COMPASS

Compact Prefabricated Air Insulated Substation

ABB 2

Focus factory

The ABB Focus Factory based in Lodi, Italy is

one of the facilities belonging to the ABB Group,

it deals with High Voltage electrical apparatus

with a build-up area of 12,000 square meters.

It is a global focus factory and is a centre of excel-

lence when it comes to designing and manufac-

turing high voltage hybrid-breakers and switch-

gears. A market leader, it exports approximately

80% of its products worldwide. Production is

organized according to “Lean Production” crite-

ria and is managed by means of an integrated

ERP system.

The quality of the manufacturing processes is

guaranteed by the “Six Sigma” system. The qual-

ity system conforms to ISO 9001 standards,

the environmental management system to ISO

14001 standards, and the health and safety man-

agement system to OHSAS 18001 standards for

building sites, all certifi ed by an external inde-

pendent organization.

ABB 3

Laboratories

ABB plant has internal laboratories equipped with

state-of-the-art equipment in order to carry out

material experimental, climatic, mechanical life,

electromagnetic compatibility, commissioning

and dielectric tests. Type and routine tests ascer-

tain whether the components, construction stages

and fi nished products comply with the strict spec-

ifi cation requirements. The Test Laboratory is ac-

credited by an external independent organization

and complies with UNI CEI EN ISO/IEC 17025

Standards.

Production

Thanks to the new shop-fl oor layout, designed ac-

cording to the Just in Time, Lean Manufacturing

and Theory Of Constraints techniques, the pro-

duction workfl ow is managed on an “Assemble

to Order” basis, i.e. each module is fully assem-

bled and manufactured once the order has been

received. The output of each production line is a

completely assembled and tested product, ready

for an easy and fast erection and commissioning.

Service

Thanks to its Service structure, ABB plant pro-

vides all the backup to customers after sales needs:

analysis and modifi cation of existing installations,

diagnosis of modules conditions, solution for life

cycle cost reductions, upgrading to achieve com-

pliance with Standards and laws, retrofi tting and

revamping interventions, training and updating

of maintenance personnel, as well as emergency

interventions.

ABB 4

Introduction

Way back in 1996, ABB introduced a simple, in-

tegrated and innovative 123 kV to 170 kV high

voltage switchyard module, called COMPASS.

COMPASS combines some of the benefi ts of the

open air connected substation with a very com-

pact and smart design, allowing contractors and

end-users to plan, build and maintain high volt-

age substations with the minimum engineering,

labour and civil construction costs.

COMPASS is the right choice:■ in the new greenfi eld substation, where the

Life Cycle Cost of a switchyard is the critical

factor, COMPASS is cost effi cient, particularly where ground space is at a premium.

■ when it comes to retrofi tting, and the substa-tion needs to be expanded with limited ground space available or the existing area must be re-duced (suburban areas, etc.).

All these benefi ts have created a new market

where ABB is the price performance leader and

technology trend setter: ABB has sold more than

1,300 units around the world during the past 10

years.

ABB 5

COMPASS means COMpact Prefabricated Air-

insulated SubStation and includes all the high

voltage functions of a single bay in just one

module. Each phase includes:■ One Circuit Breaker with BLK Drive (both

single- and threephase operation)

■ Two Disconnectors with their own motor/manual Drive

■ Two Earthing Switches with their own motor/manual Drive

■ One Current Transformer

■ One Voltage Transformer

■ One Surge Arrester

■ Local Control Cabinet.

COMPASS can be equipped with both silicone

or porcelain insulators.

The position of the these functions is shown in

the diagram below.

What is COMPASS?

Circuit breaker

Disconnector switch

Current transformer

Voltage transformer

Surge arrester

ABB 6

The entire COMPASS Module is

fully designed, assembled and test-

ed according to the IEC Standards

in the ABB Adda plant and can

be transported to the installation

site on a simple truck or container

without having to be disassembled

in any way. This means that there’s

no need for the main electrical tests

to be conducted on site.

A COMPASS switchyard is very

simple, fast and inexpensive to

erect: this is thanks to it’s design,

which not only reduces the erec-

tion and commissioning phases,

but also allows a lot of space to be

saved thanks to the NABLA self

supporting bus bar system.

This means that there’s no need to

have bus bar post insulators in order

to support the actual bus bar sys-

tem, because weight is supported by

the COMPASS modules.

The result of all this is an important

cost reduction on site.

Transport, erection, maintenance

ABB 7

The module can be easily serviced and inspected

by lowering the mobile part. This means that the

bay can be checked or repaired on site: the tech-

nicians work with their feet on the ground, inside

an earthed structure (Faraday cage): safety and ef-

fi ciency are thus assured.

If major maintenance is required, the mobile part

of the bay can be easily removed and taken to a

workshop.

The complete bay can be totally replaced in ap-

proximately three hours. This saves time and cuts

the consequent inconvenience down to the mini-

mum. One spare mobile part of a bay is therefore

recommended if the user is particularly concerned

with cost of any resulting damages.

Phase 1 Phase 2

Phase 3 Phase 4

ABB 8

ABB R&D department has designed a new ver-

sion of COMPASS in compliance with the latest

state-of-the-art dictates for high voltage equip-

ment. This new COMPASS features lots of in-

novations:

■ completely new design so as to include the voltage transformer and surge arrester in the apparatus

■ better weight distribution that improves the center of gravity position and reduces the total weight of COMPASS

■ a new disconnector motor mechanism that’s extremely simple and reliable thanks to a dras-tic reduction in the number of movable parts (pinion gear and rack system)

New Features

■ the motor drive can be used as a circuit breaker operating mechanism instead of BLK. A mo-tor drive is a digitally controlled motor that di-rectly shifts the circuit breaker contacts. ABB has developed a servomotor system with digital control that’s able to directly drive the circuit breaker contacts in a highly accurate and reli-able way. The number of moving parts in the drive is reduced to just one, e.g. the rotating motor shaft

■ the UniWire Local Control Cabinet (based on Programmable Logic Controller philosophy) can be installed inside the control cubicle, as well as the integrated protection relay.The UniWire cubicle is designed to replace the tra-ditional wired logic using electromechanical components with a programmable logic con-troller, while maintaining the same CB operat-ing mechanism, DS drive, etc.

The wiring diagrams are simple, the cubicle tidy and mainly formed by standardized parts, with lots of space for the wiring duct, terminal blocks and customer’s equipment.

In addition, station moni-toring with the circuit breaker and discon-nector control functions can be integrated into one commer-cial high performance protection and control IED.

■ silicone bushings that provide better dielec-tric and mechanical strength

■ it has also unique characteristic of been self cleaning. This means that silicone bushing do not need particular mainte-nance

ABB 9

Installation Type Indoor – Outdoor

Environmental Conditions

Maximum air temperature + 40 °C

Minimum Air Temperature - 30 °C (*)

Altitude 1000 m

Maximum wind speed 130 Km/h

I ll i T I d O d

Normal Service Conditions

Rated voltage kV 123 145 170

Lightning impulse withstand voltage

To earth & between phases kV 550 650 750

Across the isolating distance kV 630 750 860

Power frequency withstand voltage

To earth & between phases kV 230 275 325

Across the isolating distance kV 265 315 375

Rated Frequency 50 (60) HZ

Rated normal current 1600 A (up to 2000 A)

Rated short time withstand current 40 kA

Mechanical stress on terminals According to IEC

Rated supply voltage of closing and opening devices and auxiliary circuits 110 VDC

Rated supply voltage of closing and opening devices and auxiliary circuits 400/230 VAC

Degree of protection of enclosures IP44 (**)

Seismic withstand factor 0.5 g

Rated voltage kV 123 145 170

General Characteristics

Data Sheet

Normal Characteristics

(**) Other on request.(*) Other on request.

55

52

48

100

100

100

ABB 10

Environmental protection is one of ABB’s top

corporate priorities. We consider environmental

issues in all our operations and productions.

ABB develops its processes and manufactures its

products by respecting the environment, in com-

pliance with ISO 14001 dictates. We design our

processes and products in order to reduce the im-

pact on the environment as much as possible (the

Environmental Impact

greenhouse effect, acidifi cation, photo oxidant

formation, ozone depletion, etc.).

We carefully consider and evaluate the impact on

the environment by means of Life Cycle Assess-

ment (LCA), in accordance with ISO 14040.

A product environmental performance must be

ascertained on the basis of a LCA. LCA is a useful

method for calculating a product environmental

impact.

Silicone COMPASS is the result of our efforts in

relation to environmental issues. It has been de-

signed in compliance with the philosophy of the

COMPASS project, which combines functional

and reliable systems with use of highly recyclable

materials.

Moreover, COMPASS is so compact that it re-

duces the area required for the complete substa-

tion by about 50% (over 65% for HV switch-

yard alone). This consequently reduces the use of

gas and materials, such as SF6, steel, aluminium,

iron, etc.

The compact structure of COMPASS plus use of

eco-effi cient materials make Silicone COMPASS

a product that conforms to the standards of sus-

tainable development recognized throughout the

world.

Considering the greenhouse effect, silicone

COMPASS reduces environmental impact by

about 50% as compared to a conventional com-

plete substation.

COMPASS Substation

Standard Substation

Erection time

Green house effect

Area

ABB 11

Lay Out

Single-bay substation

ABB 12

Lay Out

3-bays substation

Incoming-line / Busbars / Transformer bay

NABLA Busbar system

ABB 13

4-bays substation, ring main scheme

Incoming-line / Busbars / Transformer bay

NABLA Busbar system

ABB 14

4-bays substation, ring main scheme + bus sectionalizer

Incoming-line / Busbars / Transformer bay

Lay Out

NABLA Busbar system

ABB 15

A comprehensive environmental, quality, health

and safety system testifi es to our commitment

towards reducing the impact produced by our

processes on the environment and improving the

health and safety of our employees.

Our Quality Management System has been certi-

fi ed according to ISO 9001 since 1992, while our

Environmental Management System has been

certifi ed according to ISO 14001 since 1998.

Through the Environment Product

Declarations (EPD) and friendly

Environmental Performance Dec-

laration, ABB Adda provides the

necessary information about the

environmental performance of

the products during their whole

Life Cycle, in compliance with the

Standard Requirements (“Specifi c

Product Requirements”).

Quality

The target of our High Voltage Products division

is to be the Quality Leader in our industry and to

be clearly perceived as such by Customers.

To achieve this goal, we give Quality aspects a

priority, especially at operational level. All the in-

ternal and external functional areas are involved

in maintaining and improving the global quality,

across all the processes.

ABB 16

Quality

A sample test plan ensures that the incoming ma-

terials have been regularly inspected.

On the other hand, materials, parts or components

from new suppliers or from a critical supplier are

automatically fl agged for 100% inspection.

Special destructive and non-destructive tests are

conducted in our laboratories. Here, we check

for compliance with the technical specifi cations

or with prototypes through tests such as overpres-

sure, corrosion, hardness, etc.

All instruments and equipment used for testing

are systematically and periodically calibrated by

our metrological laboratory.

Standard operation procedures are essential to

ensure a correct assembly process.

The documents provide step-by-step assembly

instructions for each part we manufacture.

All assembly and test checklists

are collected and stored in a fi le

to ensure that the products and

single sub-materials are fully

traceable.

The fi nal tests prove that the product conforms

to the customer’s specifi cations and to the appli-

cable International Standards (e.g. IEC).

■ IEC 62271-203-SF6-Switchgear

■ IEC 60694-High Voltage Switchgear

■ IEC 62271-100 circuit breakers

■ IEC 62271-102 disconnector/earthing switch

■ IEC 60044-1 current transformers

■ IEC 60137 bushing

■ IEC 61462 insulator.

The test results and the Declaration of Conform-

ity to customer specifi cations and to the appli-

cable international standards are included in the

test report.

The completeness of the supply is verifi ed in the

fi nal inspection, performed on each product.

ABB S.p.A. Power Products DivisionUnità Operativa Adda-HVVia dei Ceramisti, sncLocalità San Grato26900 LodiItaly

Phone: +39 0371 452.1Fax: +39 0371 452.222

www.abb.it

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Note. 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 does not accept any re-sponsibility 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 – in whole or in parts – is forbidden without ABB’s prior written consent.Copyright© 2007 ABB - All rights reserved.