The block packaged transformer substation
- Unit transformer substations with voltage of 35, 110, 220 kV
- Technical characteristics
Scope of application
SVEL Group makes modular integrated transformer substations, voltage classes: 6 (10), 35, 110, 220 kV (Тech.conditions 3412-001-63920658-2009), carrying out functions of a general contractor (ready-to-operate).
Modular integrated transformer substations is designed to receive, convert and distribute electric power of three-phase alternating current, 50Hz power frequency. BKTP can be used on the territory of the Russian Federation and abroad to provide energy to the industrial objects of oil and gas industry, mining industry, the machine-building enterprises, railway transport, urban and utility facilities, agricultural zones and big construction sites.
Тype variants of modular integrated transformer substations are designed on the base of the book «Тype principle electric diagrams of distribution equipment with voltage 6-750 kV, substations and application notes» №14198тм-т1, «ENЕRGОPROEКТ» Institute, Моscow city — 1993.
Modular integrated transformer substations are designed for outdoor installation on the height nor more than 1000m above the sea level and operating conditions, corresponding to versions УХЛ (NF) and ХЛ, placement category 1 according to GOST standard 15150.
Modular integrated transformer substations, voltage classes 6 (10) — 220 kV, designed by specialists of SVEL Group, are modern layout solutions, corresponding to “The rules on design of power electric installations”, and also requirements and recommendations of JSC «FSK ЕES».
The main parameters and characteristics of modular integrated transformer substations correspond to the values, indicated in the table «Теchnical parameters of modular integrated transformer substations ».
The present catalog contains the description, main characteristics, diagrams and other technical information concerning modular integrated transformer substations and its component parts.
MITS — 110 — 4Н — 16 — УХЛ1
MITS — Modular integrated transformer substation;
110 — Nоminal voltage = 110 kV;
4Н — Diagram of the switchgear electrical connections;
16 — Transformer cаpacity = 16000 kVА;
УХЛ1 — Climatic modification УХЛ(NF) of the placement category 1 according to GOST 15150.
Теchnical pаrаmеters of the factory-assembled switchgears
№ Pаrаmeter Charаcteristics Remarks Outdoor switchgear 220 kV Outdoor switchgear 110 kV Outdoor switchgear 35kV Side 6(10) kV 1 Nоminal voltage, kV 220 110 35 - - highest 220 110 35 - - medium 35, 110 35 - - - lowest 6, 10, 35 6, 10 6, 10 - - 2 Power transformer capacity, kVА Up tо 125000* Up tо 63000* Up tо 16000* - *to be approved according to the requirements of the substation project 3 Nоminal current, А The switchgear cubicles 1000, 2000 630, 1000, 2000 630, 1000 - According to the diagrams: 110-12…13; 220-7…14. Cabinet of the switchgear input - - - 630, 1000, 1600, 2500, 3150 See the catalog «Factory-assembled switchgears» Circuits of lines and electrical jumpers max 1000 max 630 max 630 - - Circuits of power transformers 630 630 630 - - Circuits of the assembled busbars 1000, 2000 1000, 2000 630, 1000 - - 4 Through current of short circuit (amplitude), kА 65, 81* 65, 81* 26 51, 81* *For switchgear cubicles and assembled basbars with In=2000А 5 3 sec withstand thermal current, kА 25, 31,5 25, 31,5 10 - - 6 Climatic modification and the placement category У — ХЛ placement category 1 GOST 15150 7 The wind speed grade I — V PUE (the 7th edition) 8 The ice-covered ground grade I — VII PUE (the 7th edition) 9 The air pollution concentration I — IV GOST 28856 10 Seismicity of the construction site, points 7 — 9* According to МSK-64 scale; *reinforced supporting metal structures 11 Average lifetime of BKTP, years 30 -
Modular integrated transformer substations may consist of:
- Power transformers (аutotransformer);
- Outdoor switchgears 220, 110, 35, 6(10) kV;
- Rigid and flexible busbars;
- Cable structures;
- Cabinets of the secondary control wiring;
- Contact-stretching accessories;
- Outdoor factory-assembled switchgears (10) 6 kV;
- Substation control house (SCH);
- Lighting mast and lightning;
- Lightning protection (lightning rods etc);
- Safety fence of the substation
The completeness of modular integrated transformer substations can be modified according to the individual requirements of the project and the Customer and shall be indicated in the questionnaire of a substation (see Annex: «Questionnaire»).
Power transformers installed in modular integrated transformer substation, designed and made by SVEL Power transformers, are used for energetic objects, electrified transport and substations of the industrial enterprises rated up to 250 МVА, voltage classes are up to 220 kV (of ТДН, ТРДН, ТДТН types) according to the range of GOST 12965-85. Power transformers, made by domestic and foreign manufacturers also can be applied.
Converter transformers are used for plants of nonferrous metal electrolysis and chemical factories, electric drive of rolling mills and electric-arc furnaces in metallurgy, electrified railway and industrial transport, specific electro-physical research installations. Transformers meet all the requirements of GOST 16772-77.
Outdoor switchgears 6 (10), 35, 110, 220, as a part of BKTP, are switchgears with supporting metal structures, having high voltage equipment installed on them, also rigid busbars, the elements of flexible busbars, cable structures, cabinets of the secondary control wiring, earthing elements. Supporting metal structures for the high voltage equipment are made for modular integrated and separate units versions. (Тechnical conditions №5264-002-63920658-2009 «Меtal structures for modular integrated transformer substations of 6(10) — 220 kV).
Supporting metal structures are certified according to the system of GOST Р, their quality and carrying capacity are confirmed with calculations and test reports:
- Test report № 19-10 dated 16.03.2010 of the Test center «Stavan-tеst» of JSC «The Ural Institute of Metals», reg. № РОСС RU. 0001.22ЭФ05 dated 28.05.2007;
- Test report №15.04.10 dated 05.04.2010 of the Test center «UralNIIAS» of JSC «The Ural research institute of architecture and construction», reg. № РОСС RU.0001.22СЛ07 dated 04.12.2009
Outdoor switchgears 110 kV (Diagram 110-4Н)
- Supporting blocks
- High voltage equipment, including equipment of the high-frequency communication
- Rigid busbars
- Contact-stretching accessories
- Cable structures
- Cabinets of the secondary control wiring
- Support insulators
- Elements of earthing and lightning protection
- Service platform
Figure 1 — Composition of the ORU-110 kV development of SVEL Group
Figure 2 — Lay-out example of the outdoor switchgear-110 kV (diagram 110-4Н) designed by SVEL Group
Metal structure with the installed high voltage equipment has the following designation:
Abbreviation for the high voltage equipment:
ВЗ — high-frequency choke
ОПН — overvoltage limiter
ВК — Breaker
ОПНн — overvoltage limiter of the neutral
ЗЗ — earthing lead
ПР — fuse
КЗ — short-circuiter
РЗ — disconnector
КМ — cable coupling sleeve
СИ — pulse counter
КС — coupling capacitor
ТН — voltage transformer
ОД — isolating switch
ТТ — current transformer
ОИ — supporting insulator
ТСН — service transformer
ШО — busbar support
ФП — coupling filter
ШО — busbar support
Б. 110. ВК — 25 / 14,5 — УХЛ1
Б — Supporting block
110 — Nоminal voltage 110 kV
ВК — Breaker
25 — Height of the supporting metal structure 25 dm = 2500 mm.
14,5 — Distance between phases in the breaker 14,5 dm = 1450 mm.
УХЛ1 — Climatic modification УХЛ (NF), placement category 1.
Figure 3 - Block disconnector Б.220.Р3.2(1)-25,8/35,7-УХЛ1
Figure 4 - Block razedenitelya, current transformers, insulators Б.220.Р3.2/ТТ/ОИ-25/35,7-УХЛ1
Figure 5 - Power of the coupling capacitors Б.220.ВЛ-25,8/35-УХЛ1 and block breaker Б.220.ВК-18/23-УХЛ1
Figure 6 - Power switch Б.220.ВК-25,8/35,7-УХЛ1
Figure 7: Block breaker Б.110.ВК-0,7/14,6-УХЛ1 and Block breaker Б.110.Р3.2(1)-25/20-УХЛ1
Figure 8 - Power switch Б.110.ВК.-22,3/17,5-УХЛ1 and Block insulators Б.110.ОИ-24,5/20-УХЛ1
Figure 9 — receiving unit ВЛ Б.110.ВЛ-24,6/26-УХЛ1 and Block of current transformers Б.110.ТТ-21/20-УХЛ1
Figure 10 — Neutral grounding block Б.110.3Н-32/00-УХЛ1 and Block of voltage transformers Б.110.ТН-22/20-УХЛ1
Figure 11 — Block coupling capacitors Б.110.КС-24,6/20-УХЛ1 and Block of overvoltage Б.110.ОПН-26,6/20 УХЛ1
Figure 12 — Block breaker with acute renal failure (for two-winding power transformer) Б.035.ВК/Р3.2/ОПН-14/10-УХЛ1 and Block breaker with acute renal failure (for three-winding power transformer) Б.035.ВК/ТТ/РЗ/ОПН-14/10-УХЛ1
Figure 13 — Block voltage transformer Б.035.ТН/Р3.1/ПР/ОИ-20/10-УХЛ1 and Block of voltage control Б.035.ТН/Р3.1/ПР/ОИ-20/10-УХЛ1 (compact)
Figure 14 — block disconnector Б.035.Р3.2.(1)-21/10-УХЛ1 and block insulators Б.035.ОИ-35/10-УХЛ1
Figure 15 — Block insulators Б.010.ОИ-23/05-УХЛ1
Modular integrated version:
* Тhe type of equipment is according to the completeness
Example of designation of the modular integrated design:
КБМ. 110. ВК/ РЗ/ ТТ — УХЛ1
КБМ — Mоdular integrated design,
110 — Nоminal voltage 110 kV,
ВК/ РЗ/ ТТ — Breaker/ Disconnector/ Current transformer,
УХЛ1 — Climatic modification УХЛ (NF), placement category 1
Rigid busbars, designed by specialists of SVEL Group are designed to transfer and distribute the electric power between the high voltage equipment in outdoor and indoor switchgears of Modular integrated transformer substations. Rigid busbars are made according to the technical conditions 0ЭТ.538.002 «Rigid busbars for outdoor switchgears of voltage classes 6 (10) — 220 kV». Application of rigid busbars allows to refuse from the busbars portals, making foundations under them and laying of flexible connections, this leads to the floor space reduction of the switchgear, the reduction of mounting works and materials saving.
Figure 16 —Rigid busbars according to the diagram 110-4Н
Designation of the rigid busbars:
Pаrameters of the rigid busbars
Pаrameter Version Rated current, А 1000 2000 Short-time thermal current (3 sеc.), kА 31,5 Short time electrodynamic current (impact value, <0,1 sеc.) kА 80 Climatic modification and the placement category according to GOST 15150-69 УХЛ 1 — ХЛ 1
Design of the rigid busbars consists of the following elements and units:
- Busbars of tubular and plane section are made of aluminum alloy 1915.Т, having good electrical conductivity and rather high strength;
- Connections of the busbars are made as steel clamps of round or plane section and they are located on a support plate. The connection elements allow to make a rigid fixation of the busbar (console), or free fixing, that gives possibility for lengthwise movement of the busbar if the temperature deformations occur (joint-hinge);
- Cоmpensators of the temperature deformations are made of aluminum wire, grade А, acc.to GOST 839-80. The wire section is chosen depending on the rated current value. The cоmpensators also play the role of a current-carrying flexible connection between the busbars.
Connections of the busbars:
Connections of the busbars 110 kV.
Fixing of the horizontal busbar and asupport plate is done with steel clamps of round section with thread.
Figure 17 — Connections of the busbars 110 kV
Connections of the busbars 220 kV
Fixing of the horizontal busbar is done with bent clamps of sheet steel
Figure 18 — Connections of the busbars 220 kV
Rigid busbars are designed for rated currents from 1000 А tо 2000 А.
From the outside the busbar surface can have a varnish-and-paint coating, or color marking done with ring markers that are made of a heat shrink tube. Colors depend on phases according to PUE.
Rigid busbars are designed for outdoor installation at the height of nor more than 1000 m above the sea level and operating conditions, corresponding to versions УХЛ (NF) and ХЛ, placement category 1 according to GOST standard 15150.
At present the rigid busbars using cast supports are being designed.
Figure 19 — Design of the cast busbar supports
Figure 20 — Rigid busbars on the cast supports
Advantages of the rigid busbars with cast supports
Increased mechanical strength
Application of bolt connections instead of welded ones when mounting the busbars allows to avoid the risk of annealing the metal and the reduction of mechanical strength of the busbars in zones with welded seams.
High exploitation reliability of electrical contacts
As all mechanical forces occurred in the connections of busbars are received by cast supports, this allows to exclude the negative influence of such conditions on the state of electrical contacts in flexible connections.
The compensation of heat expansion and deviation of foundations
The cast busbar supports provide the possibility for free busbars movements at the temperature length change, аnd also at small deviation of foundations that occur at the construction and exploitation.
High speed and simplicity of the busbar assembly and disassembly
Rigid busbars have a high degree of prefabrication. Application of cast busbars supports and bolt connections allows to make a fast assembly without welding equipment and to change busbars quickly.
Long-term color marking of phases
Phase marking is carried out with cuts of high voltage heat shrink tube made by «WOER»™ company. This color covering has a wide range of working temperatures, a humid resistance, long service life holding the color and it’s universal (Marking is possible in any zone of the busbar of any length acc. to the customer requirements). This color marking corresponds to the requirements of PUE.
High damping properties
Application of the cast busbar supports allows to significantly reduce or damp completely the amplitude of wind resonant oscillations of the busbars due to the dissipation of energy on a big friction surface in cast supports (they play a damper role).
Contact-stretching accessories are applied for electrical connection of the high voltage equipment. “SVEL” Group” uses certified contact-stretching accessories for its substations (line, сoupling, supporting, stretching, protective, соnnecting accessories) that are maintenance free during the whole service life.
They include the following components:
- Сonducting flexible connections: aluminum or steel reinforced aluminum wires according to GOST 839-80. The wire brand, its section and number of wires in a phase are defined based on the project documentation for substation and depending on the rated currents and requirements of PUE;
- Contact clamping device: type certified devices, used to connect flexible wires with the outputs of high voltage equipment. They are chosen depending on the wire section and type of material of the equipment contact plates;
- Stretching and supporting elements: type clamps designed for laying the flexible connections inside the outdoor switchgear acc.to the requirements of PUE, аnd also to be connected to the power lines.
Control and power cabling is carried out through domestic and foreign hinged cable trays. The hinged cable trays are mounted directly on the supporting metal structures. Cables go down to the ground cable routing. The application of hinged cable trays allows to refuse from laying the ground cable routing along the outdoor switchgear; it saves the time for mounting and reduces expenses on the substation.
The secondary control wiring from the equipment to the cable trays and from the trays to the terminal-block cabinets is laid in metal hoses or in plastic corrugated hoses.
The necessity of including in the scope of supply the suspended cable arrangement is to be indicated in the questionnaire of the substation.
The location of the cable routing is defined by a design organization.
Factory-assembled switchgears 10 (6) kV
Factory-assembled switchgears КРУ 10 (6) kV, designed by specialists of SVEL Group, are applied as distribution points of the modular integrated transformer substation. Factory-assembled switchgear by SVEL consists of separate cabinets and the equipment in each has the same type of connection to the collecting busbars.
The designed factory-assembled switchgears have the following advantages:
- Possibility to install any type of equipment inside the cubicles;
- Factory-assembled switchgears by SVEL consist of blocks, it leads to the quick realization of the customer wishes (it’s enough just to change a block);
- Small dimensions due to the maximum use of the inside space;
- The structure doesn’t have welded seams, the connections are either bolt or riveted, and it allows to apply a galvanized sheet for all elements of the factory-assembled switchgears by SVEL;
- The double metal-particle coating of metal structures allows to avoid corrosion during 25 — 30 years.
The detailed technical information about factory-assembled switchgears is given in the catalog «Factory-assembled switchgears of КРУ — СВЭЛ series».
Substation control house
The Substation control house (SCH) is designed and used for a trouble-free transmission and distribution of power. The SCH is a modular house, where we locate the equipment of auxiliary circuits of the relay protection, the automatic equipment, the equipment of control and of the high-frequency connections, of the telemechanics.
The SCH consists of separate functional units, that are joined together and installed in a house where the following equipment is already arranged: the auxiliary low voltage electrical switchboard of direct and alternative current, devices of the relay protection, the automatic equipment, the equipment of control and alarm signaling. All essential that is necessary for functioning is provided in this house: electrical heating, lightning, air ventilation and communications.
The number of units in the SCH and arrangement of auxiliary rooms, the type of contol panels are defined by a project organization individually for a specific object according to the recommended arrangement.
As a rule the SCH consists of:
- Control panel of differential protection of the power transformers;
- Panels of the automatic control of power transformers under load;
- Control panel with the section switches;
- Protection panel of the upper voltage line;
- Panels of the voltage protection;
- Input and distribution of auxiliary voltage for the substation;
- Control cabinet of the control current;
- Set of a power supply without failures for the control current;
- System of the central alarm;
- Control panels of the high-frequency communication;
- The Control panel of teleautomatics;
- Terminal-block cabinets.
Terminal-block cabinets are provided to connect the outside control cables. These cabinets are installed in every row of the low voltage electrical switchboard of the relay protection and automatics.
Lightning of the SCH is carried out with luminescent lamps. The heating is carried out with electrical heaters, located along the walls and in the floor. Manual or automatic control of the heating.
The SCH is equipped with a natural inlet ventilation via special louvre windows and the exhaust ventilation with a fan. Installation of an air conditioner is also possible.
Pоrtals are designed and manufactured on the base of the book «Universal steel portals of the outdoor switchgears 35 -150 kV» №3.407.2-162, «Universal ferroconcrete and steel portals of the outdoor switchgears 220-330 kV» №3.407.9-149, designed by the North-West department of «ENERGOSETPROEKТ» Institute, also the portals can be customized.
Portals can have a hot-dip galvanized coating acc. to GOST 9.307, or can be made with cold galvanizing.
At present the portals on bolt connections are being designed.
Lightning masts and lightning
For technical lightning of BKTP we apply lightning installations with two lamps, 1000Wt each, oriented to opposite directions along the cubicles. As a rule, the lightning installations, are fixed on the supporting metal structures of the receiving unites of the support insulators, at the hight of about 7m above the layout level. The design of the lightning installations allows to maintain the lamps directly from the ground.
Lightning masts are also applied for lightning of BKTP. They are manufactured on the base of the book «Projector masts and free-standing lightning rods» №3.407.9-172, designed by the North-West department of «ENERGOSETPROEKТ» Institute.
Earthing of the metal structures with the high voltage equipment, of the power transformers tanks, of the cabinets of factory-assembled switchgears and of the other metal parts is carried out with steel strips 4х40 GOST 103-76, one end of which is connected with the equipment using the earthing bolts and another end is welded with beams or frames of the support structure for the electrical equipment. The support structure is earthened directly to the earthing loop of the substation by welding. The earthing strip is covered in black color in its location. The earthing loop of the substation is calculated by the project organization.
The elements of BKTP can be installed on different foundation types. The type and its location is defined by the project organization basing on the geological engineering survey.
The following foundations are applied:
- slightly underground;
- monolith foundation post;
- piled (stands, screw piles, drilled piles, drive piles);
- single foundation beam;
- double foundation beam.
When the supporting metal structures are installed on the piled foundations and foundation beams it’s necessary to apply some adapter elements (grillage) that are screwed with the support plates of the metal structure columns.
For other types of foundations the columns of metal structures are installed directly on the foundations using the anchor bolts. The support plates of columns have Ш35 mm holes for the anchor bоlts М30 of the square 400х400 mm.
It’s possible to install the supporting metal structures on the foundations according to the individual requirements of the project.
The function of the outside lightning protection at the object is performed with lightning rod and lightning conductors, which provide protection from direct lightning strokes. Lightning rods are installed on the busbar portals 35-220 kV and supports of power lines 35-220 kV.
The system of the outside lightning protection, based on the lightning protection grid, is designed individually for each object.
The Safety fence of ьodular integrated transformer substations is made according to our own design documentation. The fence consists of the welded mesh panels, which are assembled directly at the object by welding with stand supports from steel tube. On the top of the fence all around there is a spiral barbed-wire fence ОКС 54/10 acc.to ТУ-1470-001-39919268-2004.
Filling-in of the questionnaire
The questionnaire is filled-in according to the set form. Changing of the form, its dimensions and content is not admissible. The questionnaire form for Modular integrated transformer substation is given on the page 40-41 of this catalog. The questionnaire forms for the factory-assembled switchgears and the SCH are filled-in according to the catalogs of this type of products.
The questionnaire form, signed and stamped by the Customer, shall be sent to the Manufacturer in 1 (оne) copy.
All columns of the questionnaire form shall be filled-in, in case of the data absence in columns it’s necessary to make a line.
In the part «Installed equipment» it’s necessary to indicate the type and all parameters of the equipment indicating in the column «additional requirements» the conditions that influence on the completeness and design of the equipment incorporated in BKTP.
In the part «Requirements to the rigid busbars», it’s necessary to indicate the values of the short-time thermal current and electrodynamic withstand current, the admissible continuous current of the rigid busbars. It’s also necessary to indicate the type of rigid busbars (welded or on the cast supports) and variant of marking (ring markers or continuous covering).
In the part «Climatic conditions of the construction site» it’s necessary to fill-in all columns, excluding «Additional requirements». The material and the type of the supporting metal structures as well as the design and diameter of the busbars in the rigid busbars depend on correct filling-in of this part.
In the part «Additional requirements» it’s necessary to indicate the type and the height of the foundation above the layout level (+0.000), and also this part is important if you order suspended cable structures.
In the part «Scope of supply» blocks shall be indicated according to the above indicated designation (see the part Outdoor switchgears). If you order portals and lightning masts you should indicate their complete designation according to the type catalogs of this product. (see the part Portals).
The questionnaire shall have the following attachments: a single-line diagram, the layout and dimensions of the substation, the foundations and supports.
The most complete and correct filling of the questionnaire significantly reduces time for additional approvements and development of the design documentation for modular integrated transformer substation.
- Certificate of SROs 'Energostroy' of the admission to a particular kind or kinds of work that affect the security of capital construction Validity is not limited
- Certificate of SROs 'Energoprojekt' of the admission to a particular kind or kinds of work that affect the security of capital construction Validity is not limited
- Valid until 21/07/2017
Advantages SVEL Modular integrated transformer substations
Reduction of term for project designing
Use of catalogs with typified product.
Easy ordering process
Use of symbols for the main component parts of KTPB, that reduces the time to approve an order.
Universality of modules — possibility to install any type of high voltage equipment taking into account individual requirements of a project.
Possibility to modernize the existing switchgears
- Modules are adaptable to any type of equipment.
- Rigid busbars can be installed on a wide range of support insulators and disconnectors.
- Layout design of the outdoor switchgear takes into account the individual requirements of a project.
Reduced delivery time
Presence of the developed design documentation.
Reduced period of mounting
- Application of bolt connections instead of welded ones in modules with equipment and in rigid busbars.
- Check assembly at the manufacturer allows: to exclude incomplete supply; to check assembling of the equipment.
- Application of rigid busbars allows to refuse from the busbars portals, making foundations under them and laying of flexible connections.
Reduced floor space to arrange the switchgears
- Application of rigid busbars allows to refuse from the busbars portals, as a result it reduces the distance between the switchgear cubicles.
- Application of the modular integrated design allows to reduce the number of foundations in comparison with the design of separate units.
- Application of the suspended cable arrangement allows to refuse from the expenses on the additional works of laying the ground cables.
- Рosition of cabinets of the secondary control wiring directly on the supporting metal structure of modules allows to refuse from the expenses on making foundations under them.
Unit transformer substations with voltage of 35, 110, 220 kV