Outdoor modular transformer substation type ST7 with 35/6 kV oil or dry type transformers, and complete switchgear

35 and 6(10) kV type SPY

Operating Manual 1YMS603002-en

Table of contents
1. 1.1 1.2 1.3 2. 2.1 2.2 2.3 Introduction Substation applications Operation conditions3 Conforms to standards Substation technical documentation Single-line diagram Substation components Spare parts 8. 9. 9.1 9.2. 9.3. 9.4 Substation protection from atmospheric surges Transport Railway transportation Road transportation T ransportation on the substation own skids Fixing substation blocks on transport platforms

3. Technical specifications and main equipment 3.1. Complete 35 kV switchgear block 4. 5. 6. 7. Substation secondary circuits Substation design

10. Substation assembly and setting up 10.1 Preparation of the site 10.2. Substation assembly 10.3 Visual inspection of the devices and apparatus 10.4 Mechanical tests 10.5 Earthing resistance measurement 10.6 Electrical measurements 11. Commissioning

Advantages of the substation 12. Operation Installation of control cables between blocks 13. Periodical inspections, overhauls and maintenance

NOTE! The following documents should be included with this manual: COMPLETE SWITCHGEAR TYPE SPY for 12 kV rated voltage and up to 3150 A rated current, with vacuum circuit-breakers type VD4 Technical description and operation instructions COMPLETE SWITCHGEAR TYPE SPY for 35 kV rated voltage and up to 3150 A rated current, with vacuum circuit-breakers type VD4 Technical description and operation instructions
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1. Introduction
1.1 Substation applications (Fig. 1 and 2) The ST7 transformer substation with oil or dry type transformers for rated power from 2,500 kVA to 16,000, is designed to supply 3-phase, 6(10) kV, 50 Hz high voltage power to the power consuming objects. The substation power supply is 35 kV (two overhead 35 kV lines), and the power distribution (converted by power transformer) is 6(10) kV. The type ST7 substation is designed in particular to supply power to oil, gas and other installations (group pump plants, drilling and mining). This manual contains general technical specifications of the substation, operation conditions, list of components, concise design description, list of instruments and equipment, packaging and transport information, and practical recommendations regarding installation, setting up, adjustment, service and maintenance. To understand this documentation you should refer to operating documentations of the substation components. When operating the substation, apart from this document, you should follow your national regulations: Work safety in power systems, and Power system installation regulations. 1.2 Operation conditions Normal substation operation is guaranteed when observing the following climate conditions: - Ambient temperature between 55C and +40C. - Relative humidity at +20C below 90% - Max. substation installation altitude below 1000 m - Max. thickness of icing 20 mm at the wind speed of up to 38 m/sec. 1.3 Conformity to standards The transformer substation type ST7 conforms to international IEC standards and the requirements of GOST 1516.3 standard regarding lightning impulse test voltage and power frequency voltage for 35 kV and 6(10) kV.

three block segments (depending on the substation single-line diagram). Segments are transported separately and joined together on site. Components for connection of blocks with detailed installation instructions. 2.3 Spare parts The delivery includes a full spare parts kit, work safety accessories, and mounting equipment as agreed during contract preparation.

3. Technical specifications and main equipment

3.1. Complete 35 kV switchgear block (Fig 3) consists of two separately transported segments, joined together on site of substation destination. 3.1.1 General specifications: Rated voltage ...............................................................35 kV Rated frequency ...........................................................50 Hz Rated current of busbars .............................................630 Rated short time current, 1s...........................................16 k Rated peak withstand current.......................................40 k 35 kV circuit-breaker type: vacuum circuit-breaker type VD4 with spring/motor drive 3.1.2 Main parts of the 35 kV switchgear: - 35 kV switchgear (item 1.1) with 35 kV / 1250 A vacuum circuit-breakers type VD4; - 3-pole switch-disconnectors type -2-35/10001 (item 1.2) with manual drive type -5-21 or type -00-21 (item 1.6) equipped with mechanical and electromagnetic interlocks and latching contacts for indication system. - GXD51 (item 1.3) surge arresters for 40.5 kV operating voltage, and 10 kA nominal discharge current; - Surge arrester operation counters type GLKA (item 1.4) (one piece per each phase); - 35000:v3/100:v3/100:3V voltage transformers, built into the busbars of the bus coupler and bus riser panel, separately for each section of the complete measuring module. 3.1.3 Primary block circuits For the primary circuits, each section of the 35 kV block consists of the following panels: 35 kV incoming line feeder with equipment located on the block roof (substationary outdoor version) The panel is equipped with the following (see Fig. 3): - 3-pole switch-disconnector type -2-35/10001 (35 kV/100 A) (item 1.2), equipped with two earth contacts, - manual drive type -05-21 (item 1.5) for the switch-disconnector, with built-in latching contacts for indication of position and earthing switch, and with mechanical and electrical interlocks; - surge arresters type GXD 51 (item 1.3) with operation

2.

Technical documentation of the substation

2.1 Single-line diagram The substation type ST7- 35/6 kV single-line diagram with oil or dry type transformers is shown in the complete set of the substation diagrams. 2.2 Substation components The substation consists of the following functional modules: 35 kV switchgear block (Fig. 3) Two oil or dry type transformer blocks 35/6 kV, 2,500 kVA, 4,000 kVA, 6,300 kVA, 10,000 or 16,000 kVA, with manual or automatic voltage regulation on the 35 kV ide 6(10) kV switchgear block (Fig. 4), with vacuum circuitbreaker type VD4 in withdrawable version, consisting of two 6 kV sections, arranged in two-row design, in two or

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counters type GLKA (item 1.4), one piece per each phase; Surge arresters type GXD 51, to provide proper operation of the surge arrester operation counters, are isolated from the framework of the block with support insulators for a voltage of 1 kV. Connection of the 35 kV line to the substation is performed through the power supply terminals (item 1.6), fixed to the 35 kV support insulators (item 1.7). 35 kV bus coupler panel with circuit-breaker type VD4 in indoor, withdrawable version. The panel is equipped with the following: - 35 kV (35 kV, 1250 A, 25 kA) withdrawable vacuum circuit-breaker type VD4 - 300/5/5 A current transformers (other rated currents are available) - voltage transformers type VEN-36-14 with built-in fuses type 17CAV, 36 kV, 2 A. 35 kV bus riser panel The panel is equipped with the following: - 35 kV withdrawable busbar disconnector - voltage transformers type VEN-36-14 with built-in fuses type 17CAV, 36 kV, 2 A. 35/6 kV power transformer panel with vacuum circuitbreaker (indoor version, withdrawable). The panel is equipped with the following: - 35 kV (35 kV, 1250 , 25 kA) withdrawable vacuum circuit-breaker type VD4 - xxx./5/5 A current transformers, one per each phase. (Primary current of the current transformers depends on the power of the power transformer) Auxiliary transformer panel The panel is equipped with the following: - 35/0.231 kV, 100 kVA dry type transformer - 36 kV disconnector with 36 kV fuses Detailed information on the use of the 35 kV panels can be found in the technical description the SPY-35 switchgear operating instructions.

3.3.2

The complete switchgear type SPY consists of the following 6(10) kV panels: - two incoming panels - two voltage transformer panels - from six to nine outgoing panels for overhead or cable lines in section one - from six to nine outgoing panels for overhead or cable lines in section two - two busbar coupler circuit-breaker panels (with circuitbreaker and disconnector in each section adequately) - two capacitor battery panels - two capacitor batteries from 600 up to 1200 kVAr Detailed information on the use of the 35 kV panels can be found in the technical description the SPY-6 switchgear operating instructions. 3.3.3 Basic equipment of the 6(10) kV primary circuits panel consist of the following: - three-pole vacuum breakers type VD4, 12 kV, 630 or 1250 A in withdrawable version - current transformers type IMZ10, 12 kV - truck with voltage transformers in epoxy insulation type UMZ12-1, 6000:3/100:3/100:3V, 100 V, with fuses - outdoor surge arresters type GXD10 for 8 kV operating voltage and 10 kA discharge current - indoor surge arresters type GXR8 for 6.4 kV operating voltage, 10 kA discharge current (in 6(10) kV outgoing lines) - power fuses type WBP-6 for protection of voltage transformers. Each 6(10) kV panel is equipped with secondary circuit cabinet for control measurements, indication and telemechanics.

4.Substation secondary circuits

The substation secondary circuits are made according to the substation electrical diagrams. Detailed description of all functions of secondary circuit diagrams is included in the following documents: 1. OUTDOOR TRANSFORMER SUBSTATION type ST7 with 35/6 kV oil type transformers for the power of .kVA, with 35 kV and 6(10) kV vacuum circuit-breakers, and with a complete switchgear type SPY . Electrical diagrams of primary and secondary circuits. Telemechanics. 2. The technical documentation for the substation microprocessor device providing measurement, automatics, remote control and switchgear protection. Operators manual.

3.2 Power transformer block The substation uses a 35/6 kV power transformer oil or dry type, with the power of 2,500 kVA, 4,000 kVA, 6,300 kVA , 10,000 kVA or 16,000kVA with the following features: - manual voltage adjustment on the 35 kV side, after disconnection of 35 kV and 6 kV power, or - onload automatic voltage adjustment 3.3 6(10) kV switchgear block (Fig. 4) The 6(10) kV switchgear block consists of two or three segments (depending on the single-line electrical diagram of the substation), separately transported and joined on site. 3.3.1 General specifications: - rated voltage.........................................................6(10) kV - operating voltage................................................7 .2(12) kV - rated current of busbars.................................up to 3150 A - rated short time current, 1s......................................20 kA - rated peak withstand current....................................50 k - number of overhead and cable outgoing lines.........12 pcs. - vacuum circuit-breaker type.......................................VD4
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5.Substation design
5.1 The equipment and construction elements of each substation block are placed on separate skids and fixed using bolts. The skids are designed to be moved using a caterpillar tractor or lifted by a crane, and placed on a transport platform.

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5.2 Connections of the substation primary circuits are made with copper bars. Earthing connections are made with Zinc plated flat bars or copper bars. 5.3 Connections of the substation secondary circuits and connections between individual blocks are made using insulated copper wires or multi-conductor cables. Bars for connection of individual blocks, multi-conductor cables for power, control and indication connections between blocks are supplied with the substation. 5.4 The 35 kV switchgear block consists of two, and the 6(10) kV block of two or three segments, designed like prefabricated kiosks, joined together on site. Each kiosk of the prefabricated block of the 35 kV and 6(10) kV switchgear is equipped with double, water-proof roof, and external walls with thermoinsulation. Both gable walls, joined together during assembly of the block, are closed for transport with removable boards, protecting the kiosks internal equipment from atmospheric influences. Kiosks joints are sealed during assembly of the substation. The necessary external design elements of the block are delivered as complete set along with the substation equipment. Every block of the 35 kV and 6(10) kV switchgears provides a service corridor with two entrances. 5.5 High voltage panels of the 35 kV block with vacuum circuit-breaker and section disconnector are delivered in withdrawable version. All HV panels of the 6(10) kV switchgear block, except the capacitor battery cabinet, are delivered in withdrawable version. Panels with withdrawable parts are fitted with mechanical and electrical interlocks designed to prevent: - withdrawing of the truck with HV circuit-breakers into the service or testing position with closed circuit-breaker; - closing the circuit-breaker before locking the truck in service or testing position; - closing the earthing switch before moving the truck out to the testing position; - moving the truck into the service position with earthing switch on; 5.6 All metal parts of the substation are earthed to the metal skid framework. Each skid provides two earthing bolts for connection of the external earthing circuit. 5.7 The substation steel structure is made of Al/Zn plated steel sheet and painted. 5.8 Busbars and HV bar connections are painted with the following color paints: - yellow phase A, - green phase B, - red phase C, - black earth and earthing bolt heads. 5.9 The substation also provides: - service corridor lighting, - lighting of individual LV compartments of panels, - substation external lighting.
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5.10 Enclosure of the kiosk The enclosure of each 35 kV and 6 kV kiosk consists of the following elements: - bottom, - side walls, - roof. 5.10.1 Kiosk bottom The kiosk bottom is made as a carrying frame filled with thermoinsulation material, and allowing to join the block skids. The carrying framework has welded terminals marked with earth sign for connection of the substation external earthing circuit. All the 35 kV panels, 6(10) kV panels, auxiliary transformers, 110 V= and 220 V/50 Hz equipment cabinet, are joined to this frame, according to the single-line diagram. The kiosk bottom is fitted with special towing hooks mounted into the skids, used to lift the block for transport and to set it in the destination position. Blocks are lifted using a special traverse with ropes, supplied with the substation blocks. 5.10.2 Side walls Each side wall consists of a carrying frame and steel internal and external cover sheets, with thermoinsulation material between them. Doors with protective roofs are mounted in the side walls, allowing to enter the substation service corridor and access the internal equipment for service and maintenance. The corridor entry doors are equipped with door-locks. The doors provide eyelets and padlocks for sealing the substation. Other doors to the service corridor are also equipped with PANIC type door locks to provide safety of the substation personnel, and allow to open the door from inside. The side doors that provide access to the MV transformer compartment, panel bars with circuit-breaker and 35 kV coupler busbar or MV transformer, are locked with special pull-locks and triangular head bolts, engaged using special keys. 5.10.3 Roof of the kiosk The roof consists of a carrying frame and steel internal and external cover sheets, with thermoinsulation material between them. The roof protects the block interior from atmospheric influences. Supporting structures and 35 kV input panel primary circuit equipment are mounted to the 35 kV block roof. The complete 35 kV bushing insulators are mounted to the block roof, after removal of the transport cover. Use new seals with this operation. Support structures and 6(10) kV surge arresters are mounted to the 6(10) kV block roof. The complete 6(10) kV bushing insulators with metal covers are mounted on the roof of 6(10)kV kiosk, after removal of the transport cover. Use seals with this operation.

6. Advantages of the substation

Dimensions and transport weight of the completely assembled 35 kV and 6(10) kV blocks allows to deliver them by rail, truck or by ship.
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All individual substation blocks are designed for moving them on their own skids. The distance between skids along the substation axis is 1880 mm, and skid width is 400 mm. On the site of destination the substation can be mounted on: - special platform or concrete foundation, at the proper level to provide protection from flood or snowdrifts (see Fig. 5 and 6), - directly on flattened and dried land. The block unit pressure on the ground is below 5 N/cm2. The substation type ST7 is designed for operation without necessary presence of the substation operating personnel. The installed (inside the blocks) automatic temperature and humidity control systems guarantees normal operating conditions (Ambient temperature between 55C and +40C) for the primary and secondary circuit indoor equipment. The substation is designed to co-operate with remote control and service systems (telemechanics) in the following scope: - performing On/Off cycles of the 35 kV and 6(10) kV circuit-breakers, - applying interlocks to the individual automatic systems - indication of warning and emergency conditions at the substation - indication of 35 kV and 6(10) kV circuit-breaker operating positions - indication of improper heating operation - measurement of electrical values - fire indication system. The secondary AC and DC current devices are supplied from auxiliary power transformer, and do not require any additional supply from secondary circuits. All protection, automatics, control, measurement and indication systems are performed using different types of integrated microprocessor devices built into the LV panel cabinet, depending on the electrical diagrams. Detailed descriptions of all the substation secondary circuits are included with the substation electrical diagrams. The substation provides earthing for any part of the primary circuits with power off, using substationary earths. Simultaneously, the substation performs earthing interlock of the parts of primary circuits with power on. Switching operations using the 35 kV switch-disconnector incoming panel are performed outside of the block, with manual drive fixed to the side wall of the block. Switching operation using the 35 kV and 6(10) kV coupler circuit-breaker are performed from the service corridor or by means of telemechanic systems (see substation electrical diagrams). The cabinets and 110 V= and 220 V, 50 Hz secondary devices are accessed and serviced from the substation service corridor. Insulation of secondary circuits air or solid/air. Overhead power line panels are equipped with support insulators and bushing insulators. Indoor outgoing panels are equipped with epoxy support insulators and bushing insulators. High arc protection sensitivity, internal arc detection and isolation system, and immediate pressure reduction system
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make the 35 kV and 6(10) kV blocks of the ST7 substation safe for personnel and resistant to internal arc faults. Complete factory assembling of primary and secondary circuits reduces time of site assembly, which is limited to the mounting of the 35 kV blocks, support structures and 35 kV incoming panel equipment, dismantled before handling for transport. The assembly on site also requires connection of 35 kV and 6(10) kV block secondary circuits, connection of telemechanics concentrator (not included in the delivery), connection of the substation to the 35 kV overhead lines, insertion and connection of 35/6 kV power transformer primary and secondary circuits (supplied by the client). Design solutions, construction materials and anti-corrosion coatings guarantee many years of reliable operation of the substation, even in harsh natural environments.

7 . Installation of control cables between blocks

Install the designed cables and optical cables for connection of block secondary circuits in a special, sealed cable duct, supplied with the substation blocks. Fix the duct to the block base. Duct length (number of segments) can be determined on site; it depends on the distance between blocks.

8.Protection of the substation from atmospheric lightining discharge

Protection from atmospheric lightining discharges coming over the 35 kV overhead lines is provided by GXD51 surge arresters, installed in three phases from the side of 35 kV substation income see Fig. ST7-05/03-01. The GXD51 surge arresters are installed on the substation block roof, and are equipped with operation counter mounted outside the side wall of the 35 kV block. GXD51 surge arresters and cables from the arresters to the operation counters are isolated from the block structure using 1 kV support insulators. Protection of the substation and the near power lines from the lightning discharges should be made according to the local regulations.

9.Transport
Dimensions and weights of individual 35 kV and 6 kV blocks allow them to be transported using railway, truck and water transport means. The 35 kV and 6 kV blocks are also designed to be moved on their own skids. Skid distance is 1880 mm, skid width is 400 mm. The block unit pressure on the ground is below 5 N/cm2. Loading of the blocks onto the transport platforms is performed with a crane of the proper capacity, using a special traverse with ropes, supplied with the substation blocks 2) Disassembled devices should be placed inside the service corridor or in additional wooden boxes. Detailed description of all packaging can be found in PACKAGING TRANSPORTATION Instructions, found on each piece of a delivery.

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9.1 Railway transportation Use a crane with proper capacity to load the substation onto the rail cars. Lifting of blocks is allowed only using a special traverse with ropes, supplied with the substation blocks, and only using special hooks in the block base, marked according to standards. 9.2. Road transportation T ransportation of the substation on the road can be performed using special transport platforms. Lifting of blocks is allowed only using a special traverse with ropes, supplied with the substation blocks, and only using special hooks in the block base, marked according to standards. 9.3. Transportation on the substation own skids The substation blocks are designed to be moved on their own skids at short distances, on ground roads, with the speed of up to 20 km/h. 9.4 Fixing substation blocks on transport platforms To prevent longitudinal movement of the block on the transport platform place wedges on both ends of the skids, and secure the wedges with an additional supporting beam. Lateral movement of the block on the platform is prevented by beams fixed along each skid. Wedges and beams should be made of wood, and fixed with proper nails to the platform floor.

10.3 Visual inspection of the devices and apparatus When the assembly is finished, perform the following: - make sure the assembly was properly made - tighten bolts for equipment mounting and supporting structure - carefully clean all substation components to restore proper insulation - repair all damages of the anti-corrosion coatings caused by transport - perform inspection of the earthing equipment - remove all foreign items from the substation blocks - check for presence of 36 kV fuses in voltage transformer protection 10.4 Mechanical tests Perform the following: - set the 35 kV and 6 kV circuit-breaker type VD4 and its drive according to the Instructions of installation and operation of circuit-breaker type VD4 - test the operation of the 35 kV switch-disconnectors of incoming panels, paying special attention to the proper operation of the operating drive and earthing switch, according to the instructions - test operation of the 35 kV switch-disconnectors and their drive that protects the MV transformer, paying special attention to proper operation of the operating blades, according to the apparatus instructions - test the 35 kV and 6 kV circuit-breakers for proper operation - test all interlocks for proper operation 10.5 Earthing resistance measurement Use technical method of earthing resistance measurement. The value of the resistance should meet the requirements given in local regulations. 10.6 Electrical measurements Perform the following: - test the electrical strength of main circuit insulation or its fragments. The value of the resistance should meet the requirements given in national regulations. - test the electrical strength of the secondary circuit insulation or its fragments. The value of the resistance should meet the requirements given in national regulations. - perform inspection of all secondary circuit connections in all blocks and substations.

10. Substation assembly and setting up

10.1 Preparation of the site Each time, before installing the substation in a new place, prepare the site in the following way: - level and dry the area or built a special platform, or drive proper piles into the ground - install protective and operating earthing circuits - set the supporting structure of 35 kV and 6 kV overhead lines - build an external fence around the substation site (fence elements are not supplied). 10.2. Substation assembly Assemble the substation in the following order: - set substation blocks as indicated in the Fig ST7-05/03-02 - mount the 35 kV incoming panel in the space provided, according to the Fig. ST7-05/03-01 and Fig. 3 - assemble the 6 kV switchgear block - assemble the 35/6 kV power transformer block - mount external protection elements of secondary circuit block interconnections - connect secondary circuits between blocks according to the electrical diagrams - make settings of the secondary microprocessor device for protection, control, measurement and automatics - connect the substation to the telemechanics system - insert the 36 kV, 3.15 A fuses that protect the MV auxiliary transformer and the fuses that protect the 35 kV and 6 kV voltage transformers - connect the substation blocks to the external earthing circuit
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11. Commissioning
When all works, measurements and tests are successfully performed, connect the 35 kV overhead lines. Perform the commissioning of the substation in accordance with all your country regulations and procedures.

12. Operation
Operation and maintenance of the substation should be performed by properly trained personnel, in accordance with the contents of this manual, and especially with national regulations regarding HV equipment operation.

13. Periodical inspections, overhauls and maintenance

General inspection of the substation and installed equipment should be performed during every visit of the operating personnel, and also: - after automatic switch off caused by a fault current - in case of detection of short circuit of one phase to the ground - after severe storms and lightning in the substation neighborhood. When planning a general overhaul perform the following steps: - create a plan of the overhaul - obtain all the necessary instruments, spare parts and materials - instruct the overhaul team. During the overhaul: - perform the overhaul according to the plan - clean the insulators and insulation materials - check bolt joints - check interlock mechanisms - check HV apparatus and their connections - check secondary circuit equipment and connections.

NOTE
Inspections and overhauls should be performed at intervals indicated by the manufacturers of the equipment installed in the substation, unless the national regulation require shorter periods for specific apparatus.

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1 2 3 4 5 6 7 8 9 10 11 35 kV block 35/6 kV power transformer block 35/6 kV power transformer block 6 kV block Busbar bridge 35 kV to the power transformer Busbar bridge 35 kV to the power transformer Busbar bridge 6 kV to the 35/6 kV power transformer 4000 kV 6 kV incoming busbar bridge 6 kV overhead line entry Busbar bridge 35 kV to the 35/6 kV power transformer 6 kV cable connection compartment Fig. 1 General view of the transformer substation type ST7: A) with oil and air transformers and with cable outgoing lines B) with dry transformers and cable outgoing lines

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1 2 3 4 5 6 35 kV block No.1 35 kV block No.2 T ransformer block No.1 T ransformer block No.2 6 kV block No.1 6 kV block No.2

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Fig. 2. General view of the transformer substation type ST7: top view

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1.1 1.2 1.3 1.4 1.5 1.6 1.7 35 kV switchgear panel 35 kV switch disconnector 35 kV surge arrester Surge arrester operation counter Switch disconnector drive Line terminal Support insulator Fig.3 35 kV block of the substation type ST7

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4.1 4.2 4.3 4.4 4.5 Outgoing overhead line panel Outgoing cable line panel Service corridor 6 kV incoming busbar bridge support structure for 6 kV overhead line.

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Fig.4 6(10) kV block of the substation type ST7

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1 2 3 4 5 35 kV block no. 1 35 kV block no.2 T ransformer block 6 kV block Supports pillars Fig.5 ST7 substation block arrangement plan with oil transformers

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1 2 3 4 5 35 kV block no. 1 35 kV block no. 2 T ransformer block 6 kV block Supports pillars

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Fig. 6 ST7 substation block arrangement plan with dry transformers

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ABB Sp. z o.o. Branch Warsaw ul. Zegaska 1, 04-713 Warsaw Poland

1YMS603002-en Publication 09.2004