© ABB Group June 20, 2013 | Slide 1
The ZX-Family ABB Gas-insulated medium voltage primary switchgear
Eldred van Straten, GIS Marketing SSA – Kigali, Rwanda 2013
© ABB Group June 20, 2013 | Slide 2
Career 1991 – 1999 Commissioning Engineer Eskom (National PTM&C) - Johannesburg 1999 – 2007 Technical Manager: Power System Protection Nelson Mandela Bay Municipality – Port Elizabeth 2007 – Present Senior Sales Engineer ABB South Africa – Port Elizabeth - Utilities and Industry (Eastern Cape area) - Wind Business Coordinator (South Africa) - MV GIS Promoter (SSA) since Nov 2012
Background of speaker Eldred van Straten - Career
© ABB Group June 20, 2013 | Slide 3
Location Port Elizabeth, South Africa
Background of speaker Eldred van Straten - Location
© ABB Group June 20, 2013 | Slide 4
Background of speaker Eldred van Straten – Location Port Elizabeth, South Africa
© ABB Group June 20, 2013 | Slide 5
Standards for MV switchgear Internal Arc in Switchgear Primary MV GIS Application and Concepts ZX Family Common characteristics and family members ZX Technology Benefits ZX “Live” ABB Calor Emag – Location, Portfolio, Key data ZX from manufacturing to operation Cost of ownership Conclusion
The ZX-Family Agenda
© ABB Group June 20, 2013 | Slide 6
Standards for MV Switchgear
© ABB Group June 20, 2013 | Slide 7
Primary Distribution Switchgear, History of standards IEC 60694 – Standard for switchgear
IEC 60694 Common Specifications for switchgear
Standard concerned mainly with the electrical capability of switchgear, i.e. Ratings and functionality.
Type testing consisted of:
Short time current withstand
Dielectric withstand
Temperature rise
IP rating
Specification concentrates on electrical
capability
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Primary Distribution Switchgear, History of standards IEC 60298 – Standard for switchgear
IEC 60298 Additional standard for switchgear
Standard in addition to the established IEC60694 standard where safety from internal arc is then considered:
Type testing consisted of:
Internal arc testing for operator safety
Short time current withstand
Dielectric withstand
Temperature rise
IP rating
First edition 1990
Specification includes
internal arc capability “safety”
© ABB Group June 20, 2013 | Slide 9
Primary Distribution Switchgear, History of standards IEC 62271 -200 New standard for switchgear
IEC 62271-200 New Classifications for Switchgear (Replacing IEC 60289)
Broader definition “Metal Enclosed” with specific definitions to cover all types of switchgear
Partitioning – (PM, PI)
Interlocking – (Tool / Interlock based)
Loss of service continuity (LSC)
Internal arc classification IAC according to the new IEC 62271-200 Annex A
First edition of standard 2003
Specification improves on internal arc
capability, and other important safety features
© ABB Group June 20, 2013 | Slide 10
Common numbering of publications
IEC 62271 series
HIGH-VOLTAGE SWITCHGEAR AND CONTROLGEAR Old IEC number, if any
Part New title
1 Common specifications IEC 60694
2 Seismic qualification for rated voltages of 72,5 kV and above -
100 High-voltage alternating current circuit-breakers IEC 60056
101 Synthetic testing IEC 60427
102 High-voltage alternating current disconnectors and earthing switches IEC 60129
103 Switches for rated voltages above 1 kV and less than 52 kV IEC 60265-1
104 Switches for rated voltages of 52 kV and above IEC 60265-2
105 Alternating current switch-fuse combinations IEC 60420
106 Alternating current contactors and contactor-based motor-starters IEC 60470
107 Alternating current switchgear-fuse combinations -
108 Switchgear having combined functions -
109 Series capacitor by-pass switches -
200 AC metal-enclosed switchgear and controlgear for rated voltages above 1 kV and up to and including 52 kV
IEC 60298
Standards IEC 62271 – Series for MV switchgear
All Standards are important for MV Switchgear
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MV Switchgear- IEC 62271-200
Circuit Breakers- IEC 62271-100
Current transformers - IEC 60044-1
Voltage transformers - IEC 60044-2
Earth Switches - IEC 62271 – 102
Cable Live VDS - IEC 61243-5
Cable Compartment
© ABB Group June 20, 2013 | Slide 12
Primary Distribution Switchgear, History of standards Certification of switchgear
Switchgear is considered compliant if tested in accordance with test procedures and parameters of standard. Certified and tested equipment can be
considered as:
Safe to operate
High in quality
Reliable
Functional
Internal Arc in Switchgear
© ABB Group June 20, 2013 | Slide 13
What is an internal arc
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Characteristics of an internal arc is the result of a rapid release of
energy due to an arcing fault between phases, neutral or a ground.
arises when current passes through a dielectric, usually air
dissipates maximum peak power
has a temperature up to five times the surface temperature of the sun
(20,000°C)
has a light intensity more than 2000 times that of normal office light
causes volumetric expansion of approximately 40,000 x
© ABB Group June 20, 2013 | Slide 15
Rodents, Reptiles and insects
Mislaid and forgotten tools
Faulty insulation or operation
Accidents during work
Causes of an internal arc
© ABB Group June 20, 2013 | Slide 16
Effects of an Internal arc
Effects of an internal arc fault Pressure increases in an enclosed compartment Rapid onset (<15 ms) results in explosive forces Thermal effects, and hot gases present The longer the arc is allowed to burn the greater the risks of damages, and injuries to nearby
personnel.
1 10 100 1000
Con
sequ
ence
of
Inte
rnal
arc
faul
t
time in ms
Cable fire Copper fire Steel fire
Conventional protection device - Dramatic consequences expected - Severe injuries and equipment damage (Dependant on switchgear design)
Fast protection devices - Limited consequences expected for people and equipment damage (Dependant on switchgear design)
© ABB Group June 20, 2013 | Slide 17
Phases of an Internal Arc
1 Compression Phase
2 Expansion Phase
3 Emission Phase
4 Thermal Phase
Four phases of the pressure curve for an internal arc fault
0
0.2
0.4
0.6
0.8
1
1.2
1.4
1.6
1.8
2
0 10 20 30 40 50 60 70 80 90 100
time (ms)
Ove
r Pre
sseu
re in
cub
icle
(Bar
)
1 2 3 4
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Phases of an Internal Arc
1 Compression Phase
2 Expansion Phase
3 Emission Phase
4 Thermal Phase
© ABB Group June 20, 2013 | Slide 19
Criteria for switchgear to comply with
IEC 62271- 200 Annexure A 1. Correctly secured doors and covers
do not open
2. No fragmentation of the enclosure occurs within the test time
3. Arcing does not cause holes in the accessible sides, up to a height of 2m
4. Indicators do not ignite due to effect of hot gases
5. The enclosure remains connected to its earthing point
Criteria to pass arc test according to 62271-200
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Internal Arc IEC 62271 -200 Type test.
Type test comprises of: Simulation of an internal fault in a switchgear
compartments Resulting in a destructive arc
Fire and hot gases Fast pressure rise
Simulation of an operator standing next to the switchgear by means of cotton indicators
After the fault current has been switched off:
Assessment of the test: - Visual inspection - High-speed video - Oscillograms
If test was successful, a type test report can be issued
A type test report provides evidence for health and safety of operators!
UniGear ZS1 with arc ducting undergoing an internal arc test
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Internal Arc IAC Classification
Front Lateral
Rear
ZX1.2 Gas Insulated Switchgear
© ABB Group June 20, 2013 | Slide 22
100 ms 700 ms
Feeder CB
Remote Switchboard
I>
Incomer CB
Local Switchboard
ARC I>
I> I>
Fault persists even if CB is operated by Arc protection system
Incomer cable fault has to be cleared by remote CB Therefore switchgear must be able to withstand an arc fault for ≥ 500 ms
400 ms
20 ms
ABB Primary Distribution Switchgear Primary protection from 1 second IAC Rating
© ABB Group June 20, 2013 | Slide 23
Primary MV GIS Application
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Primary MV GIS Switchgear for the primary distribution level application
Industry
Primary distribution
level
Secondary distribution
level
Household
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Primary MV GIS Applications
Power supply utilities Power and transformer stations
Industry Steelworks, rolling mills, etc. Chemical industry Automobile industry Petrochemicals (pipeline systems) Mining Marine Offshore facilities, oil rigs Ships
Transport Airports, harbours, railway
Services Shopping centres, hospitals
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MV Switchgear What do customers need ???
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What do our customers in Rwanda require? Deliver and distribute energy without interruptions Highest availability of equipment Minimise accidents and dangers to human life Highest safety for employees Small footprint Space saving Reduced installation time Easy busbar installation arrangement Reduce total cost of ownership Cost effective solution, low overall lifetime costs
ZX Technology Addressing pain points and needs
© ABB Group June 20, 2013 | Slide 28
k
ZX ZX video clip
ZX Family Key features and family members
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High dielectric strength Insulates 2.5 times better than air Enables compact design with less raw materials (= less CO2)
Environmentally relevant properties Non-reactive and non-toxic No damage to the ozone layer But relevant as greenhouse gas (MV GIS - incl. RMU - adds up
< 0.005% to the greenhouse effect in Germany) ABB approach: ZX closed cycle concept & extremely low
leakage rates (<0.1% p.a.)
Legislation & Limitations MV GIS customers do not have to report SF6 amounts! No limitation of use!
Primary MV GIS Sulphur Hexafloride (SF6)
© ABB Group June 20, 2013 | Slide 30
SF6
SBB - AIS
Space saving GIS = 60 %
DBB - AIS
Space saving GIS = 70 %
Primary MV GIS AIS and GIS footprint of 10 units: 36kV, 1250A, 25kA
DBB - GIS
SBB - GIS
© ABB Group June 20, 2013 | Slide 31
Primary MV GIS AIS and GIS concept
AIS Concept
Medium voltage air insulated
Ambient conditions have influence on insulation behavior (humidity, dirt, vermin, salt air, dampness)
Dimensioning and aging behavior depends on insulation quality
Vacuum interrupting medium
SF6
GIS Concept
HV parts are located inside hermetically sealed gas compartments, air is replaced by insulation gas (SF6)
Ambient conditions have no influence on insulation behavior (insulation capability constant over lifetime, independant of altitude of site, no influence by humidity, dirt, vermin, salt air, dampness )
Reduced dimensions
Maintenance free
Vacuum interrupting medium
© ABB Group June 20, 2013 | Slide 32
ZX Family Key features and family members
ZX2
24 40,5 kV
...40 kA ...4000 A
...31,5 kA ...2500 A
(SBB/DBB)
36 12
ZX0 (SBB)
...25 kA ...1250 A
0
ZX0 ZX1.2
ZX2
ZX0.2
(SBB) ZX1.2
(SBB) ZX0.2
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ZX Family Gas Compartment Segregation ZX0
SF6
Block design
Up to 5 panels in a block
Most economical of the ZX range
Lower availability due to panels sharing a gas compartment
© ABB Group June 20, 2013 | Slide 34
ZX Family Gas Compartment Segregation ZX0.2
SF6
One gas compartment per panel
Solidly insulated busbars
Three position disconnector and circuit breaker in one chamber
© ABB Group June 20, 2013 | Slide 35
ZX Family Gas Compartment Segregation ZX1.2 & 2
SF6
2/3 gas compartments per panel
Busbars in SF6
Can isolate faulty CB chamber and return busbar to service
Highest availability
© ABB Group June 20, 2013 | Slide 36
ZX Family Panel components
1
4
5
6
8
9
13 14 15
16
17
12
14
10
11
2 3
12
7
Double busbar feeder for 2000A
1 HMI of control unit 2 Three-position switch operating mechanism 3 Three-position switch 4 Gas density sensor (temperature compensated) 5 Circuit-breaker operating mechanism 6 Secondary terminals of current transformer 7 Cable socket 8 Cable plug 9 Electronic of control unit 10 Voltage transformer 11 Multifunctional socket 12 Pressure relief disk 13 Current transformer 14 Pressure relief duct 15 Circuit-breaker 16 Measuring sockets for capacitive voltage indication
system 17 Busbars
SF6
© ABB Group June 20, 2013 | Slide 37
Internal Arc Classification according to IEC 62271 – 200: IAC AFL(R)
IAC Internal arc classification
A Switchgear installed in closed rooms with access restricted to authorized personnel only, 300 mm distance between indicators and panel
FL(R) front, lateral, rear
I 25kA, 31.5kA, 40kA
Time 0.1s, 0.5s, 1s
ZX complies with all relevant IEC standards!
ZX Family IEC 62271 – 200, Internal Arc Classification (IAC)
Tested for highest safety!
© ABB Group June 20, 2013 | Slide 38
ZX Family Key features – SF6 evacuation valve and repair opening
Flexibility to open and repair the panels at site!
© ABB Group June 20, 2013 | Slide 39
ZX Family Features – plug-in technology
Surge arresters
Voltage transformers
Test plugs BB extension
Cable plugs
Blind plugs
Secondary equipment
© ABB Group June 20, 2013 | Slide 40
ZX Family Features – plug-in busbar connections
Simple and safe installation: Factory-tested panels
Reproducible electric connection of primary conductors
Short installation time
No gas works at site!
No screw connection of primary conductors!
© ABB Group June 20, 2013 | Slide 41
ZX Family Shared features – concepts of protection and control
Type
RELION® (multifunctional relays)
PCU100/200 (panel control unit)
Semaphore indicators and control switches
Full flexibility!
© ABB Group June 20, 2013 | Slide 42
ZX Technology Benefits
© ABB Group June 20, 2013 | Slide 43
ZX Technology Our solution – Highest safety for employees
All live parts are touch-proof! Probability of internal faults is
minimized! Even in the unlikely case of an
internal fault: Personnel is completely safe due
to pressure relief duct system!
© ABB Group June 20, 2013 | Slide 44
ZX “Live” From manufacturing to operation
© ABB Group June 20, 2013 | Slide 45
ABB Calor Emag Medium Voltage Products Focused Feeder Factory – location Ratingen
© ABB Group June 20, 2013 | Slide 46
ABB Calor Emag Medium Voltage Products Product portfolio
VD4 ZX-Family Vacuum interrupters
Components
Apparatus
Gas-insulated switchgaear
Poles
© ABB Group June 20, 2013 | Slide 47
ABB Calor Emag Medium Voltage Products Key data
Experience in GIS: since 1965 2. generation of MV GIS: first ZV, since
1995: ZX Product types: ZX0, ZX0.2, ZX1.2, ZX2
© ABB Group June 20, 2013 | Slide 48
ZX “Live” Manufacturing of ZX
© ABB Group June 20, 2013 | Slide 49
ZX “Live” Quality control – panel testing primary part
Factory-assembled and tested panels of highest quality!
Functional test Gas tightness test (leakage rate below 0,1% p.a.) High voltage test of the main circuit
Power frequency withstand voltage Partial discharge measurement
© ABB Group June 20, 2013 | Slide 50
ZX “Live” Delivery of ZX panels
Complete switchboards
Factory assembled / factory tested /
factory gas filled Single panels as transport units
SF6 factory-filled to operating
pressure Prepaired for transport via crane or
fork lift
© ABB Group June 20, 2013 | Slide 51
ZX “Live” Easy installation of ZX panels
Simple and quick installation
Installation on floor frames or
intermediate floor system
Simple connection of panels via
plug-in technology
Cable connection via cable plugs
© ABB Group June 20, 2013 | Slide 52
ZX “Live” Easy installation of ZX panels
© ABB Group June 20, 2013 | Slide 53
Primary MV Switchgear AIS and GIS – Costs of ownership
© ABB Group June 20, 2013 | Slide 54
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Determinants: Availability – rate of failure Maintenance – costs and resulting down time of system Space requirements on civil works and transport Lifetime Time for installation and testing at site Interest rate Inflation rate
Primary MV Switchgear AIS and GIS – Costs of ownership
© ABB Group June 20, 2013 | Slide 55
0 40 10 t (a)
P (Rand)
20 30
Initial Investment Costs
GIS AIS
Primary MV Switchgear AIS and GIS – Costs of ownership
0
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Cost simulation!
Primary MV Switchgear AIS and GIS – Costs of ownership
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Assuming Price (GIS) = +20% of Price (AIS) implies: You get an GIS for the costs of an AIS – plus another at least 10 years of FREE operation! The acummulated costs/year of operating a GIS are 20-25% lower than operating an AIS!
Primary MV Switchgear AIS and GIS – Costs of ownership
© ABB Group June 20, 2013 | Slide 58
Conclusion ZX advantages
© ABB Group June 20, 2013 | Slide 59
Conclusion Reference customer specification
© ABB Group June 20, 2013 | Slide 60
Conclusion ZX advantages
Space saving
Simple and safe installation due to plug-in technology
No gas handling at site
Protected against ambient conditions
Minimum maintenance, maintenance-free MV part
Increased availability, less downtime of plant
Increased safety for staff
Reduced lifecycle cost and total cost of ownership