1077 Session 2022

B3 – Substations & Electrical Installations

PS 3 / Integration of Intelligence on Substations

Test, Installation and Operational Experiences of World’s First Substation

Integrating Digital, Intelligent and Greenhouse-Gas free T&D Equipment

Dirk HELBIG, Matthias HEINECKE, Mark KUSCHEL, Peter MENKE,

Richard SCHULZ, Puneet SINGH
Siemens Energy
Germany
dirk.helbig@siemens-energy.com

Marcel ENGEL, Fred OECHSLE

Netze BW
Germany
ma.engel@netze-bw.de, f.oechsle@netze-bw.de

SUMMARY
Our power systems and grids are transforming rapidly, driven to realize a climate-neutral world and
society. How will future grids of a climate- and CO2 neutral world look like? Cigre technical brochure
“Future grids” describes the main drivers: Reduction of CO2 emissions, network availability, public
acceptance, economic transmission, and distribution and increasing electrical energy consumption [1].
Grid operators drive sustainability and digitalization to realize future grids. Sustainability focussing on
a greenhouse-gas free, safe and reliable T&D equipment without harmful substances and digitalisation
to ease operation, asset management and service. The electrical networks of the future require a new
generation of flexible devices to be able to integrate fluctuating renewable power generation and the
increasing demand of electrical energy of mobility, housing, and industry effectively. Substation
equipment overstress management will be a key challenge for grid operators [2].

Future T&D equipment will be resilient and greenhouse gas-free to enable CO2 neutral electrical grid
operation for a CO2 neutral world. By integrating low power instrumental transformers (LPIT), a
combination of Rogowski Coil and capacitive voltage sensor, the measured values are digitized directly
at the switchgear. Moreover, LPITs offer the opportunity of highly compact design. A process bus
according to IEC 61850 ensures redundant and IT-secure communication between the sensors and the
protection and automation systems. Additionally, new digital functionalities are installed: Integration of
advanced sensors, IoT-connectivity, cloud and edge technology, digital twins, and artificial intelligence
to increase the resilience and operate and maintain the grids of the future more effective [3]. This paper
describes a next generation substation combining innovative digital and sustainable technology. Tests
and installation experiences will be presented. Commissioning is planned in 2022 [4].

KEYWORDS
T&D equipment, SF6 free, GHG free, Digitalization, Low-Power Instrument Transformers, Sensors,
digital twin, intelligence, digital substation, IEC 61850
1 INTRODUCTION – THE NEED FOR A NEXT SUBSTATION GENERATION
Our power systems and grids are transforming rapidly, driven to realize a CO2 neutral world and
society. How will future grids of a CO2 neutral world look like? Cigre technical brochure “Future
grids” describes the main drivers: Reduction of CO2 emissions, network availability, public
acceptance, economic transmission, and distribution and increasing electrical energy consumption [1].
Grid operators worldwide drive sustainability and digitalization to realize future grids, Figure 1.

Figure 1: Power grid operators globally are committed to the UN global sustainability goals, report
according the GHG protocol and take actions to become carbon neutral.

2 REQUIREMENTS TO THE NEXT SUBSTATION GENERATION –

ECO-EFFICIENT AND DIGITALIZED
Distribution system operators are also being impacted by the major trends of our times. For one,
increasingly volatile power generation is presenting a challenge to transmission as well as distribution
networks. Handling growing electromobility and increasing electrification is a major challenge,
particularly for local grids. This requires a continuous expansion and reinforcement of the distribution
grids and installation of new substations.

Digitalisation offers a great opportunity here: a high degree of automation based on data transparency
is the key to efficient and resource-saving expansion and operation of the grids, while at the same time
ensuring a high level of supply security. By integrating machine learning and AI into the planning, and
maintenance processes, the grids can be renewed and expanded in an even more targeted manner.

Another important requirement is sustainability. Electrical installations should not only be built in a
resource-saving way, but the individual equipment should also use climate- and environmentally
friendly non-toxic and safe materials, be space-saving and show consideration for the local flora and
fauna e.g., by promoting local biodiversity.

The next substation generation must combine both aspects - it has to provide a variety of data in a simple
way, use intelligent protection and automation systems, and dispense with the use of insulation and
switching technologies with a high GWP.
3 TECHNOLOGIES OF THE NEXT SUBSTATION GENERATION
3.1 Decarbonization: SF6-free, F-gas-free, and GHG-free grid technologies

In the last years completely SF6 free, F-gas free and greenhouse gas free products with zero CO2
emissions were developed, installed, and put into operation. The products are based on compressed
synthetic air (80 % N2 and 20% O2) insulation and vacuum-interrupter technology. By end of 2021,
more than 1900 units were ordered globally and more than 700 are in successful operation in onshore
and offshore installations. This prevented the production, installation, and destruction of SF6 in the total
amount of 2,700,000 tons of CO2 equivalent, Figure 2.

Figure 2: References for GHG-free power grid products from a European manufacturer: >1900 units
contracted; >700 units in operation: 2,700,000 tons of CO2e not produced and installed, Status 2021

The new equipment is not only completely greenhouse gas and halogenated gas free, but also superior
in technical functionalities. Figure 3 gives an example of the test results of the next generation GHG-
free GIS; the main technical benefits are -50°C operating temperature, 10.000 min. nom. current
switching operations, 30 min. short-circuit current operations. This increases the resilience of the
product, substation, and the entire grid with less maintenance work [5]. More information and return of
the greenhouse free products are described in [7, 10]

Figure 3: Superior test results of GHG-free GIS compared to gas-breaker technologies; -50°C operating
temperature, 10.000 min. nom. current switching operations, 30 min. short-circuit current operations
3.2 Digitalization: Low-Power Instrument Transformers (LPIT)
The LPIT device combines a Low Power Voltage Transformer (LPVT) and a Low Power
Current Transformer (LPCT) fully compliant to the IEC 61869 series of standards. It provides a
safe, reliable and standardized solution for measurement and protection applications in GIS
without neither saturation nor ferro-resonance phenomena. The LPIT sensors (Figure 4 left) are
integrated (sealed for life) in cast resin GIS partition and hereby protected against outer impacts
like mechanical shock, vibration, rust or overheating. The measurement is based on Rogowski
coils for current and capacitive voltage sensors. Two redundant sets of Rogowski coils and one
set of capacitive voltage sensors for three phases are integrated in the same GIS cast resin
partition.
Gas tight partition
Metal flange

3-phase
contact
system

Connection box for each

phase

Figure 4: Photo of the 145 kV GIS partition with integrated LPIT Sensors (left) and schematic overview
about the 145 kV synthetic air GIS space and weight savings by the LPIT (right)

For redundancy purposes the two sets of LPIT sensors are connected to two IO-modules which
are usually part of two Merging Units (Figure 5). The Merging Unit provides two redundant
digital communication interfaces, each having implemented following standards: Station bus
according to IEC 61850-8-1 and Process bus according to IEC 61850-9-2 / IEC 61869-9. A
detailed description of a control and protection system using LPIT can be found in [8]. Overall
the use of LPITs provides a number of benefits vs. conventional instrument transformers:
▪ Smaller size and weight of the entire GIS due to smaller dimensions of the sensors and their
integration into a GIS partition (Figure 4 right)
▪ Easy connection with lower cabling and wiring effort
▪ High reliability and long lifetime expectance due to the robust design embedded in cast resin
▪ Less insulation gas in the switchgear
▪ Excellent overvoltage performance - no need for disconnection during GIS or HV cable tests
▪ No hazardous overvoltage at open instrument transformer terminals
▪ A single LPIT covers all protection and metering requirements and thanks to its linearity
also a wide range of primary currents and voltages, simplifying stock management,
engineering and logistics.
▪ Flexible definition and modification of the settings for rated primary current and voltage in
the protection devices at any phase of the project and afterwards. In this way the GIS
remains flexible for future increases of its nominal current.
Furthermore, the LPIT sensors provide an improved measurement performance due to its high
linearity. It has neither saturation (unlike conventional CTs), nor ferro-resonance effects (unlike
conventional VT) and a wide frequency range for measuring harmonics up to the 50th harmonic
frequency.
Figure 5: Overview of the complete LPIT system including Merging Unit

3.3 Digitalization and Intelligence

Digitally connected products merge reliable hardware and sensors with cloud connectivity, digital twins,
and apps with artificial intelligence. It is available for the following substation equipment: Power
Transformers, Gas-insulated switchgear, circuit breakers, surge arresters, instrument transformers, and
arc-suppression coils [3].
The benefits of merging reliable hardware with digital technologies and intelligence in substation
equipment are performance increase, health, safety and environment and cost and risk reduction for the
benefit of grid operation, asset management, service and maintenance, Figure 6.

Figure 6: Operational benefits (left) and GIS Example equipped with born connected features (right)

Figure 7 shows examples of global installations. Figure 8 gives an example of a digital twin operation
of a GIS, able to give transparency about temporary or permanent overload capabilities.

Figure 7: Global installation examples – Digitalized and intelligent substation equipment

Figure 8: Digital twin operation to increase operational performance, GIS example

4 TEST AND INSTALLATION EXPERIENCES

4.1 Substation Burladingen – Layout and Installation
A new high-voltage substation is being built in Burladingen, southern Germany, Figure 9. This
substation connects Burladingen and the surrounding region with the supra-regional power grid. At the
same time, it will handle the growing use of renewable energy sources and spread of electromobility.
The new 110/20 kV substation will have an installed transformer capacity of 80 MVA and can be
expanded to 120 MVA. Construction of the project began in late 2020, and commissioning is planned
for 2022.

Figure 9: Layout and Construction site of the new 110/20 kV substation in Burladingen, Germany

One of the main features is the new 110 kV switchgear, which completely dispense with the insulating
gas sulfur hexafluoride (SF6) and thus be especially eco-friendly and greenhouse gas free. Instead of
using SF6, the rely on synthetic air in a compressed form for insulation and vacuum circuit-breakers
with a rated short-circuit current of 40 kA as switching device. This technology has already been piloted
in 2018 in the world's first installation in Noerdlingen, southern Germany [7].
To reduce the potential space requirements of the system, the use of conventional instrument
transformers was also dispensed with. Low power instrument transformer (LPIT), which are a combined
sensor of two Rogowski coils and a capacitive voltage sensor, are cast directly into the cast resin GIS
partition, figure 4 left. Using synthetic air instead of SF6 as insulating gas would normally enlarge
switchgear dimensions. When using an LPIT layout, however, significant space required by
conventional CTs and VTs may be saved, figure 4 right. This allows the eco efficient switchgear to
stay within similar dimensions known from SF6 layouts.
The current and voltage measured values by the LPITs are digitized directly at the switchgear in a
Merging Unit (figure 5) and transmitted together with all other signals via a process bus (IEC 61850-9-
2) over redundant fibre optical cables. The protection and automation system works directly and
exclusively with these sampled measured values (SMV). This saves the equivalent of 850 kg of copper
cables, which in fact help to reduce environmental impact as well. To better understand the behavior of
the LPITs in daily operation, an external conventional measuring transformer is provided. A hybrid
signal analyzer continuously compares the SMV from the LPITs with the analogue measurement signals
and records their behavior in the event of grid faults.

The switchgear, transformers, arc suppression coils and surge arresters are equipped with integrated
sensors. These transmit status data (e.g., temperature, oil levels, etc.) to a cloud storage via an IoT
protocol. Digital twins of e.g., switchgear or transformers use the collected data to better assess the
condition and behavior of the equipment and perform more targeted maintenance.

Figure 10 shows the greenhouse gas free GIS including LPITs and advanced sensors during installation.

Figure 10: Eco-efficient and digitalized: Greenhouse gas free GIS including LPITs and advanced sensors
with artificial intelligence functionality during installation.

4.2 Test results of Low Power Instrument Transformers

Type testing a combined LPIT with digital interface is a special challenge since the relevant product
standard IEC 61869-12 is not yet published.

IEC Product family standards Standard Products

61869-2 Additional requirements for current transformers
61869-3 Additional requirements for inductive voltage transformers
61869-4 Additional requirements for combined transformers
61869-5 Additional requirements for capacitive voltage transformers
61869-1 61869-6 61869-7 Additional requirements for electronic voltage transformers
General Additional 61869-8 Additional requirements for electronic current transformers
requirements general 61869-9 Digital interface for instrument transformers
for instrument requirement for
transformers electronic 61869-10 Additional requirements for low power stand-alone current sensors
instrument 61869-11 Additional requirements for low power stand-alone voltage sensors
transformers and 61869-12 Additional requirements for combined electronic instrument
low power transformer or combined stand-alone sensors
stand-alone
sensors 61869-13 Stand-alone merging unit
Therefore, both parties agreed on a set of applicable type test from IEC 61869-1, -6, -9, -10, -11 -13.
The table above gives an overview of all the relevant standards.
Some of these tests plus some special tests were done jointly in October 2021 at the Switchgear Factory
Test Laboratories in Berlin. These tests were:
• Basic accuracy tests LPVT and LPCT
• Test for accuracy in relation to replacement of components including varying the cable length
between sensors and electronics.
• Test for impact of magnetic and electric fields from other phases (crosstalk) for both nominal
as well as transient conditions
• LPVT Transient response test
• Short-time current test
• LPCT Composite error
• LPCT Transient performance (class TPM)
• Functional test of a distance protection connected to the LPIT when switch on a three-phase
fault (correct triggering, correct impedance measurement, correct zone detection)

All tests were passed successfully.

As example the results of two tests are now presented in more detail: Figure 11 shows the basic accuracy
test results of a LPIT for current measurement (class 0.2) and voltage measurement (class 0.5)
immediately after the calibration as part of the routine tests. This routine test was done with a certain IO
module as part of the test set-up. In addition, the exchange of the IO module was carried out to
investigate the influence on the accuracy. The IO module is doing the analog to digital conversion and
a replacement of this module has a certain impact on measurement accuracy. So, the question arises
what happens when at site a different IO module is used, or a defect IO module is replaced by a new IO
module some years later. To investigate and to test this, an exchange of the IO module, was carried out.
The calibration parameters were uploaded to the new IO module and the accuracy test was repeated.
The results show clearly that the LPIT stays well within the limits of its accuracy class even after
the electronics is exchanged.

Figure 11: Basic accuracy test results LPCT (left) LPVT (right) during routine tests and after a change of
the IO Module

Figure 11 shows a transient record of a COCO duty cycle in L1 with a peak current of 170 kA. The
primary current through L2 and L3 was zero.
As reference a TPY inductive current transformer (3000 A, Kssc = 26.67) was used. Both the LPIT and
the conventional CT were connected to a protection device. The measured values on the process bus
were recorded and compared via an Omicron Daneo.
During the first CO cycle the difference of the AC component of both CTs was below 2 %.
During the second CO cycle the signal of the TPY CT showed major deteriorations for unknown
reasons, while the LPIT measured current is as expected and similar to the first CO cycle.
 LPIT
Transient current through L1

TPY CT

Crosstalk in L2

Crosstalk in L3

Figure 12: Transient Performance Test of a TPY CT and an LPIT after calibration and routine test

The two lower graphs in figure 12 show the currents induced by the current flow through L1 into the
current measurements of the phases L2 and L3 (crosstalk). The crosstalk between the LPCT phases
was < 0.066% and this corresponds to an accuracy class 0.2. As the inductive reference CT channel
(blue curve) showed a higher crosstalk, the LPIT (red curve) has a superior performance.

4.3 Test results on digitally connected products

All digitally connected products passed the relevant tests for reliable substation operation, Figure 13.

Figure 13: Severe EMC, mechanical endurance, high voltage, high power and climate tests passed
Sensors and connectivity devices for Power Transformers, Gas-insulated switchgear, surge arresters,
instrument transformers and arc-suppression coils were pre-mounted in the factories. First successful
operational experiences in an AIS substation for circuit breakers and installations including AI-based
gas-trending based were collected in Germany [6]. After the energization of Burladingen substation,
further operational experiences from all installed digitally connected products will be gained.
5 SUMMARY AND OUTLOOK
Eco-efficient and digitalized substations are the foundation of a CO2 neutral power system and for global
power grids of the future. Main values for society, grid owners and operators are:
1. Zero CO2 emission
2. Compact design using LPITs
3. Flexible and resilient, integrating fluctuating renewable power generation
4. Easy operation, maintenance, and asset management

Next steps are:

1. Commissioning Burladingen substation in 2022
2. Further projects in HV and MV to reduce SF6 further, also for higher voltage levels [9]
3. Collecting operational experiences of processes, technologies, new gases, and digitalization
4. Presentation of latest status at Cigre Conference and Poster Session 2022

BIBLIOGRAPHY
[1] Cigre Study Committee B3 Substations and electrical installations. “Expected impact on
substation management from future grids” (Cigre Technical Brochure 764, 2019)
[2] Cigre Study Committee A3 Transmission and distribution equipment. “Substation equipment
overstress management” (Cigre Technical Brochure 816, 2020)
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transmission equipment in substations”, Paper B3-305, CIGRE session, Paris, 2020 & 2021
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