Clem7 Tunn Clem7 Tunnel el - IEA IEAUS UST T Prese Presenta ntatio tion n Electrical Power Systems Design July 2010
Introduct Introd uction ion – Tun Tunnel nel Mech Mechani anical cal & Electrical Services UGL Limited Infrastructure (formally ALSTOM) has a long history in the Design and Construction of the Mechanical & Electrical Services / Processes for both Road and Rail tunnels in Australia The D&C business started in 1988 with the establishment of the Sydney Harbour Tunnel Project In New South Wales to date: – Sydne Sydney y Har Harbou bourr Tunn Tunnel el – M5 Tun Tunne nell – Ea East ster ern n Dist Distri ribut butor or – Ep Eppi ping ng to to Chatsworth Chats worth Rail Rail Line – Lane Cove Cove Tunnel Tunnel In Queensland to date: Inne nerr Ci City ty By Bypa pass ss D& D&C C – So South uth Ea East ster ern n Bu Buswa sway y C – The Inn Inner er – The In Northern Northe rn Busways Busways 4 C & 5 D&C – Boggo Road Road Busway Design Design C There has been projects in both Victoria and Western Australia as well.
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Introduct Introd uction ion – Tun Tunnel nel Mech Mechani anical cal & Electrical Services UGL Limited Infrastructure (formally ALSTOM) has a long history in the Design and Construction of the Mechanical & Electrical Services / Processes for both Road and Rail tunnels in Australia The D&C business started in 1988 with the establishment of the Sydney Harbour Tunnel Project In New South Wales to date: – Sydne Sydney y Har Harbou bourr Tunn Tunnel el – M5 Tun Tunne nell – Ea East ster ern n Dist Distri ribut butor or – Ep Eppi ping ng to to Chatsworth Chats worth Rail Rail Line – Lane Cove Cove Tunnel Tunnel In Queensland to date: Inne nerr Ci City ty By Bypa pass ss D& D&C C – So South uth Ea East ster ern n Bu Buswa sway y C – The Inn Inner er – The In Northern Northe rn Busways Busways 4 C & 5 D&C – Boggo Road Road Busway Design Design C There has been projects in both Victoria and Western Australia as well.
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Presentation Contents – Design Objectives – Systems Overview – Incoming Energex Supply – LV Systems Design – HV Systems Design – Substation Arrangement – Cross Passage Arrangements – Design Documentation – Electrical Equipment – Electrical Materials
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Design Objectives – Perform all Electrical Engineering design requirements to meet the M&E Performance Specifications for successful tunnel operations – Electrical Design Reports – Design Calculations – Electrical Design _ Detail Design 50% _ DD80_Final Design – Electrical Drafting – Equipment Specification – Construction and Installation Methods and Inspection and Test documents – Equipment Factory Acceptance Tests – Cable Schedules, Installation and Termination Sheets – Commissioning Procedures and Records documentation
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Systems Overview – 2 off Incoming Energex 33kV supply rated @ 22MVA
Supply A @ Woolloongabba, Supply B @ Bowen Hills
– HV Redundancy via dual 22kV supplies to each of the 7 off Project substations – 22kV stepped down locally at each substation to 690V & 433V – Loads shared across A & B supplies with 690V & 433V switchboards in each substation – Dual 690V / 433V supplies to each 690V & 433V switchboard automatic changeover
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Systems Overview – 690V : directly supplies significant plant system motors in vicinity of substation – 433V : general light & power and small motors
Submains distribution to XPs in vicinity of substation Lighting / power / communications then distributed to devices in vicinity of XP ( 116m) ≈
– Local Energex power supplies to RSCs for surface related works – UPS system provides “essential” power to “life-safety” devices
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Systems Overview
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Incoming Energex Supply Negotiations with Energex established that 25MVA of capacity at 33kV would be available from both the North and South sides of the Brisbane River - these supplies are detailed below 33kV Supply, 25MVA Connected Capacity – ‘Supply A’ : Wellington Rd Energex Substation
Connected to Substation #1 @ SVO Site (Woolloongabba)
Reticulated @ 22kV from Sub#1 to Sub #7 via 5 off tunnel substations
Transformed (stepped down) from 22kV at each substation to 690V & 433V
– ‘Supply B’ : Victoria Park Energex Substation
Connected to Substation #7 @ NVO / TCC Site (Bowen Hills)
Reticulated @ 22kV from Sub#7 to Sub #1 via 5 off tunnel substations
Transformed (stepped down) from 22kV at each substation to 690V & 433V
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LV Systems Design There are three separate areas of LV reticulation required for tunnel operation – In Tunnel, Lighting, Ventilation and Pumping systems – External Ventilation Outlets, Waste Water Treatment, Fire Systems, and Tunnel Control Centre – External Road Lighting and Traffic control systems All of these systems require supervision from the Tunnel Operations Control System, the details of which are not included in this presentation
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LV Systems Design - Lighting The Tunnel Lighting System – 433V 50Hz Supply – Is configure as 6 switchable levels with L1 the highest luminance intensity and L6 the lowest – The tunnel entry portals utilize the higher levels with the level at any particular time automatically selected to equal the light level external to the tunnel – Internal tunnel lighting is switched between the lower levels of 5 and 6, with 6 selected during the quieter hours of the morning – Tunnel lighting is designated either essential or non-essential, essential being approximately 30% of the total installation – The essential lighting is powered from UPS supplied distribution boards whereas the non-essential is powered from normal supply
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LV Systems Design - Lighting – Lighting is configured as alternately supplied, that is every second luminaire is supplied from the A Supply with the alternate luminaire from the B Supply – There is approximately 850 individual luminaires in each of the North bound and South bound tunnels – The luminaires range in size from 150W, 250W and 400W with the higher capacity luminaires used in the portal areas
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LV Systems Design - Ventilation The Tunnel Ventilation System – 690V 50Hz Supply – In Tunnel Jet Fans are Strategically placed throughout the tunnel mounted below the smoke duct (roadway ceiling) – There are a combination of both 30kW and 45kW 690V drives for this purpose – The majority of drives incorporate Reversing DOL motor starting with electronic motor protection relays to allow monitoring of the drive condition by the tunnel control system with the direction of flow determined automatically – Electrically actuated (240V 50Hz) Smoke Dampers are mounted through the smoke duct as the passage to draw smoke from the tunnel in an emergency, essential supply
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LV Systems Design - Pumping The Tunnel Pumping System – 433V & 690V 50Hz Supply – In Tunnel Pump Stations are located at the 2 low points of the roadway – There are pump stations at the North Portal, the SVO and CC01 – The stations include both Storm Water and Ground Water Pumps the largest drive being 250kW 690V, utilizing a Soft Starter module – Smaller size drives operate at 433V There are 2 external to the tunnel, Fire Pump Stations that supply water to the tunnel deluge piping main – There is a combination of both 690V and 433V pump drives for this purpose All pumping operates automatically through process control systems
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Electrical Power System LV Systems Design – Ventilation Outlet Stations The Tunnel Ventilation Outlet Stations – 690V 50Hz Supply – There are 2 ventilation outlets one on the North the NVO with the SVO at the South – Each of these stations have 5 – Vent Fans that draw out the general roadway emissions and 5 - Smoke Fans that draw out smoke in an emergency through the smoke duct – The Vent Fan capacities are 400kW at the SVO and 450kW at the NVO – Smoke Fan capacities are 650kW at both stations – All of these drives are 690V Variable Frequency Drives. Front End Harmonic Filters are included with these drive arrangements
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LV Systems Design – Electrical Distribution The LV Systems presented above are duplicated throughout the length of the tunnel (4.5km) with Electrical Distribution Substations established at 1km intervals approximately plus there are 2 above ground substations associated with each of the vent stations, a total of 2 above ground and 5 in tunnel, having the following features – An ‘A’ LV switchroom & ‘B’ LV switchroom is provided for each substation – Each switchroom has a 690V and 433V switchboard – An ‘A’ & ‘B’ 690V (or 433V) redundant supply connects to each switchboard – Switching of the ‘A’ & ‘B’ supplies to each board is electrically and mechanically Interlocked via an automatic changeover
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LV Systems Design – Electrical Distribution 690V Motor Control Switchboard (MCS) – The MCS powers significant motors in the respective area of the substation – This typically includes the tunnel jet fans, ventilation outlet axial fans and large pumps 433V Low Voltage Switchboards (LVS) – The LVS provides power via distribution boards / panels to other equipment – A large part of the LVS distribution includes the distribution of power (essential via an UPS & non-essential) to the tunnel
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LV Systems Design – Electrical Distribution The distribution of the tunnel electrical load is shared by the 7 Substations each substation distributes minor circuits via Cross Passage Distribution Boards – South to North across the Brisbane River – #1 (surface) @ Woolloongabba / SVO Site – #2 (tunnel) @ approx XP4 (cross passage 4) – #3 (tunnel) @ approx XP15 – #4 (tunnel) @ approx XP23 – #5 (tunnel) @ approx XP30 – #6 (tunnel) @ approx XP38 – #7 (surface) @ Bowen Hills / NVO Site There are 41 Cross passages through the tunnel 17
LV Systems Design – Electrical Distribution ‘A SUPPLY’
‘B SUPPLY’ 415V Switchboard Transformer TRX212
415V Switchboard 660V Switchboard
Transformer TRX213
Transformer TRX112
Sub01 LVS211
22kV / 433V, 0.5MVA
Sub01 LVS111 Transformer TRX113
Sub01 MCS211
22kV / 690V, 5MVA
22kV / 433V, 0.5MVA
660V Switchboard
22kV / 690V, 5MVA
Sub01 MCS111 Transformer TRX222
Transformer TRX122
22kV / 690V / 433V, 2MVA
22kV / 690V / 433V, 2MVA
Transformer TRX232 22kV / 690V / 433V, 2MVA
Transformer TRX132
415V Switchboard
22kV / 690V / 433V, 2MVA
Sub04 LVS241 415V Switchboard
Transformer TRX242 22kV / 690V / 433V, 1.6MVA
Sub04 LVS141 660V Switchboard Sub04 MCS241
Transformer TRX252 22kV / 690V / 433V, 2MVA
Transformer TRX142 22kV / 690V / 433V, 1.6MVA
660V Switchboard Sub04 MCS141
Transformer TRX152 22kV / 690V / 433V, 2MVA
Transformer TRX262
Transformer TRX162
22kV / 690V / 433V, 1.6MVA
22kV / 690V / 433V, 1.6MVA
Transformer TRX272
Transformer TRX172
22kV / 433V, 1MVA
22kV / 433V, 1MVA
Transformer TRX273
Transformer TRX173
22kV / 690V, 5MVA
22kV / 690V, 5MVA
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LV Systems Design – Electrical Distribution
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LV Systems Design – Electrical Distribution
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LV Systems Design – Electrical Distribution
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LV Systems Design – Electrical Distribution
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HV Systems Design With the LV Supply Requirements established the Tunnel HV Supply potential of 22kV was chosen to establish a potential separation with Energex. 22kV Supply A: – Sub#1 to Sub#2 to Sub#3 to Sub#4 to Sub#5 to Sub#6 to Sub#7 22kV Supply B: – Sub#7 to Sub#6 to Sub#5 to Sub#4 to Sub#3 to Sub#2 to Sub#1 Supply ‘A’ equipment is physically fire separated from Supply ‘B’ equipment Transformers: – Oil type for surface substations – Dry type for tunnel substations HV Switchgear being non withdrawable is operated via 48V DC supplies 23
HV Systems Design
Transformer TRX212
Transformer TRX112
22kV / 433V, 0.5MVA
22kV / 433V, 0.5MVA
Transformer TRX213
22kV Switchboard Sub01 HVS211
33kV / 22kV 22MVA Transformer Sub01 TRX111
22kV Switchboard Sub01 HVS111
22kV / 690V, 5MVA
Transformer TRX222
22kV / 690V, 5MVA
22kV Switchboard
22kV / 690V / 433V, 2MVA
Sub02 HVS221
Transformer TRX232
22kV Switchboard
22kV / 690V / 433V, 2MVA
Transformer TRX113
Sub03 HVS231
Energex 33kV Supply Wellington Road Substation
22kV Switchboard
Transformer TRX122
Sub02 HVS121
22kV / 690V / 433V, 2MVA
22kV Switchboard
Transformer TRX132
Sub03 HVS131
22kV / 690V / 433V, 2MVA
Transformer TRX242
22kV Switchboard
22kV Switchboard
Transformer TRX142
22kV / 690V / 433V, 1.6MVA
Sub04 HVS241
Sub04 HVS141
22kV / 690V / 433V, 1.6MVA
Energex 33kV Supply Transformer TRX252
22kV Switchboard
Victoria Park Substation
22kV Switchboard
Transformer TRX152
Sub05 HVS151
22kV / 690V / 433V, 2MVA
22kV / 690V / 433V, 2MVA
Sub05 HVS251
Transformer TRX262
22kV Switchboard
22kV Switchboard
Transformer TRX162
22kV / 690V / 433V, 1.6MVA
Sub06 HVS261
Sub06 HVS161
22kV / 690V / 433V, 1.6MVA
Transformer TRX172
Transformer TRX272 22kV / 433V, 1MVA Transformer TRX273 22kV / 690V, 5MVA
22kV Switchboard
33kV / 22kV 22MVA Transformer
22kV Switchboard
22kV / 433V, 1MVA
Sub07 HVS271
Sub07 TRX271
Sub07 HVS171
Transformer TRX173 22kV / 690V, 5MVA
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HV Systems Design
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HV Systems Design
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Substation Arrangement Substation are located within the tunnel and above ground Above Ground – Substation 1 & 7
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Substation Arrangement Incoming Transformer 22MVA 33/22kV Above Ground – Substation 1 & 7
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Substation Arrangement Below Ground – Substation 3, 4, 5 & 6
Substation 6 – Southbound Tunnel 29
Substation - HV Equipment
Dry Type Transformer
High Voltage Switchboard 30
Substation - LV Equipment
Automatic Changeover
Motor Control Switchboard
Switchboard HMI Low Voltage Switchboard 31
Substation - LV Reticulation Essential Supply Uninterruptible Power Supply – A UPS system is an integral part of the LV distribution scheme providing battery backed “essential” power to “life-safety” devices and control systems – Life-safety devices are connected to “essential” distribution boards – UPS battery capacity
30 mins : Every 3rd tunnel roadway light (for Level 6 lighting) 90 mins : tunnel signage, emergency exit signage, communication system equipment 240 mins : TCC OMCS equipment
UPS System 32
Cross Passage - LV Reticulation Cross Passage Power Supply – Essential & Non-essential power is distributed from a tunnel substation to the cross passages in its vicinity
Tunnel Substation # 2 : XP01 to XP09
Tunnel Substation # 3 : XP10 to XP19, XP47 to XP50
Tunnel Substation # 4 : XP20 to XP26
Tunnel Substation # 5 : XP27 to XP34
Tunnel Substation # 6 : XP35 to XP41
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Cross Passage - LV Reticulation Cross Passage Panels (combined panel consisting of) – LV Essential Distribution Panel – LV Non Essential Distribution Panel (some XPs have 2 off) – PMCS Control Panel – Ventilation Control Panel – TTMCS Control Panel – Provides a source of power and communications / controls to the majority of devices within the immediate vicinity of the XP Other Electrical Panels – Pump Station Control Panels – Ventilation Outlet Variable Speed Drives 34
Design Documentation Electrical Design Reports – LV Electrical Supply System – NSBT-2531-EL-RP-048225 – HV Electrical Supply System - NSBT-2501-EL-RP-047852 – Tunnel/Underpass Lighting Systems - NSBT-2560-LI-RP-049050 – Earthing Design Report - NSBT-2501-EL-RP-047864 Reports were issued to the Client and Independent Verifier for each of the 4 design phases
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Design Documentation Electrical Design Calculations – LV Motor Equipment Power – Load Flow – LV Lighting Power – Load Flow – Electrical Equipment Heat Loss – LV Maximum Demand Design Calculation - NSBT-2531-EL-CA-048225 – LV Fault Level Calculation Record - NSBT-2531-EL-CA-048203 – HV Fault Level Calculations Record - NSBT-2501-EL-CA-047872 – HV and LV Protection Schemes – LV Cable Sizing – HV Cable Sizing 36
Design Documentation
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Electrical Equipment Major Electrical Equipment Requirements – 22MVA 33/22kV Auto Tap Change Incoming Transformer – Neutral Earthing Resistor – 100A/12.7kV – 5MVA (O), 2MVA (D), 1.6MVA (D), 1MVA (O) and 0.5MVA (O) Distribution Transformers – HV Switchgear Vacuum Non Withdrawable – MCS and LVS Switchboards – UPS Systems plus UPS Power Distribution – Variable Frequency Drives and Harmonic Filters – Substation and Cross Passage Distribution Boards – Pumping Motor Control Boards 38
Electrical Materials Electrical Cabling Requirements – HV 22kV Cabling – LV Consumer Mains – LV Sub Mains
10,733m 2,149m 42,797m
– LV Fire Rated Cables/sub circuits
199,503m
– LV Control Cabling 108,210m – Fibre Optic Cable – Earthing Cable
136,254m 37,653m
– Special Motor Supply Cables
3,630m
In total there are 15,026 circuits for a total length of -
844km 39
