gas-insulated switchgear elk-4, 800 kv pioneering technology for

Product brochure

Gas-insulated switchgear ELK-4, 800 kVPioneering technology for extra-high voltage applications

2 GIS ELK-4, 800 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 baysinstalled around the world. In 2009, ABB commissioned a GIS rated to handle morethan one million volts (1200 kV), with a transmission capability of 6900 megawatts,reaching new heights in terms of global voltage levels. We pioneered high-voltageGIS in the mid-1960s and with the introduction of the new 800 kV, we continueto drive technology and innovation. Our product portfolio comprises a full range ofadvanced GIS for voltages from 72.5 kV to 1200 kV.

In the early stages of extra-high voltage GIS, ABB delivered the first generation ELK-4, 800 kV GIS to South Africa to ESKOM in 1987. The substation was one of the first ever commissioned 800 kV GIS worldwide and continues to provide excel-lent service.In 2008, ABB commissioned the world’s first 1100 kV GIS in Jingmen China. And then in 2014, ABB commissioned the world’s first 1200 kV Hybrid GIS in BINA India.

ABB and 50 years of GIS innovation

ABB | GIS ELK-4, 800 kV 3

ABB and 50 years of GIS innovation 2

The ELK-4, 800 kV 4

Applications 4

Benefits 4

High performance ratings for future power demands 4

Low space requirements 4

Low environmental impact 4

Highest product quality 4

Simple and reliable 4

Maximum flexibility 5

Reliable, well proven technology 5

Technology 5

The ELK-4 gas-insulated switchgear from ABB 5

ABB’s high-voltage circuit-breaker 6

The circuit-breaker 6

The circuit-breaker operating mechanism 7

How does it work 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

ABB’s terminals and connecting elements 12

The connecting elements 12

The terminal connections 13

SF6-air bushings 13

Transformer connections 13

ABB’s local control cubicle 14

The local control cubicle (LCC) 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

Technical data 18

Table of contents


ABB holds a distinguished record of innovations in gas-insulated switchgear (GIS) technology and our latest ELK-4 series for 800 kV is designed to increase perfor-mance and enhance reliability for future power demand.

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 inside metal encapsulated enclosures. 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 upgraded product ratings up to 800 kV, 63 kA, 5000 A and 6300 A exceed the latest standards and customer specifications.The individual enclosed pre-insertion closing resistor and its switch can provide300 Ohm and above resistance and highest thermal capacity and insulation level.The highest ratings enhance the reliability and addresses future network demands.

The new design and optimized layout reduces product volume resulting in a consid-erably smaller footprint and reducing infrastructure such as land and building costs by 40 percent compared to its predecessor.

The ELK-4 is designed to enhance eco-efficiency. Optimized, lean and aluminum lightweight enclosures reduce weight up to 20 percent and the use of SF6 insulat-ing gas up to 20 percent compared to its predecessor resulting in an outstanding environmental performance. Then the lightweight enclosures of aluminum with good conductivity, no eddy-current losses and a high resistance to corrosion.

The latest ELK-4 is assembled and tested in a manufacturing facility that uses an advanced production system that adheres to ABB internal quality and manufactur-ing excellence procedures. All transportation units are produced and tested in ex-cellent conditions under the strict supervision of ABB’s engineers and GIS experts.

ELK-4 reduces complexity by a number of distinct features: Single-phase encap-sulated design, assuring minimal dielectric and dynamic stresses. Conductors and contacts are simplified and use less complex and fewer parts. Reduce variants of disconnectors to only one simple and robust variant to ensure the long term reliable production. The Current transformers are located outside the gas compartments without the need for a gas-tight feed to the secondary terminals.

The high dielectric margins enhance the reliability and even get ready for future UHV upgrade.

The ELK-4, 800 kVPerformance that addresses future power demands

Applications

BenefitsHigh performance ratings for future power demands

Low space requirements

Low environmental impact

Highest product quality

Simple and reliable


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. With 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-4 is based on pioneering GIS technology since the 1960s and installation in over 100 countries. It complies with or exceed the latest international and local standards (IEC/GB/DL/ANSI) and has been type tested in independent laboratories.

GIS from ABB is built on 50 years of pioneering research and development and experience delivering over 23,000 switchgear bays in over 100 countries. Our switchgears are crafted using standardized and modular components that enable the construction of common layouts and bus schemes.

Maximum flexibility

Reliable, well proven technology

TechnologyThe ELK-4 gas-insulated switchgear from ABB

ELK-4 switchgear components

on 3-phase 1½-breaker bay

Circuit-breakers with closing resistors

Disconnectors and earthing switches

Voltage and current transformers

Connecting elements


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

The circuit-breaker At the core of our switchgear system is the classical puffer circuit breaker with three chambers and an optimized and solid layout that optional adapt with the pre-in-sertion closing resistor stack (PIR) and the PIR switch. The KEMA-certified circuit-breaker is designed to provide optimal performance and low maintenance.

Each circuit-breaker comprises three single-phase breaker poles. Each pole consists of the hydraulic spring operating mechanism, the interrupter column with three interrupting chamber and the enclosure with the basic support structure. To guarantee simultaneous interruption, the chambers are mechanically connected in series. One set of grading capacitor for each chamber assures an equalized voltage distribution across the interrupting chambers. During overhauls, the interrupter unit can be removed easily from the enclosure or replaced by a new unit.

The circuit-breaker is of the single-pressure type and works on the well-proven arc-quenching technology. During an interruption, a compression piston in the chamber generates the SF6-gas pressure required to extinguish the arc between the con-tacts.

The pre-insertion closing resistor, which is placed in a separated enclosure and in parallel to the interrupting chamber, reduces overvoltages effectively during closing operation of long overhead transmission lines. When the circuit-breaker closes, the resistor switch closes first to insert the resistor into the circuit. After the pre-inser-tion time, the interrupter contacts close and bypass the closing resistor parts.

Circuit-breaker with operating mechanism


The circuit-breaker uses a spring operating mechanism per pole for single-pole op-eration. The mechanism combines the non-wearing properties of a hydraulic system with the robustness of mechanical spring operating mechanisms. We use spring operating mechanism in our entire GIS portfolio from 72.5 kV to 1200 kV, and we have supplied more than 100,000 spring operating mechanisms of this type.

Our spring operating mechanism is composed of a charging system, an energy storage with disk spring stack, an independent actuator piston and control valves, and auxiliary switches and position indicators. A hydraulic energy control system is integrated within a compact and sealed block that does not require any external piping. All components are easily accessible for maintenance and repair.

ChargingA pump moves oil from the low-pressure oil reservoir to the high-pressure side of the energy storage piston and compresses the disk spring stack. A micro switch stops the pump when the disk spring stack is fully-charged.

Close operationA magnetically-operated change-over valve initiates the close operation and con-nects the high-pressure side of the energy storage piston to the actuator piston. Both sides of the actuator piston are connected to the high-pressure reservoir. Due to the different areas of both surfaces of the actuator piston, the circuit-breaker closes and stays in a closed position.

Open operationThe trip coil operates the change-over valve and connects the actuator piston to the low-pressure reservoir. The circuit-breaker opens and stays in an open position due to the difference in pressure.

The circuit-breaker operat-ing mechanism

How does it work

Breaker closedBreaker open Spring operating mechanism


ABB’s disconnectors and earthing switchesConvenient operation and serviceability

Disconnectors provide a safe insulating gap to isolate sections with different poten-tial, for example busbar disconnectors, which isolate a feeder. The angular discon-nector integrated in the busbars ensures the highest degree of flexibility in layout-ing. It is also possible to accommodate a maintenance earthing switch in the same enclosure.

The operating mechanism is of modular design. The modular design enables rapid replacement of complete modules, thus ensuring greater service friendliness and excellent access for maintenance and repair. Inspection of the main contact status is possible through a big size viewport in the enclosure so as to provide a visible isolating distance.

The disconnector

Disconnector without earthing switch


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 and the fast-acting earthing switch is located in the equipment itself and controlled via the control cubicle. Inspection of the main contact status and the gap between contacts is also possible through a big size viewport in the enclosure.

In certain cases, an interposed insulation is fitted between the earthing switch and the enclosure. This provides access to the active parts for measuring purposes through the closed contacts, without opening the enclosure. During normal opera-tion the insulation is by-passed.

The earthing switch

Fast-acting earthing switch


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


Current transformer

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.

The current transformer


ABB’s terminals and connecting elementsMaximum flexibility

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

The ELK-4, 800 kV GIS has a parallel compensator to allow for heat expansion, vibrations during operation and tolerances in the lengths of specific components. Moreover, lateral disman tling units guarantee hassle-free assembly and dismantling.

The connecting elements

Straight with or without flange Angle element

T-element Cross-shaped

Lateral dismantling unit

Parallel compensator


The terminal connections

SF6-air bushings

Transformer connections

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

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

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.

Transformer connectionSF6-air bushing with silicon insulator


ABB’s local control cubicleA comprehensive scalable solution

The local control cubicle (LCC) includes all required functions for the control and supervision of the GIS bay. As an integral part of the ELK-4 GIS, the LCC is factory-tested before shipment. This reduces installation and commissioning time to a minimum and eliminates errors during site installation.

The local control cubicle is based on the Bay Control Solution concept BCS as a comprehensive scalable solution for control cubicles. The BCS is suitable for all types of switchgear used in transmission and subtransmission systems and every possible busbar configuration. The BCS includes all required functions for control and supervision of a complete GIS as well as the marshalling of all connections to and from the GIS bays.

The local control cubicle is fitted with pre-wired interface terminal blocks for the connection to feeder and station protection. This interface includes all needed measuring values of the feeder as well as protection trips and signals from the auto-reclose system. Additional pre-wired terminal groups are provided for the connec-tion to remote control systems and remote alarm systems. On customer’s request additional functions (optional) can be provided. Standardized plug connections instead of terminal connections are available.

The local control cubicle (LCC)


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 standards (IEC/GB/DL/ANSI). In addition, our products have been type tested in independent labo-ratories. Our certified design and manufacturing processes guarantee the highest quality of our products.

ELK-4 components 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.

Pre-assembled and pre-tested function components reduce the installation work significantly. Bays are coupled using standard tools and gas handling is minimized. Site testing according to standards and ABB quality assurance procedures include leakage checks on flanges, control and monitoring functions, resistance measure-ments 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 supervi-sor. 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 different standards – IEC – GB / DL – ANSI


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-4 product is composed of three phases: manufacture, use and 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 a 50-year life time. The disposal phase refers to SF6-gas handling and the energy for making 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 – Compact design with fewer transportation units 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 drives result in lower auxiliary power supply con-sumption

– 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


The first 800 kV GIS substation in the world for ESKOM in South Africa


Technical dataELK-4, 800 kV

ELK-4, 800 kV Product ID 2GHV013559M0001

Rated voltage kV 800

Power-frequency withstand voltage, 1 min. kV 960

Power-frequency withstand voltage, 1 min. across open contacts kV 960 + 462

Lightning impulse withstand voltage kV 2100

Lightning impulse withstand voltage across open contacts kV 2100 + 650

Switching impulse withstand voltage kV 1550

Switching impulse withstand voltage across open contacts kV 1425 + 650

Rated frequency Hz 50/60

Rated continuous current A 4000 / 5000 / 6300

Rated short-time withstand current kA 63

Rated withstand impulse current kA 171

Circuit-breaker

First pole-to-clear factor 1.3

Rated breaking current, 50/60 Hz kA 63

Rated making current, peak value kA 171

Drive type hydro-spring

Rated opening time ms < 26

Rated break time ms < 40

Rated closing time ms < 70

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, 10,000 CO

Capacitive current switching test class C2

Disconnector and earthing switch

Capacitive current switching capability mA 2000

Bus transfer current switching capability A/V 1600/100

Opening/closing time s < 2.5

Mechanical endurance of disconnector class M2, 10,000 CO

Mechanical endurance of earthing switch class M2, 10,000 CO

Fast-acting earthing switch

Switching performance making capacity: Current kA 63

Switching performance Inductive currents: Voltage kV 25

Switching performance Inductive currents: Current A 200

Switching performance capacitive currents: Voltage kV 32/100

Switching performance capacitive currents: Current A 50

Closing time s 1.2

Opening time s 0.8

Classification for mechanical endurance, exceed M1 CO 3000

Classification for electrical endurance class E1

5420

8034

1390

0


Voltage transformer

Rated output (total) VA 300

Rated accuracy class % 0.2

Rated thermal power (total) VA 2000

Rated voltage factor 1.5/30 s

Number of secondary windings 3

Current transformer

Cores for metering, as well as cores for protection

SF6-air bushing

Continuous bending load N 3500

Test bending load N 7000

Creepage distance mm/kV 27.5

ABB High Voltage Switchgear (Xiamen) Co., Ltd.Guanghui Building, 6# Chuangxin 3rd Road,Torch Hi-Tech Development Zone, Xiamen,361006 Fujian, P. R. ChinaPhone: +86 592 5710330Fax: +86 592 5710331

www.abb.com

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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.

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gas-insulated switchgear elk-4, 800 kv pioneering technology for

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