REPORT

66/33/11 kV Substation Design Report

Northern Region, Greater Noida(GIS Substation)
Abstract-This report outlines the need of the GIS technology integration in the power system in areas like GREATER NOIDA, It gives a study report regarding an installation of distribution GIS substation. The report includes space consideration with other technical information of substation erection.

I. SITE PROFILE Greater Noida or new Okhla industrial development area are came into being as Industrial Township in 1976 catering to Delhis commercial needs and addressing its concern over polluting industries. Greater Noida is the Planning Marvel and an emerging Dream Township. The Total Notified Area: 36,000 hectares Already urbanized in Phase I: 5,000 hectares Organisable area: 12,000 hectares (by 2011) City planned for a population of: 0.7 million (by 2011) & 1.2 million (by 2021) Industry led development: 3000 hectares (to be developed by 2011) Strategic Location within NCR * Well linked to domestic & international markets. The year 2010-11 proved to be a bad year for industrial development in Noida and Greater Noida. A total of 319 units shut operations during the last financial year, more than 50% up from the figure of 205 a year ago. Also, in 2009-10, a total of 1,610 new units came up. But in the last financial year, only 1,360 units were set up. Poor power supply and deteriorating law and order situation remained the main issue. Greater Noida Industrial Development Authority falls within the National Capital Region of Indias capital - New Delhi and is adjacent to Noida, one of the largest industrial townships in Asia. It conceptualizes the needs of a fast developing city of the future. The Action Plan and execution is at par with global standards and is aimed at accelerating the growth of industrial, IT and institutional sectors in the country.Ecotech is Greater Noida's exclusive Industrial area..Industrial investment taking place in Greater Noida is now over Rs. 10,000 crores. It has now become one of the favoured locations for good industrial investment especially of multinational investment because of its good infrastructure near Delhi and effective single window system of speedy decision making and clearances.

To sustain this increase in demand of power consumption more and more challenges are faced by the government authorities to maintain the power quality and integration of new technologies in the power system to make it more reliable. As a part of this problem substation technologies have come up with up gradation from Air Insulated substation to the GIS (Gas Insulated Substation). Gas insulated switchgear (GIS) is a proven technology used throughout the world that offers many advantages over a conventional substation. A primary advantage is its compactness, which allows a GIS to be placed closer to a load centre, and it is more aesthetically attractive, resulting in quicker installation time, reduced maintenance, higher reliability and safety, and excellent ability to withstand seismic events. When all these advantages are taken into consideration, a gas-insulated substation is a costeffective to a convention in an urban community and NOIDA region also demand such new technologies to be implemented considering the rate of the industrialisation and urbanisation. The problem of power quality has been a major threat, causing interruption of supply and voltage sags which ultimately have led to declining production and profitability of the industries. As the reference of this background Uttar Pradesh Power Corporation Limited (UPPCL) has proposed many GIS substation to be installed and one of them is being decided to be erected at the GREATER NOIDA which takes power from the substation PALI located about 30km. PALI substation draws power from the generation plant 650 km far situated at Rihand Thermal power plant

Fig 1: Single Line Diagram of Proposed GIS substation:

II.LAYOUT AND DESIGN CONEPT The proposed substation is connected to Pali substation and draws power at 66kV and fed power with in all four outgoing feeders with voltage levels 33kV and 11kV.The proposed layout is given in Fig. 1.The specification covers scope of design, electrical specification of the components used, monitoring system, safety and precaution standards considering the climatic condition of the site. It is desirable to have the INDOOR gis considering the scarcity of land and also the high cost of the land. The scope also covers provision of modular design considering future expansion in the load demand. A. Material and design Aluminium or aluminium alloys shall be used preferably for the enclosures. The material and thickness of the enclosure shall be selected to withstand an internal arc and to prevent a burnthrough or puncturing of the housing within the first stage of protection, referred to a short-circuit current of 40 kA. For supervision of the gas within the enclosures, density monitors with electrical contacts for at least two pressure levels shall be installed. The circuit-breakers, however, might be monitored by density gauges fitted in circuitbreaker control units. The manufacturer assures that the pressure loss within each individual gas compartment and not referred to the total switchgear installation only will be not more than 1% per year per gas compartment.Each gas-filled compartment shall be equipped with static filters of a capacity to absorb any water vapour penetrating into the switchgear installation over a period of at least 25 years. B. SF6 Sulphur hexafluoride is an inert, nontoxic, colourless, odourless, tasteless, and non-flammable gas consisting of a sulphur atom surrounded by and tightly bonded to six fluorine atoms. It is about five times as dense as air. SF6 is about 100 times better than air for interrupting arcs. SF6 is a strong greenhouse gas that could contribute to global warming. At an international treaty conference in Kyoto in 1997, SF6 was listed as one of the six greenhouse gases whose emissions should be reduced. Field checks of GIS in service for many years indicate that the leak rate objective can be as low as 0.1% per year when GIS standards are revised.

Fig. 2 GIS assembly

C. Circuit Breaker GIS uses dead tank SF6 puffer circuit

breakers. The nozzles on the circuit breaker enclosure are directly connected to the adjacent GIS module. Enclosure material will be aluminium alloy.Circuit breakers are equipped with self-blast interrupters. require minimum maintenance and only a low amount of switching energy. Table No.1
(High voltage Alternating current circuit breakers: IEC 62271-100)
1 2 3 4 5 6 Rated voltage Rated current Rated frequency Rated short-circuit breaking current Rated break-time Rated short-circuit making current 72.5 kV 1600A 50Hz 25 kA rms, 3 sec 3 cycle 62.5 kA peak

D. Disconnector (Isolator) Disconnect switches have a moving contact that opens or closes a gap between stationary contacts when activated by an insulating operating rod that is itself moved by a sealed shaft coming through the enclosure wall. The moving contact velocity is relatively low and the disconnect switch can interrupt only low levels of capacitive current or small inductive currents.

Table No.2
(Alternating current Disconnector (isolators) and earthing Switch IEC 62271-102)
1 2 3 4 5 Rated voltage Rated current Rated short-time current Rated control and operating voltage Type of operating mechanism 72.5 kV 1600 A 25 kA rms, 3 sec 110/220 V DC Motor operated Mechanically ganged Operated

H. Voltage Transformers VTs are inductive types with an iron core. The primary winding is supported on an insulating plastic film immersed in SF6. The VT has an electric field shield between the primary and secondary windings to prevent capacitive coupling of transient voltages. (IEC 60044) Table No.4
1 2 3 4 5 6 7 Rated voltage Highest system voltage Rated frequency P F(dry) withstand voltage Voltage factor 1.2/50 micro sec. lightning impulse withstand voltage Grounding 66kV 72.5kV 50Hz 140kV 1.2 continuous 350kVp Effective

6 a

Rated insulation level Power frequency withstand voltage - phase to phase, between phases rms - Across the isolating distance Lightning impulse withstand voltage - phase to phase, between phases

140 kV 160 kV rms

350 kV peak

I.Bus E. High Speed Earthing Switch (IEC 62271 102 class B) as mentioned above. Fast acting grounding switches shall be of three phase, encapsulated, three phase linkage group operated by a maintenance-free selfcontained electrical motor. They shall also have facilities for emergency manual operation and the necessary operating handles or hand cranks shall be supplied.DC motor operation (220 V) completely suitable for remoteoperation and a manual emergency drivemechanism is required. F. Maintenance Earthing Switch (IEC 62271 102 class B) as mentioned above. G. Current Transformers CTs are inductive ring types installed inside the GIS enclosure. The GIS conductor is the single turn primary for the CT. CTs inside the enclosure are shielded from the electric field produced by the high voltage conductor or high transient voltages can appear on the secondary through capacitive coupling. Table No.3 To connect GIS modules that are not directly connected to each other, an SF6 bus consisting of an inner conductor and outer enclosure is used. Support insulators, sliding electrical contacts, and flanged enclosure joints are usually the same as for the GIS modules. J. Bushings Outdoor bushings shall be provided for connection of conventional external conductors to SF6 GIS. Suitable clamp & connectors shall be supplied with bushing. The dimensional and clearance requirements for the metal clad enclosure shall be maintained as per requirement of relevant standards.Only SF6 insulated composite silicon bushings will be provided. The terminals on the outdoor bushings shall be a solid stem with dimensions specified. K. GIS Connection x Gis to transformer

Transformers will be connected to the GIS by termination of 66 kV XLPE power cable. The connection between GIS and high voltage cable at GIS end will be done through cable termination / cable sealing end. For transformer end connection the cable termination on structure shall be provided outdoor. The plug in cable sealing ends for XLPE cables will consist of gas tight plug in sockets and prefabricated plugs with grading elements of silicone rubber. x Gis to line

The 66 kV line will be terminated to GIS by XLPE power cable. x 66 kV Power Cable connection

The connection between GIS and high voltage cable at GIS end is done through cable termination / cable sealing end. Plug in cable sealing ends for XLPE cables will consist of gas tight plug in sockets, and prefabricated plugs with grading elements of silicone rubber. A separate cable basement is provided for cable entry, its distribution and installation. All end cable modules will be suitable for connecting single core, XLPE specified cable. L. Metal-Enclosed Surge Arresters The 60 kV, hermetically sealed, Gapless, ZnO, Surge arrestor, suitable for use with GIS. for each phase, at the 66 kV line underground cable entry terminals of GIS shall be provided, if indicated in Schedule of requirements. Each Surge Arrester shall be provided with self-leakage current monitoring device at convenient elevation. M.Power Transformer Type and Ratings: x x x x Max. Continuous capacity: ONAF 20 MVA Number of phases 3 Frequency 50 Hz(5%) Rated Voltage : 66kV 33kV

and automatic monitoring of the state of the gas. The SF6 gas monitoring device shall have two supervision and alarm settings.After an urgent alarm, operative measures can be taken to immediately isolate the particular compartment electrically by tripping circuit breakers and opening Disconnector. The gas monitoring device shall monitor at least the following, locally and on remote. i) "Gas Refill" Level- This will be used to annunciate the need for gas refilling. ii) "Breaker Block" Level- This is the minimum gas density at which the manufacturer will guarantee the rated fault interrupting capability of the breaker. At this level the device contact shall trip the breaker and block the closing circuits. iii) Over pressure alarm level- This alarm level shall be provided to indicate abnormal pressure rise in the gas compartment. It shall be possible to test all gas monitoring relays without de-energizing the primary equipment and without reducing pressure in the main section. Each gas zone shall be furnished with a gas monitoring system consisting of a gas density continuous monitoring device provided with two electrically independent contacts which operate in two stages as follows: a) First alarm: At a gas density normally 5 to 10% below the nominal fill density. b) Second alarm: Minimum gas density to achieve equipment ratings.

HV side LV side x Connections :

HV side LV side x

Star Star

ON load taps on HV side +5% to -15% in steps of 1.25% each Table No. 5

In special cases determined by the supplier, a third stage with a set of contacts may be necessary in certain areas. It shall be ensured that there is no chance of the gas liquefying at the lowest ambient temperature B. Local monitoring unit

Insulation Level i)Lightning withstand ii)Power frequency withstand voltage Insulation level of Bushing i)Lightning impulse voltage ii)Power frequency voltage

66kV 325kV 140kV (rms)

33kV 170kV 70kV (rms)

a) The operator must be forced in to the only safe and logical sequence to actuate the circuit breakers, Disconnector&earthing switches. b) The actual, completely closed or completely opened position of all switching devices must be checked before and after each move. c) Implementation of logic checks and issuing the resultant signals The bursting pressure of relief device should be effectively coordinated with the rated gas pressure and the pressure rise due to arcing. x x Dew point measurement meter SF6 gas leakage detector

325 kV 140kV (rms)

170 kV 70kV (rms)

III. MONITERING A. Gas monitoring unit Gas density or pressure monitoring devices shall be provided for each gas compartment. The devices shall provide continuous

x x x

Precision pressure gauge Gas-service carts Any other special tool/tackle required.

The busbar module of the combined disconnector and earthing switch contains the busbar conductors and in addition thereto a transversal arranged three position switch.. 4.Digital control and protection

C.Indicating Devices Position indicators shall be provided to clearly indicate whether a circuit-breaker is open or closed. Each circuit-breaker shall be provided with an operation counter to record the number of tripping operations performed. D. Timing Test Timing tests are to be carried out after the switch gear has been completely charged with SF6 gas. Testing instruments x x x x x Air / gas humidity tester, Gas purity detector for SO2, H2O, CF4, AIR etc., Gas leakage tester, Breaker timing measurement kit, Set of equipment for pressure measurement and gas density meter. Timing test facility shall be provided with switchgear such that it is not necessary to open up any gas section to make test connections to the circuit breaker terminals. . In case of digital control technology, the single line diagram with position indicators and control buttons is replaced by a digital human-machine interface. Digital control devices provide the same functions as conventional control technology. Furthermore a lot of versatile, additional control and protection functions can be implemented: Synchro-check,Auto re-closing Operating frequency supervision, Fault recorder, Backup protection 5.Connection to station control Communication between bay devices and the device on station level uses solely the new standardized communication protocol 6.Digital monitoring systems Either the conventional or the digital control technology is completed by digital monitoring systems. These systems operate as an add-on to the existing control technology and do not interact with the switchgear protection. Monitoring systems improve the overall availability by continuous supervision of all vital functions of the switchgear. This ensures an early detection of critical situations and scheduling of countermeasures into non-critical times. 7.A new way of Testing Gas Insulated Switchgear: A voltage withstand test is necessary during the commissioning of gas insulated high-voltage switchgear (GIS). To date, the test was performed by connecting a high-voltage test transformer and a heavy control unit to the GIS. New technology combines the multi-functional primary test system CPC 100 with the newly developed CP RC package, Together, they form a resonant circuit..The package is connected to a voltage transformer, which is specially designed for this purpose . 8.Digital Relay: Modern digital relays can be used for control as well as for protection and other secondary functions. Because of this, it is possible to group

E.SCADA The technologies developed are ranging from the actual building and integrated SCADA based monitoring system, through the compact gasinsulated Switchgear and transformers with integrated control and protection equipment to the SF6 Gas Management Plan (GMP) built around the world. With all incoming and outgoing feeders taking the form of cables, the building has no high voltage-carrying elements on its outer walls. IV. MODERN TECHNIQUES 1.Innovative and safe circuit breaker technology requiring minimum space. The circuit breaker can therefore be designed quite simple and reliable. Interrupting unit based on the self blast principle and hydromechanical spring operating mechanism for a reactionless, reliable switching with soft extinction behavior. 2.Integrated technology Two different types of enclosures are available to integrate the combined disconnector and earthing switch into the building block system. 3.Busbardisconnector and earthing switch module

and combine different functions using just software tools. Increased availability through self supervision and selfchecking of the electronics for the remaining hardwired connections V. GROUNDING GIS are subjected to the same magnitude of ground fault current and require the same lowimpedance grounding as conventional substation. a strong grounding system is necessary.

The inductive voltage against ground in each part of the enclosure will not be more than 65 Volts. Where operating mechanism cabinets are mounted on the switchgear, the grounding will be made by separate conductor. Bay control cabinets will be grounded through a separate conductor. All conduits and control cable sheaths will be connected to the control cabinet grounding bus. All steel structures will be grounded. Each removable section of catwalk will be bolted to the support structure for ground continuity. The enclosure grounding system will be designed to minimize circulating currents and to ensure that the potential rise during an external or internal fault is kept to an acceptable level. . connectors will be of sufficient mechanical strength to withstand electromagnetic forces as well as capable of carrying the anticipated maximum fault current without overheating by at least from two paths to ground from the main ground bus. The guidelines of IEEE Std. 80-2000 on GIS grounding, will be taken into consideration while designing the grounding system for GIS

Material used:
Copper-clad steel Copper is a common material used for grounding. Copper conductors, in addition to their high conductivity. Size of conductor-6AWG Area of grounding earth mat-40ft x 60ft

Equipments used:
1. grounding connectors Connecting all GIS equipment, Bus duct, enclosures, control cabinets supporting structures etc. To the ground bus of GIS 2.Connecting ground bus of GIS to the ground mat riser.-GIS is housed on GIS floor. There will be under-ground mat below the substation. There will be adequate number of Galvanized steel risers to be connected to grounding mat. Enclosures and circulating currents: the continuous-type enclosures provide a return path for induced currents so that the conductor and enclosure form a concentric pair with effective external shielding of the field internal to the enclosure To limit the undesirable effects caused by circulating currents, The possible solutions to reduce the earth electrode resistance are taken as: 1. Use of High density grid: 2.Connection to the reinforced concrete mat:. 3.Use of deep driven ground rods The following points will be considered: The grounding arrangement of GIS will ensure that touch and step voltages are limited to safe values. Theenclosures of the GIS will be grounded at several points such that there will be a grounded cage around all live parts.

Grounding of GIS foundations

A simple monolithic concrete steel reinforced slab is advantageous both as an auxiliary grounding device and for seismic reasons. If a continuous floor slab is used, a good adjunct measure is to tie its reinforcing steel mesh to the common ground bus (main ground bus) so that both the GIS enclosures and the structural steel in and above the foundation will be approximately the same potential level

VI. Testing
Three types of testing has to be performed:

1.Type Tests:
1. Tests to verify the insulation level (Lightning impulse, Switching impulse and ac withstand test with PD) test on each GIS device (CB, Disconnector, bus, etc): 2. Dielectric tests on auxiliary circuits. 3. Tests to prove the radio interference voltage (RIV) level. 4. Tests to prove the temperature rise of any part of the equipmentand measurement of the resistance of the main circuit.

5. Tests to prove the ability of the main and earthing circuits to carrythe rated peak and the rated short time withstand current. 6. Tests to verify the making and breaking capacity of the includedswitching devices. 7. Tests to prove the satisfactory operation of the included switchingdevices. 8. Tests to prove the strength of enclosures. 9. Verification of the degree of protection of the enclosure. 10. Gas tightness tests 11.additional tests on auxiliary and control circuits.

4. Measurement of the resistance of the main circuit. 5. Tightness test. 6. Design and visual checks. 7. Pressure tests of enclosures. Each cast aluminium enclosure of the switchgear shall be pressure-tested to at least double the service pressure 8. Functional tests 9. Tests on auxiliary circuits, equipment and interlocks in the controlmechanism. 10. Pressure test on partitions.

12. Tests on partitions. 13. Tests to prove the satisfactory operation at limit temperatures. 14. Tests to prove performance under thermal cycling and gastightness tests on insulators. 15. Tests to assess the effects of arcing due to an internal fault. 16. Seismic test

3.Tests after installation of complete GIS at Site:

After installation and before being put into service, the GIS will betested in order to check the correct operation and dielectric integrity ofthe equipment as laid down in IEC 62271-203. Tests will include the following: 1. Dielectric tests on the main circuits.

17. Test on Auxiliary switches (Electrical & Mechanical Endurance,Heat run, IR & HV test) 2.Routine / Acceptance Testing:
During manufacture and on completion, all equipment will be subjected to the Routine tests as laid down in IEC Standard IEC 62271-203. Tests will include the following: 1.Dielectric test on the main circuit. The dielectric routine test consists of a power frequency voltage test on the main circuit including PD measurement according The PD level needs to be lower than 5 pC. 2.PD test: No measurable partial discharge is allowed at 1.1 line-to-line voltage (approx. twice the phase-toground voltage). This test ensures maximum safety against insulator failure, good long-term performance and thus a very high degree of reliability. 3. Tests on auxiliary and control circuits.

2. Dielectric tests on auxiliary circuits.

3. Measurement of the resistance of the main circuit. 4. Gas tightness tests. 5. Checks and verifications. 6. Gas quality verifications. 7. On site power frequency voltage withstand test with PD test. 8. Functional & interlock tests for all items 9. Demonstration of operational compatibility with SCADA 10. Visual inspection, checks & verifications. 11. Mechanical operation tests of circuit breakers, Disconnectors and earthingswitches and high-speed earthing switches 12. Insulation resistance measurement 13. Tests on CTs and PTs 14. Tests on Surge Arresters

VII. FAULTS AND PROTECTION

Table No.7 Line

66 kV

Faults Status of GIS:

1. mis-operation : grease hardening , corrosion of switchgear, broken shaft 2.insulating materials : contact badness of electrodes, tran sient over voltage, tracking phenomena of the polymeric insulation material. 3. damage of bushing : defect in voltage screen 4. breakdown of elbow connector : surface damage, loose contact of connector 5. others : moisture absorption, trouble of control circuits.

Protection Adapted
Directional O/C & E/F Protection Local Breaker Backup Non-Directional O/C & E/F Protection Local Breaker Backup

Type of relay
Numerical Relay with IEC 61850 Protocol Integrated in Dir. O/C & E/F Protection Integrated in Dir. O/C & E/F Protection Integrated in Dir. O/C & E/F Protection

33/11 kV

VIII. LOAD SPECIFICATIONS As GIS compactness allowed erecting the substation in the vicinity of the load, the proposed GIS can sustain the power demand of the fast growing NOIDA region at industrial level. The substation will have 20+20=40 MVA of installed capacity. There will be in all four outgoing feeders, two with voltage rating of 33kV and two with 11kV.The substation mainly aim to supply the industrial load with stipulated quality regulations. We are also expecting general residential load. The two 11 kV feeders will take care of the load in the close region. For the load which are expected in near future 33 kV feeders are provided that can fed power to the another substation and then to consumer. At present 47 large and small scale industries are working with their full capacity. As the growth of NOIDA in the recent past many more industries are expected in this region, some of them are listed below. Table No.8
Type Engineering Material Science Automobile Paint Automobile Parts Consumer Electronics Manufacturing Software/IT services Research and Development Present 12 2 5 2 5 9 4 8 1 Upcoming 17 4 5 6 11 7 20 -

Protection :
Arc detection systems Arc detection systems are protection systems that use sensors to detect the presence of an internal arc and then isolate the faulted section by opening of the incoming or feeder circuit breaker. In general three types of systems exist, 1. Light detection systems 2. Pressure rise detection systems 3. Micro switches situated on pressure relief devices - A high speed fault diverter switch used in response to arcing anywhere within the substation to connect the gas-insulated high-voltage conductor to ground for each phase of the system at high speed to divert the fault current to ground Protection of Power Transformer: Table No.6
Incipient faults below oil level resulting in decomposition of oil Large internal faults (phase-tophase, phase-to-ground) below oil level. Faults in tap-changer. Buchholz relay Sudden pressure relay Pressure relief relay Buchholz relay Percentage differential protection. High speed high-set overcurrent relay. Over fluxing protection Over voltage protection Earth fault relay Differential protection Thermal overload relay Temperature relay sound alarm Surge arrester R-C Surge suppressors

Saturation of magnetic circuit Earth Faults Overload

High voltage surges due to lightning, switching etc.

Industries mainly demand loads like induction motors, water pumps, small furnaces and other. Beside the different industries nominal load of residential area must be handled by the substation. The substation will be designed to run 24 hour to ensure continuous power supply to the industries that are running in three shifts.

Feederand Bus Coupler Protection:

IX. SPACE REQUIREMENT The proposed 66/33/11 kV substation is of INDOOR type and will be planned in a building. The Fig shows the vertical section of the building and placement of the various components. For design purposes indoor temperaturesof 5 C to +40 C and outdoor temperaturesof 25 C to +40 C shall be considered. The floor area of 20 ft x 8 ft complies with the ISO 668 standard for the switch gears. The power transformer demands floor area of 30

ft. x 20 ft. Such two transformers will be installed and hence the overall floor area required for flooring is 40 ft. x 60 ft. X. SYSTEM CONDITIONS DATA AND CLIMATIC

Table No.9
Sr. No .
1

Particula rs
General

Value

I ii ii i 2

Installatio Indoor GIS n No. of 3 phases Standards IEC and IS applicabl e Configuration I Number of Feeder Bay Ii Number of transform er Bay Iii Number of Bus coupler Iv GIS to Transform er Connectio n V GIS to Feeder connectio n Vi Number of VT Vii Number of SA Viii Future extension possibility

3 double bay 2

XLPE power cables

XLPE power cables 3 2 One spare Feeder Bay Two spare capacitor banks Occasional 50 -5 38 III/25mm/ kV 50

Service conditions I Condensation Ii Max Temp. in Deg. C Iii Min Temp. in Deg. C Iv Daily average Temp. in Deg. C V Pollution Class vi Average no of rainy days/annum Enclosure I Material ii Painting shades and thickness Auxiliary Supply I For operation, control and signalling ii Other load

Aluminiu m alloy Shade 631 (IS:5) 220 Volts (+10%&20%) 440/230

Volts, AC 50 Hz 9 System Parameters i Rated system voltage ii One min. power frequency withstand voltage iii Rated frequency iv Rated continuous at 40 deg C ambient temp. bus bar v Feeder and transformer bay vi Rated short circuit withstand current for 3 seconds 66/72.5 kV 140kv (rms) 50Hz 2500A

1600 A 25 kA