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Lars Torstveit, ABB ASABB MV switchgearsUnigear ZS1 - air insulatedswitchgear for 12-17,5 and 24kV ABB GroupSeptember 24, 2009 Slide 1
Unigear ZS1 – the basic descriptionThe switchgear solutionintegrated stationautomation COM600Unigear ZS1 switchgearready for remote controlIEC62271-200 design, LSC2B-PM ABB GroupSeptember 24, 2009 Slide 4horizontal communicationvia IEC61850-8-1withdrawable design
Unigear ZS1 – the basic descriptionDesign of a typical functional unitLow voltage compartmentBusbar compartment – tool basedaccess for maintenance;ready for future extensionsLSC2B-PMMetal enclosed, standard classIP3XD* or IP4XInternal metallic partitioning IP2XCircuit breaker compartment –interlock-controlled access(can be combined also withprocedure-based access) ABB GroupSeptember 24, 2009 Slide 5Cable compartment –interlock-controlled access(can be combined also withprocedure-based access)
Unigear ZS1 – the basic descriptionSafety first ABB GroupSeptember 24, 2009 Slide 7 System of safety mechanical interlocks preventinghazardous access to HV compartments and dangerousoperation Additional electrical interlocks available via blocking coils(no-voltage check before the E/S operation, CB movementblocking coil, CB operation blocking coil, .) Key-locking system available on request
Unigear ZS1 – the basic descriptionDesigned and type tested as per IEC standardsType tested as per IEC62271-200: ABB GroupSeptember 24, 2009 Slide 8 Insulation level Temperature rise test Peak and short time withstand currents Making and breaking capacities of theswitching devices Functional test Protection of persons against access tohazardous parts and entry of solidforeign objects Internal Arc Classification EMC test (on typical layout and wiring)
Service continuity . ABB GroupSeptember 24, 2009 Slide 9
Unigear ZS1 – the basic descriptionService continuitySafe only access and flexibility . ABB GroupSeptember 24, 2009 Slide 10 Especially in some industrial and petrochemical applications, the service continuity belongs to the key features The service continuity and conditions for accessibility arekey aspects in top-down approach for switchgear selection
Unigear ZS1 – the basic descriptionThe categories for Loss of service continuityLSC2B - PM Segregated switchgear units(except for the main busbar) The unit can be disconnectedfrom the main busbar (LSC-2A) The unit can be alsodisconnected from its cablecompartment (LSC-2B) ABB GroupSeptember 24, 2009 Slide 11
Internal arc classified . ABB GroupSeptember 24, 2009 Slide 12
Unigear ZS1- safety aspectsInternal arc withstand capabilityAn internal arc can be caused by: Wrong sequence of the switchgear operation Internal failure of a switchgar component Flashover caused by an internal insulation failureUnigear ZS1 panels provides maximal protection with safetyinterlocking system and internal arc withstand capability ABB GroupSeptember 24, 2009 Slide 13
Unigear ZS1- safety aspectsInternal arc classification – IEC62271-200Five criterions for the IAC classification:Internal arc test in laboratoryconditions ABB GroupSeptember 24, 2009 Slide 141.Correctly secured doors and cover donot open2.No fragmentation of the enclosureoccurs within the test time3.Arcing do not cause holes in theaccessible sides, up to height of 2m4.Indicators do not ignite due to effect ofhot gases5.The enclosure remains connected toits earthing point
Unigear ZS1- safety aspectsArc time duration – influence on the damage level ABB GroupSeptember 24, 2009 Slide 15 Internal arc duration has influence onthe level of damage, generally: 500ms – severe damage 100ms – small damage 35ms – subtle damage The switchgear withstand duration shallbe stated by the manufacturer Recommended standard values for thetests are 1s, 0,5s and 0,1s (IEC62271) Unless stated otherwise, Unigear ZS1panels are type tested for 1s
Unigear ZS1- safety aspectsAccessibility class IAC AFLRPressurerelease flaps ABB GroupSeptember 24, 2009 Slide 16Unigear ZS1 is designed and tested for accessibility classIAC AFLR A – authorized personnel only F, L, R – front, lateral and rear sideArc proof installation shall always consider all the aspectsfrom the overall installation point of view (switchgear room)
Unigear ZS1- safety aspectsGas exhaust protection covers ABB GroupSeptember 24, 2009 Slide 17 From safety reasons, most of the installations require useof additional protection covers above the switchgear The application of the covers depends on the ceilingheight, rated arcing current and arc time duration Alongwith the protection covers, detectors for rapid faultclearance times are used with Unigear ZS1
Unigear ZS1- safety aspectsGas exhaust protection covers - channelsGas exhaust channels forfull IAC protection ABB GroupSeptember 24, 2009 Slide 18 First type are Gas exhaust channels with outlets, leadingthe gasses away from the switchgear room The most robust solution, tested up to 50kA/1s Requires to be considered in the civil works (wall openingsand its direction, the outlet channels) Used also when a higher IP class is required (up to IP53)
Unigear ZS1- safety aspectsGas exhaust protection covers – top chimneys ABB GroupSeptember 24, 2009 Slide 19 Second type are protection covers with top chimneys,without need for outlets from the room The solution is tested up to 50kA/0,5s In smaller rooms, pressure calculation is recommended Used also when a higher IP class is required (up to IP43)
Unigear ZS1- safety aspectsDetectors for rapid fault clearance – pressure switchesOption:Application ofoverpressure sensorsinside the panels ABB GroupSeptember 24, 2009 Slide 20Basic level:auxiliary switches on thepressure release flapsArc detection within 100ms plusdirect CB trip (40-60ms)
Unigear ZS1- safety aspectsDetectors for rapid fault clearance – optic sensorsAdvanced level:arc-protection set REA withoptic sensors and relay unitarc detection within 2,5ms plusdirect CB trip (40-60ms) ABB GroupSeptember 24, 2009 Slide 21
Unigear ZS1- safety aspectsInternal arc caused by dangerous operationsMechanical interlocks:CB rack-in/out allowed withopen CB onlyCB rack-in/out allowed onlywith closed front doorsBlocked CB closing in the interpositionRemote control for CB ON/OFF,Remote control for Rack IN/OUT(if motorized truck used)Remote control for E/S ON/OFF(if motorized E/S used) ABB GroupSeptember 24, 2009 Slide 22
Unigear ZS1production portfolio overview ABB GroupSeptember 24, 2009 Slide 23
Unigear ZS1The production portfolio overview ABB GroupSeptember 24, 2009 Slide 24Unigear ZS1 (12-17,5kV and 24kV) Standard single busbar version Double Level Double BusBar – one CB and two line disconnectors Unigear 550 (12-17,5kV) Unigear 500R (12-17,5kV) ZVC slim motor control centre (7,2kV) Is limitor (12-17,5kV and 24kV)
Unigear ZS1MV AIS 12-17,5kV and 24kV ABB GroupSeptember 24, 2009 Slide 25
Back to wall installation Maintenance andservice operationsperformed from the front Front access to all thecompartments(apparatus, busbars,cables) Comfortable front cablesaccess. ABB GroupSeptember 24, 2009 Slide 26
UniGear switchgear fixed on the skid ABB GroupSeptember 24, 2009 Slide 27
Unigear ZS1Technical parametersRated voltageTest voltage (50-60 Hz/1 min)Impulse withstand voltageRated frequencyRated current of the main busbarsRated short-time withstand currentPeak withstand currentRated circuit-breaker thermal current[kV][kV][kV][Hz][A][kA][kA][A]Internal arc withstand current[kA]Up toUp toUp toUp to1228 1)7550-60400050125630125016002000250031504000 2)5017,538 1)9550-60400050125630125016002000250031504000 2)245012550-60250031,5806301250160020002500 2)5031,51.42kV for GOST applications with insulation class B2.With cooling fan3.Note: the panels equipped with contactors or disconnector switches are limited byparameters of these devices ABB GroupSeptember 24, 2009 Slide 28
UniGear ZS1 - Single busbar systemSection viewCircuit breakers unitsW 650mm630-1250A 31,5kAW 800mm1250-2000A 50kAW 1000mm2500-4000A 50kAFused vacuum contactor units up to 12kVW 650mmH400A 50kAAll unitsH 2200mm (2675mm with exaust gas duct)DWD 1340/1390(¹)-1700(2)mmBottom entryD 1650/1700(¹)mmBottom(3) & top entryD 2170mmBottom(³) & top entry(1) 1390mm for 12/17,5kV at 3150-4000A(2) 1700mm for 24kV(3) With additional features ABB GroupSeptember 24, 2009 Slide 29
Unigear ZS1Standard units SBB – Incomer, Outgoing ABB GroupSeptember 24, 2009 Slide 30 Withdrawable circuit breaker Dedicated earthing switch with making capacity Customizable control cabinet, always fit to the application Available also with withdrawable cable VT, optional busbarCT and many other features .
Unigear ZS1Deep units SBB – Incomer, Outgoing ABB GroupSeptember 24, 2009 Slide 33 Applications demanding use of 2 sets of CTs/VTs, forexample with a dedicated CT for differential protection Applications demanding high number of cables per phase Applications demanding connection of the power cablesfrom top side Can be combined with standard units into one switchgar
UniGear Double level system UniGear ZS1 double level UniGear ZS1 double levelduplex. ABB GroupSeptember 24, 2009 Slide 35
UniGear ZS1 double level / double level duplexElectrical characteristicsRated voltageTest voltage (50-60 Hz/1 min)Impulse withstand voltageRated frequencyRated short-time withstand currentPeak withstand currentInternal arc withstand currentRated current of the main busbarsRated current branch connection ABB GroupSeptember 24, 2009 Slide 36[kV][kV][kV][Hz][kA 3s][kA][kA 0,5s][kA 1s][A][A]Up toUp toUp toUp toUp 01600630100012501600
UniGear ZS1 double levelSection viewCircuit-breakers unitsW 750mm630-1000A 31,5kAW 900mm1250-1600A 50kAFused vacuum contactor units up to 12kVW 750mmH400A 50kAAll unitsH 2700mmD 1976mmDW ABB GroupSeptember 24, 2009 Slide 37Bottom & top entry
UniGear ZS1 double levelSection viewGas partmentApparatuscompartment ABB GroupSeptember 24, 2009 Slide 38
UniGear ZS1 double level / double level duplexCompound configuration with single and double level unitsFull single line diagramLRLRLROutgoingfeederswith circuitbreakers ABB GroupSeptember 24, 2009 Slide 39LRLROutgoingfeeders withcontactorsLRLRLRLLRMetering unitOutgoingfeederLRRIncomingfeederBus tieBus riserIncomingfeederLRMetering unitOutgoingfeederLRLROutgoingfeeders withcontactorsLRLROutgoingfeederswith circuitbreakers
Unigear ZS1The main components used in SBB and DBB unitsUnigear ZS1 panels are available complete with the latestABB technologies ABB GroupSeptember 24, 2009 Slide 45 Vacuum and SF6 circuit breakers Vacuum contactors CTs, VTs and sensors Protection relays Earthing switch Surge arresors Cable termination kits
The main components of Unigear ZS1Apparatus – circuit breakers 12-17,5 and 24kV ABB GroupSeptember 24, 2009 Slide 46 VD4 – unique ABB vacuum technology with embeddedsealed-for-life poles, spring actuator for 30.000 operations VM1 – unique ABB vacuum technology with embeddedsealed-for-life poles, magnetic actuator for up to 100.000operations HD4 – SF6 technology, suitable for applications sensitiveto dielectric and dynamic stresses, capacitor banks etc.
The main components of Unigear ZS1Apparatus – vacuum contactors 7,2 and 12kV ABB GroupSeptember 24, 2009 Slide 47 V-contact VSC – fused contactor with permanent-magnetactuator, single or double command version, suitable forhigh number of hourly operation V-contact V (abandoned) – contactor with electro-magneticactuator, single command version (electrical latching) ordouble command version (mechanical latching)
The main components of Unigear ZS1Measurement – Current transformers ABB GroupSeptember 24, 2009 Slide 48 Cast epoxy resin, supporting type TPU 4, 5, 6 – used forcurrents 2500A, with optional capacitive sensor for CPI Cast epoxy resin, ring type KOKS – used for high currentsin panels 4000A Optional use of types KORI and BD – LV ring CTs installedon insulated primary conductor for MV (12-17,5kV) Alternative installation also as busbar CT (TPU type)
The main components of Unigear ZS1Measurement – Core balance Current transformers ABB GroupSeptember 24, 2009 Slide 49 Ring types of KOLMA/KOLA family Reconnectable or split-types available Methods of the CBCT installation: Separately, bellow the switchgear panel Inside the cable compartment (if allowed by distances) Inside in a special bottom-mounted cable box
The main components of Unigear ZS1Measurement – Voltage transformers (cable side) ABB GroupSeptember 24, 2009 Slide 50 Cast epoxy resin type TJC 4, 5, 6 – single pole, fixedwithout fuse (standard) Cast epoxy resin type TJP 4, 5, 6 – single pole with HVfuse, mounted on VT truck Double pole VTs can be mounted in some special cases Auxiliary VT for aux. power supply can be used, if needed(for Self-powered substations without DC systems)
The main components of Unigear ZS1Measurement – Voltage transformers (busbar side) ABB GroupSeptember 24, 2009 Slide 51 Cast epoxy resin type TJC 4, 5, 6 – single pole, fixedwithout fuse in separate top-mounted box Cast epoxy resin type TJP 4, 5, 6 – single pole with HVfuse, VT truck in Apparatus compartment
The main components of Unigear ZS1Measurement – Electronic transformers (sensors) ABB GroupSeptember 24, 2009 Slide 52 Replacement for conventinal inductive CTs and VTs withone current sensor (Rogowski coil) and voltage detector KEVCD – light weight current and voltage combisensorwith optional capacitive sensor for CPI Linear response, designed for use with ABB relays REF Low energy output – reduced cost of ownership!
The main components of Unigear ZS1Measurement – Electronic transformers nto REFAdaptationto REF ABB GroupSeptember 24, 2009 Slide 5343CustomersbenefitEnergy TCO(NPV)PurchaseEnergy TCO(NPV) Conventional inductive Instrument Transformers consumesignificant amount of energy, and thus contribute to powerlosses in substation in significant way Sensor technology dramatically reduces energyconsumption of Switchgear and its total cost of ownership
The main components of Unigear ZS1Protection relays and IEDsREF 542 Suitable for switchgear withsingle busbar, double busbarand duplex systems;feeder, transformer andmotor protection ABB GroupSeptember 24, 2009 Slide 54 REF 542 feeder terminals (IEDs) for protection, control,measurement and supervision, including power quality Interactive mimic diagram PLC functions for automation and sequence logic functions Excellent for use with ABB combisensors KEVCD Variety of communication standards, including IEC 61850;available as Webserver
The main components of Unigear ZS1Protection relays and IEDsREF 541, 543, 545Suitable for switchgear withsingle busbar, double busbarand duplex systemsREM 543, 545Machine protection terminalRET 541, 3, 5Transformer protection ABB GroupSeptember 24, 2009 Slide 55 REF 541/3/5 feeder terminals (IEDs) for protection, control,measurement and supervision Interactive mimic diagram PLC functions for automation and sequence logic functions Excellent for use with ABB combisensors KEVCD Variety of communication standards, including IEC 61850via SPA-ZC 400
The main components of Unigear ZS1Protection relays and IEDsREX 521Suitable for single busbarswitchgear, incoming/outgoing or motor feeder ABB GroupSeptember 24, 2009 Slide 56 REX 521 feeder relay for protection, measurement andsupervision Excellent for use with ABB combisensors KEVCD Variety of communication standards, including IEC 61850via SPA-ZC 400
The main components of Unigear ZS1Protection relays and IEDsCOM 600Station automation device,all-in-one communicationgateway and user interfacefor utility and industrialdistribution substations ABB GroupSeptember 24, 2009 Slide 57 IEC 61850 gateway connectivity between substation IEDsand network-level control and management systems Flexible platform for substation-level automation tasks Web technology, access via a web browser as the humanmachine interface (HMI)
The main components of Unigear ZS1Surge arrestors ABB GroupSeptember 24, 2009 Slide 59 Additional protection against overvoltages in the network The surge arrestors are placed in cable compartment,instead of one position of the cable connections There are used ABB surge arrestors of type MWD inUnigear ZS1 panels
The main components of Unigear ZS1Cable termination kitsRecommended cable terminations kits for Unigear ZS1: ABB GroupSeptember 24, 2009 Slide 60 ABB type SOT 12-36kV indoor for 1-core or 3-core XLPEcables, for standard applications ABB type APIT 12-36kV indoor for 1-core or 3-core XLPEcables, for extremely high demands (polluted areas etc.)
Unigear 550MV AIS 12-17,5kV ABB GroupSeptember 24, 2009 Slide 61
Unigear 550Basic information ABB GroupSeptember 24, 2009 Slide 62 12-17,5kV panels available up to 1250A and STC 31,5kA Simple and compact panels for lower ratings, developedfrom and directly connectable with Unigear ZS1 Perfectly suitable for common distribution applications asMV/LV substations, etc.
Unigear 550Technical parametersRated voltageTest voltage (50-60 Hz/1 min)Impulse withstand voltageRated frequencyRated current of the main busbarsRated short-time withstand currentPeak withstand currentRated circuit-breaker thermal current[kV][kV][kV][Hz][A][kA][kA][A]Internal arc withstand current[kA]1.Up toUp toUp toUp toOnly in combination with Unigear ZS1 panels ABB GroupSeptember 24, 2009 Slide 6312287550-604000 1,51)
Unigear 550Standard units SBB – Incomer, Outgoing, BT, M ABB GroupSeptember 24, 2009 Slide 64 Space-effective solution, 550mm wide panel withwithdrawable circuit breaker Dedicated earthing switch with making capacity Customizable control cabinet Directly connectable with Unigear ZS1
Switchgear units produced by other ABB factoriesUnigear ZVC - slim MCC up to 7,2kV ABB GroupSeptember 24, 2009 Slide 72 Compact 325mm motor control unit with fused vacuumcontactor, produced by ABB Australia Suitable as motor feeders for power plants, industry, . Directly connectable with Unigear ZS1 Up to Ir 400A and STC 50kA Electrical life of the contactor 100,000 operations(closing-opening)
Switchgear units produced by other ABB factoriesIs Limiter panel 12-24kV ABB GroupSeptember 24, 2009 Slide 73 Solution for switchgear applications with high STC ratings– protection by Is Limiter panel produced by ABB Germany Directly connectable with Unigear ZS1 The device consists of main conductor (Ir 4000A) withfast switch and high rupturing capacity fuse in parallel Short-circuit current limited at the first rise, in less than1ms
Unigear ZS1 – interbay and upstream communicationHorizontal interpanel communication - GOOSECommunication bus, IEC618650-8-1 multicastmessaging, data shared across the IEDsLocalHMIStation bus IEC 61850Electrical control system- SCS & GWDCS/NCCMonitoring, control, settingsInterlocking, shared external signalsTime synchronizationExternal signalsFlexibility - programming isindependent of wiringFaster transfer of signals between IEDsthan with the conventional wiring ABB GroupSeptember 24, 2009 Slide 80
Unigear ZS1 – interbay and upstream communicationStep 2: Integrated station automation COM600Ethernet, IEC61850-8-1 ABB GroupSeptember 24, 2009 Slide 82Integrated station automation (industrialcomputer) COM600 station computer as control andmonitoring unit webserver with own IP address communication gateway betweenthe switchgear IEC 61850 and uppersystemsCompact and robust design with IP44,suitable for installation into Unigear ZS1switchgears
Switchgear healthy monitoringsystems ABB GroupSeptember 24, 2009 Slide 85
Unigear ZS1 – switchgear healthy monitoring systemsContinuous overheating supervision – SensycalABB Sensycal unitup to 12 IR sensor unitsMODBUS outputMain busbar systemPower cables terminations ABB GroupSeptember 24, 2009 Slide 86
Unigear ZS1 – switchgear healthy monitoring systemsProvision for periodic thermal inspection via IR cameraPower cables terminationsInspection windows forportable IR camera ABB GroupSeptember 24, 2009 Slide 87
Unigear ZS1 in switchgear rowsBusbar bridges ABB GroupSeptember 24, 2009 Slide 88
Busbar bridges for Unigear ZS1Principles of usage ABB GroupSeptember 24, 2009 Slide 89 Busbar ducts are an alternative solution for cases, whenthe connection can not be achieved by power cables Typical applications Long switchgears as primary stations, bridges help toreduce the switchgear room size Rings inside building complex
Busbar bridges for Unigear ZS1Interconnection with bus coupling or as a direct ABB GroupSeptember 24, 2009 Slide 90In principle, there are 2 basic ways of the interconnection: Direct busbar interconnection, without coupling CB Busbar interconnection with bus CB coupler in (at least)one of the interconnecting panels.In the second case, additional 500mm rear-mounted box isneeded in order to loop the connection back to the top
Busbar bridges for Unigear ZS1Electrical parametersBusbar duct type ABB GroupSeptember 24, 2009 Slide 91ARated voltageRated power frequency withstand voltageRated lighting impulse withstand voltagePanel width 650mmRated current of busbars1)Rated dynamic current1)Rated short-time withstand current 3 sPanel width 800mmRated current of busbars1)Rated dynamic current1)Rated short-time withstand current 3 sPanel width 1000mmkVkVkVRated current of busbars1)Rated dynamic current1)Rated short-time withstand current 3 252)1250/250063251.For the rated dynamic and short time current, the particular busbar ducts are designedin compliance with design rules for Unigear ZS1 panels of the same parameters2.Busbar ducts rated 4000A requires forced ventilation
Busbar bridges for Unigear ZS1Standardized and customized ducts ABB GroupSeptember 24, 2009 Slide 92Classification (internal): Standardized (modular) busbar ducts for applicationsfront-to-front with an aisle width from 1800 to 3000mm Customized, design-to-order for a particular project:Side-by-side, Back-to-back, special arrangements.
Busbar bridges for Unigear ZS1Modular concept for the standardized ductsBasic structure of the standardized modular duct: ABB GroupSeptember 24, 2009 Slide 93 Two corner coupling modules bolted to the swg. frame Two fixed outer modules bolted to the corner modules One central module, put over the fixed outer modules andfixed as per the exact aisle width
Busbar bridges for Unigear ZS1Construction of the standardized ducts ABB GroupSeptember 24, 2009 Slide 94 Frame/Enclosure modules made of AlZn coated steelsheets (Ir 2500A) or as a combnation of AlZn withstainless steel and aluminum sheets (influence of magneticcurrents at Ir 3150A and 4000A) The main busbar system is made of flat copper profiles,with single (Ir 1250 A), double (Ir 2500 A) or triple (Ir 4000 A) profile
Busbar bridges for Unigear ZS1The aisle widthSwitchgear AThe distance is measured fromthe front panel frame edges ABB GroupSeptember 24, 2009 Slide 95Aisle width frame-to frameSwitchgear BEven for the modular bridges, theaisle width is an importantinformation, which shall beconfirmed before the productionrelease
Unigear ZS1 as a switchgearpre-assembled on frame ABB GroupSeptember 24, 2009 Slide 98
Unigear ZS1 as a switchgear on frameSwitchgear panels supplied in pre-assembled blocks ABB GroupSeptember 24, 2009 Slide 99 Pre-assembled „switchgear blocks“ ofUnigear ZS1 panels on a supportingframe Excellent for cases when site servicesand labour cost are very high Reduced installation time, fast trackenergization Two delivery options: Complete switchgear on commonframe, typically up to 10 panels Pre-assembled switchgear blocksper 3-4 panels
ABB GroupSeptember 24, 2009 Slide 100
VD4 - unique ABB vacuum technology with embedded sealed-for-life poles, spring actuator for 30.000 operations VM1 - unique ABB vacuum technology with embedded sealed-for-life poles, magnetic actuator for up to 100.000 operations HD4 - SF6 technology, suitable for applications sensitive
