Fundamentals of Modern Electrical Substations Part 1: Mission of Electrical Substations and their Main Components

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1 Fundamentals of Modern Electrical Substations Part 1: Mission of Electrical Substations and their Main Components Course No: E Credit: 2 PDH Boris Shvartsberg, Ph.D., P.E., P.M.P. Continuing Education and Development, Inc. 9 Greyridge Farm Court Stony Point, NY P: (877) F: (877)

2 FUNDAMENTALS OF MODERN ELECTRICAL SUBSTATIONS Part 1: Mission of Electrical Substations and their Main Components Boris Shvartsberg, Ph.D., P.E., P.M.P Boris Shvartsberg

3 Introduction One of the main goals that every electrical utility company has is transportation of electrical energy from the generating station to the customer, while meeting the following main criteria: High reliability of power supply Low energy cost High quality of energy (required voltage level, frequency etc.) Part 1 of this course series is concentrated on demonstrating how modern power systems are arranged to accomplish all these goals; what place electrical substations have in the overall power system structure; and how important they are for reliable and effective operation of power systems. Part 1 also provides an overview of substation major equipment, explaining the mission, and arrangement of each component. To better understand the importance of electrical substations, let s start with a discussion about the structure of the power systems and their main components. Power System Structure The typical power system structure is shown in Fig. 1. Where: 1 = Generator 2 = Generating station s step-up transformer substation 3 = Extra high voltage step-down transformer substation 4 = High voltage step-down transformer substation 5 = Distribution substation 6 = Distribution Transformer 7 = Transmission and Distribution Lines 8 = Customer Fig. 1. Power System Structure and Main Components Boris Shvartsberg 1

4 The elements from 2 to 7 are the components of the utility company Transmission and Distribution (T&D) Systems, with typical power system voltages as follows: Generation: Up to 25 kv Transmission: kv Subtransmission: kv Distribution: 4 13 kv Customer: Up to 600 V Justification for Voltage Transformation As we can see from Fig.1, along the route from the source to the customer, electricity is undergoing numerous transformations, with generating voltage getting stepped-up to transmission level with a follow-up decrease down to distribution and eventually customer levels. Why do we need to do it? As previously mentioned, the utility company wants to keep energy costs down. One of the ways to do it is to reduce power and energy losses, which may be accomplished by raising the voltage level, because power losses P have a functional relationship with voltage level described in the following equation: Where: S = transported apparent power L = distance to the customer V = system voltage level P = F (S 2 xl/v 2 ) (1) As we can see, there is a reverse proportion between power losses and voltage level in the 2 nd degree. For example, if we increase voltage 10 times, power losses will be 100 times smaller. Another benefit from raising the voltage is a reduction of voltage drop, which is related to voltage level V as follows: V = F (SxL/V) (2) Having a smaller voltage drop in the system helps the utility company to meet its other objective to provide the customer with a high quality electrical energy meeting specific voltage level requirements. That s why we increase voltage for transmission of electrical energy, but after it is delivered to the area where customers are located, we gradually lower the voltage to the safe utilization level (208/120 V, for example). Obviously, electrical transformer substations are playing a major role in accomplishing this task. The number of steps in 2012 Boris Shvartsberg 2

5 raising and lowering the voltage is being defined through optimization studies performed by utility company planners. Mission of Substations Electrical Substations have the following mission to accomplish: Step-up and step-down voltage transformation Connection of separate transmission and distribution lines into a system to increase efficiency and reliability of power supply Sectionalizing of power system to increase its reliability and operational flexibility substation called switching substation Let s discuss the meaning of sectionalizing of power system, the reasons for it, and the benefits that it has using as an example power line connecting two substations shown in Fig.2. Fig.2. Sectionalizing of Power Systems. As we can see, this line has circuit breakers on both ends and four taps feeding the customers (later we ll talk about circuit breakers in a greater detail). Before sectionalizing, any fault on the line would lead to circuit breakers on both ends of the line opening (tripping) to isolate the fault. When it happens, all four customers will lose power supply. Let s assume that we install another breaker in the middle of the line (see Fig.2 After sectionalizing ); i.e. split the line in two sections or sectionalize it. If we do it, the same fault on the line will again lead to the opening of two adjacent breakers to isolate the fault: one installed in the beginning and one in the middle of the line. The 2012 Boris Shvartsberg 3

6 difference is that after the fault is isolated, one half of the line still remains in service feeding two out of four customers. So, by sectionalizing the line, we increased reliability of customer power supply. Main Components of Substations To fulfill their mission, substations include the following components: Power Transformers Circuit Breakers Disconnecting Switches Circuit Switchers Instrument Transformers Bus Relays and Instruments Auxiliary A.C. and D.C. Systems Overvoltage and Lightning Protection Systems Grounding System Remote Control and Operation Systems Each of these components has its own tasks to accomplish, which we ll discuss in a greater detail in the next several sections of the course. Power Transformers Power transformers are needed to fulfill the main duty of substations: step-up and stepdown voltage transformation. The following main components of transformers may be listed: Windings Core Tank Bushings Insulating medium (oil, gas) Cooling system (fans, pumps) The different types of transformers may be distinguished based on following: Connections between the windings: Transformers - Windings linked magnetically, isolated electrically Autotransformers - Windings linked magnetically, connected electrically Number of windings: 2012 Boris Shvartsberg 4

7 Two-winding transformers, for example 138/26 kv Three-winding transformers (every winding has a different voltage), for example, 138/26-13kV Transformers with a low voltage split windings (low voltage windings have the same voltage), for example: 138/13-13 kv Number of phases: Single-phase Three-phase Cooling class: OA liquid-immersed, self-cooled OA/FA, OA/FA/FA - liquid-immersed, self-cooled/forced air cooled has one or two sets of fans OA/FA/FOA - liquid-immersed, self-cooled/forced air cooled/forced air forced liquid cooled has fans and oil pumps The cooling options mentioned above are for power transformers using liquid insulation between their windings and transformer tank. Usually, the mineral oil is used for insulation and heat transfer from the windings. The higher the transformer load is, the higher the temperature of insulating oil will be. Because there is a maximum temperature for each type of insulating oil that can t be exceeded without oil losing its insulating abilities, there is a maximum transformer load that may be carried respectively. To increase transformer loading capabilities, the insulating oil should be cooled off to keep its temperature below the limit. This cooling is provided by the application of radiators, forced air cooling systems (fans) and forced liquid cooling systems (oil pumps). Each transformer may have several stages of cooling to allow for a gradual load increase. As an example, let s consider three-phase two-winding transformers shown in Fig. 3 and 4. Fig /4 kv 6.0/9.0 MVA OA/FA Transformer 2012 Boris Shvartsberg 5

8 Fig /13 kv 27/36/45 MVA OA/FA/FA Transformer 13/4 kv transformer (see Fig. 3) has one set of cooling fans, as well as load ratings of 6.0 MVA without fans and 9.0 MVA with fans running. 138/13 kv transformer (see Fig.4) has 2 sets of fans, as well as load ratings of 27 MVA without fans, 36 MVA with one set of fans and 45 MVA with two sets of fans running. Transformer fans are usually operated automatically through control schemes based on the use of oil temperature sensors. Voltage Transformation Equation The following relationship exists between transformer primary (V P ) and secondary (V S ) voltages and primary and secondary winding numbers of turns: Where: V P / V S = N P / N S N P = Primary winding number of turns N S = Secondary winding number of turns Example: 230/13 kv single-phase step-down transformer has a primary winding with 300 turns. How many turns a secondary winding should have? Solution: 230/13 = 300/ N S N S = (300x13)/230 = Boris Shvartsberg 6

9 Circuit Breakers The mission of circuit breakers is an interruption of load and rated short circuit current for circuit protection. They are widely used to sectionalize power systems (see Fig. 2). The main components of circuit breakers are: Interrupter Bushings Insulating medium (oil, gas) Bushing current transformers Operating mechanism Circuit breakers may be designed for either outdoor or indoor installation. Examples of different circuit breakers are shown in Fig. 5 through 7. Fig kv Outdoor 2000 A Circuit Breaker Fig kv Outdoor 2000 A Circuit Breaker 2012 Boris Shvartsberg 7

10 Fig kv Indoor Switchgear Draw-out Type 2000A Circuit Breaker Disconnecting Switches The mission of disconnecting switches is to isolate de-energized circuits. This is mostly required when we need to take either circuit or equipment (breaker, transformer, etc.) out of service for repair or maintenance and need to provide safe visible breaks on both sides of the de-energized element of the power system. What is important here is to remember that disconnecting switches cannot interrupt neither fault nor load current, and that is their major functional difference from the circuit breakers. However, because of these limited functions, disconnecting switches are much cheaper than circuit breakers. The main components of disconnecting switches are: Post insulators Live parts Operating mechanism The following types of disconnecting switches may be listed: Vertical break Double break Center break Side break Group operated (all 3 phases open simultaneously): Manually or motor operated Hook-stick switches (each phase open individually): Manually operated using the insulated stick Examples of some of these switches are shown in Fig. 8 through Boris Shvartsberg 8

11 1 = Base 2 = Post Insulators 3 = Blade 4 = Jaw 5 = Hinge end Fig. 8. Single Pole of Vertical Break Air Switch Fig. 9a Fig. 9b Fig kv 2000 A Double Break Disconnecting Switch in Closed (a) and Open (b) Positions 2012 Boris Shvartsberg 9

12 Fig kv Disconnecting Switch with Insulating Barriers between Phases Circuit Switchers So far, we ve discussed two major substation switching devices: circuit breakers which can interrupt any load and rated fault current, as well as disconnecting switches which practically cannot interrupt any current. Very often, we need a switching device which is functionally located somewhere in between: it can interrupt any load and some fault current, and at the same time, can safely isolate the circuit. This device is called a circuit switcher. Its mission is to interrupt the load and rated short circuit current up to 20 ka. The main components of the circuit switchers are: Interrupter Isolating disconnecting switch Operating mechanism An example of a typical circuit switcher is shown in Fig. 11. This device has the interrupting part of a circuit breaker and the isolating part of a disconnecting switch. Fig kv 1200 A Circuit Switcher Substation Bus Systems 2012 Boris Shvartsberg 10

13 All substation elements (transformers, breakers, disconnecting switches etc.) should be electrically connected in accordance with a planned substation arrangement. This connection is provided by substation bus system. There are the following main types of substation busses: Open air rigid bus Strain bus Gas insulated (GIS) bus Cable bus Let s consider all these types and discuss what they consist of and what their strengths and weaknesses are. 1. Open Air Rigid Bus: Main components: Supporting structures: frames, columns Post insulators Bare copper or aluminum conductor: tubular, busbar, cable Connectors: bolted or welded Advantages: Simplicity More economical Ease of trouble shooting Short repair time Disadvantages: Lower reliability Exposure to weather, animal contact, etc. Need for a large land area Frequent maintenance The examples of a typical open air rigid bus and connector used to assemble it are shown in Fig. 12 and 13, respectively. Fig kv Open Air Bus on Post Insulators 2012 Boris Shvartsberg 11

14 Fig. 13. Bolted Aluminum T-Conector 4 IPS Main to 4 IPS Tap 2. Strain Bus: Main components: Supporting structures: towers, frames Strain insulators with hardware Flexible aluminum or ACSR (aluminum with a steel core) conductors Advantages: Need for a smaller land area Simplicity More economical Ease of trouble shooting Short repair time Disadvantages: Lower reliability Exposure to weather, animal contact, etc. Frequent maintenance The examples of a typical strain bus and insulator assembly are shown in Fig. 14 and 15, respectively. Fig kv Strain Bus on Steel Towers 2012 Boris Shvartsberg 12

15 3. Gas Insulated Bus (GIB): Fig kv Strain Insulator Assembly Main components: Center copper or aluminum conductor Supporting insulators Insulating gas (SF6, air) Metal enclosure Bushings External supporting structures Advantages: Higher reliability Protection from weather, animal contact, etc. Need for a small land area Low maintenance (especially for SF6 bus) Disadvantages: High cost Inability to detect a gas leak (SF6 bus) Difficult troubleshooting Long repair time Example of 230 kv GIB termination is shown in Fig Cable Bus: Main Components: Cable (solid dielectric) Terminators Conduits or trays for installation Supporting structures 2012 Boris Shvartsberg 13

16 Fig kv Gas Insulated Bus Advantages: Higher reliability Protection from weather, animal contact, etc. Need for a small land area Low maintenance Disadvantages: High cost Difficult troubleshooting Long repair time The typical cable bus terminal is shown in Fig. 17. Fig kv Solid Dielectric Cable Bus Terminal 2012 Boris Shvartsberg 14

17 Instrument Transformers To adequately operate power system, it is very important to measure its main electrical parameters (voltage, current, power, etc.) which is done by using voltmeters, ammeters, wattmeters, etc. All these typical instruments are designed for very low currents (usually up to 5 amperes) and voltages (usually up to several hundred volts). At the same time, real currents and voltages in power systems are measured in thousands of amperes and volts, respectively. Obviously, these values should be reduced to make them compatible with nominal values of common instruments, which may be done using instrument transformers whose mission is: accurate primary value (current and voltage) step-down transformation for relaying and metering circuits, as well as isolation between primary and secondary circuits (mostly for safety reasons). The following standard secondary values are used for metering purposes: Currents: 1A or 5A Voltages: 115V or 120V phase-to-phase or phase-to-neutral Depending on the arrangement of instrument transformers, the following types may be noted: Current transformers: - Free standing type (see Fig. 18) - Slip-on bushing type (see Fig. 19) Voltage transformers: - CCVT s (coupling capacitor voltage transformers) (see Fig. 20) - Potential transformers (see Fig. 21) Fig. 18. Free Standing 138 kv 2000/5 A CTs 2012 Boris Shvartsberg 15

18 Fig kv 2000/5 A Bushing CT Fig kv CCVT Fig kv Potential Transformers 2012 Boris Shvartsberg 16

19 Overvoltage Protection Ones of the most common abnormal conditions in any power system are overvoltages which may take the form of surges from switching substation equipment and impulses from lightning strikes. Because these overvoltages may damage expensive elements of the power system (substation power transformers, transmission cables, etc.) an adequate overvoltage protection is installed to avoid it. The main means of overvoltage protection are: Lightning arresters Protective gaps The principle of operation of both arresters and protective gaps is based on diversion of overvoltage surges and impulses into the substation ground grid before they reach the protected equipment. The example of a typical surge arrester protecting a power transformer is shown in Fig. 22, where the surge arrester is the two-section porcelain column with a corona ring on the top. Fig kv Lightning Arrester Equipment Installation Options All substation equipment may be split in two groups: major and control. Let s define what kind of equipment belong to each of these groups and how they may be installed: Major and Control Equipment Defined: Major equipment: Power transformers Switching equipment Instrument Transformers Overvoltage protection equipment 2012 Boris Shvartsberg 17

20 Control equipment: Relay protection systems Metering systems Auxiliary AC/DC Equipment Alarm and remote control systems Major and Control Equipment Installation Options: Major equipment : Free standing Switchgear Unit substations (includes all substation components: transformer, switching equipment, etc. in one compact module) Located in station control building Control equipment: Located in station control building Unit substations Switchgear Examples of different equipment installation options are shown in Fig. 23 through 27. Fig kv Switchgear (Outside) Fig kv Switchgear (Inside) 2012 Boris Shvartsberg 18

21 Fig /13 kv 9.0 MVA Unit Substation Fig /4 kv Substation, Including: 1 = 138 kv Circuit Breaker; 2 = 138 kv Bushing CTs; 3 = 138 kv Rigid Bus, 4 = 138/4 kv Transformer; 5 = 138 kv CCVT; 6 = 138 kv Post Insulator, 7 = 4 kv Switchgear; 8 = 4 kv Rigid Bus; 9 = 138 kv Disconnecting Switch 2012 Boris Shvartsberg 19

22 Conclusion Part 1 of this course series provided an overview of modern electrical substations and their major components; concentrating on substation importance for reliable and effective operation of power systems to enable you to: Understand how power systems are arranged and what the transmission and distribution (T&D) system structure is. Identify the mission of substations and their place in the overall T&D structure. Understand what a substation consists of, and what each piece of a major equipment is for, including the following items: Power Transformers Switching Equipment Substation Bus System Instrument Transformers Means of Overvoltage Protection Know the arrangement of each major equipment component and its installation options Boris Shvartsberg 20

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