully-charged.

Close operation
A magnetically-operated change-over valve initiates the close operation and con-
nects the high-pressure side of the energy storage piston to the actuator piston.
Both sides of the actuator piston are connected to the high-pressure reservoir. Due
to the different areas of both surfaces of the actuator piston, the circuit-breaker
closes and stays in a closed position.

Open operation
The trip coil operates the change-over valve and connects the actuator piston to
the low-pressure reservoir. The circuit-breaker opens and stays in an open position
due to the difference in pressure.

Breaker closed Breaker open End view (open)

ABB | GIS ELK-3 compact, 420 kV 7

ABB’s disconnectors and earthing switches
Convenient operation and serviceability

Our disconnector and earthing switches are easy to operate and equipped with
safety features that contribute significantly to operational safety.

The disconnector Disconnectors provide a safe insulating gap to isolate sections with different poten-
tial, for example busbar disconnectors, which isolate a feeder. The ELK-3 contains
three variants – two busbar disconnectors and a linear disconnector. The linear dis-
connector can optionally be equipped with a fast-acting earthing switch and enable
the optimization of various layout configurations.

The operating mechanism is mounted in the central drive cabinet at the front of the
bay. Hand-crank access, position indicator and mechanical interlocking are features
conveniently located in the drive cabinet and are accessible from the operator’s
corridor.

Disconnector in one phase

of busbar

Busbar disconnector

8 GIS ELK-3 compact, 420 kV | ABB

Earthing switches connect isolated sections of the switchgear to the ground to The earthing switch
protect personnel during maintenance and assembly work.

Feeder terminals are often equipped with fast-acting (or make-proof) earthing
switches. These devices are able to ground induced currents on overhead lines,
discharge larger capacitances such as cables, and provide safety when the op-
posite end of a line is not properly de-energized. The fast-acting earthing switch
includes a spring operated mechanism, which is either charged by a motor or by a
hand crank.

Similar to disconnectors, the operating mechanism of the maintenance earthing

switch is located in the central drive cabinet at the front of the bay. Hand-crank
access, position indicator and mechanical interlocking, are features conveniently
located in the local control cubicle of the drive and are accessible from the opera-
tor’s corridor. The operating mechanism of the fast-acting earthing switch is located
in the equipment itself and controlled via the control cubicle.

Disconnector with fast-acting earthing switch

ABB | GIS ELK-3 compact, 420 kV 9

ABB’s voltage and current transformers
Convenient operation and serviceability

Our maintenance-free voltage and current transformers provide highly reliable me-
tering, control, and protection functions.

The voltage transformer Used for system protection, our powerful transformers offer years of trouble-free
service even for heavy-duty applications.

The single-pole inductive voltage transformers are connected to the switchgear with
a standardized connecting flange and a partition insulator. The primary winding is
coiled on top of the core and the secondary windings. The latter are connected to
the terminals in the external terminal box through a gas-tight multiple bushing.

Voltage transformer

10 GIS ELK-3 compact, 420 kV | ABB

The inductive current transformers are attached to the same housing where the The current transformer
maintenance earthing switch is located. They are located outside the gas compart-
ment eliminating the need for a gas-tight feed to the secondary terminals. Each
current transformer may contain multiple cores for metering and protection within a
single cast resin case. Current transformer parameters such as burden, ratio, accu-
racy class and transient performance are set to meet specific project requirements.
Multi-ratio transformers provide different ratios selectable by taps.

Non-conventional instrument transformers (NCIT) replace traditional voltage and Advanced features for
current transformers. The NCIT uses two redundant Rogowski coils to measure smart substations
the current value. The primary voltage is measured by a capacitive voltage divider
composed of two cylindrical electrodes, the conductor and the enclosure. The
measured values are digitally processed by the “secondary converters” and sent to
the “merging unit”. From there the data is routed through a standardized, optical
connection to the protection, measurement and control devices.

Current transformer

Non-conventional instrument
transformer (NCIT)

ABB | GIS ELK-3 compact, 420 kV 11

ABB’s terminals and connecting elements
Maximum flexibility

The connecting elements We have versatile terminal and connecting elements that enable the switchgear to
be customized to fit your project requirements. We offer connecting elements in
various shapes and sizes including elbow joints, T-elements and straight sections.

The ELK-3 GIS has a universal expansion joint to absorb heat expansion and vibra-
tions during operation and civil engineering works. During site installation, the ex-
pansion element ensures that neighboring bays can be coupled easily and flexibly.

Surge arresters Surge arresters are fully-enclosed metal components that limit switching and light-
ning over voltages. For stable and reliable operations, the ELK-3 GIS is equipped
with gas-insulated metal-oxide surge arresters. Ratings and discharge classes are
tailored to your project specific requirements.

Straight with or without flange L-element

T-element Cross-shaped

12 GIS ELK-3 compact, 420 kV | ABB

We offer a complete range of connecting elements for peripherals, such as SF6-air The terminal connections
bushings, enclosures for cable terminations and direct transformer connections.

Our standardized transformer connections link power transformers directly to the Transformer connections
switchgear via SF6 insulated bus ducts. Vibrations, thermal expansion of the trans-
former and switchgear, as well as movements resulting from the settling of founda-
tions, are compensated by bellows and expansion joints. A removable high-voltage
conductor link isolates the transformer for testing.

Our manufacturer’s accessory supply includes cable connections for fluid-filled, dry- Cable terminations
type or plug-in cable terminations. The interface for dry-type or plug-in terminations
is designed based on IEC 62271-209. A removable link disconnects and isolates
the GIS from the cable during high-voltage test for convenience and ease of opera-
tions.

Our lightweight SF 6-air bushings are available in two variants - with classical por- SF6-air bushings
celain insulators or in the standard version, with composite insulators and silicon
sheds. Creepage distance, length, and shape depend on the project-specific
environmental requirements. We provide SF6-air bushings that are maintenance-free
with self-cleaning silicon sheds and protection against sandstorms.

Transformer connection Cable connection SF 6-air bushing

ABB | GIS ELK-3 compact, 420 kV 13

ABB’s local control cubicle
Reduced commissioning and installation time
The local control cubicle
(LCC)
Advanced features for
smart substations
Conventional LCC with bay control
mimic
Modern LCC with Relion® control
IED and circuit-breaker emergency
control
14 GIS ELK-3 compact, 420 kV | ABB
The local control cubicle (LCC) includes all required functions for the control and
supervision of the GIS bay. The LCC is usually integrated and located on top of
the operating mechanism cabinet. As an integral part of the ELK-3 GIS, the LCC is
wired, factory-tested and shipped together with the bay as one transport unit. This
reduces installation and commissioning time to a minimum and eliminates errors
during site installation. Connections from the LCC’s prepared terminal blocks to
dedicated protection cubicles, control systems, power supply, and inter-bay wiring
are the only installation work done on site.
Our LCC typically contains control devices and feeder protection. Our advanced
Relion® family of protection and control-IEDs and the advanced bay control mimic
with two-handed operation for conventional control ensure the safe and economical
operation of the switchgear.
Our broad range of control and protection systems include IEC 61850 compliant
products that provide you with open, future-proof and flexible system architecture.
Our advanced local control cubicles enables monitoring and remote diagnostic
functions ensuring high availability and fast access to precise information from
anywhere in the system, speeding up responses and reducing outage time. Cyber
security is embedded as an integral part of the product to keep you worry-free.
Investing in our switchgear is safe and increases the life cycle of your equipment.
Depending on your project requirements, we also deliver standalone LCC’s with all
customary control and protection devices.
ABB’s commitment to total quality control
Highest product quality

We are committed to giving you products of the highest quality that is why we Our products are type
strive to produce only products that comply with or exceed the latest international tested according to differ-
standards (IEC/ANSI). In addition, our products have been type tested in indepen- ent standards
dent laboratories. Our certified design and manufacturing processes guarantee the –– IEC
highest quality of our products. –– ANSI/IEEE

Our ELK-3 bays are fully assembled and tested in the factory with standardized, Our products are certified
automated and reliable procedures. After routine testing, shipping units are packed by third-party organizations
in accordance with the freight carrier’s requirements, the duration of transportation, –– GOST
the dispatch route and site storage requirements. Its compact size allows functional –– LAPEM
bays to be shipped on flat racks. –– PEHLA

Pre-tested, wired and SF6 pre-filled bays reduce the installation work significantly.
Bays are coupled using standard tools and gas handling is minimized. Site testing
according to IEC/ANSI standards and ABB quality assurance procedures include
leakage checks on flanges, instrument transformer tests, control and monitoring
functions, resistance measurements and a high-voltage test. Site installation can
be carried out by ABB or by personnel from your own company under the guidance
of a certified ABB supervisor. ABB offers training courses for every aspect of GIS
installation, operation and maintenance.

ABB’s metal-enclosed gas-insulated switchgear requires minimal maintenance in

service. Under normal operational conditions, more than 50 years fault-free opera-
tion is assured with periodic visual checks. ABB Service provides competent 24/7
worldwide support in case of failures.

Section of a 1½-breaker arrangement

ABB | GIS ELK-3 compact, 420 kV 15

Enhancing eco-efficiency over the life cycle
Low environmental impact
The life cycle phases
Manufacturing phase
Use phase
End of life phase
16 GIS ELK-3 compact, 420 kV | ABB
For ABB, sustainability is about balancing economic success, environmental stew-
ardship and social progress to benefit all our stakeholders.
Sustainability considerations cover how we design and manufacture products, what
we offer customers, how we engage suppliers, how we assess risks and opportuni-
ties, and how we behave in the communities where we operate and towards one
another, while striving to ensure the health, safety and security of our employees,
contractors and others affected by our activities. In line with our business practices,
we publish environmental product declarations for each product we manufacture.
The life cycle of the ELK-3 product was separated into three phases: manufacture,
use and disposal. The manufacture scenario includes materials used, transport of
components and SF6-gas leakage rates. The usage scenario includes transport of
products to customers as well as SF 6-gas leakage rates and energy losses assum-
ing a 40-year life time. The disposal phase refers to SF6-gas leakage rates and the
energy for making recycled metals reusable.
– – Continuous improvement in product design resulted in a more compact footprint
that uses less aluminum and other metals
– – Low thermal losses due to innovative designs and material choices
– – Full bay shipment due to compact design reduces the environmental impact of
transportation dramatically
– – ABB’s factory is ISO 14001 certified for environment best practices and we also
conduct regular environment audits at our suppliers’ facilities
– – Online monitoring for preventive maintenance
– – The low operating energies used by ABB’s modern interrupters combined with the
efficient mechanical spring drives result in lower auxiliary power supply consump-
tion
– – Type tested for 0.1 percent SF6-gas leakage rate per year
–– Minimized SF6-gas leakage rates due to well proven sealing system
– – Use of material which is easy to recycle or dispose
– – Improved maintenance processes that avoid the release of gases and oil
– – Improved recycling and disposal through clear declarations adjusted to different
global boundary conditions
Worldwide success
Over 1300 bays in more than 100 substations in over 30 countries

Austria Azerbaijan Bahrain Czech Republic Denmark Finland

2 substations 1 substation 1 substation 1 substation 2 substations 2 substations
15 bays 7 bays 12 bays 7 bays 19 bays 14 bays

Germany Hong Kong Hungary India Iraq Ireland

11 substations 1 substation 4 substations 6 substations 3 substations 1 substation
47 bays 24 bays 9 bays 46 bays 30 bays 1 bay

Italy Kuwait Libya Mexico Netherlands Nigeria

5 substations 7 substations 1 substation 1 substation 4 substations 1 substation
66 bays 167 bays 8 bays 6 bays 10 bays 7 bays

Norway Qatar Russia Saudi Arabia Singapore South Africa

5 substations 4 substations 4 substations 30 substations 2 substations 3 substations
32 bays 77 bays 38 bays 382 bays 32 bays 27 bays

Spain Sweden Switzerland Taiwan Ukraine United Arab Emirates

2 substations 1 substation 13 substations 3 substations 1 substation 3 substations
12 bays 7 bays 78 bays 32 bays 5 bays 33 bays

United Kingdom US
13 substations 4 substations
71 bays 11 bays

ABB | GIS ELK-3 compact, 420 kV 17

 Main technical data
ELK-3 compact, 420 kV

3800
3225

8100
min. 2300
min. 2160

ELK-3 double busbar bay

Circuit-breakers
Disconnector and earthing switches
Voltage and current transformers
Connecting elements
Control & protection
Note: Dimensions in mm

18 GIS ELK-3 compact, 420 kV | ABB

Main data
Rated voltage kV 420
Power-frequency withstand voltage, 1 min. kV 650
Power-frequency withstand voltage, 1 min. across open contacts kV 815
Lightning impulse withstand voltage kV 1425
Lightning impulse withstand voltage across open contacts kV 1425 + 240
Switching impulse withstand voltage kV 1050
Switching impulse withstand voltage across open contacts kV 900 + 345
Rated frequency Hz 50/60
Rated continuous current A 4000/5000
Rated short-time withstand current kA 63
Rated withstand impulse current kA 170

Circuit-breaker
First pole-to-clear factor 1.3/1.5
Rated breaking current, 50/60 Hz kA 63
Rated making current, peak value kA 170
Drive type spring
Rated opening time ms < 19
Rated breaking time cycles <2
Rated closing time ms < 80
Reclosing time ms < 300
Rated operating sequence O - 0.3s - CO - 1min or CO - 15s - CO
High-speed auto-reclosing single- and three-phase
Mechanical endurance class M2
Capacitive switching class C2

Disconnector and earthing switch

Capacitive current switching capability mA 500
Bus transfer current switching capability A/V 1600/20
Opening/closing time s < 2.5
Mechanical endurance class M2

Fast-acting earthing switch

Switching performance making capacity: Current kA 63
Switching performance Inductive currents: Voltage kV 10
Switching performance Inductive currents: Current A 160
Switching performance capacitive currents: Voltage kV 20
Switching performance capacitive currents: Current A 18
Motor running time s <6

Voltage transformer
Rated output (total) VA 300
Rated accuracy class % 0.5
Rated thermal power (total) VA 2000
Rated voltage factor 1.9/8 h
Number of secondary windings 2

Current transformer
Cores for metering
Cores for protection (transient performance optional)

SF6-air bushing
Continuous bending load N 2500
Test bending load N 5000
Creepage distance mm/kV 20, 25, 31

ABB | GIS ELK-3 compact, 420 kV 19

Contact us
ABB Switzerland Ltd
High Voltage Products
Brown Boveri Strasse 5
CH-8050 Zurich / Switzerland
Phone: +41 58 588 31 86
Fax: +41 58 588 17 22
www.abb.com/highvoltage
Note:
© Copyright ABB. 1HC0086882 E01 / AB13
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 Ltd does not accept
any responsibility whatsoever for potential errors or
possible lack of information in this document.
We reserve all rights in this document and in the
subject matter and illustrations contained therein.
Any reproduction, disclosure to third parties or
utilization of its content – in whole or parts – is
forbidden without prior written consent of ABB Ltd.
Copyright© 2013 ABB
All rights reserved
Several aspects of the product described in this
brochure are subject to intellectual property
protection. In August 2012, the publicly accessible
intellectual property portfolio relating to the ELK-3
was as follows:
Granted intellectual property rights:
US-A-5723814, US-A-5753864, US7262362B2,
US7122758B2, EP1675142B1, RCD001945700
Pending applications:
EP2466706A2, EP2466604A1