PPL Gas Insulated Substations: Design Considerations and Lessons Learned. Nicholas Matone Support Engineer, T&S Standards

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1 PPL Gas Insulated Substations: Design Considerations and Lessons Learned Nicholas Matone Support Engineer, T&S Standards

2 Agenda PPL Overview Previous GIS Experience Present GIS Installations Mobile GIS Investigation Design Considerations and Lessons Learned Latest Developments

3 PPL Overview

4 PPL Overview Northeast/Central Pennsylvania 1.4 million customers 10,000 sq. mi. Predominantly rural 500kV, 230kV, 138kV, 69kV transmission voltages

5 GIS History Early generations of GIS: Vintage ~1978 GIS (Sunbury Substation) Many problems throughout its service life Catastrophic bushing failure in 2013 Vintage ~1987 GIS (Wescosville Substation) Similar problems to Sunbury Taken out of service in 2012

6 Project Overview: Sunbury 500kV Ultimate Build: Eleven breakers, six lines, two transformers Arrangement: Breaker-and-a-Half Status: Brownfield Original scope in 2013: Six breakers, two lines, one transformer (replaced old ASEA gear)

7 Project Overview: Sunbury 500kV (cont.) 2016: Two breakers, one line with ~1700 of GIL to IPP. 2017: Add second transformer connection, split transformer bay

8 Project Overview: Lock Haven 69kV Ultimate Build: Fourteen breakers, eight lines, two transformers, two capacitor banks Arrangement: Breaker-and-a-Half Status: Greenfield Original scope in 2016: Twelve breakers, eight lines, two capacitor banks

9 Project Overview: Lauschtown 500kV Ultimate Build: Eleven breakers, six lines, two transformers Arrangement: Breaker-and-a- Half Status: Greenfield Original scope in 2017: Two lines, one transformer (near completion)

10 Project Overview: Sunbury 230kV Ultimate Build: Eighteen breakers, eight lines, five transformers Arrangement: Breaker-and-a-Half Status: Brownfield Original scope for 2018: Thirteen breakers, four lines, five transformers

11 Project Overview: Wescosville 500kV Ultimate Build: Eight breakers, three lines, two transformers Arrangement: Double-Bus-Double-Breaker Status: Brownfield Original scope for 2019: Six breakers, two lines, one transformer

12 Project Overview: Palooka 230/69kV Ultimate Build: 230kV Twelve breakers, six lines, three transformers 69kV Fourteen breakers, eight lines Arrangement: Breaker-and-a-Half Status: Greenfield Original scope for 2019: Nine breakers 230kV, eight breakers 69kV, Four lines each voltage, two transformers

13 Mobile Substation Concept

14 Mobile Substation Intent Typically used for planned work, but can also be rapidly deployed for emergencies Bypass an entire 230/69kV yard Programming and most testing complete before deployment Easily transportable (no permits)

15 Key Features Relaying+SCADA+RTU built-in to LCC Panels Allows for an existing control cubicle to be taken out of service AC and DC power supplied from external sources Keeps weight down

16 230kV Mobile GIS

17 230kV Layout Two trailers, each with two breakers and three Pfisterer cable terminations Each trailer would be capable of connecting up to two transmission lines, and one centrally tapped transformer (refer to one-line) Combining the trailers will allow for up to four lines, and two transformers at one site

18 69kV Mobile GIS

19 69kV Layout Two trailers, each with four breakers and four Pfisterer cable terminations Each trailer will be capable of connecting up to three transmission lines, and one transformer (refer to oneline) Combining the trailers will allow for up to six lines, and two transformers at one site

20 Design Considerations and Lessons Learned Online Gas Density monitoring Central system to track gas density of all zones Can provide alerts to slow leaks before reaching alarm or trip level, so repairs can be planned

21 Design Considerations and Camera System Lessons Learned Makes access to viewports much easier and convenient Analog system vs central computer system? Analog provides direct connection, whereas a central computer could provide more convenience

22 Design Considerations and Additional Gas Zones Lessons Learned Typically on 3-in-1 equipment, CTs are in the same gas zone as the breaker This requires additional equipment to be taken out of service in order to de-gas the breaker Solution: ensure there is a buffer zone between the MOD and the CB

23 Design Considerations and Lessons Learned Switches for Future Expansion We originally included isolation switches to ease future expansion Due to the need to soak test the last piece of connection bus and tie into interlocking in existing LCCs, the switches proved unnecessary ORIGINAL INSTALL NEW INSTALL

24 Design Considerations and Bushing Zones Lessons Learned PPL requires gas/air bushings to be in their own gas zone Limits the extent of SF6 leakage in the case of bushing failure or vandalism

25 Design Considerations and Lessons Learned Universal Bid Documents Spec covers all voltages. Variances noted in tables Similar to IEEE C Scope template that is project specific Price and spec sheet template that vendors fill out Dedicated GIL Spec

26 Recent GIS Developments Initial Cost Estimator Tool Spreadsheet to help with high-level GIS estimates Filled in with budgetary values from vendors 69/138kV 230kV 500kV Breaker Quantity/ Line Exits Cost Breaker Quantity/ Line Exits Cost Breaker Quantity/ Line Exits Cost 6 / 3 6 / 3 6 / 3 8 / 5 8 / 5 8 / 5 10 / 7 10 / 7 10 / 7 12 / 9 12 / 9 12 / 9 14 / / / 12 Building Size (Breaker Quantity) Cost Dimensions (incl. line exits) Building Size (Breaker Quantity) Cost Dimensions (incl. line exits) Building Size (Breaker Quantity) Cost Dimensions (incl. line exits)

27 Recent GIS Developments (Cont.) Lifecycle Cost Estimator Tool Spreadsheet to help estimate maintenance costs Filled in using maintenance cycles from vendors, as well as PPL s maintenance experience

28 INPUT GIS Maintenance Costs Labor Rate/hr: $ Discount Rate: 0.11 Number of breakers: 8 Number of disconnects per breaker 5 Category Item Frequency (yrs) Manhours Cost Notes Breaker Multiplier? Disconnect Multiplier? Total Cost Building and General Costs Crane Inspection 1 $ OSHA requirement. Escorting third party inspector N N $ Building and General Costs Air Handling System 1 16 $ 1, Building and General Costs Camera System 1 1 $ Replace filters -Clean screens of dust and debris -Verify proper functionality of louvers -Verify functionality of fans/motors N N $ 1, Verify batteries charged and functional. -Verify camera is functional by spot checking several ports. N N $ Building and General Costs Miscellaneous Indoor 1 8 $ Building and General Costs Miscellaneous Outdoor $ Building and General Costs SF6 Quality checks 5 3 $ Verify building heaters are functional -Check for sources of water intrusion, correct if possible. -Spot check trenways for signs of rodent infestation/damage. -Perform a test of fire detection system -Inspect GIS grounding conductors for signs of loose or damaged hardware. N N $ Inspect grounding conductors for loose/damaged hardware -Review SF6 gauges for proper levels. Y N $ 1, Dew Point -SF6 purity -SF6 monitor switching points Y N $ 2, ABB 500 Costs Breaker Mechanism Inspection/Service 5 24 $ 2, Check switching times, oil level, carbon brushes, possible leaks, electrical connections (standard breaker service) Y N $ 21,120.00

29 OUTPUT $100, VENDOR 1 vs VENDOR 2 500kV $90, $80, $70, $60, $50, $40, Vendor 2 Costs Vendor 1 Costs Building and General Costs $30, $20, $10, $ Year of Service

30 Recent GIS Developments (Cont.) Conceptual Planning with GIS GIS previously used as a Plan B Now evaluating GIS as a viable Plan A amongst AIS alternatives Spreadsheet takes into account total lifecycle costs, as well as qualitative criteria

31 INPUT GLOBAL INPUTS: Discount Rate 0.11 Lifecycle (years) 40 OPTION 1 NAME OPTION 2 NAME GIS AIS SPECIFIC INPUTS: Frequency (yrs) Cost Frequency (yrs) Cost Initial Cost $ 38,500, $ 37,500, Failure Cost Estimate 12 $ 200, $ 120, Maintenance Item 1 1 $ 10, $ 8, Maintenance Item 2 4 $ 12, $ 30, Maintenance Item 3 12 $ 30, $ 60, Maintenance Item 4 1 $ - 1 $ - Maintenance Item 5 1 $ - 1 $ - Failure Net Present Cost $ 149, Failure Net Present Cost $ 268, Maintenance Net Maintenance Net Present Cost $ 138, Present Cost $ 205, Weight Value Rank Value Value Rank Value Initial Cost 50.0% $ 38,500, $ 37,500, Net Present Lifecycle Cost 20.0% $ 287, $ 474, Security 5.0% Extremely Good 0.05 Very Good Permitting 10.0% Good Bad Land Acquisition 0.0% Neutral 0 Neutral 0 Schedule 5.0% Good Good Safety 2.5% Extremely Good Very Good Ecological Impact 2.5% Good Bad Air Pollution Tolerance 0.5% Extremely Good Good Appearance/Aesthetics 1.0% Very Good Good Audible Noise 0.5% Very Good Good EMF 0.0% Extremely Good 0 Good 0 Disposal Concerns 3.0% Neutral Very Good % RANK RANK Soft Considerations

32 $45,000, $40,000, $35,000, $30,000, $25,000, $20,000, $15,000, $10,000, $5,000, $ GIS AIS OUTPUT Option Net Present Costs Option Rankings Failure Net Present Cost Maintenance Net Present Cost Initial Cost Soft Considerations Net Present Lifecycle Cost Initial Cost 0 GIS AIS

33 Questions/Comments? Nicholas Matone 2 North Ninth Street, GENN5 Allentown, PA Work: (610) Mobile: (570) NMatone@pplweb.com

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