PASS M0 - Innovative solutions for distribution substations up to

PASS M0Innovative solutions for distributionsubstations up to 170 kV

The conceptIn the today’s changing market, thesubstation is becoming more and more akey element to meet end users requirementssuccessfully and economically. Many existingsubstations have outlived their operational lifeand a one-to-one replacement of conventional AIScomponents like circuit-breakers anddisconnectors is not economically advisable;completely new substations have to meet toughrequirements in terms of occupied space,environment and availability. Substationsextensions require high flexibility on primaryequipment, to cope with already existing controlsystems, lack of available space, limited downtime.PASS M0 is the ideal primary equipment to meetall the above scenarios and it is the result of adifferent thinking; think for the performance of thesubstation as a complete system.PASS M0 switchgear limits the number ofequipment to what is really necessary to assurethe best functionality of the bay; its modular designassures all the possible substation layouts can berealized.BusBarFig. 1PASS M0 in its standard configuration (Single BusBar):1: Combined disconnector/earthing switch2: Circuit-breaker3: Current transformer.LineThe flexibilityPASS (Plug And Switch System) is based on ABBextensive experience in manufacturing bothairinsulated switchgear (AIS) and gas-insulatedswitchgear (GIS).PASS can also be thought as “Performance AndSave Space”: any substation layout can be metwhile making efficient use of available space.Performance is guaranteed by the wealth ofexperience in research and development,manufacture and operation of switchgear whichconstitute the basis of ABB know-how.The key characteristic of PASS is its compact andmodular design which encompasses severalfunctionsin one module, as for example:● Bushings for connection to one or two BusBarsystems● One circuit-breaker● One or more combined disconnector/earthingswitches● One current transformer2 - PASS M0

Fig. 2The diagram shows PASS M0 inDouble BusBar configuration.1: Combined disconnector/earthingswitch on BusBar 1 and BusBar 2.2: Circuit-breaker.3: Current transformer.LineBusBar 2PASS is equivalent to a high voltage bay.In PASS M0 all live parts, excluding BusBars, areencapsulated in a grounded aluminium tankwhich is filled with pressurised SF6 gas. Each polehas its own enclosure, to increase availability andsafety. The enclosures are of casted and weldedaluminium construction.Using standardised components, the addition of asecondary BusBar system to PASS M0 isstraightforward.As the picture Fig. 3 shows, with such aconfiguration PASS M0 is a complete High Voltagesubstation in incoming/outgoing configuration:● the first bushings are connected to the powertransformer;● the second bushings are connected to theoutgoing line;● the third bushings are connected to theincoming line.Therefore there is no traditional BusBar, i.e. theBusBar is realized within the PASS M0 by meansof the first and second bushings.PASS M0 in this configuration is a reallybreakthrough as system concept (patented) fordistribution substation.Fig. 3 - PASS M0 Double BusBar.PASS M0 - 3

General descriptionCircuit -breakerThe PASS M0 circuit-breaker is a single pressureinterrupter operating on the well-established selfblastprinciple.The energy for interrupting currents is partlysupplied by the arc itself, thereby reducing theenergy requested from the operating mechanismof about 50% compared with a conventionalpuffer-type circuit-breaker.Combined Disconnector/Earthing SwitchPASS M0 is equipped with a three pole operatedcombined disconnector/earthing switch. Theoperating principle (patented) is based upon therotary motion of the contact which can be closedon the BusBar, earthed or left in the neutralposition.The mechanism is composed of minimal numberof mechanical components and it is intrinsicallyreliable, and maintenance free. This modulardesign can be applied to PASS M0 in SingleBusBar configuration, Double BusBarconfiguration and on all the bushings: BusBar orline sides.All the combinations are possible.In both cases, Single BusBar and Double BusBar,the position of the combined disconnector/earthing switch is clearly indicated at all times byan indicator which is mechanically coupled to theshaft. In addition to this, a visual confirmation ispossible by means of a view port in the enclosure.The disconnector/earthing switch may, in anemergency, be operated manually by means of acrank.Current TransformerPASS M0 is equipped with a conventional currenttransformer, to meet customer requirements, e.g.for retrofitting. Several combinations of cores forprotection and measurements with differentburdens are available. Up to 5 cores can be fittedinto the current transformer.BushingsOverhead lines and BusBars are connected to thePASS M0 by air bushings. The main insulation iscompressed SF6-gas. The insulator consists of anepoxy impregnated fibreglass tube with siliconrubber sheds. The flanges are heatshrunk andglued onto the tube making an extremely strongand gastight joint. The silicon rubber sheds arecast onto the tube and chemically bonded to it,thus allowing no moisture or contamination toenter between them. The silicon rubber sheds arehydrophobic and give very good rain and pollutionperformance. The main features are:Fig. 4The operating mechanism is of the spring type. This typeof drive stores energy in a spring which is dischargedduring operations.• high safety (crack and explosion resistant)• low weight• excellent pollution and rain performance• sandstorm resistant• maintenance free.SF6 Gas SystemThe compact design of the PASS M0 module isdue to the excellent insulation qualities of SF6gas. Its dielectric strength in a homogeneous fieldis about 2.5 times greater than that of air at thesame temperature and pressure. The design of thelive components is such that the field distributionis as homogeneous as possible, which allows theintrinsic strength of the insulating gas to be utilizedmost efficiently.❑ SF6 gas pressures of the PASS M0module at 20 °C• Filling pressure ........................ 680 kPa (abs)• First alarm level ........................ 620 kPa (abs)• Nominal insulation pressure(blocking pressure) ................ 600 kPa (abs)Filling pressure is about 15% higher than thenominal insulation pressure. This guaranteessufficient gas density over a long operationalperiod. To ensure minimum gas loss duringoperation all enclosures, connections and valvesare subjected to severe gas-tightness tests in thefactory.❑ Gas density controlEach PASS M0 pole builds a single gas compartment.Since the dielectric strength of the switchgear andthe breaking capacity of the SF6 circuit-breakerdepend on the density of the SF6 gas, a gas densityrelay is installed to control gas density and detectleakage.4 - PASS M0

Fig. 5Combined disconnector/earthing switch for PASS M0 Single BusBar.The contact is closed on the BusBar.Fig. 6The combined disconnector/earthing switch for the Double BusBarconfiguration is achieved using a combination of two disconnector/earthing for the Single BusBar.In the picture the right contact is closed whereas the left one is open.❑ Over-pressure reliefTo protect against excessive over-pressure dueto unlikely internal arc faults a metal rupturediaphragm(rupture disk) is installed. When a predeterminedoverpressure is reached, the rupturedisk will break open and relieve the pressurewhich would otherwise cause the enclosure itselfto rupture. Deflectors in front of the diaphragmsensure the safety of personnel.Support structureThe support structure for the PASS M0 moduleis hot-dip galvanised and painted for protectionagainst corrosion. It is designed in such a wayto offer the maximum support and robustnesswhile keeping civil works at minimum.Integration with secondary systemPASS M0 is equipped with a conventionalprocess coupling: e.g. auxiliary contacts forcircuit-breaker and disconnector/earthing switchpositions and relay outputs for signalling (e.g.SF6 lock out).This conventional interface allows the PASS M0to be connected with any control and protectionsystem, thus enabling retrofitting and upgradingof already existing substations.Once installed in the field, two multipolar cablesfrom the local control cubicle are the only itemsto connect PASS M0 to the control and protectionsystem.Environmental impact and Life Cycle CostPASS M0 is kind to the environment. Global lifecycle cost and impact on the environment wereconsidered during PASS M0 design sincebeginning. Compared to a conventional airinsulated solution which implements the samefunctions, PASS M0 meets the following targets:• SF6 reduced by 80%• maintenance cost reduced by 38%• space reduced by 70%• total life cycle cost less than 60%Compared to a conventional 5 bays H layout airinsulated substation, the global life cycle costfor PASS M0 is estimated to be more than 30%lower (see diagram on page 28).Moreover PASS M0 has been subject to the LCA(Life Cycle Assessment), a study that coversall environmental aspects during the whole lifeof the product.In this regard, EDP (EnvironmentalProduct Declaration) provides a quantitativeand verified description of the environmentalperformance of PASS M0, viewed from a comprehensivelife circle perspective.TransportationNo special arrangements are needed for shippingand transportation. PASS M0 fits into a standardtruck container and does not require anypackaging. Once on site a simple 30° rotation ofthe outer poles is needed for the final layout ofPASS M0.The following pictures show PASS M0 145 kVin Single and Double BusBar configuration intransportation and operation positions.The compactness in both positions is selfevident.PASS M0 - 5

Fig. 7APASS M0 145 kV SBBTransportation Position.Fig. 7BPASS M0 145 kV SBBOperation Position.Fig. 7CPASS M0 145 kV DBBTransportation Position.Fig. 7DPASS M0 145 kV DBBOperation Position.6 - PASS M0

Manufacturing and Quality AssuranceManufacturingPASS M0 is born from the wealth ofexperience in research and development,manufacturing and operation of switchgearswithin ABB Power Technologies in Lodi. Partswhich are not directly manufactured aresupplied by other ABB companies. The choiceof materials, suppliers, sub-assemblies andworking procedures is governed by the internalstandard quality assurance programs, whichmeet the requirements laid down by ISO 9001and 14001.On-site assemblyA PASS M0 module is equivalent or almostequivalent to a complete bay. It allows theinstallation of substations in a short period of time:each bay can be unloaded from the trailer anddirectly installed on the platform foundation(extremely small).The on-site erection of PASS M0 modules issimplified since PASS M0 is assembled in thefactory before the shipment.The installation of a PASS M0 requires about afew hours with a crew of two (not including gashandling).StandardsPASS M0 meets the requirements set out in thefollowing documents:• IEC (all relevant standards - see technicaldata)• ISO 9001 and 14001.The enclosure complies with the followingstandard for pressure vessels:• CENELEC EN 50052.Quality handbooks and inspection plans can beprovided to the customer on request.Quality assurance testingType testsAll type tests specified by the relevant IECstandards have been passed. Tests can berepeated on request at customer’s expense.Copies of certificates and reports can be providedon request.Routine testsBefore leaving the factory all PASS M0 units aresubject to the following routine tests:• AC High voltage test;• dielectric tests on auxiliary control units;• pressure tests of the enclosure according toCENELEC-EN 50052 1986 TC 17C WG MPE.The enclosure is tested at double the designoverpressure for one minute. This test alsomeets the requirements of IEC 60517;• gas tightness;• mechanical functional test of all moving parts;• test of all equipment and accessories;• AC high voltage test with PD measurement.These tests ensure perfect functionality of allcomponents before they leave the factory. Atest report is produced for all tests. If sorequired customers can attend routine testinghaving received invitations well in advance.On-site testingAfter final assembly or commissioning of thesubstation, the following tests are made:• mechanical functional testing of circuitbreaker,and combined disconnector/earthingswitch;• testing of SF6 gas-tightness;• random sampling of moisture content inindividual components;• checking and functional testing of control andauxiliary equipment.After completion of these tests a handover reportis completed.Fig. 8A UNI EN ISO 9001Italian Certification ofCompanies QualitySystemsB UNI EN ISO 14001Certification ofCompaniesEnvironmentalManagement SystemsPASS M0 - 7

PASS M0 technical dataGeneral RatingsRated frequency ..................................................................................................................................... 50/60 HzRated voltage .......................................................................................... 170 kV ............... 72,5/123/145/170 kVRated current ....................................................................................................................................... .2500 A (1)Max. test voltage:a) Phase to ground:Rated short time power frequency withstand voltage, 1 min ......... 325 kV ................ 140/230/275/275 kVRated lightning impulse withstand voltage 1,2/50 µs ...................... 750 kV ................ 325/550/650/650 kVb) Across isolating distance (circuit-breaker, disconnector):Rated short time power frequency withstand voltage, 1 min ......... 375 kV ................ 160/265/315/315 kV.Rated lightning impulse withstand voltage 1,2/50 µs ...................... 860 kV ................ 375/630/750/750 kVRated short time withstand current (3 s) ..................................................................................................... 40 kARated peak withstand current .................................................................................................................... 100 kAAmbient temperatureMin. (2) ............................................................................................... -25 °C ...................................... - 30 °CMax. ..................................................................................................................................................... + 55 °CGas loss per year ......................................................................................................................................... < 1%WeightSingle BusBar ..................................................................................................................................... 1900 kgDouble BusBar ................................................................................................................................... 2150 kgIncoming - outgoing ............................................................................................................................ 2300 kgSF6 pressures (20 °C) (absolute values)Filling pressure ............................................................................... 700 kPa .................................... 680 kPaFirst alarm level .............................................................................. 660 kPa .................................... 620 kPaNominal insulating pressure (blocking pressure) ......................... 640 kPa ................................... .600 kPa(1) Up to 3150 A, on request.(2) Lower temperatures can be reachedby a gas mixture on request.Circuit-breakerSingle interrupter, type LTB-DRated short circuit breaking current ..................................... 40kA / 50 HzRated short circuit breaking current ..................................... 40kA / 60 HzRated short circuit making current (close and latch) ............... 100 kA pK.Line charging switching ............................................................................... 63ACable charging switching .......................................................................... 160ADrive ........................................................ 3 poles spring operated / Single poleType ....................................................................................... BLK 222 / BLK 82Rated operating sequence ............................................. O-0.3 s-CO-1min-COOpening time ......................................................................................... =

Disconnector/Earthing SwitchDrive .............................................................................. 3 poles motor operatedRated supply voltage of auxiliary circuits ............................................ 110VDCSwitching time from line to earth ................................................................ 5.5 sEmergency manual operation possible (hand-crank).Contact position visible through porthole.Current TransformerType ........................................................................................................ ring CTMeasurement class ...........................................................................0.2/0.5/1.0Protection class ............................................................ meets all requirementsIP code (IEC 60144) .................................................................................. IP 54• Current Transformer (example)• Current ratio ................................................................... .300-600/1-1-1 A• Cores ....................................................................................................... 3• Accuracy class ........................................................ 10 VA, cl. 0.2, FS

Substation layouts with PASS M0 innovative solutionPASS M0 IOSFig. 9The cooperation with Enel in Italy originated acompletely new system concept - patented - fordistribution substations. The principle is to usecomponents for double BusBar system for aSingle BusBar substation configuration.PASS M0 for Double BusBar fits very well in thisconcept and it is used as a complete HVsubstation.No traditional BusBar are used, i.e. the BusBar isinside the PASS M0 (see single line diagram fig. 9).Customer requirements in terms of current andvoltage detection and measurements are fulfilledby non conventional sensors on board of PASSM0. Conventional current transformer is alsoavailable.PASS M0 used in this configuration presents a lotof advantages for customer:• reduction of occupied space;• reduced environmental impact (more andmore a critical factor in highly populated andhighly industrialized countries);• reduction of losses due to smaller MVnetworks (HV can be brought closer to theend user and the number of HV substationscan be substantially increased);2Fig. 101. Single line diagram (PASS M0 IOS substation, ENEL).2. PASS M0 Double BusBar Fed-through.10 - PASS M0

Fig. 11APASS M0 IOS 145-170 kVTransportation Position.Fig. 11BPASS M0 IOS 145-170 kVOperation Position.• reduction of short circuit current (benefits forall the equipment);• easy installation;• reduced commissioning time of the wholesubstation;• substation is completely transportable (threepieces: HV switchboard PASS M0, powertransformer, MV feeders);• reduced life cycle cost.Fig. 12Fed-through S/S The total substation area including highvoltage equipment, transformer, medium voltageequipment and control cubicles is ~40m x 18m only.PASS M0 - 11

Some applicationsH scheme single BusBar substationThe drawing below shows a H scheme Single BusBar indoor substation, composed by 2 incomingfeeder bays and 2 trafo bays. It also presents a coupling bay.There is a PASS M0 for each bay (total 4). The switchyard area is 16mx22m.Fig. 13H scheme Single BusBarindoor substation.Single BusBar with coupling bayThe drawing below shows a substation Single BusBar with 6 feeder bays, 2 trafo bays and 2 spare baysfor future expansions. A bus coupler bay is present. There is a PASS M0 for each bay (total 11).The switchyard area is 14mx54m.Notice that PASS M0 can be moved in order to fulfill the BusBar phase distance.Fig. 14Single BusBar withcoupling bay, top view.12 - PASS M0

Fig. 15Transformer and line bays.Fig. 16Coupling bay, section view.PASS M0 - 13

PASS M0 variantFig. 17 B - PASS M0 IOS.Fig. 17 A - PASS M0 SBB with GIS VT’s.Fig. 17 D - PASS M0 DCB.14 - PASS M0Fig. 17 C - PASS M0 DBB.

Fig. 19Fig. 18PASS M0 SBB cable ends.Fig. 20PASS M0 SBB with additional Current Transformer.PASS M0 DCB cable ends and bushing.PASS M0 - 15

PASS M0 115/34.5 - 30 MVAFig. 21Mobile Substation intransport condition.PASS M0 115/34.5 - 30 MVAFig. 22Mobile Substation inoperating condition.16 - PASS M0

PASS M0 132/20 - 25 MVAFig. 23Mobile Substation intransport condition.PASS M0 132/20 - 25 MVAFig. 24Mobile Substation inoperating condition.PASS M0 - 17

PASS M0 Railway Mobile SubstationFig. 25Mobile Substation forItalian railway in transportcondition.Fig. 26Mobile Substation forItalian railway in operatingcondition.18 - PASS M0

LCC - Life Cycle Cost (examples from OSCAR)Fig. 27 A-BCustomer needs:– feed energy to S/S A, B, C– minimum space– maximum availability on S/S B– cost.ABCustomer solution:– conventional Double BusBar system.Fig. 27 C-DCPASS M0 solution:– PASS M0, Single busbar– same functionalities– reduced space occupation– reduced cost.DLife Cycle Cost comparisonINITIAL COST:engineering, civil works,components, secondaryequipment, space acquisition,erection, spare parts, etc.FIXED COST:Operation and maintenance.VARIABLE COST:repairing, power interruption,energy interruption.Fig. 28PASS M0 - 19

Fig. 29Component details.AA1. Position indication circuit-breaker.A2. Gas connection.A3. Density sensor.1B23C12B1. Position indication combined disconnector.C1. Combined disconnector drive.C2. Transmission shaft.DD1. Circuit-breaker operating mechanism.20 - PASS M0