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07 Oct, 2025
Posted by corustartech
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High Voltage Switchgear Installations: Key Planning Considerations

Planning a high-voltage switchgear installation requires careful consideration of several interconnected factors. 

This guide offers a clear summary of the core concepts, from application voltage levels to the pros and cons of various station layouts and designs.

A Guide to Planning High Voltage Switchgear

Effective high voltage switchgear installation hinges on three key criteria: Voltage Level, Plant Configuration, and Proper Dimensioning.

1. Voltage Level: HV installations are essential for power transmission, and are also used for distribution and coupling power supplies in both three-phase and HVDC systems. The appropriate voltage level for a project depends on factors like network configuration, power requirements, transmission distance, environmental conditions, and the type of consumer.

Common HV applications and their typical voltage ranges include:

  • Distribution and Urban Networks: > 52 – 245 kV
  • Industrial Centres: > 52 – 245 kV
  • Power Plants and Transformer Stations: > 52 – 800 kV
  • Transmission and Grid Networks: 245 – 800 kV
  • HVDC Transmission: > 300 kV

2. Plant Concept & Configuration

The station layout, defined by a single-line diagram, determines availability and reliability. Key trade-offs are between cost, flexibility, and maintenance complexity. The overall availability (reliability) of a switching station is determined by:

  • Circuit Configuration: This is the number of ways network nodes can be linked via circuit breakers and isolators.
  • Component Reliability: This showcases the failure rate of key components like circuit breakers, isolators, and busbars.
  • Maintenance Requirements: The frequency of maintenance and the time required to repair those key components.

Here is a comparison of common station configurations, highlighting their advantages and disadvantages:

a) Single Busbar: It is the least expensive, but a single fault can cause a total outage.

b) Single Busbar with Bypass: This concept allows breaker maintenance without shutdown, but it can be vulnerable to busbar faults.

c) Double Busbar: This offers high flexibility and easy maintenance. However, a fault on a busbar can disconnect multiple branches.

 d) 2-Breaker System: There is a high availability of the 2-breaker system, but the downside is that it is the most expensive option.  

e) Ring Bus: It is quite cost-effective and flexible for maintenance, but a fault can break the ring.

f) 1½-Breaker System: With this system, there is excellent flexibility and availability, but it requires more breakers and complex protection systems.

3. Dimensioning & Design:

Once the voltage level and station concept are selected, the system must be properly dimensioned. This involves checking the distribution of power and current, and determining the currents that will occur under both normal and short-circuit conditions. This involves defining:

  • Insulation Coordination
  • Safety Clearances
  • Protection Schemes
  • Thermal and Mechanical Stress Limits

Switchgear Designs

The common types of high-voltage switchgear designs are: 

  • Conventional (Air-Insulated): Used outdoors for 123 – 800 kV. In the case of indoor and outdoor situations, lower voltages between the ranges of 52 – 123kV are usually applied. 
  • Gas Insulated Switchgear (SF6-Insulated): The compact design for indoor and outdoor locations uses a wide range across 52 – 800 kV. The GIS is mostly used outdoors in special cases. 
  • Hybrid (Air/SF6): An economical solution for upgrading stations, typically used outdoors for 245 – 500 kV.

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