Disconnecting Circuit Breakers: Buyer's and Application Guide

Disconnecting Circuit Breakers
Buyers and Application Guide

Edited by
ABB AB
High Voltage Products
Department: Marketing & Sales
Text: Per-Olov Andersson, Carl Ejnar Slver, Lars Haglund
Layout, 3D and images: Mats Findell, Karl-Ivan Gustavsson
SE-771 80 LUDVIKA, Sweden
2 Buyers and Application Guide | ABB Disconnecting Circuit Breakers

Table of contents
Introduction 4
Abbreviations 5
Definitions 6
Switchgear specification 7
Availability 10
Switchgear single line philosophy 15
Design 19
Standards and testing 27
Environmental aspects 29
Substation design 32
Cost optimizing 37
Processes and support 38
Inquiring and ordering 40
Protection and control IEDs 42
ABB Disconnecting Circuit Breakers | Buyers and Application Guide 3

Introduction
Compact air insulated HV switchgear with Disconnecting Circuit Breakers

ABB has a century-long experience of building substations for high voltage systems.
In time with developing, designing and manufacturing of all vital switchgear appara-
tus also the switchgear design has been improved through the years.
One important step in the switchgear design during the latest years is that ABBs
well known high performance circuit breakers now also are available as Discon-
necting Circuit Breakers. This means that the disconnecting function is included in
the circuit breaker and no separate disconnectors are necessary. By this move it is
now possible to build substations with minimized need of maintenance and space,
low failure rate, increased safety and low Life Cycle Cost, i.e. Compact Air Insulated
Switchgear.
Product range
Disconnecting Circuit Breaker, DCB, can be delivered as separate apparatus or
included in deliveries of complete switchgear bays.
Type LTB 72.5 LTB 145 HPL 170 - 300 HPL 362 - 420 HPL 550
Rated voltage, kV 72.5 145 170 - 300 362 - 420 550
Rated current, A 3150 3150 4000 4000 4000
Circuit breaking current, kA 40 40 50 63 63
Rated frequency, Hz 50/60 50/60 50/60 50/60 50
Bay design
DCB use a circuit breaker support structure, on which also earthing switch and
current transformer can be mounted. Further more a complete factory made busbar
structure, with necessary primary electrical connections can be included.

Introduction
Line Entrance Module

A separate structure called Line Entrance Module, LEM, is available for supporting
apparatus, which not are suitable to be erected on the circuit breaker structure. The
breaker structure together with a LEM, are normally the only structures needed to
house the HV-apparatus in a switchgear bay, built with DCB.
Primary switchgear apparatus

ABB offers a complete range of primary apparatus for use in Air Insulated Switch-
gear. Further information will be found in the Application and Buyers Guide for each
product according to table below.
Product Buyers Guide Application Guide

Live Tank Circuit Breakers 1HSM 9543 22-00en 1HSM 9543 23-00en
Outdoor Instrument Transformers 1HSM 9543 42-00en 1HSM 9545 40-00en
Surge Arresters 1HSM 9543 12-00en -
Abbreviations
In this document abbreviations according to the list below are used.
CB Circuit Breaker
DCB Disconnecting Circuit Breaker
DS Disconnecting Switch
ES Earthing Switch/Grounding Switch
SA Surge Arrester
CT Current Transformer
CVT Capacitor Voltage Transformer
VT Voltage Transformer
PI Post Insulator
BB Busbar
PT Power Transformer
AIS Air Insulated Switchgear
GIS Gas Insulated Switchgear
SF6 Sulphur hexafluoride gas
OHL Over Head Line
CL Cable Line
SLD Single Line Diagram
LEM Line Entrance Module
CCC Central Control Cabinet
MDF Manual Disconnecting Facility
IED Intelligent Electronic Device
MV Medium Voltage
HV High Voltage
S/S Substation
LCA Life Cycle Assessment
LCC Life Cycle Cost

Definitions
Special definitions used in this document.

For definitions in general see IEC 60050.
Disconnecting Circuit Breaker Circuit Breaker with integrated disconnector function.
Interlocking of unintentional operation and blocking of closing
function is integrated.
Line Entrance Module Structure for supporting one or more switchgear apparatus such
as Voltage Transformer, Surge Arrester and Earthing Switch.
Manual Disconnection Facility A facility for manual disconnection of an apparatus, i.e. DCB
or CT, in case of failure or for maintenance. Opening a bolted
predefined connection normally performs the disconnection.
Availability The fraction of time that the electric power is available at a
(at a certain point of a network) certain point in the network
Availability depends on both planned and unplanned outages
(maintenance and repair)
Unavailability The fraction of time that the electric power is not available at a
(at a certain point of a network) certain point of a network
Often expressed in hours per year
Reliability The probability of failure-free supply of power at a certain point
(at a certain point of a network) of a network during a specified period of time
The reliability concept only considers the systems ability to
function correctly when it is in service, i.e. interruptions due
to planned maintenance are not considered
Unreliability The probability that one or more interruptions of the power sup-
(at a certain point of a network) ply will occur at a certain point of a network during a specified
period of time
Often expressed as expected number of interruptions per
100 years
Intelligent Electronic Device Unit equipped with a processor used for protection and control
of electrical systems.
Symbols
In this document symbols as below are used in Single Line Diagrams.
Legend
Circuit breaker
Disconnector
Disconnecting Circuit Breaker
Voltage transformer
Current transformer
Surge arrester
Earthing switch

Switchgear specification
A complete Switchgear specification contains among other parts,

specification of the primary electric apparatus and systems.
Optimization of overall costs is a necessary measure in the deregulated
energy market. The optimization of substations and their development is
an objective continuously pursued by ABB. The focus is set on functional
requirements, reliability and cost over the total life cycle.
Apparatus specification
The conventional way is to in detail specify all the equipment and the substation
scheme. All apparatus are specified with quantity and data. Also the scheme, which
often is based on traditional thinking, is fixed. In this case the asset owner get
equipment which is exactly what he wants to have and what he is used to buy. This
way of specifying the equipment normally gives no alternatives to propose other
solutions with better performance to lower the Live Cycle Cost.
To open up for other solutions sometimes a clause saying that bidder are free to
propose other equipment, is added to the inquiry.
Functional specification
The main task for a substation is to transfer power in a controlled way and to make
it possible to make necessary switching/connections in the grid. Thereby another
way of specifying the equipment when planning a new plant or refurbish an old, can
be to make a functional specification.
In this case the bidder is free to propose the best solution taking in account all the
possibilities that can be gained by using the best technique and the latest devel-
oped apparatus and systems, in combination with the requirements set up for the
substation and the network.
For example, basic requirements in a functional specification can be:
Number and type of system connections

System electrical data
Energy and transfer path through the system
Unavailability related costs
Based on the functional specification ABB often can propose an alternative solu-
tion, which gives better performance to considerable lower costs.
To back up the decision-making, availability calculations, life cycle cost calculations,

environmental influence report etc. can be provided by ABB.
As the supplier takes a greater part of the design, it is important that all surrounding
questions as scope of supply, demands from authorities, special design conditions
etc. are known in the beginning of the project.

Switchgear specification
Example of apparatus specification
Inquiry:
Please quote for apparatus for a 132 kV switchgear in 5 bays according to specifi-
cation and enclosed single line diagram:
5 High Voltage Circuit Breaker 145 kV, 3150 A, 31.5 kA

12 Motor operated Disconnector 145 kV, 2000 A, 31.5 kA with integrated motor operated
Earthing Switch
6 Current Transformer 145 kV, 400/5/5/5/5 A. Core data
9 Current Transformer 145 kV, 2000/5/5/5/5 A. Core data
12 Voltage Transformer 145 kV, 132000/3:110/3:110/3 V. Core data...
12 Surge Arrester 132 kV
132 kV, 2000 A, 31.5 kA
Line 1 T1 T2 Line 2 Bus coupler
The suppliers will quote for their best prices for the apparatus and the customer
can pick apparatus with the lowest price from different suppliers. The customer will
hence have a cost optimized set of apparatus.

Example of functional specification
Inquiry:
Please quote for one 132 kV switchgear with 2 incoming lines and 2 transformer
feeders.
An existing line shall be cut up and connected to the substation.

Maximum energy transfer through the substation is 120 MVA.
Power can flow in either direction. Maximum Ik 21 kA.
Transformer data 132/11 kV, 40 MVA, U k = 8%
Planned maintenance can be done in low load periods but one of the transformers must always be
in service.
132 kV, 2000 A, 31.5 kA
Line 1 T1 Sectionalizer T2 Line 2
In this case ABB will quote a solution with Disconnecting Circuit Breakers, which
will give an optimized total cost. The customer will have a quotation of complete
switchgear with a minimum of apparatus and high availability.
The Single Line Diagram shows a solution with Disconnecting Circuit Breakers.

Availability
Availability and reliability

A major concern of a substation owner or operator is to minimize outages caused
by scheduled maintenance, as well as repair work after possible failures. Ways to
achieve this goal is equipment with low maintenance requirements, and suitable
substation configurations. The quality of a certain substation in this respect is
often expressed as availability (or unavailability). The availability, e.g. of an outgo-
ing bay in a substation, is the fraction of time that electric power is available at that
point. The unavailability, i.e. the fraction of time that electric power is not available,
is normally expressed in hours per year.
Another major concern is to avoid any blackouts for power consumers, or loss of
connection e.g. to generating power stations. Such events are entirely related to
unplanned outages due to faults (since planned maintenance would not be allowed
to give such consequences). The quality of a certain substation in this respect is
often expressed as reliability (or unreliability). The reliability, e.g. of an outgoing bay
in a substation, is the probability of failure-free supply of power at that point during
a specified period of time. The unreliability may be expressed as expected number
of interruptions per years, or as outage time in hours per year.
Evolution of circuit breakers and disconnectors

Development in CB technology has lead to significant decrease of maintenance and
increase of reliability. Maintenance intervals requiring de-energizing of the primary
circuit, of modern SF6 CBs is 15 years or more. At the same time development of
open air DSs has focused around cost reductions by optimizing the material used,
and has not given significant improvements in maintenance requirements and reli-
ability. The maintenance interval for open-air DS main contacts is in the order of 2-6
years, differing between different users and depending on the amount of pollution
due to industrial activities and/or natural pollution such as sand, salt.
Bulk oil breakers

Failure and maintenance rate
Air blast breakers

Disconnectors with
open contacts
Minimum oil breakers
SF6 Circuit breakers
1950 2010

Reliability of CBs has increased due to evolution of primary breaking technology,
from air blast to minimum oil, and into todays SF6 type of CBs. At the same time
the number of series interrupters has been reduced and today live tank CBs up to
300 kV are available with only one interrupter per pole. Removal of grading capaci-
tors for live tank CBs with two interrupters has further simplified the primary circuit
and thus increased the reliability. Today CBs up to 550 kV are available without
grading capacitors, enabling the development of DCBs up to this voltage level. Op-
erating mechanisms for CBs have also improved going from pneumatic or hydraulic
to spring type leading to more reliable designs and less maintenance.
Calculations
Computer software for availability and reliability calculations is available within ABB.
This makes it possible to compare different substation solutions. It is easily found
that configurations containing conventional disconnectors in most cases give a
higher unavailability and unreliability than configurations with DCBs.
Improved availability with DCB

A typical power path through a substation may be divided into three main parts:
line, power transformer and switchgear. Lines and power transformers have relative-
ly high maintenance requirements. They are the dominating cause for maintenance
outages in substations supplied by single radial lines, or with only a single trans-
former. In such cases maintenance of switchgear equipment is of secondary impor-
tance. On the contrary, if power can be supplied from more than one direction and
the substation is equipped with parallel transformers, the overall unavailability of the
substation, due to maintenance, may be directly related to the switchgear equip-
ment. Decisive factors are then the HV equipment used, as well as the configuration
(single line diagram) of the substation.
The dominating reason for unavailability of a certain part of a substation is (sched-

uled) maintenance.
In the past when CBs were mechanically and electrically complicated and therefore
needed a lot of maintenance the focus was on how to isolate the CBs for main-
tenance and keeping the other parts of the substation in service. The substations
were accordingly built with CBs surrounded by a lot of DSs to make it possible to
isolate and maintain the CBs. Now, since modern CBs need less maintenance than
conventional DSs, it gives better results to use DCBs.
As an example, a comparison is made between a traditional double busbar solu-

tion with separate CBs and DSs versus a sectionalized busbar solution with DCBs
including manual disconnecting facilities MDF. The 132 kV substation has four
overhead lines, two power transformers and one bus-coupler or bus-section CB.
Maintenance intervals assumed were 5 years for open air DS and 15 years for CB
and DCB. Introduction of the DCB thus reduces the average unavailability due to
maintenance from 3.1 to 1.2 hours per year.

Availability
4.0
Outage duration (hrs/year)
3.1
2.0
1.2
0
CBs + DSs DCBs

The reduction of maintenance activities will give the following advantages:
More satisfied consumers, depending on substation/network topology the main-

tenance can lead to loss of power supply to some consumers
Less risk for system disturbances (black-outs) since the risk for primary faults
during a maintenance situation is higher than during normal service (people in
the substation) together with a weaker system due to the maintenance (not all
equipment in service)
Less cost for manpower to make the actual maintenance work at site
Higher personnel safety since all work in the substation high voltage system is
a potential risk for injury of the personnel due to electrical shock, falling from
heights, etc.
Improved reliability with DCB

For single line configurations with only one CB per bay, a primary fault on one of the
outgoing objects plus CB failure for that bay would lead to de-energization of one
busbar section. A failure in the bus-section or bus-coupler breaker will lead to loss
of the whole substation.
For important substations it might not be accepted from system security perspective
to have a risk of loosing the whole substation at a primary fault. To make the substa-
tion immune against busbar faults and to minimize the disturbance if a CB fails to
open at a primary fault, 1 -breaker or 2-breaker configurations can be used.
As an example, consider a typical 420 kV substation with three OH-lines, two power
transformers and one shunt reactor. A comparison is made between a traditional
type of solution with CBs and DSs versus a solution with DCBs including manual
disconnecting facilities MDF.

Availability
Outages of an incoming/outgoing bay due to faults in the switchgear are shown in

the diagram. Such unplanned outages may be very problematic and lead to unac-
ceptable loss of power supply to consumers. Failure frequency input are taken from
international statistics sources such as CIGR, which gather information from actual
apparatus in service. Since the DCB is very similar to a traditional CB, failure statis-
tics is assumed the same for CB and DCB. Introduction of the DCB thus reduces
the outages with 50%.
Outage duration (hrs/year)
0.3
0.2 0.19
0.1
0.09 { 50%
0
CBs + DSs DCBs
The examples shown are very typical. Substation solutions with DCB generally have
much improved availability and reliability, compared to traditional solutions.

Switchgear single line philosophy
When designing a new substation a lot of considerations have to be taken. One of

those is the Single Line Diagram (SLD). When elaborating the SLD the main goals
are to create a solution, which gives highest possible safety for the staff and optimal
service security. Many factors such as the load, the surrounding power network, ef-
fects of power loss, reliability and maintenance need for apparatus etc. are influenc-
ing the final decision.
Traditional approach
By tradition the most important aspect has been to isolate the circuit breaker in a
system for maintenance or repairing. Examples of traditional SLD are shown below.
Common for these is that the circuit breaker easily can be isolated without affect-
ing the power flow in the busbar and, when bypass DS or transfer bus is used, not
either in the actual load.
Single bus Single bus Double bus Single bus + Double bus +
bypass DS transfer bus transfer bus
On the other hand, if a CB in such a system fails to open, all the busbars have to be
deenergized before the CB can be isolated.
Furthermore even the disconnectors had to be maintained and to make that possi-
ble without taken the complete S/S out of service, double busbars were introduced.
I.e. the main reason for double busbar systems is to allow DS maintenance.

New possibilities
As earlier shown under chapter Availability, modern SF6 CBs have better mainte-
nance and failure performance than DSs. That means that the traditional way of
building S/S with many busbar systems and DSs rather decrease the availability
than increase it. Taking only above into consideration the best way to increase the
availability is to delete all DS and only use CBs. However, due to safety aspects a
disconnector function is necessary. In a Disconnecting Circuit Breaker this discon-
nection function is integrated in the circuit breaker and it is then possible to design
DS free S/S solutions.
DCB is suitable to be used in systems as:
Single busbar system

Sectionalized single busbar system
Double busbar/double breaker system
Ring bus system
Breaker and a half system
If double busbar or transfer bus system is a demand it can preferably be replaced

by a double busbar/double breaker system.
Single busbar
Single busbar is the least complicated system. It can preferably be used in smaller
switchgear with single line feeding. The availability rate is almost similar to that for
the line.

H-configuration/Sectionalized single busbar
H-configuration/Sectionalized single bus is used for smaller distribution S/S. With 2
incoming lines and 2 transformers, the probability that power is available on the MV
bus is very high. For a distribution S/S a sectionalized single bus has better perfor-
mance than a conventional double busbar system.
Double busbar/Double breaker

Double busbar/double breaker system has the best performance regarding availabil-
ity, reliability and service conditions. As no DS are used there is no need for a bus
coupler. By installing CTs in both CB branches all breakers in the S/S can normally
be closed. If a failure appears in a line or busbar only the affected CBs are tripped.

Ring bus
Ring bus is suitable for smaller S/S up to 6 objects. The availability performance is
very good as each object can be fed from two directions. The disadvantage contra
sectionalized single bus is that the busbar system is more complicated which need
more space and affects the overview.
Breaker and a half

Breaker and a half system is used for bigger transmission and primary distribution
S/S. Different ways of connecting the transformers are used. The availability and
reliability is high as each object normally are fed from two directions. One disad-
vantage is that if one busbar is out of service, the two objects are connected to the
other bus via one CB.

Design

The Disconnecting Circuit Breaker is based on ABBs well known circuit
breakers LTB D and HPL B. The basic circuit breaker functions for a DCB are
exactly the same as for a CB. The circuit breakers are described in the Live Tank
Circuit Breaker, Buyers Guide, 1HSM 9543 22-00.
The additional feature for a DCB is that it is also approved as a disconnector. That
means, when the CB is open, the normal CB contact set fulfills all DS requirements.
As the disconnecting function is inside the breaking chamber, there is no visible

opening distance.
Locking of CB
It is of highest importance that the CB remains in open/disconnected position when
it is used as DS.
Because of that, the DCB is equipped with a mechanical locking device which oper-
ates directly on the shaft that moves the CB main contacts. When the mechanical
locking is activated, it is impossible to close the breaker. Even if the closing latch of
the CB accidentally opens the CB will stay in position.
This locking device is operated by a motor unit, which allows remote operation.
Electrical data: Motor 450 W

Heater 25 W
Auxiliary contacts
The motor unit is also equipped with auxiliary contacts for interlocking and indica-
tion purposes. The standard setup contains 5 contacts NO and 5 contacts NC in
open position and also 5 contacts NO and 5 contacts NC in closed position.
Electrical data according to Class 1 of IEC 62271-1: 110 VDC, 10 A, L/R = 20 ms
The locking device is prepared for manual operation but this is intended to be used
only in emergency situations.
When the locking is activated a padlock can be applied. The padlock mechanically
prevents moving of the locking device,
The position of the locking device is firmly indicated on the unit.
The type designation for the locking device is AD100.
Three phase operated CBs has one common locking device for the three phases
while single phase operated CBs has one locking device for each phase.

Design
Locking device, AD100, 145 kV DCB
The disconnecting circuit breaker is locked in Locking activated and padlock applied.
open position. The sign indicates locked.
Emergency operation of locking device.

Earthing switch (Grounding switch)
As there is no earthed part between live and disconnected contacts on a DCB, it
is important to lead any eventual creepage current to earth just to secure that the
disconnected part not will attain voltage. Because of that the DCB system shall
be equipped with an earthing switch. For single busbar applications 300 kV this
earthing switch is erected on the same structure as the DCB and the fixed contacts
are placed on the connection flange. For higher voltages than 300 kV, the earthing
switch is always placed apart from the DCB.
In systems where the object is fed from two directions, e.g. double busbar/double
breaker or breaker and half systems, it can be more practical to place the earthing
switch in the common connection point, separated from the DCBs.
The ES is placed outside the breaking chamber and the position of the earthing
blades can clearly be seen from outside. I.e. you dont have to come close to live
apparatus to look through a peep-hole to see the position. This is an important
safety feature as the disconnection function not is visible.
For security reasons the operation of the ES shall be done remotely and hence it is
equipped with a motor operated device, type designed AD350.
This device operates, via a linkage system, the earthing blades of the ES. Indication
labels on the operation device shows the position.
Electrical data: Motor 450 W

Heater 25 W
Earthing switch in unearthed position. Earthing switch in earthed position.

Design
Auxiliary contacts
Auxiliary contacts for interlockings and external indicators are available. The stan-
dard setup contains 5 contacts NO and 5 contacts NC in open position and also 5
contacts NO and 5 contacts NC in closed position.
Electrical data according to Class 1 of IEC 62271-1: 110 VDC, 10 A, L/R = 20 ms
Three phase operated ES has one common operating device for the three phases
while single phase ES has one operating device for each pole.
The ES operating device is prepared for manual operation but this is intended to be
used only in emergency situations.
When the ES is closed a padlock can be applied. The padlock mechanically pre-
vents moving of the ES.

Electrical interlocking
Besides the mechanical locking of an open DCB, electrical interlockings shall be
applied as:
DCB closed Locking inactivated and interlocked

Earthing switch open and interlocked
DCB open and locking not activated DCB can be operated
Locking device can be operated
Earthing switch operation interlocked
DCB open and locking activated Earthing switch can be operated
DCB operation interlocked
Earthing switch closed Locking operation interlocked
DCB operation interlocked
Earthing switch open and locking not activated DCB can be operated
Earthing switch operation interlocked
Earthing switch open and locking activated DCB open and interlocked
Earthing switch can be operated
Circuit breaker
Closing CB
AD100
Locking device
Operating AD100 M
AD350
Earthing switch
M
Operating AD350
Principles of the electrical interlocking system

Design
Composite insulators
Composite insulators with silicone rubber shields (SIR) offer many advantages over
traditional porcelain insulators and provide new possibilities to improve safety and
availability. Distinguishing qualities are high flashover resistance, low weight and
stability against UV absorption.
The high flashover resistance is obtained through the chemical nature of silicone
which makes the insulator surface hydrophobic. As the hydrophobic surface pre-
vents pollution to stay on it, the risk for current paths is minimized. The diagram
shows the difference in leakage current between porcelain and silicone insulators
during a salt fog test.
Porcelain
Leakage current (A)
0.1
0.01
Silicone
0.001
0.2 0.4 0.6 0.8 1
Leakage current over time at salt fog test
The low weight decreases the static forces on structures and foundations. This is
also an advantage in earthquake areas as the dynamic forces will be much less.
Easier transport and handling are also obtained by the lower weight.
The stability against UV absorption together with the high leakage current withstand
give a product with eminent aging durability.
Furthermore the silicon rubber is non-brittle which minimize the risk for damages
during transport, installation and service as well as in case of vandalizing. The non-
brittle property also prevents scattering of pieces, dangerous for personnel and
other equipment, in case off a puncture caused by internal overpressure or external
damage.
More information about composite insulators can be found in the brochure High
Voltage products with composite insulators, 1HSM 9543 01-06.
As a conclusion of above, ABB has chosen composite insulators with silicone rub-
ber as standard for DCB.

Design
Manual disconnecting facility

Sometimes it can be practical to disconnect a unit from the busbar or the line dur-
ing maintenance or repair. This is not a special demand for solutions with DCB, but
it has been emphasized as a tool to further decrease the unavailability.
A Manual Disconnecting Facility, MDF, is a point in the switchgear prepared for fast
opening up of the primary connection, e.g. between a line and the busbar. The work
is so far intended to be done under voltage free and maintenance earthed condi-
tions. When a DCB is disconnected in this way the other parts of the substation
may be reenergized during work on the DCB itself.
The MDF consists of standard clamps and a wire or tube. The connection points
for the MDF are arranged so that when the MDF is removed, there are necessary
safety distances between the disconnected apparatus and the busbar or line. Thus
the busbar and line can be reconnected to power during the maintenance or repair
work of the apparatus.
Operating a MDF for a three phase unit is intended to take less than 2 hours.
Note that a MDF is not to be compared with a disconnector as it is maintenance

free and is intended to be used only on rare occasions.
Example of MDF
Closed
Open
Example from indoor substation, Sweden

Design
Steel structure
Steel structures for DCB, line entrance
module and bay assemblies are made
of hot dip galvanized steel.
Dimensions are adapted to the de-

mands for mechanical endurance and
electrical safety distances specified in
applicable IEC standard.
Necessary connection points for earth-

ing grid are drilled in the structure.
For 72.5 145 kV the steel structure

for the DCB also can house the current
transformers. For 245 kV and above
the CTs are placed on a separate structure.
A complete unit containing DCB, ES, CT, CVT and SA on the same structure is
available for 72.5 kV
Complete unit 72.5 kV
Line Entrance Module
Apparatus which not can be erected together with the DCB must have their own
structure. For that purpose a line entrance module is available. The LEM can be
equipped with CVT, ES and SA.
Bay design
For switchgear up to 300 kV pre-designed complete busbar systems with support
structure and primary connections are available.
Hence it is possible to order complete factory made switchgear bays.
Seismic withstand capability

There are many zones in the world where earthquakes may occur, and where the
equipment should be designed to withstand the corresponding stresses. To demon-
Line Entrance Module strate the earthquake withstands capabilities ABB makes tests and calculations for
the different apparatus and applications.
For seismic withstand capability please refer to Buyers Guide for respective
apparatus.

Standards and testing
Applicable standards
The applicable standard for DCB is IEC 62271-108. (High-voltage alternating cur-
rent disconnecting circuit-breakers for rated voltages of 72.5 kV and above)
This standard basically refers to the standard for Circuit breakers,

IEC 62271-100 and for Disconnectors, IEC 62271-102.
That means that a DCB fulfills all normative demands for a CB as well as for a DS.
In addition to that, IEC 62271-108 provides how to interlock and secure a DCB
against unintended operation as well as how to test the DCB to show the isolation
performance after long time in service.
Other switchgear apparatus

All switchgear apparatus as Voltage Transformers, Current Transformers and Surge
Arresters are tested according applicable standards. The apparatus are described
in actual Buyers Guide as:
Outdoor Instrument Transformers 1HSM 9543 42-00

Surge Arresters 1HSM 9543 12-00
Type tests
All apparatus have passed type tests according to applicable standards. For further
information refer to Buyers Guide according to above.
Selected specimens of complete switchgear bays have been type tested in order to
verify the design.
DCB Combined function test (IEC 62271-108)

The DCB shall fulfill the dielectric requirements for the isolating distance not only
in new condition but also after long time service. Therefore the dielectric withstand
across the isolating distance shall be demonstrated after a mechanical operation
test as well as after the specified short-circuit test duty.
Type test reports are available both as summary of type tests and as complete type
test reports. The reports are distributed on request.

Standards and testing
Routine testing
The applicable standards for the different functions in a switchgear bay also de-
scribe the Routine Test procedure. Additional non-specified tests could also be
performed if ABB find it necessary to ensure safe and perfect operation.
Thus the Routine Test procedures for included apparatus are described in the
Buyers Guide for each apparatus as:
Outdoor Instrument Transformers 1HSM 9543 42-00

Live Tank Circuit Breakers 1HSM 9543 22-00
Quality control
ABB AB, High Voltage Products in Ludvika has an advanced quality management
system for development, design, manufacturing, testing, sales and after sales
service as well as for environmental standards, and is certified by Bureau Veritas
Certification for ISO 9001 and ISO 14001.
Certification
Awarded to
consisting of HV Breakers and HV Components
Ludvika, Sweden
part of ABB AB, Division Power Products and Power Systems
Bureau Veritas Certification certify that the Management Systems of the above
organisation has been audited and found to be in accordance with the requirements of
the management system standards detailed below
Standards
SS-EN ISO 9001: 2008

SS-EN ISO 14001: 2004
OHSAS 18001: 2007
Scope of supply
Development, design, manufacturing, sales and after sales service of:

Surge arresters and accessories of surge arresters including application for HVDC
and reactive power compensation and transmission line arresters.
Live tank breakers, breaker components and air insulated switchgear modules.
Current transformers, inductive and capacitive voltage transformers and coupling
capacitors for high voltage application.
Power Capacitors and system for harmonic filtering and reactive power
compensation.
Original Approval Date ISO 9001: 13 November 1992
Original Approval Date ISO 14001: 8 September 1998
Original Approval Date OHSAS 18001: 22 April 2009
Subject to the continued satisfactory operation of the organisations Management Systems,

this certificate is valid until: 25 April 2012
To check this certificate validity please call +46 31 60 65 00
Further clarifications regarding the scope of this certificate and the applicability of the management systems requirements may be
obtained by consulting the organisation
Jan-Olof Marberg, Technical Manager, Bureau Veritas Certification Sverige AB
Date: 22 April 2009
Certificate Number: 9000174/E
Bureau Veritas Certification Sverige AB, Fabriksgatan 13, 412 50 GTEBORG, Sverige
Electronic copy only

Electronic copy only

Environmental aspects
We in ABB have a clear direction to decrease the environmental stresses caused by

systems and apparatus designed and delivered by us. Thus we are approved ac-
cording to environmental management systems ISO 14001 and ISO 14025.
Therefore, during the development of DCB and systems based on DCB, the envi-
ronmental aspects always have been in the centre.
SF6 gas - Live tank Circuit breakers

DCB is based on ABBs SF 6 filled live tank circuit breakers.
SF 6 is a gas with outstanding isolating and extinguishing qualities and is for the time
being the only technical and commercial alternative for HV CBs. However, SF6 has
the drawback that it contributes to the greenhouse effect and must therefore be
handled with caution. First of all the used amount must be kept as low as possible,
and that is the case for ABBs designs, which e.g. contains less than 10 kg for a 145
kV DCB. Then the leakage rate has to be minimized. IEC allows a leakage of maxi-
mum 0.5% per year which is fulfilled with good margins. Laboratory tests have shown
leakage rates less than 0.1% for ABBs live tank circuit breakers. Hence, the low
volume together with the low leakage rate leads to outstanding low SF6 emissions.
Furthermore, ABB has well described routines how to handle SF6 from production
of the CB till taking it out of service.
Use of raw material

As the number of primary apparatus is decreased compared to conventional solu-
tions, the total use of raw material is reduced significantly. This refers to all kind of
material which normally is used in switchgear apparatus as: steel, aluminum, cop-
per, plastic, oil etc.
Number of foundations - use of concrete

Switchgear based on DCB need much less foundations than conventional switch-
gear as the number of primary apparatus is less. Also the system where apparatus
can be mounted on shared structures minimizes the number of foundations. Typi-
cally, a substation with DCBs needs only half or less of the number of foundations
compared to a conventional substation.
Transports
Transports are considered as a big contributor to the negative environmental influence.
The DCB system will of course reduce that part as the less use of material and the
decreased number of apparatus implies less transports.

Environmental aspects
Example - LCA study for 145 kV DCB with earthing switch

A LCA study was made for a 145 kV DCB, including the operating mechanism,
earthing switch and support structure. The study took into consideration the envi-
ronmental impact of the entire life cycle, and fulfilled the requirements of ISO 14040.
It was based on the following assumptions:
40 year life span

Electrical losses for 50% of rated normal current, i.e. 1575 A per phase
Three-pole operated DCB, resistance 32 /pole, heater 70 W continuous, plus
70 W thermostat controlled 50% of time
Several different environmental impact categories may be considered in LCA stud-

ies, such as acidification, ozone depletion and global warming.
In the present case, evaluation was made with regard to the global warming poten-
tial (GWP). This is generally the dominating impact category for products consum-
ing energy during their lifetime. The result is expressed in kg CO2 equivalents. The
impact from electric energy consumption is based on a mix of power generation
systems relevant for the OECD countries, and considering the LCA perspective:
0.6265 kg CO2 per kWh.
Energy and material SF6
End of life
Use
Manufacture
-10000 10000 30000 50000 70000 90000
kg CO2 equivalents

As shown in the figure, electric energy consumption during the usage phase con-
tributes most to the global warming potential. Resistive losses in the main circuit
are responsible for 70% of this energy consumption. The rest is shared by the
thermostat controlled heater (10%) and the anti-condensation heater (20%) in the
operating mechanism. It was assumed that the thermostat controlled heater was
connected during half of the usage phase.
The contribution during the usage phase related to SF6 leakage to the atmosphere
is less than 10% of the total. This is a result of the small gas volume and low rela-
tive leakage rate of the live tank design. The contribution was calculated assuming
a relative SF6 leakage rate of 0.1% per year, which is typical for this type of DCB. At
end of life, it was assumed that 1% of the gas is lost, while the rest is recycled.
Example Comparison of electrical losses

As seen in the previous example, electrical losses give the largest environmental im-
pact. Therefore it is very interesting to compare the electrical losses for an arrange-
ment with traditional DS-CB-CS to those of the DCB. The following additional data
were used for the 145 kV DS-CB-DS arrangement:
Three-pole operated CB, resistance 32 /pole, heater 70 W continuous, plus

70 W thermostat controlled 50% of time (i.e. the same data as for the DCB)
Motor operated DS, resistance 59 /pole, heater 50 W continuous
Connections between DSs and CB: 8 m Falcon ACSR, diam. 39.3 mm,
289 /pole
The results, valid for the 40 year time span, are shown in the table. The energy sav-
ings by using DCB correspond to almost 700 tons of CO2, or around 17 tons per
year. For a complete substation, with several bays, the difference will be even larger.
Switching equipment Electrical energy consumed Corresponding CO 2 release

MWh Metric tons
DS-CB-DS 1217 762
DCB 120 75
The losses also have a direct economical value. The difference in accumulated loss-
es between the two solutions is more than 1000 MWh. (As an intellectual experi-
ment you can compare the cost for these losses with the cost for the DCB system).

Substation design
Planning of a new S/S includes a lot of disciplines. In this document we will only
touch those which are related to the difference between using DCB and conven-
tional equipment.
Single line diagram

Factors influencing the SLD are the grid, the load, future extensions, unavailability
aspects, costs, site etc.
By using DCB, complicated busbar systems can be avoided. This facilitates the
switchgear design and allows solutions with highest availability rate and best over-
view to optimized cost.
Specification
The SLD is base for the specification which can be a complete apparatus specifica-
tion or a functional specification.
An apparatus specification has the advantage that the projector exactly specifies
what he wants and he will get equal quotations from all bidders.
A functional specification opens up for the bidder to propose other ideas regarding
apparatus and systems and the bidder can sometimes quote more cost effective
solutions.
Anyhow it is important that the inquiry allows the bidder to quote for alternatives to
that specified in the specification, without being disqualified.
Switchgear Specification Manager

Irrespective of the way of specifying, the customer/projector may want to give tech-
nical requirements and data for the apparatus.
For this purpose a computer based tool, called Switchgear Specification Manager
(SSM), is available by ABB.
Contact your local ABB representative for further information.
Safety distances
IEC and other standards prescribe distances in switchgear. Those standard values
can sometimes be strengthened by the customer due to local conditions.
Special attention must be paid to the distance To nearest live part also called
section clearance. This distance must be established between all live parts and the
place in the switchgear where work shall be performed.
The table shows example values which always most be coordinated with the de-
mands for the actual installation
Example values for distances (mm)

72.5 kV 145 kV 245 kV 420 kV
Lowest insulator base to earth 2250 2250 2250 2250
Earth and lowest live part 3000 3770 4780 5480
Between phases 630 1300 2100 4200
Phase to earth 630 1300 2100 3400
Transport way profile 700 1520 2350 3230
To nearest live part 3000 3270 4280 4980

Maintenance earthing
When working in switchgear all metallic parts of apparatus or other parts, which
shall be touched, must be connected to earth. This can be done either by fixed
earthing switches or by portable earthing devices. Connection terminals for portable
earthing devices are often preinstalled.
Terminal for portable earthing device
Earth blade
Part which can be live
When installing the portable earthing connection terminals, it is important to con-

sider all possible live parts and place the terminals so that the connection of the
earthing device can be done in a safe way. See example distance X in the figure
above.
X is dependent on voltage level and type of earthing device.
WARNING!
All work related to the circuit breaker shall be made with disconnected and earthed
conductors. Follow all regulations and rules stated by international and national
safety regulations.

Substation design
Three phase portable earthing device Connection clamp for earth connection
Phase connection terminal Earthing device connected to phase terminal

Switchgear layout
ABB has the possibility to at short notice produce a layout proposal for DCB solu-
tions, based on preconfigured building blocks. This early layout can be the base to
find the best and final layout for the project.
The example below shows a switchgear for 145 kV with sectionalized single busbar
system, two lines and two transformers.
A 46000
C
6000
A B B
9000 9000
Section A-A Section B-B Section C-C
Extension of existing substation

The different way to build a HV Switchgear bay with DCB compared to the tradition-
al way with disconnectors makes the concept very useful when extending existing
substations.
The disconnector free layout gives small dimensions for the extension. Very often it
is possible to replace one existing bay with two new based on DCB
The solution depends on the new load, existing busbar system and space at site.
Single busbars are preferably extended just with a new bay with DCB instead of CB
and DS.
A double busbar can be extended as double breaker system with DCB.
Transfer bus system and system with bypass disconnector are preferably extended
as a single bus system with just one DCB.

Substation design
Extension of traditional double busbar system
Extension of transfer bus system
Replacing of apparatus
It sometimes can be necessary to replace switching apparatus in existing switch-
gear apparatus by apparatus, but for some reason the same type is not available or
suitable.
Even in this case DCB can be a good solution. In single busbar systems one DCB
replaces the conventional setup of CB and DS. In a double busbar system the
three (two) DS and the CB are replaced by a double breaker solution with two DCB.
Transfer bus and bypass DS systems are preferably treated as single bus systems
and thus the DS and CB are replaced only by one DCB.
The bay will have considerably lower unavailability and unreliability after refurbishing
with DCB than after corresponding replacement apparatus by apparatus. This can be
proven by calculations, and is due to the low failure and maintenance rates of DCB.

Cost optimizing
By omitting disconnectors when using DCB in the switchgear, the substation can be
built much smaller and more cost effective.
The space saving can be in the range of 20 to 50%. All cost connected to planning,
design, building, maintenance and service are lower due to less number of appara-
tus and partly pre designed solutions.
In the table you can put your own figures and make a cost comparison for your
actual project.
DCB Conventional
Foundations
Civil work
Primary connections
Connection tubes/wires
Auxiliary cabling
Erection and commissioning
Design and planning
Project management
Primary apparatus
Busbar system
Failure and maintenance
Other
Total
The chart below shows a cost comparison between a conventional solution and
DCB. The example contains a five bay single busbar distribution substation.
Cost
Design and planning

Civil work and sitework
Busbar and connections
Failure and maintenance
Primary apparatus
0
Conventional DCB

Processes and support
Design support
ABB has a long experience in substation design and can support in all stages and
to different extent due to demands for actual project.
Thus all cases from turn key to single apparatus delivery are supported.
For DCB solutions we have the possibility to create a layout proposal together with
a SLD to be used for quotations and for early discussions regarding replacing tradi-
tional solutions with DCB.
Even if the delivery is limited to loose apparatus, some switchgear design support as
switchgear layout, foundation plan, and support structure design can be supplied.
Delivery processes
The circuit breaker organization is process-oriented with focus on deliveries to cus-
tomers. The process is continuously optimized with respect to time and quality.
Sales & order handling

In order to assure that the deliveries fulfill the requirements in the purchase order
(P.O.) special attention is focused on:
Assuring the handover of the P.O. from the sales to the order department.
Order clarification, assuring the particular tasks of order, order design, purchas-
ing and production departments.
Possible order modifications.
The tools to monitor the orders are continuously improved in order to give our cus-
tomers the best possible service.
Supply management and purchasing

The circuit breaker unit has well defined processes for selection and approval of
suppliers.
Special attention is addressed to audits at the suppliers plant, the manufacturing,

Inspection and Test Plan (ITP) and the On Time Delivery (OTD) monitoring.
The suppliers are evaluated at regular intervals with respect to quality and OTD.
Production and assembly

All employees are trained and certified with respect to their responsibilities.
Inspections and test plans together with inspection records and control cards have
been prepared for all circuit breakers in order to assure that all activities and the as-
sembly are performed according to the specification.

Service and spares
The circuit breaker unit takes care of the customers requirements with respect to
service and spare parts. Certified traveling service engineers are available at the
plant in Ludvika. Also, in order to be able to assist our customers as fast as pos-
sible, local service centers are established in several parts of the world.
Research & Development

The R&D process is utilizing a project management model with well-defined gates in
order to assure that all customer requirements and technical issues are addressed.
Erection and commissioning

Erection and commissioning is a part of ABBs engagements for turn key and
complete switchgear deliveries. Even for other scope of delivery and for loose DCB
deliveries ABB can take the responsibility for erection and commissioning.
Please include erection and commissioning in your inquiry.
In case of emergencies a 24-hour telephone support is available

phone: +46 70 3505350.
By calling this number customers will get in touch with one of our representatives
for immediate consultancy and action planning.

Inquiring and ordering
Disconnecting Circuit Breakers
The Switchgear Specification Manager (SSM) documents can preferably be used as

enclosure to the inquiry for specification of DCB.
Otherwise, as a minimum the following information is required and can copied, filled in
and sent along with your inquiry.
PROJECT DATA
End customer
Name of project
Standard / Customer specification
Number of circuit breakers
Delivery time
APPLICATION
Line
Transformer
Reactor banks
Capacitor banks
Other service duty
Number of operations per year
SYSTEM PARAMETERS
Rated voltage
Rated frequency
Rated normal current
Maximum breaking current
LIWL (Lightning impulse 1.2/50 s)
SIWL (Switching impulse 25/2500 s, for Um 300 kV)
Power frequency withstand voltage
Grounded / Ungrounded neutral
AMBIENT CONDITIONS
Ambient temperature (max - min.)
Altitude (m.a.s.l.)
Earthquake withstand requirements

BASIC MECHANICAL PARAMETERS
Three-pole / Single-pole operation
Type of high voltage terminal (IEC/NEMA/DIN)
Minimum creepage distance mm or mm/kV
Phase distance (center-to-center)
Support structure (height)
OPTIONAL MECHANICAL PARAMETERS

Bursting discs
Bracket for CT
Primary connections CB CT
Manual trip
DATA FOR OPERATING MECHANISM

Control voltage (Coils and relays)
Motor voltage
AC-voltage (Heaters, etc.)
Number of free auxiliary contacts
Special requirements
ACCESSORIES
SF6 gas for pressurizing
Gas filling equipment
Controlled Switching (Switchsync)
Condition monitoring (OLM)
Test equipment
- SA10
- Programma
Tools
Spare parts

Protection and control IEDs
ABB Substation Automation Products has an outstanding experience of IEDs

(Intelligent Electronic Device) for Protection and Control systems in substations for
distribution, subtransmission and transmission networks.
IEDs for Distribution Switchgear

For Standard Distribution Switchgear, ABB Substation Automation Products can
provide Ready to connect IEDs which give cost effective solutions for protection,
control and monitoring of overhead lines, cables and power transformers.
Description of the IEDs

Distance protection IEDs for main or back-up protection in solidly or high imped-
ance earthed systems.
Full scheme distance, overcurrent, residual overcurrent and voltage protection
are examples of included protection functions.
Synchro-check and energizing-check, autorecloser, disturbance/event recorder
and fault locator are examples of included control and monitoring functions.
Overcurrent and earth fault protection IED for back-up protection in solidly or
high impedance earthed systems.
Non-directional and directional overcurrent and residual overcurrent protection,
voltage and breaker protection are examples of included protection functions.
Autorecloser, event and trip value recorder are examples of included control and
monitoring functions.
Transformer protection IEDs for power transformers connected to ring bus,

double breaker bus or 1 breaker bus with solidly or high impedance earthed
neutral points.
Transformer differential, overcurrent, earth fault, thermal overload d voltage pro-
tection are examples of included protection functions.
Voltage regulation by controlling the on-load tap changer position, disturbance
and event recorder are examples of included control and monitoring functions.
These pre-configured IEDs are easy to order, contribute to reduced engineering

time and give efficient commissioning.
Enquires and orders must be sent directly to ABB Substation Automation through
your local ABB representative.

Operation sequence
Interlocking status
Activity Order Indication Result Electrical Mechanical Local / Padlocking
interlocking interlocking Remote
Connect Close Closed 1 Breaker closed AD100 open AD100 open Remote
AD350 open AD350 open
Open Open Open 0 Breaker open AD100 open AD100 open Remote
Disconnect Disconnect Blocked 1 Breaker blocked AD100 closed AD100 closed Remote
Earth Earth Earthed 1 Earthing switch AD100 closed AD100 closed Remote
closed AD350 closed AD350 closed
Secure the Local Padlock the
disconnection breaker in open
position
Secure the Local Padlock the
earthing earthing switch in
closed position
Presentation of DCB in HMI

A new graphic symbol for drawings and illustration have been decided and intro-
duced in IEC 60617, please se figure below. There is no standard for representation
of DCB in HMI; however we recommend the following dynamic illustration to be
used. The dynamic symbols shall be able to demonstrate the different operations
modes or sequences for the DCB, se table of operational sequences.
DCB symbol according Open Closed Open and Locked

to IEC 60617

Contact us
ABB AB Copyright 2010 ABB. All rights reserved
Publication 1HSM 9543 23-03en, Edition 2, 2010-01 Disconnecting Circuit Breakers, Buyers and Application Guide
NOTE! ABB AB is working continuously to improve
SE-771 80 LUDVIKA, SWEDEN the products. We therefore reserve the right to change
Phone: +46 (0)240 78 20 00 designs, dimensions and data without prior notice.
Fax: +46 (0)240 78 36 50
E-Mail: [email protected]
www.abb.com
www.abb.com/highvoltage

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Disconnecting Circuit Breakers

Buyers and Application Guide

2 Buyers and Application Guide | ABB Disconnecting Circuit Breakers

Switchgear single line philosophy 15

Standards and testing 27

Processes and support 38

Inquiring and ordering 40

Protection and control IEDs 42

ABB Disconnecting Circuit Breakers | Buyers and Application Guide 3

Compact air insulated HV switchgear with Disconnecting Circuit Breakers

4 Buyers and Application Guide | ABB Disconnecting Circuit Breakers

Line Entrance Module

Primary switchgear apparatus

Product Buyers Guide Application Guide

ABB Disconnecting Circuit Breakers | Buyers and Application Guide 5

Special definitions used in this document.

Disconnecting Circuit Breaker

6 Buyers and Application Guide | ABB Disconnecting Circuit Breakers

A complete Switchgear specification contains among other parts,

For example, basic requirements in a functional specification can be:

Number and type of system connections

To back up the decision-making, availability calculations, life cycle cost calculations,

ABB Disconnecting Circuit Breakers | Buyers and Application Guide 7

Example of apparatus specification

5 High Voltage Circuit Breaker 145 kV, 3150 A, 31.5 kA

132 kV, 2000 A, 31.5 kA

Line 1 T1 T2 Line 2 Bus coupler

8 Buyers and Application Guide | ABB Disconnecting Circuit Breakers

An existing line shall be cut up and connected to the substation.

132 kV, 2000 A, 31.5 kA

Line 1 T1 Sectionalizer T2 Line 2

ABB Disconnecting Circuit Breakers | Buyers and Application Guide 9

Availability and reliability

Evolution of circuit breakers and disconnectors

Bulk oil breakers

Air blast breakers

SF6 Circuit breakers

10 Buyers and Application Guide | ABB Disconnecting Circuit Breakers

Improved availability with DCB

The dominating reason for unavailability of a certain part of a substation is (sched-

As an example, a comparison is made between a traditional double busbar solu-

ABB Disconnecting Circuit Breakers | Buyers and Application Guide 11

12 Buyers and Application Guide | ABB Disconnecting Circuit Breakers

More satisfied consumers, depending on substation/network topology the main-

Improved reliability with DCB

ABB Disconnecting Circuit Breakers | Buyers and Application Guide 13

Outages of an incoming/outgoing bay due to faults in the switchgear are shown in

14 Buyers and Application Guide | ABB Disconnecting Circuit Breakers

When designing a new substation a lot of considerations have to be taken. One of

ABB Disconnecting Circuit Breakers | Buyers and Application Guide 15

DCB is suitable to be used in systems as:

Single busbar system

If double busbar or transfer bus system is a demand it can preferably be replaced

16 Buyers and Application Guide | ABB Disconnecting Circuit Breakers

Double busbar/Double breaker

ABB Disconnecting Circuit Breakers | Buyers and Application Guide 17

Breaker and a half

18 Buyers and Application Guide | ABB Disconnecting Circuit Breakers

Disconnecting Circuit Breaker