21, rue d’Artois, F-75008 PARIS http : //www.cigre.org B3-206 CIGRE 2012 ENHANCEMENT OF SUBSTATION RELIABILITY BY RETROFITTING EXISTING BUS CONFIGURATION APPLYING HYBRID SWITCHGEAR S. CHAREONSRIKASEM* K. ANANTAVANICH S. PRUNGKHWUNMUANG Electricity Generating Authority of Thailand (EGAT) T. SUWANASRI King Mongkut’s University of Technology North Bangkok (KMUTNB) Thailand SUMMARY The electric power demand in Thailand has continuously increased. Hence it is essential for the electric power utility to improve its transmission system reliability to support this load growth. One of the most effective ways to improve the transmission system reliability is the enhancement of bus scheme e.g. from the main and transfer bus scheme to the double bus double breaker scheme or the breaker and a half scheme, which usually needs more space. Therefore, the area extension for the substation is normally required. On the other hand, the cost of real property increases steadily and sometimes the physical constraints or environmental impacts may also play a significant role. These factors lead to strict constraints in terms of space extension especially in case of urban conventional substations. For this reason, the so-called hybrid switchgear, a mixed technology switchgear making use of Gas-Insulated Switchgear (GIS) modules with an Air-Insulated Switchgear (AIS) or a GIS busbar i.e. outdoor GIS, has drawn more and more attention in this application due to its advantages particularly with respect to space requirement and interface to the existing conventional switchgear. In this contribution, a pilot project using hybrid switchgear to reconfigure the bus scheme of a 115 kV conventional substation is introduced. For EGAT’s 115 kV conventional substations, the typical bus scheme is the main and transfer bus scheme which has a relatively low reliability. In order to find out the suitable bus scheme for this project from the reliability and economical points of view, the substation reliability and life cycle cost calculations with different common bus schemes are carried out. It has been shown that in this case the double bus double breaker scheme is the best one in terms of reliability and economy. However, the enhancement of the bus scheme using AIS means an area extension which is impossible in this case. On the other hand, the application of GIS would lead to an exceedingly high investment costs. As a result, the hybrid switch is applied to overcome the area constraint while the investment costs are not unacceptably high. In order to build up the double bus double breaker scheme from the existing main and transfer bus one, the conventional disconnecting switch close to the transfer bus needs to be replaced by a hybrid *somchai.char@egat.co.th switchgear module consisting of a circuit breaker, two disconnecting switches in combination with earthing switches each with an integrated disconnector, and a current transformer. The integrated disconnector enables the routine insulation tests of the circuit breaker without de-energizing the nearby line or busbar. The replacement work utilises the N-1 criterion of the substation for power transmission so that the substation bay can be de-energized one by one without affecting the availability of power supply. The modular and compact designs of hybrid switchgear reduce the installation process and thus the installation time. KEYWORDS Hybrid Switchgear, Substation reliability, Bus Scheme, Enhancement, Retrofit. 1. INTRODUCTION The fast increases in population, living standards and industrial consumption lead to the rapid growth of the electricity demand in Thailand. In addition to the sufficient and firm generation of electricity, the security of electricity supply must also be improved to meet this increasing need. Hence, it is an essential duty of the electric power utility to accordingly enhance its transmission system reliability. One of the most effective means is the improvement of substation bus arrangement resulting in an increase in the substation and thus overall reliability. However, this upgrade usually needs more space and therefore the area extension for the substation is required. On the other hand, the cost of real property increases steadily and sometimes the physical constraints as well as environmental impacts play a significant role. All of these factors lead to difficulty in terms of space extension particularly in case of conventional substations which require a lot of area. For this reason, the so-called hybrid switchgear (Fig. 1), a mixed technology switchgear making use of Gas-Insulated Switchgear (GIS) modules with an Air-Insulated Switchgear (AIS) or a GIS busbar i.e. outdoor GIS, has increasingly found its applications especially in substation extension due to its advantages with respect to space requirement and interface to the existing conventional substation. Fig. 1: Hybrid switchgear combining both AIS and GIS technologies and taking the advantage of the two different technologies [1] In this contribution, a pilot project of EGAT applying hybrid switchgear to retrofit bus arrangement of an existing 115 kV conventional substation in order to improve its reliability is introduced. For EGAT’s 115 kV conventional substations, the typical bus arrangement is the main and transfer bus which has relatively low reliability but sufficient for the area where the power consumption is not high. In order to increase the substation reliability resulting from the growing power demand, the bus scheme must be reconfigured. For this purpose, substation reliability and Life Cycle Cost (LCC) calculations with different common bus schemes are performed to find out the most suitable bus scheme for the substation under consideration. Three different substation technologies, AIS, GIS and 1 hybrid switchgear, are compared to each other to see their suitability for this project. Afterwards, the reconfiguration of the bus arrangement applying hybrid switchgear is treated. A special requirement is introduced here to increase the substation reliability during some scheduled routine tests of the circuit breaker. Finally, the replacement work for this project is presented. Since it is more or less an extension work, the existing parts or components have to be considered in the construction. Certain approaches e.g. for de-installing the existing components, transporting the hybrid switchgear to the desired positions, connecting them to the rest of substation within a short time and affecting the availability of power supply as low as possible are necessary. 2. EXISTING SUBSTATION Nakhon Chaisri (NCS) substation is one of the most important substations in Thailand. It is located in Nakhon Pathom province, central part of Thailand, and has to supply the electric power to industrial customers. The NCS substation is composed of a 230 kV and a 115 kV substation located in the same fence. The 230 and 115 kV substations are connected together via three 300 MVA auto transformers. The 230 kV substation is the indoor GIS type installed in a clean building. The bus configuration of the GIS is the double bus single breaker scheme. The 230 kV substation consists of three 300 MVA transformer bays connected to the 115 kV substation, a bus coupling bay and two transmission line bays where the power supply to the 115 kV substation is received from here. From experience, the 230 kV substation has shown only a few minor problems, which may be attributed to the advantage of GIS technology. In contrast to the 230 kV substation, the 115 kV substation is the outdoor AIS (conventional) type exposed to fluctuating weather and environmental conditions. The failure of the equipment is often caused not only by the weather and moisture in air, but also by other uncontrollable factors such as bird droppings, bee colonies, herd of birds, and etc. The scheme of the 115 kV substation is the main and transfer bus scheme which has comparatively low reliability. The 115 kV substation comprises three 300 MVA transformer bays connected to the 230 kV substation, three bays for step down transformers to supply 22 kV customers, a tie bay, two bays for other 115 kV transmission lines and two bays to supply 115 kV customers. In order to increase the reliability of the 115 kV substation to support the rapid load growth in the future, the enhancement of the bus configuration is required. 3. SUBSTATION RELIABILITY CALCULATIONS With the aid of substation reliability calculations with different bus schemes, it is possible to find the best bus scheme suitable for the considered substation from the reliability point of view. In this work, the failure rate λ and unavailability U of the substation are chosen as the criteria for the substation reliability consideration. They result from the failure rate and unavailability of the major substation components in series and parallel while only active and overlapping failure events of those components are considered here. Since the probability that the overlapping failure event of three or more components occurs is negligibly small, the overlapping failure events higher than the second order are not taken into consideration. In general, the approximate equations for components in series and two components in parallel can be expressed as follows [2]: Components in series Two components in parallel n λs = ∑ λi [failures/year] (1) [hours/year] (2) [hours] (3) λ p ≈ λ1λ2 (r1 + r2 ) [failures/year] (4) i =1 n U s ≈ ∑ λi ri U p ≈ λ p rp = λ1λ2 r1r2 [hours/year] (5) i =1 rs ≈ Us λs rp = r1r2 r1 + r2 [hours] (6) 2 where r the repair time in hours and subscripts s and p denote the values for components in series and two components in parallel, respectively. The repair times resulting from equations (3) and (6) are the mean values for each case. In order to simplify the calculation, the repair and down times are assumed to be the same. The failure rates and down times for a single outage of the major equipment of EGAT’s 115 kV conventional substations are shown in Table 1. As an important active component which has to energize and de-energize the circuit quite often, the circuit breaker has the highest failure rate among all the components. The passive components especially current and voltage transformers have much lower failure rates compared to that of the circuit breaker. Although the disconnecting switch is an active component, it has a negligibly low failure rate. This may be described by the fact that the disconnecting switch is normally closed and opened without load (only with small capacitive currents). Moreover for EGAT’s 115 kV conventional substations, manual operation (by hand) of the disconnecting switch is usually specified which may result in a reduction of the failure rate caused by the operating mechanism unit. Table 1: Failure rates and down times of the major equipment of EGAT’s 115 kV conventional substations Failure rate λ [failures/year⋅⋅unit] Items Busbar Circuit breaker Current transformer Disconnecting switch Voltage transformer Power transformer (230 kV/115 kV) 0.0094 0.0153 0.0002 negligibly low 0.0003 Repair Down time [h] 0.5 12 8 4 8 0.0067 48 Maintenance Scheduled maintenance Down time [h] Interval [yr] 72 10 72 12 72 12 360 6 When calculating the failure rate and unavailability of the substation, the failure rate and unavailability of each outage event caused by a single component (obtained from Table 1) or two components at the same time (obtained from Table 1 together with equations (4) to (6)) is summed up corresponding to equations (1) to (3) [3]. If the failure of the component(s) does not lead to a power outage on the customer (line) side, it is not included in the calculation. The outage caused by the scheduled maintenance is not taken into consideration here because the scheduled maintenance is normally well planned and thus the unintentional outage is unlikely. Furthermore, if the failed component can be isolated by the corresponding disconnecting switches nearby it without a complete outage on the customer side, the repair or down time of 0.5 hour is used instead of the value in Table 1. This is the time that the substation operator requires to open the disconnecting switches manually. The calculated overall values of the failure rate and unavailability of EGAT’s 115 kV conventional substations with different common bus configurations are shown in Table 2. Table 2: Calculated values of the failure rate and unavailability of EGAT’s 115 kV conventional substations with different common bus schemes Bus schemes Main and transfer bus Breaker and a half Double bus double breaker Total failure rate λt [failures/year] 0.115 0.077 0.031 Total unavailability Ut [hours/year] 0.197 0.385 0.157 It can be seen that the existing main and transfer bus scheme of the 115 kV NCS substation has the highest failure rate among the three common bus schemes. If it is changed to the breaker and a half scheme, the failure rate is reduced about 33% but the unavailability increases 95%. The double bus 3 double breaker scheme yields both the lowest failure rate and unavailability and thus is the best one in terms of reliability. 4. LIFE CYCLE COST CALCULATIONS AND SUBSTATION TECHNOLOGIES Life Cycle Cost or LCC is an economical calculation method to determine the total cost of a technical system during its lifetime so that the system with different schemes or technologies can be economically compared to achieve a worth investment. For electrical substations, in addition to the investment costs, the outage costs usually contribute a large portion to the total cost. Therefore, it is possible for the grid owner to gain the low cost of electrical energy with high reliability. By employing the LCC calculation together with the failure rate and unavailability of the substation, the best bus scheme for the specified area in the network from the economical and reliability points of view can be found. On the other hand when choosing between AIS, GIS and hybrid switchgear technologies, their investment costs and the physical and environmental constraints on the substation location generally play a crucial role. Nevertheless, other factors like construction and installation times may occasionally be the decisive factors. In order to find out the most suitable bus scheme from the economical point of view for upgrading the 115 kV NCS substation, the LCC calculations for the 115 kV conventional substations with different common bus schemes are carried out. The LCC of the substation is composed of the Investment Costs (IC), Operating Costs (OC1), Maintenance Costs (MC), Outage Costs (OC2) and Rest value (R) as shown in the following equation [3]: LCC = IC + OC 1 + MC + OC 2 + R (7) In this case, the Investment Costs (IC) are divided into the equipment costs, construction and installation costs and real estate prices. Since the amounts of some basic common equipment like power transformer, control and communication units, etc. are usually independent on the bus scheme, their costs are not included in the equipment costs. For comparison purpose, it is sufficient to include only the costs of the equipment of which the quantities are varied depending on the bus scheme. Those equipment are the power circuit breaker, the disconnecting switch, the voltage and current transformers and the protection system. In order to obtain the equipment costs for each common bus scheme, the costs of mentioned equipment are summed up according to their different quantities in the minimal cut sets applied in the calculations of failure rate and unavailability of the substation. The construction and installation costs are related to the equipment costs. On the other hand, different bus schemes require different amounts of area for the switchyard leading to differences in real estate prices. The conventional substations with the breaker and a half and double bus double breaker schemes basically need larger areas than those with the main and transfer bus scheme. The OC1 are the expenses related to the operation of equipment e.g. salaries of personnel, cost of electricity, etc. The MC are the expenses required for fixing out of order or broken equipment and performing routine actions to keep the equipment in working order or prevent trouble from arising. In general, both of them are expressed in terms of annual costs. In order to calculate the OC1 and MC of the equipment over their lifetime, the net present value is applied, the sum of the present values of the individual future cash flows of the same entity taking inflation and returns (e.g. from interest rates) into account. For a constant annual payment A over N years, the net present value Bn,const can be determined by [4]: Bn, const = qN − 1 ⋅ A = β (N , inom ) ⋅ A q N ⋅ (q − 1) (8) with q = 1 + (inom / 100 ) and inom = (1 + (ireal 100 )) ⋅ (1 + z1 ) − 1 . inom, ireal and z1 are the nominal interest rate, the real interest rate and the inflation rate, respectively. 4 The OC2 are the damage costs resulting from the power outage. With the aid of the interruption cost per kW and the interrupted energy cost per kWh, the outage costs OC2 per year taking into account the failure rate λt and unavailability Ut of the substation are: OC 2 per year = Psub (x ⋅ λt + y ⋅ U t ) (9) where Psub is the power of the substation in kW, x the interruption cost per kW and y the interrupted energy cost per kWh. The OC2 over their lifetime can then be determined by applying the net present value. However, in this case, the yearly increase of the power demand and thus the power of the substation must be considered as well. Hence, the net present value with a constant increasing rate Bn,inc is applied [4]: (q *) − 1 ⋅ A = β (N , i , z ) ⋅ A q* ⋅ 1 1 nom 2 1 q (q *)N ⋅ (q * −1) N Bn , inc = (10) with q* = q (1 + (z2 / 100 )) . A1 is the initial annual payment and z2 the increasing rate. The annual payment increases yearly with the increase of power demand. The rest value R means the remaining value of an investment after a period of usage. For the upgrading project like this case, the existing equipment can further be used independently on the bus schemes of the substation. Consequently, the rest value R is the same for all bus schemes and thus neglected in the consideration. The parameters for the LCC calculations are listed as follows: OC1 per year = 0.5% of the equipment costs, MC per year = 1% of the equipment costs, N = lifetime of the equipment = 30 years, z1 = inflation rate = 3%, ireal = real interest rate = 7%, inom = nominal interest rate = 10.21%, outage costs = 10.38 THB/kW and 75.37 THB/kWh [5], Psub = power of the substation = 400 MW, z2 = increasing rate of the substation power = 5 to 10%, R = rest value = 0. The LCC components of the 115 kV NCS substation (AIS type) with different bus schemes are presented in Table 3. Table 3: LCC components of the 115 kV NCS substation (AIS type) with different bus schemes Bus schemes IC [THB] Main and transfer bus 23.36 M Breaker and a half 28.07 M Double bus double breaker 29.93 M (1 EUR = 41.06 THB on 5 January 2012) OC1 + MC [THB] 0.24×β (30,10.21) M 0.30×β (30,10.21) M 0.33×β (30,10.21) M OC2 [THB] 6.41×β 1 (30,10.21,z2) M 11.9×β 1 (30,10.21,z2) M 4.86×β 1 (30,10.21,z2) M The calculated LCC of the 115 kV NCS conventional substation with different bus schemes depending on the increasing rate of the substation power z2 are shown in Fig. 2. The double bus double breaker scheme yields the lowest LCC and thus is the best bus scheme for the 115 kV NCS substation from the economical as well as reliability points of view. This is due to the predominant contribution of the outage costs to the LCC. Although the double bus double breaker scheme has comparatively high investment as well as operating and maintenance costs, its failure rate and unavailability are much lower than those of the other bus schemes resulting in the lowest value of the outage costs. With the increasing rate of 5%, which is roughly the average power demand growth of Thailand in the meantime, the LCC of about 15.5 million THB can be saved when using the double bus double breaker scheme instead of the main and transfer bus one. The change of the bus scheme will even be more economical if the increasing rate of the power demand becomes higher. The breaker and a half bus scheme gives the highest LCC because of its relatively high investment costs and particularly unavailability and therefore not appropriate in this case. 5 400M Main and transfer bus Breaker and a half Double bus double breaker 350M LCC [THB] 300M 250M 200M 150M 100M 50M 0M 0 2 4 6 8 10 Increasing rate z2 [%] Fig. 2: Calculated LCC of the 115 kV NCS conventional substation with different bus schemes depending on the increasing rate of the substation power z2 When choosing between the substation technologies, the conditions on the substation location as well as the advantages and disadvantages among the technologies have to be considered. The AIS or conventional type is advantageous with respect to the equipment cost while a lot of space (clearance) is usually required for the substation. Hence, this kind of switchgear is basically not suitable for the metropolitan area where real estate prices are particularly high. In contrast, the GIS technology offers a possibility to build up the substation within a small or limited area. Therefore, it is proper for the urban area where the land is expensive. However, the equipment investment costs of GIS are quite high due to the state-of-the-art technologies and a lot of material applied. For this reason, it must usually be traded off between the real estate prices and equipment investment costs before using the GIS. In the case of 115 kV NCS substation, however, the physical and time constraints play a key role in choosing the switchgear type for the upgrading project in addition to the investment costs. The use of AIS for upgrading the bus scheme from the main and transfer bus to the double bus double breaker scheme is impractical here because the area extension is limited and the upgrading project should be finished within a short period of time in order to affect the system reliability in the region as low as possible. With respect to the area limitation, the GIS technology would be of advantage. However, the investment costs would be exceedingly high for the upgrading because all the existing conventional equipment could not be used anymore in the substation i.e. an investment for an almost completely new GIS substation is required. Additionally, EGAT usually requires a building for housing the GIS substation and preventing it from the exposure to the fluctuating weather conditions. This increases the total investment cost for the GIS. In order to overcome the aforementioned constraints, the hybrid switchgear is applied in this project. The hybrid switchgear technology gains the advantages from both AIS and GIS technologies, which make it capable of being applied within a compact area while its equipment costs are between those of GIS and AIS. Furthermore, the hybrid switchgear can be connected with the existing major equipment in the substation regardless of whether they are AIS or GIS. The module concept inherited from the GIS provides the reduction of construction and installation times as well as maintenance effort. 5. RECONFIGURATION OF BUS SCHEME APPLYING HYBRID SWITCHGEAR In order to upgrade the main and transfer bus to the double bus double breaker scheme, the lower disconnecting switch close to the transfer bus basically need to be replaced by a circuit breaker and 6 two disconnecting switches (Fig. 3). The disconnecting switches are usually used to isolate the circuit breaker and thus enable its maintenance without de-energizing the line and busbar. The earthing switches may be integrated to the disconnecting switches in order to discharge dangerous induced voltages and currents during maintenance. For the 115 kV conventional substation, the bay length will increase from 35 m to 42 m when changing from the main and transfer bus to the double bus double breaker scheme (the breaker and a half scheme requires even much more bay length which is 65 m). However, with the application of the hybrid switchgear, the replacement of the lower disconnecting switch with a circuit breaker and two disconnecting switches can be done without any further space requirement (Fig. 4). Main Bus No. 1 Main Bus DS DS DS CB CB DS DS DS DS DS DS CB CB CB CB DS DS DS DS DS DS DS CB CB CB DS DS DS DS Upper Part DS Lower Part Transfer Bus CB: Circuit Breaker DS: Disconnecting Switch Main Bus No. 2 Fig. 3: Upgrading from the main and transfer bus to the double bus double breaker scheme 35 m (a) 42 m (b) 35 m (c) Fig. 4: Substation layouts with different bus schemes and switchgear types: (a) Main and transfer bus scheme with AIS, (b) Double bus double breaker scheme with AIS, (c) Double bus double breaker scheme with AIS for the upper bus and hybrid switchgear for the lower bus For this application, the gas-insulated hybrid switchgear module consisting of a circuit breaker, two disconnecting switches each in combination with an insulated earthing switch (two three-position disconnecting switches) and a current transformer is specified for each bay (Fig. 5). Unlike the conventional equipment, each earthing switch here is required to have a disconnector to enable the maintenance people to measure the contact resistance or perform insulation tests of the circuit breaker without de-energizing the line or main bus next to the tested circuit breaker (Fig. 5). This is required in favour of better substation reliability during those scheduled tests. 7 CB: Circuit Breaker CT: Current Transformer TPS: Three-Position Switch CT TPS CB Disconnector Hybrid Switchgear TPS (a) (b) Fig. 5: Single line diagram of the specified hybrid switchgear: (a) single hybrid switchgear, (b) installations in the substation establishing the double bus double breaker scheme 6. REPLACEMENT WORK Since this project is an upgrading work, proper switching and construction plans as well as interfacing to the existing components of the substation are necessary. The upgrading work should be completed within a short period of time affecting the supply of power to the customers as low as possible. The existing bus scheme of the 115 kV NCS substation is the main and transfer bus of which the transfer bus is normally not energized. The substation has the N-1 criterion for power transmission which secures the supply of energy to the customers to a certain extent. Hence, the reconstruction of the transfer bus from the low to high profile bus to establish another main bus should first of all be carried out. Then, the replacement and relocation of the equipment can be done. The N-1 criterion for the lines coming to and going from the substation offers the possibility to de-energize the substation bays one by one without interrupting the power supply. Due to the fact that the existing lower disconnecting switches are located close to the access road in the substation, the hybrid switchgear can easily be transported to their locations through the access road. The relatively light weight of hybrid switchgear enables a further carriage by a forklift to the installation location. The transportation of hybrid switchgear through the energized parts is unproblematic because of the compact size of hybrid switchgear as well as high clearances in the AIS substation. It should be noted that during the installation of the hybrid switchgear a power supply through the remaining circuit breaker and protection system is possible (radial bus scheme) if necessary. The combination of required equipment in a compact switchgear module reduces the number of wiring and connections and thus the installation time. 7. CONCLUSION In this contribution, the enhancement of substation reliability by reconfiguring the existing bus scheme applying the hybrid switchgear is presented. For this purpose, a pilot project for upgrading an important 115 kV conventional substation with the main and transfer bus scheme is introduced. In order to find out the best bus scheme for the substation under consideration in terms of reliability and economy, the substation reliability and Life Cycle Cost (LCC) calculations with three different common bus schemes are performed. As the criterion for the substation reliability, the failure rate and unavailability of the substation are applied, resulting from failure events of major substation equipment (power circuit breakers, busbars, etc.) in series and parallel together with the available data of their failure rates and repair times. It has been found out that the double bus double breaker scheme yields the lowest failure rate and unavailability compared to the main and transfer bus as well as breaker and a half schemes. The LCC calculations show that the double bus double breaker scheme is the best one for this case not only from the reliability but also from the economical points of view. However, the reconfiguration of the bus scheme using Air-Insulated Switchgear (AIS) technology requires an area extension for the substation which is limited in this case. On the other hand, Gas- 8 Insulated Switchgear (GIS) technology would lead to an exceedingly high investment costs. Therefore, the hybrid switchgear taking the advantages from both AIS and GIS technologies is chosen in this project to cope with the space constraint while the investment costs are acceptable. In order to buildup the double bus double breaker scheme, the existing lower disconnecting switches of the main and transfer bus scheme are replaced with the hybrid switchgear modules each consisting of a power circuit breaker, two disconnecting switches in combination with earthing switches and a current transformer. A disconnector integrated with the earthing switch is required in order to enable the routine insulation tests of the circuit breaker without de-energizing the nearby line or busbar. The N-1 criterion of the substation for power transmission makes the replacement work possible without affecting the availability of power supply. ACKNOWLEDGEMENT The authors would like to thank the Transmission System Maintenance Division, EGAT, especially Mr. Suthep Singharerg for providing the data of failure rate and repair time of substation equipment. 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