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MV/LV PREFABRICATED SUBSTATIONS :

LESSONS LEARNED WITH IEC 62271-202

Conference Paper November 2011

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MV/LV PREFABRICATED SUBSTATIONS : LESSONS LEARNED
WITH IEC 62271-202
Marc BIDAUT, Schneider Electric, France, marc.bidaut@schneider-electric.com
Thierry CORMENIER, Schneider Electric, France, thierry.cormenier@schneider-
electric.com
ABSTRACT
The publication of a new edition of a product standard is
often the opportunity for the customers to revise their
specifications and for the manufacturers of launching new
products. The type tests list and routine tests required for a
HV/LV prefabricated substation will be used as discussion
thread with a review of the evolutions of the user's needs
and solutions which are proposed to them.
KEYWORDS
IEC 62271-202, HV/LV prefabricated substation, HV/LV,
type test, routine test.
INTRODUCTION
In June 2006 the International Electrotechnical Commission
(IEC) published the first version of new standard IEC 62271-
202, related to the prefabricated substations HV/LVBT,
which cancelled and replaced earlier IEC 61330 standard
published ten years ago.
Very quickly the reference to this new standard appeared in
the customer specifications and the invitations to tender. As
regards manufacturers of new products were born to
answer the requirements of qualification with type tests and
also an increasing demand of more complex substations
such as for example those intended for the photovoltaic
solar farms.
HV/LV prefabricated substations are segmented in two big
families:
- substations intended for the electricity distribution
companies, generally qualified like products with
definite configuration and limited options
dedicated to answer series markets;
- substations intended for various applications for
industry and infrastructures, defined by project,
and thus often specific. For those whose lay-outs
are recurring it can be applied a conformity to IEC
62271-202 standard. The others can be regarded
as HV installations complying with IEC 61936
standard, and carried out in prefabricated
enclosures which follow the recommendations of
IEC 62271-202 standard.
Generally the electricity distribution companies refer to the
whole series of type tests of this IEC 62271-202 standard.
For the specific products the temperature-rise test and the
tests to assess the effects of internal arc fault remain most
relevant and required. The performances of degree of
protection, mechanical withstand, currents flow in the
earthing circuits are generally validated by generic tests
carried out during the validation of a technology (Doors /
Ventilations / Material / Section and fixing of the earthing
circuits).
The variety of transformers with powers from 250 to 3150
kVA, with liquid dielectric or of dry type, their respective
coils heating up 35 to 65K or 60 to 150K, the HV and LV
switchboards versions, the various operation modes with or
without operation area, the most required enclosure
temperature classes (5, 10 or 20K) as well as the degrees
of protection of the various compartments IP23 to IP56,
would give while being minimalist, by regrouping of
performance, more than 380 configurations, occulting the
levels of rated currents and voltages.
An organized process for the conformity evaluation of a
range is necessary. The rules for the choice of the
representative samples are based on healthy technical and
physical principles and are justified by calculations. Figure 1
show as example the minimal quantities which could be
retained for a range of HV/LV substation, and giving place
to as many tests as of alternatives.
Transformer power 3
Transformer type (oil or dry) 2
Transformer temperature rise 2
HV switchboard 2
LV switchboard 2
Enclosure class 2
Operation mode 2
Degrees of protection 2
Figure 1: Minimalist regrouping of configurations for
a range of HV/LV substations
The type tests list of IEC 62271-202 standard is thus the
discussion thread which we will follow in the continuation of
the document.

TESTS TO VERIFY THE INSULATION LEVEL
OF THE PREFABRICATED SUBSTATION
Since the HV switchgear, HV/LV transformer and LV
switchgear contained in a prefabricated substation have
been type-tested according to their relevant standards, tests
to verify the insulation level applies only to the HV and LV
interconnections.
The majority of the manufacturers of prefabricated
substations make a systematic use of HV interconnections
made with HV cables equipped with by type-tested earth-
shielded connectors which thus do not require a type test. In
the other cases it is necessary to carry them out.
The electricity distribution companies show each day
through their specifications, their control, their knowledge
and field-expertise of typologies of load which are more and
more changing with the increasing number of micro-
producers on their networks.
In certain areas where the seasonal average of the ambient
temperature can reach 35C, we noted that the limits of
temperature rise prescribed could be reduced until 35-40K
for oil and coils, corresponding to the prescriptions of the
IEC 62271-202 (Appendix D) and the IEC 60076-7 (see
figure 2).

With regard to the LV interconnection, to answer the

customers specifications and/or for a greater safety and
easier installation, the use of insulated cables is very
widespread and makes it possible to be freed from the type
tests.
In the other cases such as the use of bars partially or not
insulated, the design of LV interconnection must be
subjected to lightning impulse-voltage tests and the shortest
creepage distances must be measured and be in conformity
with the requirements of Table 4 of IEC 60664-1.
On the other hand, for the routine tests, a power-frequency
voltage test of the HV interconnection is necessary. Thus
targeting the optimal quality, these unitary tests are carried
out on the manufacturing sites of these interconnections.
Finally the dielectric tests of the auxiliary circuits which are
not requiring expensive equipment are very easily carried
out during the final control of the manufacturing of the
substations aiming at checking the good performance of
protection relays and other devices.
TESTS TO PROVE THE TEMPERATURE RISE
OF THE MAIN COMPONENTS CONTAINED IN
A PREFABRICATED SUBSTATION
The introduction of the enclosure temperature class 5K was
beneficial for the geographical areas having high ambient
temperature thus making it possible to reduce the versions
of transformers temperature rise limits.
It is important to remind that the valorisation of this class is
related to the choices of the of the transformer temperature
rise limits and thus to the total losses. The same
prefabricated substation can classifies at the same time
class 10K for a transformer 1000 kVA 60-65K and class 5K
for a transformer 1000 kVA 40-45K.
Figure 2: IEC 62271-202 and IEC 60076-7
f (class, ambient , load factor, O/W transformer
temperature rise)
The experience from laboratories reveals that some
customers specifications can be contradictory between the
prescribed assigned thermal class of enclosure and
temperature rise limits required by the IEC 61439-1 for low
voltage equipment already qualified outside an enclosure.
Let us take the case of a LV switchboard prescribed by an
electricity distribution company and qualified as a free-
standing product. For its use in a prefabricated substation it
can require a class of enclosure 15K so that the limits of
temperature rise values of the IEC 61439 are not reached
whereas the specification of the prefabricated substation
prescribed a class of enclosure 20K.
TESTS TO PROVE THE CAPABILITY OF THE
MAIN AND EARTHING CIRCUITS TO BE
SUBJECTED TO THE RATED PEAK AND THE
RATED SHORT-TIME WITHSTAND CURRENTS
Checking by type tests of the electrodynamics withstand of
various types of LV interconnections made of insulated
cables or bars makes it possible to validate design
principles transposable from a type of substation to another.

It is also necessary to mention that if the envelope of a

prefabricated substation can have different degrees of
protection (for example with or without gaskets for the
doors) it is preferable to carry out a test of evaluation of this
thermal class with the maximum of losses and the most
demanding degree of protection.

Figure 3: Checking of the electrodynamics withstand
of a LV interconnection
The test of the earthing system remains important to verify
the mechanical withstand under electrodynamics stresses.
Sometimes the over sizing in a customer specification of its
cross section on HV side appears shifted compared to the
value of the fault current conditioned by the type of earthing
of the neutral.
In addition some devices for fault current flow to the ground
through solid walls must be tested under the real conditions
of use so that it is possible to guarantee the operational
safety, instead of undergoing only type tests the in open air,
which facilitates heat exchange. The figure 4 shows
successively the product as it must be installed according to
the user guide, the type test of the product alone, the type
test of the product installed which result is non-conformity.
Figure 4: Tests of earth fault current flowing device
FUNCTIONAL TESTS TO PROVE
SATISFACTORY OPERATION OF THE
ASSEMBLY
Checking of the possibility to perform all the necessary
commissioning, operational and maintenance activities of
the prefabricated substation is quite seldom the subject of a
separate type test report. In fact for some of the electricity
distribution companies, the process of validation includes,
beyond the inspection of prototypes before the tests, one
probationary period on the network for a limited series of
substations samples.
For the prefabricated substations designed for specific
projects, these checks are carried out during the routine
tests and the customer acceptance of the complete
equipment in factory.
TESTS TO VERIFY THE DEGREE OF
PROTECTION
It is essential to have a degree of protection adapted to the
environmental conditions of the substation. For protection
against the water penetration in the case of substations for
wind farms in the very hot climates according to the IEC
62271-1, the IPx3 degree appears insufficient and the IPx4
degree could appear more adapted but it is constraining to
perform the natural ventilation expected with increasingly
large powers of transformers installed. There is no, for now,
a definition and a type test for a degree of protection against
horizontal water projections, which could be more adapted
to this type of use.
In addition many of the electricity distribution companies
would wish to specify IP23D degree privileging natural
cooling but they also wish that the penetration of the wire of
1mm should not be limited in length to 100 mm in order to
ensure a better safety when it is made use of connections of
transformer not ensuring protection of the people against
direct contacts to the active parts.
Finally the verification of the degree of protection IP5X is
confronted with a lack of means of tests adapted and in fact
a dust room of sufficient capacity to receive a complete
HV/LV substation. The alternative used for a
compartmentalized metallic substation was to test only one
separated compartment.
Figure 5: Verification of the degree of protection IP5X
of a separated compartment
TESTS TO VERIFY THE WITHSTAND OF THE EMC COMPATIBILITY TESTS
ENCLOSURE OF THE PREFABRICATED As HV and LV switchboards having been checked by type
SUBSTATION AGAINST MECHANICAL tests for their level of emission and immunity it is not
STRESS necessary according to IEC 62271-202 standard to carry
out tests on the complete substations.
If calculations notes are chosen for this checking, they will
Indeed this test is difficult to carry out of due to the number
have to take into account the performances required by the
of possible configurations in HV/LV substation as said in the
IEC standard [1] but also by the national or local
introduction, and in addition with the multiplication of
regulations. Complementary type tests can be realized to
communication technologies for measurements and remote
evaluate the behaviour during the phases of transport and if
control.
necessary lead to require adapted wedging. Indeed
substations without good wedging can be subjected to
When measurements are carried out on complete
accelerations higher than 7g. Beyond the validation test, the
prefabricated substations they relate to the intensity of the
substations can be equipped with detectors of shocks, for
magnetic field generated in the vicinity of the enclosure of
deliveries towards remote sites (wind, photovoltaic)
the substation. A technical report IEC TR 62271-208
borrowing ways not very suitable for motor vehicles, and in
dealing with solutions to measure or calculate the
the case of use of trucks with blade shock absorbers
electromagnetic fields in the vicinity of HV and HV/LV
instead of hydro pneumatic shock absorbers (+30% of
equipment was published at the end of 2009.
constraint).
In practice, the normative configuration of the temperature
FOR PREFABRICATED SUBSTATIONS CLASS rise test of HV/LV substations, requiring a short-circuit on
IAC-A, IAC-B OR IAC-AB, TESTS TO ASSESS transformer LV side and a second upstream of LV
THE EFFECTS OF ARCING DUE TO AN equipment does not reflect the real conditions of
INTERNAL FAULT electromagnetic fields emission , however it is not rare to
see proposals for combined tests. Figure 7 shows
Internal arc withstand initiated by a three-phase fault in the cartography of measurement where the central part
main compartment of the HV switchgear intended to check corresponds to measurements on the roof, the single non
the conformity to class IAC B helped to improve the accessible side, and around measurements on the various
mechanical resistance of the enclosures against faces of the substation enclosure.
overpressures and the control of hot gases in the case of a
possible internal fault.
Usually it is preferable to carry out this test on enclosures
having the minimal degree of protection IP23D when the
substation comprises a transformer, or having a maximum
degree of protection when the substation does not comprise
a transformer. Figure 6 shows an example of internal arc
test of a 36kV equipment associated with its compartment.

Figure 7: Examples of electromagnetic field

measurement (in T) on a HV/LV substation.
Figure 6: IAC-AFL-16kA 1s + IAC-AB-16kA-1s
TESTS TO VERIFY THE SOUND LEVEL OF A
PREFABRICATED SUBSTATION
This test, optional, has for principal interest to provide the
data of what is obvious with knowing that in front of the
ventilation openings there is little attenuation of the noise
transmitted by air. The enclosure of a prefabricated
substation generally reduces the sound power of the
transformer only of a few dB(A). The results of the noise
level measurement of a HV/LV substation must be
compared with the values of the local regulations and if
necessary provisions of minimum distance from public
places to the substation or use of transformer with reduced
noise must be considered.
TESTS NOT BEING MENTIONED IN THE IEC
62271-202 STANDARD
These tests are specific because not listed in the standard
of reference [1], they depend on the market segments and
the national regulations. They are relative to concerns such
as the performance of fire resistance, the impact of a flood,
the effect of the solar radiation etc.
Figure 8 shows temperature measurements during a test of
resistance to fire REI 90/RE 180 of a concrete wall of 10cm
alone which could reach performance REI 120 (INTO
13501-2) with an additional plaster screen. In the absence
of type test, the thickness of this wall should be increased to
160 mm for a load-bearing wall according to IN 1992-1-2
Eurocode 2: Design of concrete structures Part 1-2:
General rules Structural fire design.
Figure 8: Temperature measurements during a test of
fire resistance of a concrete wall.
Figure 9 shows a test comparable to IPx7 on an
underground substation where a metallic device was added
in periphery in order to fill with water all the volume from the
half height of the walls until 30cm above the top of the
openings (hatches). The purpose was to check the
tightness of these openings.
Solutions are implemented by manufacturers to face the
possible floods, until 30cm for the 1000kVA or 2*630kVA
underground substation intended for the urban areas
mentioned above, and until 45cm for a 160kVA substation
dedicated to the rural areas.
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Figure 9: Tests and additional provisions to face the
possible floods.
SIMULATIONS
Many simulations can be carried out to evaluate many
specific configurations but it is essential to check the validity
by comparing with type test results. These simulations
become essential as soon as it is understood that a single
configuration cannot correspond to the most constraining
configuration for the whole of the type tests series.
Example: the most constraining configuration for a
temperature-rise test will not be that most constraining for
an internal arc test, the same for the evaluation of the noise
level.
CONCLUSION
Since 2006 IEC 62271-202 standard became a reference
as product standard for HV/LV prefabricated substations.
The type tests are applied in their entirety, even partially
according to the market segments, to these requirements
are added those of the national regulations which can
require complementary tests. Thus the topics developed in
this article will help to support later evolutions of IEC 62271-
202 standard.
REFERENCES
[1] IEC; 2006; IEC 62271-202 HV/LV Prefabricated
Substations, IEC, Geneva, Switzerland.
[2] C.Sujatha, P.Tejesu HEAVY VEHICLE DYNAMICS-
COMPARISON BETWEEN LEAF SPRING AND
HYDROPNEUMATIC SUSPENSIONS. Machine
Dynamics Laboratory, Applied Mechanics Department,
Indian Institute of Technology Madras Chennai; India
[3] T.Cormenier, L.Vieu-Viennet, P.Brun; 2011 CIRED
N477; NEW UNDERGROUND HV/LV
PREFABRICATED SUBSTATIONS FOR BETTER
INTEGRATION IN THE ENVIRONMENT, Frankfurt,
Germany