AT SERIES – Containerized Substation for Outdoor Installation

AT SERIES

AT SERIESThe AT series Medium Voltage heavy-duty substation for outdoor installation is a free standing, containerised unit, specifically designed for job site electrification.

It is completely self contained and is easily movable. It can be lifted with the transformer fitted.

The substation is provided with MV switchboard, transformer and LV switchboard, designed to suit customer requirements.

Construction

The AT substation, which is painted both outside and inside is totally enclosed and is completely water proof for outdoor installation.

The structure is fully sealed with panels manufactured from 2.5 mm thick steel plate reinforced as appropriate.

The transformer is installed into a totally separate section accessible through independent outside end doors.
A removable roof section above the transformer allows lifting by crane if required.

Access to the LV switchboard panels is through personnel doors in the side of the container. All substation doors are mounted with inox steel hinges.

All bolts, screws and mechanical devices have anti-corrosion treatment.
All the internal equipment is provided with mechanical safety interlocks in order to avoid dangerous situations arising.

Painting

  • The substation is painted and finished to the following specification:
  • sandblasting of all surfaces
  • one coat rust-preventative epoxy type paint, 40 micron thick
  • two coats, air-dried epoxy enamel, 60 micron thick, colour standard RAL 1006 yellow
  • the roof and underside are covered by an additional coat of bituminous paint.
SIZE AND POWERAT SERIES (1600 - 3500 kVA)
SIZE 1(L x D x H)mm4540 x 2400 x 2590
SIZE 2(L x D x H)mm6058 x 2400 x 2590
SIZE 3(L x D x H)mm7500 x 2400 x 2590
SIZE 4(L x D x H)mm9125 x 2400 x 2590
SIZE 5(L x D x H)mm12190 x 2400 x 2590
TECHNICAL DATA
Rated system voltageKV12-24-36
Insulation level at 50 Hz for 60 secondsKV28-50-70
Impulse insulation levelKV60-125-170
Rated frequencyHz50-60
Rated secondary voltageVValue on request
HIghest capacity of transformerKVA4000
Auxiliary voltageVac/Vdc230 Vac/24-48 Vdc
Enclosure (with cabinet closed)IP549 - IPH6
Operating ambient temperature-10 / +40ºC
Humidity (non condensing)Rh 85%
TransformerMineral oil or cast resin dry-type


Download PDF English Data Sheet

ATX SERIES Pressurized Substation

Certified EEX-P Group I for tunnelling with presence of methane.

A Pressurized substation is defined as “having an internal overpressure housing EEx-pdia I 150°C”, suitable for group I conditions and classified zones.

The ATX series pressurized free substation is a free standing containerised unit, specially designed for civil engineering construction sites where there is the presence of gas. It is completely self contained and thanks to its strong structure it can operate in very severe ambient conditions.

Construction

The substation, which is painted both outside and inside is totally enclosed and is completely waterproof.

The structure is fully sealed with panels manufactured from 2.5 mm thick steel plate, reinforced as appropriate

All bolts, screws and mechanical devices have anti-corrosion treatment.

Painting

The substation is painted and finished to the following specification:
• sandblasting of all surfaces
• one coat, rust-preventative epoxy type paint, 40 micron thick
• two coats air-dried epoxy enamel, 60 micron thick, colour standard RAL 1013 white.
• non standard paint finishes are available on request

Pressurisation devices

Pressurisation equipment includes:
• EEx-d housing involving electronic system for pressurisation and purging control
• EEx-i safety devices for purging and pressurisation control
• purging pneumatic system including washout valve, pneumatic on-off valve, manual register,
air rolling shutter
• holding pressure system including pressure reducer, pressure gauge and on-off valve

Pressurisation system overview

The specially designed structure allows the operator to enter the substation without any loss of pressure. This is achieved using a double stage incoming door acting as an air lock.

The pressurisation system and the cooling system are fed with dry compressed air in the pressure range 3.5 ± 7.5 bar from a standard industrial compressor.

Reducers and filters condition the air to ensure that dry and clean instrument quality air is passed into the substation

The pressurisation cycle involves first an initial purging phase of the machine at start up, followed by a permanent cycle to maintain and control the internal overpressure.

The higher pressure is utilised for the initial purging phase but during the holding phase the rate falls to 10% or less and is required only for compensating air leakage.

The working overpressure is maintained at around 2 – 5 mbar (200-500 Pa) with a low level alarm set to 0,6 mbar (60 Pa).

Size and power ATX Series

Series ATX65L.*** (250-800kVA)

Overall dim. (LxDxH) mm 7310 x 2400 x 2590

Series ATX95L.*** (250-800kVA)

Overall dim. (LxDxH) mm 10310 x 2400 x 2590

TECHNICAL DATA FOR 24kV
Rated voltageKV24
Insulation levelKV50
Impulse insulation levelKV125
Rated frequencyHz50-60
Rated secondary voltageVup to 1000
Transformer CapacityKVA800
Fixed P.F.C.U.kVARup to 30
Automatic P.F.C.U.kVARup to 300
Auxiliary voltageVac/Vdc230/24 230
Enclosure (ingress protection degree)IP549 - IPH6
Operating ambient temperature-10 / +40ºC
Humidity (non condensing)Rh 85%
Altitude1000 m a.s.l.

SIERRA SERIES – up to 36KV Prefabricated Compact Substation

SIERRA SERIES

SIERRA SERIESSIERRA II series, type tested prefabricated compact substation, suitable for secondary distribution.

No costs for on site assembly and minimal civil engineering. The small profile makes SIERRA II easy to install discretely in sensitive locations. It guarantees an high level of personal safety.

Construction

SIERRA II is totally enclosed metal cladding, self-contained and weatherproof, ready to be placed upon a concrete base pad.

  • The unit is typically divided into three rooms for the medium voltage switchgear, low voltage switchboard and distribution transformer.
  • The transformer is located in the middle of the substation while the MV and LV compartments are located at both ends of the substation adjacent to the corresponding bushings of the transformer.
  • The substation may be operated from the outside (Non Walk-in Accessibility Type B).
  • The electrical equipment is cooled by natural ventilation through openings in the substation.
  • The unit is mainly made of corrosion resistant 2mm AlZn-coated steel sheet. The aluminium and the zinc alloy coating provide protection against corrosion due to harsh environment conditions. In addition, 3mm galvanized steel sheets are used to make the support in the base frame (oil collection pit) stronger.
  • The oil collection pit, which can take 100% of the transformer’s oil volume, is integrated into the substation base frame.
  • Enclosure, with closed door is IP43. Doors can be fitted with gaskets in order to have degree of protection IP54.
  • Last finish coat is a powder paint of polymer resin base.

MV Compartment

This compartment can be equipped with wide varieties of MV switchgear. For voltages up to 24kV, the basic configuration is a SF6 insulated RMU which consist of two load break switches and one switch-fuse combination for transformer protection, all contained in a single sealed tank. Same configuration is also available for voltages up to 36kV.

Transformer Compartment

This compartment is specially designed to provide the transformer with adequate airflow cooling through well sized openings. The compartment is provided with a pressure relief system integrated in the ceiling/roof. As an option, a floor mesh can be provided to prevent entry of small animals and other foreign objects, assuring in the meanwhile continuous airflow and circulation. Oil-immersed or dry type transformers can be accommodated on this compartment.

Low Voltage Section

This compartment contains the Low Voltage Distribution Board (LVDB), which is fed from the secondary side of the transformer. The LVDB can be designed in different arrangements and configurations in order to suit any specific application. Inside the panel can be installed Air circuit breakers (ACB’s), Moulded case circuit breakers (MCCB’s), LV Fuse switches Instrumentation and metering

Ventilation

Natural ventilation is provided through ventilation for air intake at the bottom of the walls. The air is extracted through ventilation openings at the top of the walls, and natural air circulation ensures sufficient cooling to the distribution transformer.

As standard SIERRA II is classified and type-tested in accordance with temperature class K20. Temperature class K10 can be achieved by increasing the ventilation area for the transformer room.

Ground System

The substation forms a complete metallic bolted structure. Each compartment is provided with grounding busbars. Bonding and interconnection of the grounding buses are made of 70mm2 bare stranded copper conductors.

The ring main unit (RMU) and the low voltage panel (LVDB) are provided with grounding bus that can be connected to the grounding system at site.

Standards Reference

The SIERRA II range is designed and type-tested in accordance with EN 61330, which covers the following test programs:

  • Test to verify the insulation level of prefabricated substation
  • Test to prove the temperature rise of the main components contained in a prefabricated substation
  • Test to prove the capability of the earthing circuits to be subjected to rated peak and rated short-time withstand current
  • Functional test to prove satisfactory operation of the assembly
  • Test to verify the degree of protection
  • Test to verify the withstand of the enclosure of the prefabricated substation against mechanical stress
  • Additional type test in accordance with EN 61330 and PHELA Recommendation n.7 05/2004
  • Test to assess the effects of arcing due to internal fault.

Main components are type-tested in accordance with their individual standards:

Medium-voltage switchgear

EN 60265: High-voltage switches
EN 60298: Metal-enclosed high-voltage switchgear
EN 60694: High-voltage switchgear

Low-voltage switchboard

EN 60439: Low-voltage switchgear and control gear

Distribution transformer

EN 60076: Power transformers

Compliance to other applicable Standards and Council Directives is indicated on the Declaration of Conformity draft in accordance to EN 45014 “General criteria for suppliers declaration of conformity”.

Moreover WE WALTER has adopted a quality management system for engineering, construction and testing processes compliant with the requirements of EN ISO 9001:2000.

TECHNICAL DATA
Transformer Rated PowerkVA630-12501600-2500630-1250
Primary Rated VoltagekVA12-2412-2424-36
FrequencyHz50-6050-6050-60
Internal arc withstand current 1"kA161616
Overall dimensionsL (mm)300030003000
W (mm)210021002100
H (mm)234026402640

PAK SERIES – Reinforced Substation for Tunnelling

PAK SERIES

PAK SERIESPAK series, medium voltage electrical mobile substation for tunnelling and mining installation, is a reinforced unit, that can be installed on a truck, skid mounted or placed on a wagon, for easy handling in the tunnel.

Extremely robust and resistant to heavy mechanical stress, PAK substation can operate in extreme environmental conditions.

It conforms to European Standard IEC, Tunnelling and Mining Rules.

Construction

PAK substation is manufactured with 5 and 3 mm thick cold-worked and continuous welded steel plate.

Substation doors are mounted by inox steel hinges. Bolt, screws and mechanical devices have anti-corrosion treatment.
Enclosure, with closed door, is IP549.

Painting

Substation is painted and finished to the following specification:

  • sheet degreasing with synthetic thinner
  • sanding with scotch-brite 3M for zinc passivated steel supports
  • one coat antirust epoxide primer, 25 micron thick
  • two coats epoxide enamel, 60 micron thick
SIZE AND POWER - CLASS 12 KV
air insulated switch disconnector
SIZE 10(LxDxH) mm 3050 x 1650 x 950100 ÷ 250 KVA
SIZE 11(LxDxH) mm 3250 x 1650 x 950315 ÷ 630 KVA
SIZE 12(LxDxH) mm 3550 x 1650 x 950800 ÷ 1000 KVA
tee switch
SIZE 13(LxDxH) mm 4350 x 1650 x 950100 ÷ 250 KVA
SIZE 14(LxDxH) mm 4550 x 1650 x 950315 ÷ 630 KVA
SIZE 15(LxDxH) mm 4850 x 2000 x 950800 ÷ 1000 KVA
SIZE AND POWER - CLASS 24 KV
gas (SF6) insulated switch disconnector
SIZE 20(LxDxH) mm 3350 x 2000 x 1100100 ÷ 250 KVA
SIZE 21(LxDxH) mm 3550 x 2000 x 1100315 ÷ 630 KVA
SIZE 22(LxDxH) mm 3850 x 2000 x 1100800 ÷ 1000 KVA
SIZE 23(LxDxH) mm 4050 x 2000 x 11001250 KVA
tee switch
SIZE 24(LxDxH) mm 3850 x 2000 x 1100100 ÷ 250 KVA
SIZE 25(LxDxH) mm 4250 x 2000 x 1100315 ÷ 630 KVA
SIZE 26(LxDxH) mm 4350 x 2000 x 1100800 ÷ 1000 KVA
SIZE 27(LxDxH) mm 4550 x 2000 x 11001250 KVA

Medium Voltage Switchboard

The medium voltage switchboard is installed in a separate section segregated from the LV side, which includes:

  • an earthing switch disconnector on the incoming line
  • an on load switch disconnector with tripping coil combined with current limiting fuse (switch fuse combination)
  • an earthing switch disconnector on the outgoing line

Transformer

To comply with current standards, different types of transformer can be provided with the substation according to customer requirements:

  • Cast resin transformer (50-1250 KVA)
  • Silicon oil transformer (50-1250 KVA)
  • Dry-type transformer (50-1250 KVA)

Low Voltage Switchboard

The low voltage switchboard is fitted into a separate section segregated from the MV side. It includes the main circuit breaker to protect the transformer against short circuit, overload and earth-fault.

The design arrangement of the LV utilities is manufactured to suit customer specifications and can include moulded case circuit breaker (MCCB), load break disconnector combined with current limit fuses, earth leakage protection, starters, small PLC and measuring devices as well as automatic power factor correction unit.

TECHNICAL DATA
ClassKV1217,524
Dielectric withstand voltageKV283850
Impulse withstand voltageKV6075125
Rated primary voltageKV101520
Rated frequencyHz50/6050/6050/60
Rated Secondary voltageV400400400
Auxiliary voltageVac/Vdc230/24230/24230/24
Transformer capacityKVA up to 1250
Enclosure (with cabinet closed)IP549
Operating ambient temperature-10 / +40ºC
Humidity (non condensing)Rh 85%

PAK-exp SERIES – Certified EEX-P Group I Pressurized Substation for Tunelling

PAK-exp SERIES – Certified EEX-P Group I Pressurized Substation for Tunelling

Pressurized substation is defined as “internal overpressure housing EEx-pdia I 150°C”, suitable for group I (coal mines with presence of firedamp) and classified area for zones C1ZO – C1Z1 – C1Z2 – C1ZR. PAK-exp series pressurized substations have been developed in two different design:

  • design Eex_p I (group I) for underground applications with presence of firedamp (CH4).
  • design Eex_p II (group II) for petrolchemical applications.

The difference between these two versions is the Eex_d box in which are installed instruments for purging and pressurization control.

Construction

Substation, painted both outside and inside is totally enclosed type and
water proof.

The closed-packed structure and the panels are manufactured with 2.5 mm thick steel plate conveniently reinforced.

Bolt, screws and mechanical devices are anti-corrosion treated.

Painting

The substation is painted and finished in accordance to the following procedure:

  • sunblasting of the whole surface
  • a coat of rust-preventive paint epoxy type, thickness 40 micron
  • two coats of air-dry epoxy enamel, thickness 60 micron
  • standard RAL 1013 white.

Presurization Equipment

Pressurization equipment includes:

  • EEx-d housing involving electronic system for pressurization and purging control
  • EEx-i safety devices for purging and pressurization control
  • purging pneumatic system including washout valve, pneumatic on-off valve, manually register, air rolling shutter
  • holding pressure system including pressure reducer, pressure gauge and on-off valve

Pressurization System Overview

The pressurization cycle involves firstly a purging phase at machine start up, then a permanent phase for internal overpressure holding and control.

The fluid engaged consists in dry and clean instrument air. Network pressure required is included in the range 7,5 to 3.5 bar. The biggest rate is required for the purging phase while for holding phase the rate falls till 10% or less and is engaged just for compensate eventual losses. Working overpressure is kept around 2 to 5 mbar (200-500 Pa) with alarm set on 0,6 mbar (60 Pa).

At the beginning of the purging phase, a pneumatic valve opening full rate incomes.

An EEx-i safety device for rate control pulls the time count (fixed in 30 minutes). If the rate falls under the set value, the count stops and re-starts when reset usual rate conditions.

Ending the purging phase, the holding rate is started-up by reduced pressure at 5 mbar. In the meantime purging phase stops and machine can be started.

If the internal overpressure falls under 0,6 mbar, pressure lack
alarm incomes.

If the overpressure resets within 30 min. from depressurization, it isn’t
necessary a new purging phase.

The pressurization system and the cooling system are fed by compressed dry-air, pressure 4 ± 7,5 bar. Switches working have been protected by an external door; external doors can be opened without any pressurization loss.

TECHNICAL DATA FOR 24kV
Rated voltageKV24
Insulation level at 50 Hz for 60 secondsKV50
Impulse insulation level (KV BIL)KV125
Rated frequencyHz50-60
Rated secondary voltageVup to 1000
Highest capacity of transformerKVA1250
Fixed P.F.C.U.kVARup to 40
Automatic P.F.C.U.kVARup to 400
Auxiliary voltageVac220
Enclosure (with cabinets closed)IP549 - IPH6
Operating ambient temperature-10 / +40ºC
Humidity (non condensing)Rh 85%
Altitude1000 m a.s.l.

DESERT SERIES – Containerized Substation for Desert

Desert Containerized Substation

DESERT MV SERIES Prefabricated Substation can be used to supply quick and reliable energy in places where energy is not very accessible. DESERT MV SERIES Prefabricated Substation is a self contained and completely integrated unit designed for a specific purpose. It complies with local regulations concerning weight and dimensions for transportability and services, and for all specified conditions in respect of climate and electricity demand.

Construction

The housing of the compact substation is a totally enclosed, metal clad and weatherproof container mainly constructed using steel frames and corrugated panels welded by CO2 shielded Arc welding.

The building is typically divided in three rooms for the medium voltage switchgear, the distribution transformer and the low voltage distribution board.

The transformer is located in the middle while the M.V. and the L.V. room are located at either end of the building adjacent to the corresponding bushing of the transformer.

The substation may be operated from the inside (walk in type – Accessibility type B). Prefabricated Compact Substation in accordance to IEC/EN 61330 is classified and type-tested with temperature class K20.

Two different cooling systems will be provided – one for the transformer room (Forced ventilation) and one for the H.V. and L.V. rooms (HVAC).

The Prefabricated Substation has IP54 protection, in accordance with EN 60529.

TECHNICAL DATA
Overall Dimensions W x D x HISO standard 20-30-40' or tailor made upon request
Protection DegreeIP54-9
Substation typeWalk-in
Accessibility TypeB
Temperature ClassK20
Cooling SystemForced Ventilation (Transformer Room)
Air Conditioned (MV and LV Room)
Operating Temperature-5 ÷ +55ºC
Relative Humidity5 ÷ 95%
Installation1000 m. above sea level
Roof load withstand2500 N/m2
Withstand wind loads700 Pa
Withstand mechanical impacts20 J
Ice thickness10 mm
Rated System VoltageUp to 36kV
Rated Power InstalledUp to 4MVA

MV Room

This room can be equipped with wide varieties of MV switchgear. For voltages up to 36kV, the basic configuration is a SF6 insulated RMU which consists of two load break switches and one switch-fuse combination for transformer protection, all contained in a single sealed tank.

Transformer Room

This room is specifically designed to provide the transformer, oil immersed or cast resin type, with sufficient volume of airflow for cooling through adequately sized and professionally designed ventilation openings.

Low Voltage Room

This room houses the Low Voltage Distribution Board (LVDB), which is fed from the secondary side of the transformer. The LVDB can be designed in different arrangements and configurations in order to suit any specific application.

Standars Reference

The Prefabricated Compact Substations, Series AT-DSRT, are designed and type-tested in accordance with IEC/EN 61330 ( Standard for High-Voltage/Low-Voltage Prefabricated Substations)
Main components shall be type-tested in accordance with their individual standards:

HIGH-VOLTAGE SWITCHGEAR

IEC/EN 62271-200 High-voltage switchgear and controlgear Part 200: AC metal-enclosed switchgear and controlgear for rated voltages above 1 kV and up to and including 52 kV

LOW-VOLTAGE SWITCHBOARD

IEC/EN EN 60439: Low-voltage switchgear and controlgear assemblies – Part 1: Type-tested and partially type-tested assemblies

DISTRIBUTION TRANSFORMER

IEC/EN EN 60076: Power transformers

ENCLOSURE

ISO 830: Freight containers-terminology
ISO 668: Series 1 freight containers-classification, external dimensions and ratings
ISO 1496-1: Series 1 freight containers-specification and testing
ISO 3874: Series 1 freight containers handling and securing
IEC/EN 60529: Specification for degrees of protection provided by enclosures (IP code)

Compliance to other applicable Standards and European Council Directives will be indicated in the Declaration of Conformity draft in accordance to EN 45014 “General criteria for suppliers declaration of conformity”. Moreover WE Walter S.r. l. adopt a quality management system for engineering, construction and testing processes compliant with the requirements of EN ISO 9001:2000