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Gas-insulated switchgear ELK-3 C, 420 kVHigh performance in a smaller footprint

2 GIS ELK-3 C, 420 kV | ABB

ABB is a leader in power and automation technologies that enable utility and indus-try customers to improve their performance while lowering environmental impact. The ABB Group of companies operates in around 100 countries and employs about 150,000 people.

ABB offers a wide range of high-voltage products up to 1200 kV that help enhance the reliability, efficiency and quality of power in transmission and distribution grids, power plants and industries while minimizing environmental impact. The wide prod-uct range is complemented by a comprehensive service offering.

ABB is the global leader in high-voltage GIS technology with more than 23,000 bays installed around the world. In 2009, ABB commissioned a GIS rated to handle more than one million volts (1200 kV), with a transmission capability of 6900 megawatts, reaching new heights in terms of global voltage levels. We pioneered high-voltage GIS in the mid-1960s and with the introduction of the compact 420 kV, we continue to drive technology and innovation. Our product portfolio comprises a full range of advanced GIS for voltages from 72.5 kV to 1200 kV.

ABB and 50 years of GIS innovation

ABB | GIS ELK-3 C, 420 kV 3

ABB and 50 years of GIS innovation 2

The ELK-3 C, 420 kV 4

Applications 4

Benefits 4

High performance ratings in a compact design 4

Low space requirements 4

Shortest transportation, installation and commissioning time 4

Low environmental impact 4

Highest product quality 4

Convenient operation and serviceability 4

Maximum flexibility 5

Reliable, well proven technology 5

Advanced features for digital substations 5

Technology 5

The ELK-3 gas-insulated switchgear from ABB 5

ABB’s high-voltage circuit-breaker 6

The circuit-breaker 6

The circuit-breaker operating mechanism 7

ABB’s disconnectors and earthing switches 8

The disconnector 8

The earthing switch 9

ABB’s voltage and current transformers 10

The voltage transformer 10

The current transformer 11

Advanced features for digital substations 11

ABB’s terminals and connecting elements 12

The connecting elements 12

Surge arresters 12

The terminal connections 13

Transformer connections 13

Cable terminations 13

SF6-air bushings 13

ABB’s local control cubicle 14

The local control cubicle (LCC) 14

Advanced features for digital substations 14

ABB’s commitment to total quality control 15

Enhancing eco-efficiency over the life cycle 16

The life cycle phases 16

Manufacturing phase 16

Use phase 16

End of life phase 16

Worldwide success 17

Technical data 18

Table of contents

4 GIS ELK-3 C, 420 kV | ABB

ABB holds a distinguished record of innovations in gas-insulated switchgear (GIS) technology and our latest ELK-3 series for 420 kV is designed to break several performance barriers.

In a power system, switchgear is used to control, protect and isolate electrical equipment thereby enhancing the reliability of electrical supply. With GIS technology, key components including contacts and conductors are protected with insulating gas. Compactness, reliability and robustness make this a preferred solution where space is a constraint such as in mega cities or in harsh environmental conditions.

The compactness of this GIS, which has a dimension of 7715 mm (length) x 2250 mm (width) x 4378 mm (height including voltage transformer), makes it ideal for installations with constrained space and fast installation requirements where a traditional GIS with the 420 kV, 5000 A and 63 kA ratings does not fit.

The new design reduces product volume by up to 33 percent compared to its predecessor resulting in a considerably smaller footprint and reducing infrastructure such as land and building costs by 40 percent.

Due to the 420 kV’s compact and advanced design, it can be factory assembled and fully tested, and shipped as one bay with all secondary cabling and local con-trol cubicle in a container and on low bed trailers instead of many assembly units delivering a remarkable 40 percent reduction in installation and commissioning time compared to competing switchgears.

In addition to time and cost efficiencies, the ELK-3 C is also very environmentally friendly. Because of its smaller size, the amount of SF6 insulating gas required is about 40 percent less than competing switchgears.

The reduced amount of sealing, flange connections and support structures makes efficient use of resources by reducing thermal losses and infrastructure investments. The use of less packing material and streamlined transportation improves your carbon footprint.

The latest ELK-3 is fully assembled and tested in a manufacturing facility that uses an advance flow production system that adheres to ABB internal quality and manufacturing excellence procedures. All bays are produced and tested in excellent conditions under the strict supervision of ABB’s engineers and GIS experts.

Together with the integrated local control cubicle front panel, the drive cubicle for all drives for disconnector and earthing switches provides easy access for opera-tion of the equipment. The drives carry position indicators, hand crank access and padlocks at the operator corridor.

Gas density information can be supplied with combined density sensor/monitor and indicated on the front panel. All instrument transformers are wired to the control cubicle and have no additional interfaces in-between. A service platform above the bays gives convenient access to viewports and gas handling equipment.

The ELK-3 C, 420 kVPerformance that addresses today’s power challenges

Applications

BenefitsHigh performance ratings in a compact design

Low space requirements

Shortest transportation, installation and commis-sioning time

Low environmental impact

Highest product quality

Convenient operation and serviceability

ABB | GIS ELK-3 C, 420 kV 5

Full sets of standardized connection elements allows for all possible configurations and building optimization, including integration into existing buildings, giving you ut-most flexibility in the shortest possible delivery time. We offer standardized solutions for the switchgear as well as for the control cubicle. With fewer parts to connect and specific flange protection against environmental elements, you are assured of a highly reliable SF6 insulation.

ABB believes that innovation is key to ABB’s competitive advantage and it has consistently invested in research and development to become a market leader. The ELK-3 is based on pioneering GIS technology since the 1960s and installation in over 100 countries. It complies with or exceeds the latest international standards (IEC/ANSI) and has been type tested in independent laboratories.

To ensure an interoperable and future-proof substation, the ELK-3 has been de-signed to incorporate the core values of the IEC 61850 standard. The standard defines strict rules for realizing interoperability between functions and devices used for protection, monitoring, control and automation in substations independent of the manufacturer which means investing in the latest 420 kV GIS is safe and the life cycle of your equipment is long-term.

The ELK-3 GIS from ABB is built on 50 years of pioneering research and develop-ment and experience delivering over 23,000 switchgear bays in over 100 countries. Our switchgears are crafted using standardized and modular components that en-able the construction of common layouts and bus schemes.

Maximum flexibility

Reliable, well proven tech-nology

Advanced features for digital substations

TechnologyThe ELK-3 gas-insulated switchgear from ABB

ELK-3 switchgear components

Circuit-breakers

Disconnector and earthing switches

Voltage and current transformers

Connecting elements

Control & protection

6 GIS ELK-3 C, 420 kV | ABB

ABB’s high-voltage circuit-breakerReliable, well proven technology

At the core of our switchgear system is the advanced double-motion puffer circuit-breaker with one chamber and an optimized and compact layout that minimizes the volume of SF6 insulating gas required by 20 percent. The PEHLA-certified circuit-breaker is designed to provide optimal performance and low maintenance.

Each circuit-breaker comprises three single-phase breaker poles. Each pole con-sists of the spring operating mechanism, the interrupter column with one interrupt-ing chamber and the enclosure with the basic support structure. During overhauls, the interrupter unit can be removed easily from the enclosure and replaced by a new unit.

The circuit-breaker uses the double-motion puffer operating principle. At high cur-rents, the energy to extinguish the arc is produced by the arc and by the puffer. At low currents, the energy to extinguish the arc is only supplied by the puffer.

Double-motion puffer interrupters with one interrupting chamber require far less op-erating energy than single-motion puffer two-chamber interrupters with comparable performance reducing significantly the weight on the foundation. Arcing contacts on both sides of the breaker are coupled by a gear and move in opposite directions (double-motion), which minimizes mechanical reaction forces and further reduces the necessary energy for operation.

The circuit-breaker

Circuit-breaker with operating mechanism

ABB | GIS ELK-3 C, 420 kV 7

The circuit-breaker has one compact operating mechanism per pole for single- and three-pole operation. We use the spring operating mechanism in our entire GIS portfolio from 72.5 kV to 1200 kV, and ABB has supplied more than 105,000 operat-ing mechanisms worldwide with this operation principle.

The operating mechanism has a modular design where the working module, operat-ing the breaker, is surrounded by the other functional parts of the operating mecha-nism. This arrangement provides compactness and easily accessible modules.

The hydraulic pump moves oil from the low pressure oil reservoir to the energy storage side, builds up pressure and charges the spring assembly. When required this energy is released to operate the circuit-breaker. To achieve this, the hydraulic pressure is applied to the piston of the main cylinder by a valve.

The main cylinder’s design is based on a differential piston principle:The upper side of the piston is always connected to high pressure (red). A valve is used to connect the lower side of the piston either to high or low pressure (blue). For a close-operation the difference of the piston’s pressurized areas is relevant. For an open-operation the difference in the pressure on the piston’s areas is rele-vant.

The energy of the movement is always provided by the spring assembly. It is partly discharged by any operation (O or C). This discharge is sensed by a spring travel switch, and the hydraulic pump is switched on. The pump replenishes the high pressure oil volume and stops after recharging. However, the stored energy of the operating mechanism is sufficient to switch a complete O-CO operating sequence without recharging.

The circuit-breaker operat-ing mechanism

How it works

Operating mechanismFunctional principle (open position)Functional principle (close position)

8 GIS ELK-3 C, 420 kV | ABB

ABB’s disconnectors and earthing switchesConvenient operation and serviceability

Our disconnector and earthing switches are easy to operate and equipped with safety features that contribute significantly to operational safety.

Disconnectors provide a safe insulating gap to isolate sections with different poten-tial, for example busbar disconnectors, which isolate a feeder. The ELK-3 contains three variants – two busbar disconnectors and a linear disconnector. The linear dis-connector can optionally be equipped with a fast-acting earthing switch and enable the optimization of various layout configurations.

The drive is mounted in the central drive cabinet at the front of the bay. Hand-crank access, position indicator and mechanical padlocking facility (with electrical inter-locking) are features conveniently located in the drive cabinet and are accessible from the operator’s corridor.

The disconnector

Busbar disconnector

Disconnector in one phaseof busbar

ABB | GIS ELK-3 C, 420 kV 9

Earthing switches connect isolated sections of the switchgear to the ground to protect personnel during maintenance and assembly work.

Feeder terminals are often equipped with fast-acting (or make-proof) earthing switches. These devices are able to ground induced currents on overhead lines, discharge larger capacitances such as cables, and provide safety when the op-posite end of a line is not properly de-energized. The fast-acting earthing switch includes a spring operated mechanism, which is either charged by a motor or by a hand crank.

Similar to disconnectors, the operating mechanism of the maintenance earthing switch is located in the central drive cabinet at the front of the bay. Hand-crank access, position indicator and mechanical padlocking facility (with electrical inter-locking) are features conveniently located in the local control cubicle of the drive and are accessible from the operator’s corridor. The operating mechanism of the fast-acting earthing switch is located in the equipment itself and controlled via the control cubicle.

The earthing switch

Disconnector with fast-acting earthing switch

Maintenance earthing switch

10 GIS ELK-3 C, 420 kV | ABB

ABB’s voltage and current transformersHighly reliable metering, control and protection functions

Our maintenance-free voltage and current transformers provide highly reliable me-tering, control, and protection functions.

Used for system protection, our powerful transformers offer years of trouble-free service even for heavy-duty applications.

The single-pole inductive voltage transformers are connected to the switchgear with a standardized connecting flange and a partition insulator. The primary winding is coiled on top of the core and the secondary windings. The latter are connected to the terminals in the external terminal box through a gas-tight multiple bushing.

The voltage transformer

Voltage transformer

ABB | GIS ELK-3 C, 420 kV 11

The inductive current transformers are of ring core type. The cores concentrically enclose the primary conductor and are located outside the gas compartment elimi-nating the need for a gas-tight feed to the secondary terminals. Each current trans-former may contain multiple cores for metering and protection. An insulation gap in the basic flange prevents the return current of the enclosure from flowing through the inside of the current transformer cores, thereby correct current readings are guaranteed. Current transformer parameters such as burden, ratio, accuracy class and transient performance are set to meet specific project requirements. Multi-ratio transformers provide different ratios selectable by taps.

Non-conventional instrument transformers (NCIT) replace traditional voltage and current transformers. The NCIT uses two redundant Rogowski coils to measure the current value. The primary voltage is measured by a capacitive voltage divider composed of two cylindrical electrodes, the conductor and the enclosure. The measured values are digitally processed by the “secondary converters” and sent to the “merging unit”. From there the data is routed through a standardized, optical connection to the protection, measurement and control devices.

The current transformer

Advanced features for digital substations

Current transformer

Non-conventional instrument transformer (NCIT)

12 GIS ELK-3 C, 420 kV | ABB

ABB’s terminals and connecting elementsMaximum flexibility

We have versatile terminal and connecting elements that enable the switchgear tobe customized to fit your project requirements. We offer connecting elements invarious shapes and sizes including T-elements, cross-shaped and straight sections.

The ELK-3 GIS has a universal expansion joint to absorb heat expansion and vibra-tions during operation and civil engineering works. During site installation, the ex-pansion element ensures that neighboring bays can be coupled easily and flexibly.

Surge arresters are fully-enclosed metal components that limit switching and light-ning over voltages. For stable and reliable operations, the ELK-3 GIS is equipped with gas-insulated metal-oxide surge arresters. Ratings and discharge classes are tailored to your project specific requirements.

The connecting elements

Surge arresters

Straight with or without flange Expansion joint

T-element Cross-shapedSurge arrester

ABB | GIS ELK-3 C, 420 kV 13

The terminal connections

Transformer connections

Cable terminations

SF6-air bushings

We offer a complete range of connecting elements for peripherals, such as SF6-air bushings, enclosures for cable terminations and direct transformer connections.

Our standardized transformer connections link power transformers directly to the switchgear via SF6 insulated bus ducts. Vibrations, thermal expansion of the trans-former and switchgear, as well as movements resulting from the settling of founda-tions, are compensated by bellows and expansion joints. A removable high-voltage conductor link isolates the transformer for testing.

Our manufacturer’s accessory supply includes cable connections for fluid-filled,dry-type or plug-in cable terminations. The interface for dry-type or fluid-filled termi-nations is designed based on IEC 62271-209. A removable link disconnects andisolates the GIS from the cable during high-voltage test for convenience and ease ofoperations.

Our lightweight SF6-air bushings are available in two variants – with classical por-celain insulators or in the standard version, with composite insulators and siliconsheds. Creepage distance, length, and shape depend on the project-specificenvironmental requirements. We provide SF6-air bushings that are maintenance-freewith self-cleaning silicon sheds and protection against sandstorms.

Cable connection SF6-air bushingTransformer connection

14 GIS ELK-3 C, 420 kV | ABB

ABB’s local control cubicleReduced commissioning and installation time

The local control cubicle (LCC) includes all required functions for the control and supervision of the GIS bay. The LCC is usually integrated and located on top of the operating mechanism cabinet. As an integral part of the ELK-3 GIS, the LCC is wired, factory-tested and shipped together with the bay as one transport unit. This reduces installation and commissioning time to a minimum and eliminates errors during site installation. Connections from the LCC’s prepared terminal blocks to dedicated protection cubicles, control systems, power supply, and inter-bay wiring are the only installation work done on site.

Our LCC typically contains control devices and feeder protection. Our advanced Relion® family of protection and control-IEDs and the advanced bay control mimic with two-handed operation for conventional control ensure the safe and economical operation of the switchgear.

Our broad range of control and protection systems include IEC 61850 compliant products that provide you with open, future-proof and flexible system architecture. Our advanced local control cubicles enables monitoring and remote diagnostic functions ensuring high availability and fast access to precise information from anywhere in the system, speeding up responses and reducing outage time. Cyber security is embedded as an integral part of the product to keep you worry-free. Investing in our switchgear is safe and increases the life cycle of your equipment.

Depending on your project requirements, we also deliver standalone LCC’s with all customary control and protection devices.

The local control cubicle (LCC)

Advanced features for digital substations

Conventional LCC with bay control mimic

Modern LCC with Relion® control IED and circuit-breaker emergency control

ABB | GIS ELK-3 C, 420 kV 15

ABB’s commitment to total quality controlHighest product quality

We are committed to giving you products of the highest quality that is why we strive to produce only products that comply with or exceed the latest international standards (IEC/ANSI). In addition, our products have been type tested in indepen-dent laboratories. Our certified design and manufacturing processes guarantee the highest quality of our products.

Our ELK-3 bays are fully assembled and tested in the factory with standardized, automated and reliable procedures. After routine testing, shipping units are packed in accordance with the freight carrier’s requirements, the duration of transportation, the dispatch route and site storage requirements. Its compact size allows functional bays to be shipped on flat racks.

Pre-tested, wired and SF6 pre-filled bays reduce the installation work significantly. Bays are coupled using standard tools and gas handling is minimized. Site testing according to IEC/ANSI standards and ABB quality assurance procedures include leakage checks on flanges, instrument transformer tests, control and monitoring functions, resistance measurements and a high-voltage test. Site installation can be carried out by ABB or by personnel from your own company under the guidance of a certified ABB supervisor. ABB offers training courses for every aspect of GIS installation, operation and maintenance.

ABB’s metal-enclosed gas-insulated switchgear requires minimal maintenance in service. Under normal operational conditions, more than 50 years fault-free opera-tion is assured with periodic visual checks. ABB Service provides competent 24/7 worldwide support in case of failures.

Our products are type tested according to differ-ent standards – IEC – ANSI/IEEE

Our products are certified by third-party organizations – GOST – LAPEM – PEHLA

16 GIS ELK-3 C, 420 kV | ABB

Enhancing eco-efficiency over the life cycleLow environmental impact

For ABB, sustainability is about balancing economic success, environmental stew-ardship and social progress to benefit all our stakeholders.

Sustainability considerations cover how we design and manufacture products, what we offer customers, how we engage suppliers, how we assess risks and opportuni-ties, and how we behave in the communities where we operate and towards one another, while striving to ensure the health, safety and security of our employees, contractors and others affected by our activities. In line with our business practices, we publish environmental product declarations for each product we manufacture.

The life cycle of the ELK-3 product is composed of three phases: manufacture, useand disposal. The manufacture scenario includes materials used, transport of com-ponents and SF6-gas leakage rates. The usage scenario includes transport of prod-ucts to customers as well as SF6-gas leakage rates and energy losses assuming a50-year life time. The disposal phase refers to SF6-gas handling and the energy formaking recycled metals reusable.

– Continuous improvement in product design resulted in a more compact footprint that uses less aluminum and other metals

– Low thermal losses due to innovative designs and material choices – Full bay shipment due to compact design reduces the environmental impact of transportation dramatically

– ABB’s factory is ISO 14001 certified for environmental best practices and we also conduct regular environmental audits at our suppliers’ facilities

– Online monitoring for preventive maintenance – The low operating energies used by ABB’s modern interrupters combined with the efficient mechanical spring operating mechanism result in lower auxiliary power supply consumption

– Type tested for 0.1 percent SF6-gas leakage rate per year – Minimized SF6-gas leakage rates due to well proven sealing system

– Use of material which is easy to recycle or dispose – Improved maintenance processes that avoid the release of gases and oil – Improved recycling and disposal through clear declarations adjusted to different global standards

The life cycle phases

Manufacturing phase

Use phase

End of life phase

ABB | GIS ELK-3 C, 420 kV 17

Worldwide successOver 1300 bays in more than 100 substations in over 30 countries

Azerbaijan

1 substation

7 bays

Bahrain

1 substation

12 bays

Hong Kong

1 substation

24 bays

India

6 substations

46 bays

Iraq

3 substations

30 bays

Libya

1 substation

8 bays

Portugal

1 substation

3 bays

Russia

6 substations

49 bays

Saudi Arabia

39 substations

550 bays

Switzerland

15 substations

91 bays

Turkey

1 substation

8 bays

Taiwan

3 substations

32 bays

Austria

2 substations

15 bays

Czech Republic

1 substation

7 bays

Denmark

2 substations

19 bays

Finland

2 substations

14 bays

Hungary

4 substations

9 bays

Germany

11 substations

47 bays

Italy

6 substations

74 bays

Kuwait

7 substations

167 bays

Nigeria

1 substation

7 bays

Poland

1 substation

15 bays

South Africa

3 substations

27 bays

Qatar

4 substations

77 bays

Spain

2 substations

12 bays

Sweden

1 substation

7 bays

Ukraine

2 substations

15 bays

Mexico

1 substation

6 bays

Singapore

2 substations

32 bays

Norway

5 substations

32 bays

Netherlands

4 substations

10 bays

United Arab Emirates

3 substations

33 bays

US

5 substations

18 bays

United Kingdom

16 substations

88 bays

7715

3650

4378

min

. 225

0

18 GIS ELK-3 C, 420 kV | ABB

Technical dataELK-3 C, 420 kV

ELK-3 double busbar bay

Circuit-breakers

Disconnector and earthing switches

Voltage and current transformers

Connecting elements

Control & protection

Note: Dimensions in mm

ABB | GIS ELK-3 C, 420 kV 19

ELK-3 C, 420 kV Product ID 1HC0071250M0080

Rated voltage kV 420

Power-frequency withstand voltage, 1 min. kV 650

Power-frequency withstand voltage, 1 min. across open contacts kV 815

Lightning impulse withstand voltage kV 1425

Lightning impulse withstand voltage across open contacts kV 1425 + 240

Switching impulse withstand voltage kV 1050

Switching impulse withstand voltage across open contacts kV 900 + 345

Rated frequency Hz 50/60

Rated continuous current A 4000/5000

Rated short-time withstand current kA 63

Rated withstand impulse current kA 170

Circuit-breaker

First pole-to-clear factor 1.3/1.5

Rated breaking current, 50/60 Hz kA 63

Rated making current, peak value kA 170

Drive type (operating mechanism) spring

Rated opening time ms < 19

Rated breaking time ms < 40

Rated closing time ms < 80

Reclosing time ms < 300

Rated operating sequence O - 0.3s - CO - 1min - CO or CO - 15s - CO

High-speed auto-reclosing single- and three-phase

Mechanical endurance test class M2

Capacitive current switching test class C2

Disconnector and earthing switch

Capacitive current switching capability mA 500

Bus transfer current switching capability A/V 1600/20

Opening/closing time s < 2.5

Classification of disconnector for mechanical endurance class M2

Mechanical endurance of earthing switch CO 10,000

Fast-acting earthing switch

Switching performance making capacity: Current kA 63

Switching performance Inductive currents: Voltage kV 10

Switching performance Inductive currents: Current A 160

Switching performance capacitive currents: Voltage kV 20

Switching performance capacitive currents: Current A 18

Motor running time s < 6

Classification for mechanical endurance class E1

Voltage transformer

Rated output (total) VA 300

Rated accuracy class % 0.5

Rated thermal power (total) VA 2000

Rated voltage factor 1.9/8 h

Number of secondary windings 2

Current transformer

Cores for metering, as well as cores for protection

SF6-air bushing

Continuous bending load N 2500

Test bending load N 5000

Creepage distance mm/kV 20, 25, 31

ABB Switzerland LtdHigh Voltage ProductsBrown Boveri Strasse 5CH-8050 Zurich / SwitzerlandPhone: +41 58 588 31 86Fax: +41 58 588 17 22

www.abb.com/highvoltage

Contact us

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A14Note:

We reserve the right to make technical changes or modify the contents of this document without prior notice. With regard to purchase orders, the agreed particulars shall prevail. ABB Ltd does not accept any responsibility whatsoever for potential errors or possible lack of information in this document.

We reserve all rights in this document and in the subject matter and illustrations contained therein. Any reproduction, disclosure to third parties or utilization of its content – in whole or parts – is forbidden without prior written consent of ABB Ltd.

Copyright© 2014 ABB All rights reserved

Several aspects of the product described in this brochure are subject to intellectual property protection. In September 2013, the publicly accessible intellectual property portfolio relating to the ELK-3 was as follows:

Granted intellectual property rights:US-A-5723814, US-A-5753864, US7262362B2, US7122758B2, EP1675142B1, RCD001945700, EP2466604B1

Pending applications:EP2466706A2