Mobile Substations | Design And Primary

Components
Contents

 What is Mobile Substations?

 Primary Components of Mobile Substations
 Design of Mobile Substations
 The Design of Air Insulated HV busbar
 The Design of Gas Insulation HV (GIS)
 Mobile Substations With MV Input, Low Voltage Level Output
 Effective Factors In Desinging The Mobile Substations
 Routuine Test Of MV Switchgears: (IEC62271-200)
 Factory Test Of Power Transformers

Electrical energy is generated and the voltage level is raised to the transmission level and
transmitted to further away from the generation point, and then the voltage is reduced from the
transmission level to the distribution level and is offered to the people for various purposes. We
call these facilities as transformer susbtations where voltage is increased and reduced. The
voltage level between 1 and 52 KV is used to be called the medium voltage (MV) network, and
the high voltage (HV) for the networks greater than 52 KV , and the low voltage (LV) for the
networks less than 1 kV. Today, all over 1kV networks are called high voltage networks. however,
it is still known as MV-HV-LV networks. As electrical energy is generated in rural and virgin areas,
fixed substations are usually established to reduce to distribution level after being transferred to
transmission level in these places. In these areas, fixed substations are usually established to
reduce to distribution level after being transferred to transmission level. Temporary or urgent
substations are established as mobile and used to serve energy distribution or consumption
activities in other regions when necessary.

What is Mobile Substations?

Since mobile transformer substations are generally used in remote locations, all equipment, tools
and hardware that will be required in the application should be kept in the content and no tools,
tools and equipment should be required during the application. It is one of the advantages of the
application that it provides the opportunity to be completed and commissioned as soon as
possible. Voltage levels and power determine the type of the mobile substations such as
132/33kV, 25 MVA, 33/11kV, 31,5/MVA or 2500 kvA mobile substations. Mobile substations are
designed and manufactured on one or more trailers according to the qualities of primary and
seconder circuits and presented to end users.

Mobile substations can be manufactured up to 62.5 MVA power in transmission level systems up
to 245 KV voltage level. Mobile substations can be manufactured at transmission level up to 245
KV voltage level up to 62.5 MVA power value.

Primary Components of Mobile Substations

Primary circuit elements are systems formed by high voltage or medium voltage switching and
protection elements that provide connection conditions to the primary voltage level of the
transformer. Mobile substations are usually requested as two trailers and one of these trailers
has primary circuit elements and power transformers. In mobile substations, which are only from
MV to LV voltage level, the design is requested on single trailer, and the substations which are
rarelyfrom MV to MV are also requested on single trailer.

Primary trailers can be requested as GIS (gas insulated system) or AIS (air insulated system ) at
HV level. In the mobile Transformers requested as GIS, design studies are carried out with
“hybrid system” in which HV circuit breaker, HV disconnector and grounding separator, voltage
transformers and current transformers are found in the tank filled with SF6 gas. By removing the
current transformers from the system, bushings of the transformer are designed as current
transformers and alternative price and size advantage solutions are offered. HV surge arrester
should be connected between the transformer and Hybrid GIS system. The power transformer is
also designed on the primary. In the mobile substations requested as AIS*, in accordance with
the specifications on trailers, air insulated HV separator and grounding separator, oil insulated
porcelain voltage rack, SF6 gas breaker, HV surge arrester, and current transformer or bushing
current transformer designs are made and power transformer is applied on the rear of the trailer.
Some MV/MV mobile substations also use two trailers. In the primary trailers of mobile
substation projects, MV entrance, measurement, transformer protection and internal need
transformer supply cells are found in the two-room hair kiosks and in the other room of this
kiosk, there is a transformer control panel.
It is designed in HV/MV mobile transformer projects two-room hair kiosk with independent
inputs on secondary trailer. The steel kiosk has MV switchgears in one room , and in the other
room there is a control, measurement and protection panel, a redressor, LV, AC and DC
distribution panel and a desk and chair for the personnel. On the secondary trailer, except the
steel kiosk, there are auxiliary transformer and grounding transformer, mounted batteries in
external type of battery cabinet, and cable drum.

In the secondary trey of MV/MV mobile transformer applications, there is a IP 54 protection class
two-room steel kiosk with independent gates in which the control and measurement panel , LV
AC-DC distribution panel, redressor are located with the secondary circuit MV switchgears in one
chamber. Outside the steel kiosk, there is the cable drum where the cables for the primary and
secondary connections are wrapped, the external type battery cabinet with the batteries and the
auxiliary transformer.

Some MV/MV mobile substations are requested on single trailer. In such cases , there is a control
and measurement panel in one room and an AC-DC distribution panel in the other room, with
the power transformer on the single trailer and the IP 54 Protection class steel kiosk with two
independent input gates with redresor. On the other side of the kiosk, there is the cable drum,
where the cables for the primary and secondary connections are wrapped, and the external type
battery cabinet with the batteries and the auxiliary transformer.

Design of Mobile Substations

They are designed as air insulated or gas insulated systems according to the specifications up to
245 kV insulation level.

The Design of Air Insulated HV busbar

HV voltage transformers which is the first element of the primary circuit in mobile substation
applications are manufactured in capacitive or inductive types with oil insulated and proselen
shielded. We use capacitive type voltage transformers in mobile substation applications. In order
to carry the dynamic and static loads of the conductors that provide the connection to the
powerline line, first the connection to the post insulator is made and then the input transformer
is used as the first circuit element. The purpose is to ensure that whether there is a tension in the
transmission line where the disconnector switch and circuit breaker are open, and they are also
used to lock the operations of grounding blades on the transmission line side of the circuit
breakers. Voltage transformers should consist of at least two seconders in the measurement and
protection class. The information from the measurement sequence gives voltage information to
the measurement instruments and voltage counters based on the billing. The protection
sequence provides voltage information to the protection relays with locking circuits.

The second element of the primary circuit is the HV separators and earthing switches.
Non-invasive types are used to provide electrical values which are stated in the specifications.
The disconnector switches can be manufactured with an optional manuel or single motor driven
or earthing switch. The disconnector switches, which is a single earthing switch, is applied with
earthing switches on the power transformer side and the dual earthing switches on both the
power transformer and the transmission line side. Disconnectors are installed by locking to
prevent work under load. In mobile transformer centers, the disconnectors and earthing
switches are processed from 110 VDC voltage source. Manual operations are left at the request
of personnel with a selective key. The main contacts of the disconnector provide absolute
resistance to the short circuit current due to the increase in contact pressures in cases of short
circuit currents.

The disconnectors can not

separate under load when
the circuit breaker is closed
but with the circuit breaker,
they can do the separation
process. If the earthing
switches in transmission line
traffic are requested in the
specification and there is
tension due to the voltage
information obtained from the voltage transformers at the entrance, the closing can be
prevented, if there is no voltage, the closing operation can be done. Generally, in mobile
substation applications, earthing switches are not required on the transmission line side.

The circuit element used after the HV disconnector on the primary circuit is SF6 gas cutters. They
do cut and close current for protection and operation under load, and should be selected in the
capacity to cut short-circuit current and nominal current calculated to provide the electrical
values specified in the specifications. The engine of the HV circuit breaker is applied as 110 VDC
to feed the engine, opening and grabbing coil. HV circuit breakers come to the mobile
substations disassembled and assembled on site. SF6 filling of HV circuit breaker is done after all
these assembly works are completed, so all equipment and necessary gas must be located at the
mobile substations.
In the primary circuit, the current transformers are found after the breaker, in some applications,
current transformers are used in the bushing of the transformer. The current transformers are
also manufactured as oil insulated and proselene protected. The secondary number depends on
the number of measurement and protection devices to be used. Generally, transformer
differential protection relays and spare protection relays are applied with a secondary for
measuring instruments, meters. Sensitivity classes are determined to serve these purposes in
accordance with the specifications.

In front of the transformer, porcelain or silicone coated surge arresters which provide electrical
properties in the specifications are used. Surge arresters are applied with surge counter. The
surge arresters manufactured in metal oxide type are generally applied between the current
transformer or circuit breaker in CL:2 or 3 class to discharge the voltage from the current to
withstand the current at 10 Ka levels. Also, surge arresters, which is selected according to the
same criteria, is used on the circuit where the star point of the transformer is grounded.

The last circuit element of the primary train is the power transformer. Power transformers are
required to have at least +/-8 number 1.25% with oil cooling system. Neutral point and HV
bushes are used as bushing type current transformers to save space in the design.

Onan cooling: oil cooling system with natural air circulation, ONAF cooling is the cooling form
where the oil is cooled by fans and the transformer temperature is kept under control. Fan
cooling system the power of the transformer provides a power increase between 20% and 25%
compared to Onan cooling.

OFAF cooling is the way that the oil circulation provided by the natural flow of the fan-cooled oil
to the heated core in the ONAF cooling system is done by a circulation pump.

ODAF cooling system is a type of cooling that is made by passing directly to a circulating pump of
the oil in the closed circuit, which is cooled by the fans in an external radiator, which is designed
apart from the transformer.

The most important features in transformers are the total power loss values on/off load. The
transformers manufactured for mobile substations are manufactured with special design and do
not exceed 3.500 mm in width and 3.500 mm in height. Automatic Control Panel under load is
applied in the second trailer in the kiosk. In the specifications, the vector connection group is
usually requested as YNd11.

The number of axles, length, and height of the lowbad treyler where the equipment form the
primary circuit is calculated according to the design and requested to be manufactured according
to the following criteria.

We need to determine the height of the highest equipment to be mounted on the trailer design
and the maximum permissible height on the road. Apart from this, the weights of all the
equipment to be mounted on the trailer should be determined one by one. The insulation gap
between each element and the maximum permissible jump distance value of the trailers must
also be applied according to the specifications. After all these data are obtained, the number of
axles is determined depending on the total weight of the equipment, and the total weight of the
trailer should be kept in the calculations. The size of the trailers is determined after being drawn
by considering the minimalist with the necessary insulation gaps on the trailer.

The Design of Gas Insulation HV (GIS)

If a gas insulated (GIS) system with HV circuit elements is described in the specification of mobile
substations, it is used because the voltage transformer, disconnector and earthing switches,
circuit breaker, current transformer and optionally the HG systems in which the surge arresters
are located in a tank filled with SF6 gas are less occupied. There is a power transformer behind
the GIS systems on the primary trailer where GIS systems are used. On the front side, the post
insulator should be used to carry the load of the conductor from the power transmission line. In
terms of operating limits, it is not possible to find any element other than power transformer
with HV equipment in primary trailer.

There are the steel kiosk with AC and DC power distribution board and battery charger rectifier,
measurement panel, MV switchgears on one of the rooms of secondary trailer which forms
HV/MV mobile substations, on the other room; there are control & protection panels.

Outside of the kiosk, there is an auxiliary transformer, an external type panel with the batteries
in it, and a cable drum with reducer that provides motor and circuit control between the
transformer and the MV bar input cell and the MV output cells to the distribution systems where
the cables are wrapped. The overhead line conductors to be connected to the HV transmission
line are also included in this trailer.

All the equipment to be assembled into the dimensions of the kiosk on the secondary trailer is
determined according to the terms of minimalism. It consists of two rooms, the first room
contains the MV cells and the air conditioner capable of cooling the heat energy to be released
as the nominal current passes through these cells.

Secondary circuit MV cells in air or

gas insulated cell classes are
requested as determined electrical
features in the specifications. Usually,
air insulated metal clad-grade cells
are used. Since the dimensions of the
steel kiosk are limited in height and
depth, these cells should be designed
with the pressure reduce channel at
high temperature and pressure
resulting from the possible internal
arc and this system is applied by the
channel from one or two points out
of the kiosk so that personnel safety
is ensured at the optimum level. The
important point is that the
switchgears must pass the type tests.
The point to be considered is that the cells have passed the type tests as they are applied here.
However, since the cells are mobile substation equipment, they must have passed the seismic
type tests (GR-63-core zone 4) according to the most severe conditions.

The second room of the kiosk is the control room and takes its name from the control panel
where all HV and MV switching elements are controlled and monitored. The control panel
includes protection relays that perform diff. & back-up protection of the power transformer,
switches required to make opening & closing of MV circuit breaker, disconnectors and earthing
switches, position indicators and alarm warning indicators belonging to these equipment.

Operation personnel perform all maneuvers in HV circuit via the control panel, alternatively, they
can perform manual operation by moving the selection key close to the operation location on
the field. The personnel doesn’t perform manual operations unless he has to.

The measurement of the electrical energy passing through the MV input and output switchgears
inside the measurement panel is carried out with noble and spare counters for each feeder.
These panels can be sealed.

AC axuiliary panel receives the energy from the internal demand transformer via a suitable
switch and distributes it to all devices and receptacles consumed AC energy in the field. In
addition to this, the charger of the batteries providing the DC needs, MV cells and HV equipment
and power transformer under load of the stage changer heater and other consumption points
and kiosk rooms of the rooms are fed by this panel.

The Dc distribution panel takes the DC feed from the battery and rectifier group and distributes it
to all cells and DC controlled MV equipment through a two-pole switch with appropriate
capacity.Emergency lighting systems in the kiosk rooms are also fed from this panel.

Battery charging rectifier usually provides the DC energy consumed in the system as 110 VDC as
long as the energy is present. In AC energy sections, charging of the atteries that will provide DC
voltage is also provided by the redressor.

In the selection of batteries, the total power of the system to be fed should be calculated and it
should be able to feed this power value for at least 5 hours and 8 hours in some projects.

Batteries are applied outside of the kiosk so that the hydrogen gas released from electrostatic
powder coated panel and the batteries do not affect the equipment in the kiosk.

The earthing and auxiliary transformer are chosen to ZNyn connection group and used as current
limiting for detecting and switching phase-earthing short circuit faults of HV system as well as
providing AC electricity energy to be consumed in the plant.

In some applications, they are applied with a resistance at the calculated values in order to avoid
earthing transformers from falling into resonance. In applications from OG to OG, they are not
used as grounding transformers and they only meet the 400V AC electrical power requirement of
the plant by selecting in Dyn 11 Connection Group. In this case, neutral grounding resistors are
used to limit phase earth fault currents of transformer and system.
In applications from MV to MV, they are not used as earthing transformers and they only meet
the 400V AC electrical power requirement of the plant as Dyn 11 connection group. In this case,
neutral grounding resistors are used to limit phase-earth fault currents of transformer and
system.

Neutral grounding resistors are used to limit the current value that can flow from the neutral
point of the power transformer in possible phase-earth faults. The value of the resistance is
calculated based on the current limit value to be determined. In external type galvanized sheet
metal which is resistant to atmospheric weather conditions. There are current, voltage
transformer and surge arrester in addition to the resistance. In these sensors, the system is
protected by opening the circuit breaker on the HV side of the transformer according to the
current and voltage values.

All of the cables needed to connect the mobile substation to the energy transmission or
distribution line and transfer the electrical energy from a voltage level to the energy distribution
lines at another voltage level are available as ready to be installed heads on a cable drum l. When
the trailer is positioned according to these lines, the primary line connection cables or busbars
on the drum are removed and connected to the line by taking security measures. Then, the cable
between the transformer and the secondary bus input cell is connected and connections are
made to the lines to be fed to the secondary busbar. All these connections are complemented by
the materials contained in the Mobile Substation without any material, tools and equipment.

Control and control cables are installed between two trailers. Both trailers have a plug-in plug
socket junction box and all connections are completed by plugging the plugs on both ends of the
cables into the sockets in these junction boxes. Since the plug sockets used for the connection
used for each purpose are marked, there is no possibility of incorrect connection.

Portable (Mobile) substations to MV / MV can be requested on a single or double trailer with

requiring design specifications. In the two-trailer applications, there are power transformer on
the primary trailer, air or gas insulated MV cells in accordance with the specification up to 40,5
kV in one room and in the other room there is a steel kiosk with power transformer control
and protection panel.

Outside this kiosk, there is a neutral grounding resistance with the auxiliary transformer
according to the specification. On the secondary trailer, there are gas or air insulated input and
output cells at a secondary voltage level in a room, the AC and DC distribution board in the other
room, the steel kiosk with the battery charger rectifier and outside of the kiosk, there is an
external panel with the batteries inside and a rectifier cable drum that allows the control of the
primary circuit and the secondary circuit to be connected to the lines and the connection of the
transformer to the primary and secondary circuit cells.

In mobile substations designed on a single trailer, the power transformer is applied to the
extreme point on a longer trailer compared to normal applications. After the power transformer,
there is a steel kiosk with power transformer control panel, AC and DC distribution panel and
battery charge redressor in the other room. Outside of the steel kiosk, with neutral grounding
resistance, auxiliary transformer, external type battery panel and reducer with MV input and
output cables and motor driven cable drum which can rotate at constant speed is applied.
Selection criteria of the equipment in MV/MV voltage level mobile substations on single or
double trailers are designed the same as the secondary trailers of mobile transformer centers at
HV/MV voltage levels.

Mobile Substations With MV Input, Low Voltage Level Output

The mobile substations from MV to LV are more compact, and their total weight is lighter than
other mobile substations, so they fit on the trailer. In relation to the level of LV 3200 kVA up to
4000 KVA in these applications, every equipment is designed in steel kiosk. The steel kiosk
consists of 3 rooms, the first room is the MV cells insulated by air or gas, second room is
distribution transformer, third room is equipped with an LV panel and a cable drum where all the
connection cables are available, tool box and other equipments.

Effective Factors In Desinging The Mobile Substations

The most important factor in the design of mobile substation is the characteristics of the region.
The highest altitude, relative humidity rate, seasonal average, minimum and maximum
temperature values, the effects that disturb the conductivity of the air should be known. When
designing Mobile Substation Center, this information is used when determining the energy
leakage distance (creepage distance) between the equipments. The distance between the two
trailers, primary traile and the transmission or distributions line to receive energy should be
known.

In the field, calculating earthing area that will provide the step and touch voltage values, and in
accordance with these calculations, the installation and supply of materials that will form the
earthing area is up to the responsibility of the administration of the operation. The reason is that
the specific earth resistance in different places to be applied to mobile substations differs and
this earthing area is also
required to be established
regionally different.

All tools, tools and

equipment necessary for the
operation of mobile
substation should be
identified and kept on
proper basis. Portable stairs
and walking platform should also be considered in order to provide access to the kiosks of mobile
substations.

The factory of the equipments forming the mobile substation is one of the most important issues.
All functions of the control panel are tested and all of the maneuvers must be tested by applying
the control voltage.

All protection functions must be tested when the set values are exceeded. The same procedures
must be carried out for the measuring system and ensure that the measurements are carried out
 correctly, and calibration of the instruments which require calibration must be ensured. When
the Mobile Substation reaches the application area, it must be ready to operate when the power
circuit and control connections are completed. The mobile substation is now ready to be put in
place by applying the following tests to MV cells and power transformers.

Routuine Test Of MV Switchgears: (IEC62271-200)

 Main frequency voltage tests in main circuit (70 kV, 1 minute)

 Network frequency voltage tests in auxiliary circuits

 Primary and secondary current injection and protection relays function tests and
opening supervision of characteristics

 DC isolation tests-main busbar, main busbar-earth (5 kV DC, 1 minute)

 Determination of current transformer rotation rates

 Secondary load testing

 Mechanical work experiments

 Measurement of resistance of the main

 Testing of auxiliary electrical devices

 Tests of suitability of connections

 Manual examination

 Measuring paint thickness

Factory Test Of Power Transformers

 Temperature increase test

 Short circuit test (type test)

 Measurement of zero component impedance

 Vacuum Test on Mounted Transformer

 Pressure Test of Mounted Transformer

 Measurement of audible noise level (as per the procedure specified in IEC 60076-10)

 Determination of transient regime voltage switching characteristics (IEC 60076-3)

 Assessment of the tank for proper carriage (IEC 60076-1)

 Determination of the weight of the transformer prepared for transport (IEC 60076-1)

 Measurement of energy consumption of fan motors (IEC 60076-1)

 Measurement of Winding Resistance

 Measurement of Voltage Turn Rate and Control of Phase Shift

 Measurement of capacity and loss factor

 D.C. Measuring Insulation Resistance

 Measurement of short circuit impedance and loas losses . ( According to IEC-60076-1,

article 11.4 e)

 Measurement of free loss and current ( according to IEC-60076-1, article 11.5 )

 Dielectric Strength Tests ( according to IEC 60076-3)

 Switching pulse test ( according to IEC 60076.3, article 15)

 Lightning impact test ( according to IEC60076-3)

 Tests of load level converter ( according to IEC 60076-1, article 11.7)

 Pressure Leakage Test ( according to IEC 60076-1 article 11.8 e)

 Paint Application and Quality Control

 Routine Tests in Welding Connections

 Measurement of Magnetic Flux

 FRA (Frequency Response Analysis) Test

 Oil Tests

o Power Factor (Doble, 25 °C+100°C)

o Dielectric Strength

o Acidity

o Internal Surface Stress

o Density

o Viscosity

o Number of Colors

o Amount of water
 Checking oil-soluble gases (according to the procedure specified in 60567)

 Control of all protection of fittings and transformers