Product brochure Gas-insulated switchgear ELK-3 C, 420 kv High performance in a smaller footprint
ABB and 50 years of GIS innovation ABB is a leader in power and automation technologies that enable utility and industry customers to improve their performance while lowering environmental impact. The ABB Group of companies operates in around 100 countries and employs about 150,000 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 product range is complemented by a comprehensive service offering. ABB is the global leader in high-voltage GIS technology with more than 23,000 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 6900 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 C, 420 kv ABB
Table of contents ABB and 50 years of GIS innovation 2 The ELK-3 C, 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 digital 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 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 digital 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 SF 6 -air bushings 13 ABB s local control cubicle 14 The local control cubicle (LCC) 14 Advanced features for digital 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 Technical data 18 ABB GIS ELK-3 C, 420 kv 3
The ELK-3 C, 420 kv Performance that addresses today s power challenges 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. Applications Benefits High performance ratings in a compact design 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 7715 mm (length) x 2250 mm (width) x 4378 mm (height including voltage transformer), makes it ideal for installations with constrained space and fast installation requirements where a traditional GIS with the 420 kv, 5000 A and 63 ka ratings does not fit. Low space requirements 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. Shortest transportation, installation and commissioning time 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 control 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. Low environmental impact In addition to time and cost efficiencies, the ELK-3 C is also very environmentally friendly. Because of its smaller size, the amount of SF 6 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. Highest product quality 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. Convenient operation and serviceability Together with the integrated local control cubicle front panel, the drive cubicle for all drives for disconnector and earthing switches provides easy access for operation 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. 4 GIS ELK-3 C, 420 kv ABB
Full sets of standardized connection elements allows for all possible configurations and building optimization, including integration into existing buildings, giving you utmost 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 SF 6 insulation. Maximum flexibility ABB believes that innovation is key to ABB s competitive advantage and it has consistently invested in research and development to become a market leader. The 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. Reliable, well proven technology To ensure an interoperable and future-proof substation, the ELK-3 has been designed to incorporate the core values of the IEC 61850 standard. The standard 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. The ELK-3 GIS from ABB is built on 50 years of pioneering research and development and experience delivering over 23,000 switchgear bays in over 100 countries. Our switchgears are crafted using standardized and modular components that enable the construction of common layouts and bus schemes. Advanced features for digital substations Technology The ELK-3 gas-insulated switchgear from ABB ELK-3 switchgear components Circuit-breakers Disconnectors and earthing switches Voltage and current transformers Connecting elements Control & protection ABB GIS ELK-3 C, 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 circuitbreaker with one chamber and an optimized and compact layout that minimizes the volume of SF 6 insulating gas required by 20 percent. The PEHLA-certified circuitbreaker is designed to provide optimal performance and low maintenance. Each circuit-breaker comprises three single-phase breaker poles. Each pole consists of the spring operating mechanism, the interrupter column with one interrupting 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 energy to extinguish the arc is produced by the arc and by the puffer. At low currents, the energy to extinguish the arc is only supplied by the puffer. Double-motion puffer interrupters with one interrupting chamber require far less operating energy than single-motion puffer two-chamber interrupters with comparable performance reducing significantly the weight on the foundation. Arcing contacts on both sides of the breaker are coupled by a gear and move in opposite directions (double-motion), which minimizes mechanical reaction forces and further reduces the necessary energy for operation. Circuit-breaker with operating mechanism 6 GIS ELK-3 C, 420 kv ABB
The circuit-breaker uses a spring operating mechanism per pole for single- and three-pole operation. The mechanism combines the non-wearing properties of a hydraulic system with the robustness of mechanical spring operating mechanisms. We use spring operating mechanism in our entire GIS portfolio from 72.5 kv to 1200 kv, and we have supplied more than 100,000 spring operating mechanisms of this type. The circuit-breaker operating mechanism 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 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. How it works Close operation A magnetically-operated change-over valve initiates the close operation and connects 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 C, 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 potential, for example busbar disconnectors, which isolate a feeder. The ELK-3 contains three variants two busbar disconnectors and a linear disconnector. The linear disconnector can optionally be equipped with a fast-acting earthing switch and enable the optimization of various layout configurations. The drive is mounted in the central drive cabinet at the front of the bay. Hand-crank access, position indicator and mechanical padlocking facility (with electrical 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 C, 420 kv ABB
Earthing switches connect isolated sections of the switchgear to the ground to protect personnel during maintenance and assembly work. The earthing switch 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 opposite 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 padlocking facility (with electrical interlocking) are features conveniently located in the local control cubicle of the drive and are accessible from the operator s corridor. The operating mechanism of the fast-acting earthing switch is located in the equipment itself and controlled via the control cubicle. Maintenance earthing switch Disconnector with fast-acting earthing switch ABB GIS ELK-3 C, 420 kv 9
ABB s voltage and current transformers Highly reliable metering, control, and protection functions Our maintenance-free voltage and current transformers provide highly reliable metering, 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 C, 420 kv ABB
The inductive current transformers are of ring core type. The cores concentrically enclose the primary conductor and are located outside the gas compartment eliminating the need for a gas-tight feed to the secondary terminals. Each current transformer may contain multiple cores for metering and protection. An insulation gap in the basic flange prevents the return current of the enclosure from flowing through the inside of the current transformer cores, thereby correct current readings are guaranteed. Current transformer parameters such as burden, ratio, accuracy class and transient performance are set to meet specific project requirements. Multi-ratio transformers provide different ratios selectable by taps. The current transformer Non-conventional instrument transformers (NCIT) replace traditional voltage and current transformers. The NCIT uses two redundant Rogowski coils to measure 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. Advanced features for digital substations Non-conventional instrument transformer (NCIT) Current transformer ABB GIS ELK-3 C, 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 T-elements, cross-shaped and straight sections. The ELK-3 GIS has a universal expansion joint to absorb heat expansion and vibrations during operation and civil engineering works. During site installation, the expansion element ensures that neighboring bays can be coupled easily and flexibly. Surge arresters Surge arresters are fully-enclosed metal components that limit switching and lightning 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 Expansion joint Surge arrester T-element Cross-shaped 12 GIS ELK-3 C, 420 kv ABB
We offer a complete range of connecting elements for peripherals, such as SF 6 -air bushings, enclosures for cable terminations and direct transformer connections. The terminal connections Our standardized transformer connections link power transformers directly to the switchgear via SF 6 insulated bus ducts. Vibrations, thermal expansion of the transformer and switchgear, as well as movements resulting from the settling of foundations, are compensated by bellows and expansion joints. A removable high-voltage conductor link isolates the transformer for testing. Transformer connections Our manufacturer s accessory supply includes cable connections for fluid-filled, dry-type or plug-in cable terminations. The interface for dry-type or fluid-filled 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 operations. Cable terminations Our lightweight SF 6 -air bushings are available in two variants with classical porcelain 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 SF 6 -air bushings that are maintenance-free with self-cleaning silicon sheds and protection against sandstorms. SF 6 -air bushings Transformer connection Cable connection SF 6 -air bushing ABB GIS ELK-3 C, 420 kv 13
ABB s local control cubicle Reduced commissioning and installation time The local control cubicle (LCC) 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. Advanced features for digital substations 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. Conventional LCC with bay control mimic Modern LCC with Relion control IED and circuit-breaker emergency control 14 GIS ELK-3 C, 420 kv ABB
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 strive to produce only products that comply with or exceed the latest international standards (IEC/ANSI). In addition, our products have been type tested in independent laboratories. Our certified design and manufacturing processes guarantee the highest quality of our products. Our products are type tested according to different standards IEC ANSI/IEEE Our ELK-3 bays are fully assembled and tested in the factory with standardized, automated and reliable procedures. After routine testing, shipping units are packed in accordance with the freight carrier s requirements, the duration of transportation, the dispatch route and site storage requirements. Its compact size allows functional bays to be shipped on flat racks. Our products are certified by third-party organizations GOST LAPEM PEHLA Pre-tested, wired and SF 6 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, 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 operation is assured with periodic visual checks. ABB Service provides competent 24/7 worldwide support in case of failures. ABB GIS ELK-3 C, 420 kv 15
Enhancing eco-efficiency over the life cycle Low environmental impact For ABB, sustainability is about balancing economic success, environmental stewardship 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 opportunities, 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 phases Manufacturing phase Use phase End of life phase The life cycle of the ELK-3 product is composed of three phases: manufacture, use and disposal. The manufacture scenario includes materials used, transport of components and SF 6 -gas leakage rates. The usage scenario includes transport of products to customers as well as SF 6 -gas leakage rates and energy losses assuming a 50-year life time. The disposal phase refers to SF 6 -gas handling 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 environmental best practices and we also conduct regular environmental 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 operating mechanism result in lower auxiliary power supply consumption Type tested for 0.1 percent SF 6 -gas leakage rate per year Minimized SF 6 -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 standards 16 GIS ELK-3 C, 420 kv ABB
Worldwide success Over 1300 bays in more than 100 substations in over 30 countries Austria 2 substations 15 bays Azerbaijan 7 bays Bahrain 12 bays Czech Republic 7 bays Denmark 2 substations 19 bays Finland 2 substations 14 bays Germany 1s 47 bays Hong Kong 24 bays Hungary 4 substations 9 bays India 6 substations 46 bays Iraq 3 substations 30 bays Italy 6 substations 74 bays Kuwait 7 substations 167 bays Libya 8 bays Mexico 6 bays Netherlands 4 substations 10 bays Nigeria 7 bays Norway 5 substations 32 bays Poland 15 bays Portugal 3 bays Qatar 4 substations 77 bays Russia 6 substations 49 bays Saudi Arabia 39 substations 550 bays Singapore 2 substations 32 bays South Africa 3 substations 27 bays Spain 2 substations 12 bays Sweden 7 bays Switzerland 15 substations 91 bays Taiwan 3 substations 32 bays Turkey 8 bays Ukraine 2 substations 15 bays United Arab Emirates 3 substations 33 bays United Kingdom 16 substations 88 bays US 5 substations 18 bays ABB GIS ELK-3 C, 420 kv 17
Technical data ELK-3 C, 420 kv 3650 4378 7715 min. 2250 ELK-3 double busbar bay Circuit-breakers Disconnectors and earthing switches Voltage and current transformers Connecting elements Control & protection Note: Dimensions in mm 18 GIS ELK-3 C, 420 kv ABB
ELK-3 C, 420 kv Product ID 1HC0071250M0080 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 (operating mechanism) spring Rated opening time ms < 19 Rated breaking time ms < 40 Rated closing time ms < 80 Reclosing time ms < 300 Rated operating sequence O - 0.3s - CO - 1min - CO or CO - 15s - CO High-speed auto-reclosing single- and three-phase Mechanical endurance test class M2 Capacitive current switching test 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 Classification of disconnector for mechanical endurance class M2 Mechanical endurance of earthing switch CO 10,000 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 Classification for mechanical endurance class E1 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, as well as cores for protection SF 6 -air bushing Continuous bending load N 2500 Test bending load N 5000 Creepage distance mm/kv 20, 25, 31 ABB GIS ELK-3 C, 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: 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 2014 ABB All rights reserved Copyright ABB. 1HC0086882 E01 / AG14 Several aspects of the product described in this brochure are subject to intellectual property protection. In September 2013, the publicly accessible intellectual property portfolio relating to the ELK-3 C, 420 kv was as follows: Granted intellectual property rights: US-A-5723814, US-A-5753864, US7262362B2, US7122758B2, EP1675142B1, RCD001945700, EP2466604B1 Pending applications: EP2466706A2