Bruno Rivas, Guarulhos - Brazil, April 2015 Jornadas Técnicas de ABB en Chile Innovation on Medium Voltage Switchgear May 13, 2015 Slide 1
Application 13. Mai 2015 Slide 2
PPMV Brazil Factory Unigear Insourcing Investment around 1,5MUSD RFFF since August 2008 Line s designed to 4000 panels / year May 13, 2015 Slide 3
Design concepts: Single Busbar System Back to Back System Double Level System May 13, 2015 Slide 4
Single Busbar System May 13, 2015 Slide 5
Single Busbar System Electrical characteristics Rated voltage Test voltage (50-60 Hz/1 min) Impulse withstand voltage Rated frequency Rated short-time withstand current Peak withstand current Internal arc withstand current Rated current of the main busbars Rated circuit-breaker thermal current Feeders rated current [kv] [kv] [kv] [Hz] [ka] [ka] [ka] [A] [A] [A] Up to Up to Up to Up to Up to 12 12 (*) 28 75 50-60 50 60 125 50 125 50 4000 50 4000 4000 4000 630 1250 630 1250 1600 1600 2000 2000 2500 2500 3150 3150 3600 3600 4000 4000 17,5 38 95 50-60 50 125 50 4000 4000 630 1250 1600 2000 2500 3150 3600 4000 24 50 125 50-60 31,5 80 31,5 3150 3150 630 1250 1600 2000 2500 3150 May 13, 2015 Slide 6
R L UniGear ZS1 Single Busbar System May 13, 2015 Slide 7
Double Busbar System Double Level; Double Level Duplex. May 13, 2015 Slide 8
Double Busbar System Electrical characteristics Rated voltage Test voltage (50-60 Hz/1 min) Impulse withstand voltage Rated frequency Rated short-time withstand current Peak withstand current Internal arc withstand current Rated current of the main busbars Rated current branch connection [kv] [kv] [kv] [Hz] [ka] [ka] [ka] [A] [A] Up to Up to Up to Up to 7,2 20 60 50-60 50 125 50 1600 630 12 28 75 50-60 50 125 50 1600 630 17,5 38 95 50-60 40 100 40 1600 630 1000 1250 1600 1000 1250 1600 1000 1250 1600 May 13, 2015 Slide 9
R L R L UniGear ZS1 Double Busbar System May 13, 2015 Slide 10
R L UniGear ZS1 Double Busbar System May 13, 2015 Slide 11
R L R L R L R L R L R L R L R L R L R L R L R L R L R L R L R L UniGear ZS1 Double Busbar System Metering unit Metering unit Outgoing feeders with circuit breakers Outgoing feeders with contactors Incoming feeder Bus tie Bus riser Incoming feeder Outgoing feeders with contactors Outgoing feeders with circuit breakers Earthing transformer outgoing Earthing transformer outgoing May 13, 2015 Slide 12
Back to Back System May 13, 2015 Slide 13
Back to Back System Electrical characteristics Rated voltage Test voltage (50-60 Hz/1 min) Impulse withstand voltage Rated frequency Rated short-time withstand current Peak withstand current Internal arc withstand current Rated current of the main busbars Rated circuit-breaker thermal current Feeders rated current [kv] [kv] [kv] [Hz] [ka] [ka] [ka] [A] [A] [A] Up to Up to Up to Up to Up to 12 12 (*) 28 75 50-60 50 60 125 50 125 50 4000 50 4000 4000 4000 630 1250 630 1600 1250 2000 1600 2500 2000 3150 2500 3600 3150 4000 3600 4000 17,5 38 95 50-60 50 125 50 4000 4000 630 1250 1600 2000 2500 3150 3600 4000 24 50 125 50-60 31,5 80 25 2500 2500 630 1250 1600 2000 2500 May 13, 2015 Slide 14
Back to Back System May 13, 2015 Slide 15
Safety 13. Mai 2015 Slide 16
Safety ABB Month DD, YYYY Slide 17
Safety The most complete range Complies with IEC Standards; GOST (Russia); GB (China) as well as main Shipping Registers Regulations Type tested Fully type tested according to IEC standard; Additional tests performed in compliance with shipping registers regulations; Specifically tested to be in compliance with several local requirements (e.g. GOST and GB); Seismic: IEC (IEC 68-2-6 / 68-2-57), IEEE standards (IEEE Std. 693-1997) and ETG-1020 (by calculation). Inclination test Vibration test May 13, 2015 Slide 18
Safety PM (partition metallic) and LSC2B (Busbar, feeder and apparatus compartments physically and electrically segregated) classified according the IEC 62271-200; Complete of safety mechanical interlocks (interlock-controlled or tool-based accessible compartments); Metallic shutters operated by the apparatus movement; Closed door apparatus racking. May 13, 2015 Slide 19
Safety Earthing switch With full making capacity short time withstand current for 3 seconds; Operated from the front; Provided with secure position indicators; Motor operated drive mechanism available. May 13, 2015 Slide 20
May 13, 2015 Slide 21
Safety Internal arc classified IAC AFLR according to the IEC 62271-200 Annex A UniGear is in full accordance to all the five criteria: 1. The doors of the switchboard must remain closed and no opening of the cover panels must occur; 2. Any part of the switchboard which may be hazardous for personnel must not be ejected; 3. No holes must appear in the external housing of the switchboard in any parts accessible to personnel; 4. The vertically and horizontally arranged fabric indicators placed outside the switchboard must not get burnt; 5. All the switchboard earthing connections must remain effective. Front, rear and sides arc resistance. May 13, 2015 Slide 22
Safety Arc proof Internal arc classified IAC AFLR according to the new IEC 62271-200 Annex A; Front, rear and sides arc resistance. May 13, 2015 Slide 23
Safety Wall standing solution Maintenance and service operations performed from the front; Front access to all the compartments (apparatus, busbars, cables); Comfortable front cables access. May 13, 2015 Slide 24
Safety ABB Month DD, 2015 Slide 25
Remote racking ABB Month DD, YYYY Slide 26
IR Temperature Monitoring Faulty connections due to loose screws or corrosion Increase of the contact resistance Conversion of the power to heat Damage of the switchgear Prevention by contactless temperature monitoring of the contact points with IR sensors Busbars / points of contact May 13, 2015 Slide 27
IR Temperature Monitoring Medium Voltage Switchgear May 13, 2015 Slide 28
IR Temperature Monitoring MV-cubicle Busbar / Cable conexion IR Power supply: Modbus / Profbus 24 VDC PLC Binary outputs Temperature probes Sensor IR temperature probes Temperature monitoring of up to 12 points without contacting any live parts Measurement of the ambient temperature in the cubicle with sensor May 13, 2015 Slide 29
IR Temperature Monitoring Fast detection of the presence of a hot spot in an early stage Increasing of plant safety No additional checks of the contact points necessary Decreasing of costs Passive type temperature sensors Retrofit in most existing MV-cubicles (e.g. in the cubicle s front door) May 13, 2015 Slide 30
Safety ABB Month DD, YYYY Slide 31
Gas exhaust duct Overpressure flaps May 13, 2015 Slide 32
Gas exhaust duct Without extra measures May 13, 2015 Slide 33
Gas exhaust duct Standard duct 3m B < 3.5m Compact duct 2.8m B < 3m May 13, 2015 Slide 34
Gas exhaust duct May 13, 2015 Slide 35
Gas exhaust duct Compact duct with top chimneys 2.8m B < 3m May 13, 2015 Slide 36
Arc Detection ITH ü 15 ms ITH + 60 ms CB REA ü 2,5 ms + 60 ms CB IED ü 12 ms IED + 60 ms CB UFES ü < 4 ms after detection of an internal arc fault May 13, 2015 Slide 37
Arc Protection - ITH Ith pressure switches ü Easy to use ü Fast and reliable ü Economic solution
Arc Protection - REA 3 Trip REA 101 REA 101 Trip 3 Trip 1 Trip 2 Light I> I> REA 103 REA 105 Trip 1 Trip 2 Example Sectionalizing of outgoing feeders REA 105 on the second outgoing level trips the feeder CB on detection of an arc The upstream REA 105 trips the sectionalizing CB after a preset delay if the arc has not been eliminated The two REA 101 units trip the incoming feeder CBs if the arc fault still persists May 13, 2015 Slide 39
Arc Protection - IED Relion 615 & 620 (optional) Per compartment (CB, Busbar, Cables) Economic solution May 13, 2015 Slide 40
Arc Protection - UFES + UFES + REA Versatile monitoring options with REA system: Optical detection via line or lens sensors Overcurrent detection Selective protection Circuit-breaker failure protection Ultra-fast arc extinction by UFES Certified interfaces Extremely short tripping times < 4 ms (after detection) Combinable arc protection UFES + REA May 13, 2015 Slide 41
Arc Protection - UFES
UniGear Digital Available product 13. Mai 2015 Slide 43
UniGear Digital Overview 61850 May 13, 2015 Slide 44
UniGear Digital Overview Current sensor Shielded cable with RJ45 Protection relay Adapter Voltage sensor May 13, 2015 Slide 45
UniGear Digital Overview Protection relay with IEC 61850 Current sensors Voltage sensors 1pcs 0.5kg 1pcs 2kg May 13, 2015 Slide 46
UniGear Digital Overview Keep project time schedule Comply with specifications and standards Keep cost targets Maximize integration Flexible to changes May 13, 2015 Slide 47