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ECE-402WI
Introduction
This substation design manual defines the design criteria calculated and/or selected and supported by the members of the Substation Design Group of course ECE-402WI for use with the 138 kV UMKC Substation Project. The members of this group and their primary responsibilities are: Zane Potts - Power Transformer Payam Ansari - Circuit Breakers Brandon Howland - Protective Relaying Robert Biggs - Lightning Mitigation Ehab Abdelhaq - Grounding Gary Kertz - Substation Layout The 138 kV UMKC Substation will be a conventional outdoor, air insulated, low profile, rigid bus design, utilizing SF6 circuit breakers and vertical break disconnect switches configured in a three position ring bus arrangement. The arrangement will consist of one transmission line to the new load in the East Bottoms and one transmission line to the new load in the West Bottoms and a transformer bay consisting of a 138 kV to 69 kV transformer and a 69 kV transmission line as shown on the electrical one-line diagram submitted.
Table of Contents
1 - Site Design ...........................................................................................................4
1.1 1.2 1.3 1.4 1.5 1.6 1.7 Roadways ..................................................................................................................................................... 4 Site Surfacing ...............................................................................................................................................4 Fencing and Landscaping ............................................................................................................................. 4 Security ........................................................................................................................................................ 4 Signage ......................................................................................................................................................... 4 Substation Lighting ......................................................................................................................................4 Control House ..............................................................................................................................................4 1.7.1 - Construction .........................................................................................................................................4 1.7.2 - Flooring ................................................................................................................................................5 1.7.3 - Battery Station......................................................................................................................................5 1.7.4 - Protective Fire Wall ............................................................................................................................. 5 1.7.5 - HVAC ..................................................................................................................................................5
3 - Bus construction..................................................................................................7
3.1 3.2 3.3 3.4 Basic Impulse Insulation Level ....................................................................................................................7 3.1.1 - Insulation Coordination ........................................................................................................................ 7 Environmental Considerations ..................................................................................................................... 7 Clearances and Spacing................................................................................................................................ 8 Bus Assembly Design ..................................................................................................................................8 3.4.1 - Bus Conductors ....................................................................................................................................8 3.4.1.1 - Aeolian Dampening ...................................................................................................................8 3.4.2 - Bus Fittings ..........................................................................................................................................9 3.4.3 - Bus Expansion Joints. .......................................................................................................................... 9 3.4.4 - Transition Plates. ..................................................................................................................................9 3.4.5 - Bus conductor supports ........................................................................................................................ 9 3.4.6 - Bus Elevation and Spacing...................................................................................................................9 3.5 Insulator Selection ........................................................................................................................................9 3.5.1 - Station Post Insulators .......................................................................................................................... 9 3.5.2 - Suspension Insulators ......................................................................................................................... 10 3.6 Raceway Systems ....................................................................................................................................... 10
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6 - Communication .................................................................................................31
6.1 6.2 Communications Equipment ...................................................................................................................... 31 Additional Communication ........................................................................................................................ 31
Appendix B - Bus Height .......................................................................................49 Appendix C - Rigid Bus Spreadsheet ...................................................................50 Appendix D - Isokeraunic Chart ..........................................................................52 Appendix E - Communications .............................................................................54
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1 - Site Design
1.1 Roadways
A 20ft wide road, as per design guide, will follow the interior perimeter of the substation security fence. The road will consist of a 200 mm (8-inch) aggregate base course and a 100 mm (4-inch) aggregate surface course. Pipe arch will be utilized anywhere roadway will cross a potential wiring trench location within the Substation.
1.2
Site Surfacing
The entire yard, as well as a 1 meter (3 feet) perimeter beyond the substation fence, will be covered with 4 to 6 inches of crushed rock or stone. Prior to surfacing, the ground will be sterilized in order to prevent vegetation growth.
1.3
Due to the inherent dangers associated with a substation it is necessary to prevent unauthorized access. A security fence utilizing a one foot barbed wire extension will be constructed from galvanized chain link fabric for this purpose. It will extend around the perimeter of the site. To allow entrance for utility and service traffic there shall be two 16-foot manually operated swing gates installed. They will be of chain link construction.
1.4
Security
Fencing will include provisions to facilitate locking of the entrance gates of the substation, but no further security measures will be provided.
1.5
Signage
Signage will be provided expressing the dangers within the substation as well and informing individuals that unauthorized admittance is not allowed. This signage will be well lit and in ordinance with the specifications given by the National Electrical Safety Code (NESC).
1.6
Substation Lighting
Lighting fixtures will be affixed to bus support structures. Density will be such as to provide sufficient lighting to meet local code for maintenance and repair on the substation.
1.7
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1.7.2 - Flooring
The control house floor will be a floating concrete slab 12.7 to 15.2 cm (5 to 6 inches) thick reinforced with welded wire fabric. Elevation will be 6 inches above the finished grade of the outside of the control house.
1.7.5 - HVAC
Heating and Cooling will be provided and sized as to maintain a range of 60 80 degrees Fahrenheit within the control structure. The Unit will be located on the roof of the structure as to aid in security.
2.2
Design
The steel structures will be designed using the Allowable Stress Design (ASD) approach as defined by the American Institute of Steel Constructions (AISC) Manual of Steel Construction, ASD. All structures shall conform to the requirements of Part 36 of NEMA Publication SG 6. Base plates for all support structures shall be designed to rest on leveling screws which will allow for error in level and trueness of the foundation surface as well as aid in structure alignment resulting from fabrication tolerances and buswork fit up.
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Switch support structures will be designed to remain within the deflection limitations as specified in Section SG6-36.03 of NEMA Publication SG 6
2.3
Transformer Bunding
To prevent oil migration to the environment or other site equipment in the case of a spill, a humped bund constructed of concrete will surround the power transformer. Flooring within the bund will be 1% grade, as to direct flows to an 18 deep sump to allow for pump down of materials captured within the bund. The containment basin will be fitted with a Parallel Plate Separator (PPS) to allow for rainwater/oil separation. The dimensions will be such that it will be capable of containing 110% of the oil capacity of the transformer while allowing the bund walls to be a distance from the transformer which is greater than half the height of the oil level contained within it. These dimensions will be called out in the layout drawing next semester once the size and capacity of the transformer is known.
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3 - Bus construction
3.1 Basic Impulse Insulation Level
The Basic Impulse Insulation Level was provided by Burns and McDonnell. to be 550 kV for the 138 kV line and 350 kV for the 69 kV side.
3.2
Environmental Considerations
The following environmental factors will be used in determining the most optimal design of the substation bus, insulators and support structures. Elevation Isokeraunic Level Wind and Ice Loading Design greatest 3 sec duration speeds at 30 ft. Design Maximum Ice-Radial Thickness Seismic Conditions Risk Zone 70 mph 0.5 inch 2A Less than 2,000 feet 50 60 days
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3.3
The 138 kV substation facilities will be designed to maintain a minimum of the following clearances and spacing based on the desired 550 kV BIL: Rigid bus center-to-center phase spacing, minimum Minimum phase-to-phase, metal-to-metal distance Minimum phase-to-ground Minimum vertical clearance from roadway 84 in 53 in 12 ft 25 ft
The 69 kV substation facilities will be designed to maintain a minimum of the following clearances and spacing based on the desired 350Kv BIL: Rigid bus center-to-center phase spacing (minimum) Minimum phase-to-phase, metal-to-metal distance Minimum phase-to-ground Minimum vertical clearance from roadway 60 in 31 in 11 ft 23 ft
3.4
Bus components will be sized in the design as to maintain uniformity of components and spacing requirements at both voltages. Sizing of components to maintain compliance with standards shall be determined through the use of Burns and McDonnell supplied spreadsheet.
Results of spreadsheet can be observed in appendix A.
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3.5
Insulator Selection
All insulators will be rated 550 kV BIL for the 138 KV as well as the 69 KV system to maintain uniformity. They will be dove grey in color and be of Polymer composition.
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Leakage Distance (inches): Dry Arcing Distance (inches): Dry Flashover (kV): Wet Flashover (kV): Cantilever strength (lbs.)
3.6
Raceway Systems
The raceway systems will consist of below grade pre-cast cable trench and pipe arch will be utilized as the primary wire run with the use of PVC conduit as the secondary feeders which carry wiring to the individual devices. Transitions of wire ways will be supported by the use of hand holds. NEC codes will be recognized in the installation of all race ways and control wiring.
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4 - Substation Equipment
This section summarizes the major equipment in the substation facilities
4.1
Circuit Breakers
By definition, a circuit breaker is a device that closes and interrupts (opens) an electric circuit between separable contacts under both load and fault conditions. The rating of a circuit breaker is a summary of its characteristics that identifies its application on an electric system, its performance capabilities, and its adaptability. This summary of characteristics is given principally in terms of voltages, currents, and time as described in the rating tables. This substation will use three 138KV breakers in a ring bus configuration, this ring bus will have two exit lines, and a single 138:69KV transformer line exit with breaker. Column A represents my calculations, scope contents, and IEEE Standards. Column B represents the data in breakers data sheet.
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145 KV 138 KV 750 KV 3 Cycles 135 mS 1.0 SF6 gas, Dead tank
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Provisions: Six (6) sets of 1200:5 Multi Ratio Current Transformer, Rating Factor(R.F.) 2.5, C800 accuracy class (two (2) CTs per bushing), (Scope)
Porcelain bushings (ANSI 70 gray) rated: 750 kV BIL (data sheet) Paint color will be ANSI-70 Gray. Operating mechanism will be motor charged spring-spring Single tank-mounted gas density monitor and pressure gauge. Dual trip coils with trip coil 1, trip coil 2 and close coil each on a separately fused 125V DC supply. Fuses at the breaker will be replaced with slugs in the field.
Breaker position indicator. Current transformers secondary will be grounded in control panel
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Provisions: Six (6) sets of 1200:5 Multi Ratio Current Transformer, Rating Factor(R.F.) 2.5,
C800 accuracy class (two (2) CTs per bushing), (Scope) Porcelain bushings (ANSI 70 gray) rated: 350 kV BIL (data sheet) Paint color will be ANSI-70 Gray. Operating mechanism will be motor charged spring-spring Single tank-mounted gas density monitor and pressure gauge. Dual trip coils with trip coil 1, trip coil 2 and close coil each on a separately fused 125V DC supply. Fuses at the breaker will be replaced with slugs in the field. Breaker position indicator. Current transformers secondary will be grounded in control panel
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Operator Quantity
manual 6
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Quantity
550 KV Manual with linkages for 3 Phase Operation with DC motor (details To Be Determined later) 1
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4.2
Surge Arresters
Surge arresters are designed to minimize the effects of transient voltage spikes due to switching operations and lightning strikes of currents less than Is. When the Maximum Continuous Operating Voltage (MCOV) is exceeded, the arrester reduces its internal impedance from line to ground. This action draws current through the surge impedance thereby reducing the magnitude of the wave voltage. As the voltage decreases back to MCOV, the internal impedance of the arrester increases minimizing the current flowing through it. This response protects the substation equipment from damaging voltage surges while allowing the substation to still operate. The surge arresters will be installed on both sides of the power transformer and each location where a transmission line enters and connects to the substation bus work. The surge arresters connected to the incoming lines shall have inverted skirting to prevent the accumulation of debris and possible shorting around the arrester. 138kV Surge Arrester Ratings Type: Arrester rating (duty cycle): Arrester rating (MCOV): Class: Location:
Siemens 3EL2 180-2PM31-4NHS 108 kV 84 kV Station Outdoor, vertical mounting, porcelain shell, ANSI 70 gray color
69kV Surge Arrester Ratings Type: Arrester rating (duty cycle): Arrester rating (MCOV): Class: Location:
Siemens 3EL1 060-1PH21-4YH5 60 kV 48 kV Station Outdoor, vertical mounting, porcelain shell, ANSI 70 gray color
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4.3
Power Transformer
The primary function of a transformer is to take one nominal voltage and "transform" it into another nominal voltage.
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Current At De-energized Tap Changer (DETC) HV: 4 Position / 3 steps @ 3.57% 4 3 2 1 Altitude Ambient Temperature Hi Lo Average Rise Above Ambient Tank Finish Volts kV 100 MVA 140 135 130 125 412 428 444 462 134 MVA 553 573 595 619
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The DETC operating handle shall be brought out through the side of the tank in segment 4. The Handle shall have the ability to be padlocked, and a visual indication of handle position should be visible without unlocking. Visual indication will be clearly marked with Arabic numerals in sequence with "4" being assigned to the maximum ratio. The DETC warning plate will be mounted directly above operating handle. A magnetic oil level gauge with vertical face will be located in segment 1 on both the tank and conservator. The gauges will be of dark-face and high contrast markings and dial. The dimensions will be of those found in IEEE std c57.12.10-2010 section 5.1.2. Extremes will be labeled "HI-LO" and a permanent marking of 25 oC with 10 oC divisions will be implemented. To measure top-oil temperature, a liquid temperature gauge will be located in segment 1. The display will be analog with a range from 0 to 120 oC. Faceplate will be dark-face with high contrast pointer and markings. A sensor that detects ambient temperature will be located in segment 4 just below the transformer monitoring cabinet. Under load, transformer oil increases in temperature and thus volume which causes the rubber bag in the conservator to expand. This expansion pushes air out. Conversely, the opposite happens when the oil's volume decreases. This process is called breathing. The air that is breathed in contains moisture that needs to be dehydrated since moisture compromises insulation. To remove moisture, a silica gel breather will be installed in segment 2.
The transformer is a sealed device and can become subject to excessive pressure during internal faults. To discharge overpressure, a pressure relief valve will be mounted on the top of the transformer that is rated at 10 PSI. During transformer faults, hydrogen is produced. To aid in early detection, a dissolved hydrogen & water IED (gas analyzer) will be installed which monitors hydrogen levels. The IED also monitors moisture levels to insure premature deterioration of insulation doesn't occur. The dissolved hydrogen & water monitor uses two compression fittings to supply oil (top-oil valve) and then return it (bottom
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valve). Both ball valves are next to the monitor which will be in segment 1 and are 0.5" in diameter.
To reduce shipping weight, the transformer will be shipped without oil. To prevent the entrance of moisture during transit, the transformer will be filled with dry air under pressure. A 0.5" DIA globe valve will be installed in segment 1 for this purpose. For quickly removing oil, a 3" DIA ball valve will be installed on top of the transformer between H2 and H3 for connecting to a vacuum (brass fitting). To fill the conservator with oil, a 1" DIA globe valve will be installed on the top of the conservator. At the bottom of the conservator, the same type of globe valve will be used to drain oil from the conservator. A bleeder valve will be installed on the top of conservator to release air during the filling process and breathing due to fluctuations in oil volume. To isolate the oil from the conservator from the oil in the main tank, a 3" DIA butterfly shutoff valve will be installed in the middle of the connecting pipe. A 1" DIA connection valve will be installed on top of the Silica Gel Breather in segment 2. A sudden pressure relay allows for early detection of faults that occur inside the transformer. The type used will be an under fluid sudden pressure relay which reacts to rapidly changing pressure from 10 kPa/s to 38 kPa/s. Alarm contacts will be in accordance with 5.1.10 and 5.1.11 found in IEEE c57.12.10-2010. A 2.5" DIA gate valve will be installed directly above the sudden pressure relay. A Buchholz relay will be installed between the conservator and tank which allows cheap, early direction of slow developing faults inside the transformer. During faults and overloads, the insulating oil will decompose which produces gas that accumulates at the top of the relay forcing oil down. A float system initiates an alarm. A gas sampling valve with 5/16" DIA piping for use with the Buchholz relay will be located in segment 2 and a gas accumulation pipe of 1.5" in diameter will be run across the top of the transformer.
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4.3.5 - Grounding
The transformer is the most expensive piece of equipment in the substation, so proper grounding is important to protect the investment, as well as ensuring the safety of others during a fault. A 4 x 0.25 inch copper bar will run down the side of the transformer in segment 1, along with a 2 x 0.25 inch copper bar to provide a ground path for the bushings. The larger bar is for the neutral of the high and low side bushings, whereas the smaller bar is for the tertiary. The larger bar will have 2-4/0 AWG cables on each end and the smaller bar will have a single 4/0 AWG cable on each end. Grounding will terminate to 2 stainless steel grounding pads of NEMA type 2.
4.3.6 - Transportation
Lifting, moving, and jacking facilities will be such that the ratio of ultimate stress on the material to the working stress (safety factor) is 5 when suspended and 2 or greater for pulling applications. The transformer will be shipped without oil to reduce weight. To keep moisture out, the transformer will be filled with dry air under pressure. To keep the transformer under pressure during transit, dry air canisters will be mounted on the side of the transformer in segment 4. Just above the dry air canisters will be an impact recorder to indicate any unusual impacts. The center of gravity for both dry air and filled with oil will be labeled on the side of the transformer in segment 4. The transformer's base shall be suitable for both skidding and rolling. For shipping, 4 lugs located at all 4 corners of the transformers will be used. For lifting the entire transformer, 4 lugs will be provided (2 in segment 2 & 2 in segment 4). In addition, 4 separate lugs will be provided on the core and coil assembly for lifting from the tank. For jacking the transformer, 4 jacking plates will be located on all 4 corners of the transformer and have a surface size of 17.72" x 12.99".
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4.3.10 - Conservator
The conservator tank is what keeps the transformer flooded with oil. Inside the tank is a diaphragm (rubber bag) which reacts to changes in volume of the oil. It will be located above the transformer by means of a supporting bracket in segment 2. The tank will have 2 lifting lugs for removal.
4.3.11 - Cooling
Although transformers are extremely efficient, the large currents that they are capable of generating a lot of heat that needs to be taken from the oil to maintain life expectancy. If the oil is allowed to get too hot, the insulation inside would deteriorate much more rapidly. Radiators are used to cool transformers along with other peripherals such as pumps and fans. This transformer's design will implement 2 stages of cooling and use the IEC designations which are found below. ONAN - Oil Natural - Air Natural ONAF - Oil Natural - Air Forced
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The first stage of cooling will be ONAN which is natural convection of oil through the radiator. This stage will allot 100 MVA. The next stage will be ONAF which will utilize fans to force air across the radiator. This bay of fans allows an increase of load and thus a 34% increase in MVA resulting in 134 MVA. The radiator and fans will be located in segment 3.
4.3.12 - Fans
The fan motors will be 240 V, 60 Hz, single-phase, without centrifugal switch and shall be individually fused. AC power will be provided from auxiliary transformer inside substation. The fan motors will 1/6 HP at 1140 RPM.
4.3.13 - Controls
The control cabinet will be located in segment 1 and have (2) 7 x 21.25 inch openings on the bottom for conduit.
4.3.14 - Noise
Core vibrations inside the transformer coupled with the cooling fans will generate undesirable noise at a certain SPL (Sound Pressure Level). The substations location does not pose concern of noise complaints.
4.3.16 - Neutrals
The neutral of both the high side Wye and low side Wye will be solidly grounded through the use of copper bus bars and 4/0 AWG wire as noted in the grounding section (4.3.5).
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4.4
Coupling capacitor voltage transformers or CCVT's are transformers that take the large voltages in the substation and transform them to a smaller magnitude without a phase change. Single Phase CCVT Ratings: Primary voltage: Secondary voltage: Ratio: Accuracy class: Basic Impulse Level (BIL): Total Capacitance:
138/3 kV 69/3 kV 2500/4500:1 X1-X2-X3 Winding - 0.3 W, X, Y, Z, & ZZ Burden Y1-Y2-Y3 Winding - 0.3 W, X, Y, Z, & ZZ Burden 550 kV greater than 3000 pF
Provisions: Porcelain bushing (ANSI 70 gray). Tank paint color will be ANSI-70 gray. CCVTs will be supplied with NEMA standard 4-hole pads on HV bushing terminal. Carrier accessories required on all CCVTs.
4.5
Lightning Shielding
Lightning shielding is a system designed to protect the substation equipment and bus work from lightning strikes and associated surges. The system consists of masts located on top of structural bus supports, or mounted directly on the ground. These masts are electrically connected directly to the grounding grid of the substation. This is to minimize the impedance the lightning stroke current will see, diverting it to the masts and from other substation equipment. This lightning shielding system will be designed using the Rolling Sphere method per IEEE 9982012. This method involves a sphere, of radius S, and "rolling" it around the lightning masts. Any equipment located under the tent created by the rolling sphere is assumed to be protected. However, there are no 100% effective means of lightning protection.
Rolling Sphere Example
4.5.1 -
Design
S is the strike distance (in feet) of the last stepped leader of a lightning strike. This distance becomes the radius of the sphere. To determine sphere radius S, several aspects of the substation design must be considered. The allowable surge current (Is) determines the magnitude of stroke current the substation can endure without failure due to flashover.
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Surge impedance (Zs) is the impedance of the equipment, that the surge current is passing through to ground. Surge current and surge impedance can be determined using the following equations: Zs () = 60*ln(2*he/rc) Is (kA) = 2.2*BIL/Zs where "he" is the height, in feet, of the equipment the surge current is flowing through; "rc" is the radius of the conductor, not including insulation; BIL is the Basic Impulse Level. From this, the sphere radius, S, can be calculated, according to IEEE 998-2012 equation 17. S (feet) = 26.25*Is^0.65 This sphere is then rolled around, while keeping constant contact with the mast. If any piece of equipment passes into the sphere, it is not protected and more shielding must be added for adequate protection.
4.5.2 -
Masts
There will be six (6) 65' masts and two (2) 49' masts installed. The 65' masts are for protection of the 138kV system and the 49' masts will protect the 69kV system and control house structure. These masts will be connected directly to the ground grid.
4.5.3 -
Installation
Lightning masts can be installed on top of equipment or bus supporting structures, or they can be mounted as a stand-alone on a foundation on the ground. Masts mounted to support structures allow for lightning protection inside the equipment footprint, while satisfying BIL requirements. Two of the 65' masts will be installed on top of the main supporting A-frame structure. The remaining masts will be installed as standalones at locations specified by calculations in accordance with IEEE 998-2012. Both methods of installation require the mast to be electrically connected to the substation ground grid. This is accomplished by connecting a copper cable of appropriate size from the mast to the ground grid. THIS SENTENCE DOES NOT MAKE SENSE This cable will be connected to the ground grid via to prevent contamination between the conductors that could cause a rise in impedance.
4.6
DC Station Service
The 125V DC system will consist of one battery and two chargers. Each charger and the battery will be capable of providing emergency operation and continuous control power for the
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substation facility and breaker operating power at the end of the 8 hour duty cycle. The battery will be supplied with a manual maintenance switch to disconnect the DC distribution panel from the battery. In order to calculate minimum Amp-hour output for battery and its charger it is necessary to add the amperages needed for all dc lamps in substation, relays and panel indicating lamps, communications, four simultaneous breaker operation and the current to be consumed by the DC motor of the motor operated air break (MOAB). All the calculations for battery sizing will be based on the IEEE 485-1997. The battery will be sized for a minimum Amp-hour output 470 with the following criteria: Nominal battery voltage: 125V DC Number of cells: 60 Emergency operating time: 8 hr Minimum cell voltage: 1.75V
The charger will be sized for a minimum Ampere output 40 with the following criteria: Input voltage: 240 volts - 1-phase Output voltage: 125 - 140 V Equalize timer: 0 - 72 hr Recharge time at design load: 24 hr
5 - Protective Relaying
5.1 Purpose
The objectives of protective relaying are to minimize the effects of system disturbances and to minimize the possible damage to power system equipment. Relay protection for the larger size transformers usually includes sudden pressure relays, differential relays, overcurrent relays or and ground overcurrent relays. Sudden pressure relays are the primary relay protection on a transformer.
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5.2
The control and relay panels will be designed according to the following criteria:
All relays must have the following: 1. Access to back of Schweitzer relays is required for PC connection. 2. Appropriate test/disconnect switches are required to provide connections for relay testing and isolation.
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5.3
Relay Specifications
All relay schemes shall be suitable for power line carrier connections. All relays shall incorporate event recorders, in addition, SCADA (control, indication and metering) will be required for the new equipment. This will include SCADA control (trip and close) of all circuit breakers, breaker status (52a) indication as well as additional SCADA indication and metering as indicated in the following: 138 kV Breaker B1 (East Bottoms/West Bottoms) Breaker Failure-to-Trip Relay Schweitzer SEL-035210325HXX4XX, (BFR/B1) Breaker Failure relay, suitable for use at 125V DC. To be used for 138 kV Breaker B1 failure-to-trip protection. Electroswitch series 24 Lock-Out Relay (86BF/B1) Electroswitch series 24 switch to be used as a Failure to Trip cutoff switch (FT/CO). This switch shall be utilized to disable the Failure to Trip relaying for testing and maintenance. 138 kV Breaker B1 (East Bottoms/West Bottoms) Automatic Reclosing Relay Schweitzer SEL-0351A00H23554X, (79/B1) Breaker Auto-reclosing relay, suitable for use at 125V DC. To be used for 138 kV Breaker B1 Automatic Reclosing. 138 kV Breaker B2 (East Bottoms/TR) Breaker Failure-to-Trip Relay Schweitzer SEL-035210325HXX4XX, (BFR/B2) Breaker Failure relay, suitable for use at 125V DC. To be used for 138 kV Breaker B2 failure-to-trip protection. Electroswitch Series 24 Lock-Out Relay (86BF/B2) Electroswitch series 24 switch to be used as a Failure to Trip cutoff switch (FT/CO). This switch shall be utilized to disable the Failure to Trip relaying for testing and maintenance. 138 kV Breaker B3 (TR /West Bottoms) Breaker Failure-to-Trip Relay Schweitzer SEL-035210325HXX4XX, (BFR/B3) Breaker Failure relay, suitable for use at 125V DC. To be used for 138 kV Breaker B3 failure-to-trip protection. Electroswitch Series 24 Lock-Out Relay (86BF/B3) Electroswitch series 24 switch to be used as a Failure to Trip cutoff switch (FT/CO). This switch shall be utilized to disable the Failure to Trip relaying for testing and maintenance. 138 kV East Bottoms Line Exit Schweitzer SEL-32111-4256-HNB3X4, (PR/EB) phase distance relay and ground directional overcurrent relay with fault locator and fast meter communications. New to be used to provide phase and ground protection. SCADA remote sub unknown.
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Schweitzer SEL-311B-00H24254XX, (BU/EB) phase distance relay and ground directional overcurrent relay. New to be used to provide one set of phase and ground protection. SCADA remote sub unknown. 138 kV West Bottoms Line Exit Schweitzer SEL-311L1H-3254-XXXX, (PR/WB) current differential relay and phase and ground distance relay and ground directional overcurrent relay. New to be used to provide current differential plus phase and ground primary protection. SCADA remote sub unknown. 1. Connect West Bottoms fiber optic channel to the fiber port on the back of the relay. 2. Install a Line Differential Cut-Off Switch for primary line relay which shall provide and input into the SEL-311L. Schweitzer SEL-32111-4256-HNB3X4, (BU/WB) phase distance relay and ground directional overcurrent relay with fault locator and fast meter communications. New to be used to provide phase and ground protection. SCADA remote sub unknown. 138/69kV Transformer (TR) Differential Relaying Schweitzer SEL-0587103X5X1 (87T/TR) Current Differential relay to be used as primary transformer low impedance differential protection. Appropriate test switches are required to provide connections for relay testing and isolation. Note: LOR 86TX/TR is reset by a 89b contact from the high side MOAB (A1). This is to allow the 138kV breaker to be closed after the TR MOAB is open. 138/69kV Transformer (TR) 138kV Lead Differential Relaying Schweitzer SEL-0587Z0X325H12XX high impedance bus differential relay with high energy (2) clamping MOVs. Horizontal rack mount. New, to be used for TR 138 kV bus differential protection. Electroswitch LOR, spring operated, Manual reset, multi-stage auxiliary tripping relay. New, to be used with the above SEL 587Z relay for TR 138 kV leads/bus auxiliary. 138/69kV Transformer (TR) Overall Differential Relaying Schweitzer SEL-038750-4X5HXX4XX (87OA/TR) current differential relay. New, to be used for TR overall differential protection. Electroswitch LOR, (86OA/TR) spring operated, Manual reset, multi-stage auxiliary tripping relay. New, to be used with the above SEL 587 relay for TR differential relaying. 138/69kV Transformer (TR) Ground Overcurrent Protection Schweitzer SEL-055100-3X5X1X, overcurrent relay, with metering, suitable for use at 125V DC. New, to be used for TR tertiary ground protection. 5A Phase input, 5A neutral.
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Series the Phase A and IN CT circuits. ABB AR aux tripping relay. New, to be used with the above SEL 551 relay for TR ground overcurrent.
6 - Communication
6.1 Communications Equipment
138 kV East Bottoms Line Exit RFL 9785 65-156 kHz frequency range 10 watt, 1000 Hz bandwidth, carrier relaying transmitter-receiver assembly complete with keying unit, checkback module and auxiliary power supply at 125V DC. To be tuned to 142.5 kHz. New, to be used for DCB communications on the East Bottoms 138kV exit. Monitor the checkback failure alarm by SCADA alarm point. Include hardware necessary to capture sequence of events. No voice functions necessary.
138kV Single Frequency Wave Trap for use at 142.5 kHz, minimum 2000A continuous. New, to be used for 138kV East Bottoms DCB communications on the East Bottoms circuit exit. Unit shall be coupled to phase 3. Single Frequency Resonant Line Tuner. New, to be used for 138kV East Bottoms DCB communication on East Bottoms circuit exit. Unit shall be tuned to 142.5 kHz and be used with phase 3 wave trap.
6.2
Additional Communication
General communications one line via LAN/WAN is supplied, specific models and details to be determined by utility. (see Appendix)
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7 - Substation grounding
7.1 Introduction
The grounding grid provides a common ground for the electrical equipment as well all the metallic structures in the substation. Effective Grounding system design is important as it deals with personnel safety and protection of electrical equipment. Earth Fault gives rise to potential gradient within and around the substation. This voltage gradient should not exceed the tolerable human body limit. Substation grounding grid design therefore requires calculating of parameters related to earth and grounding with a great concern for the safety of the persons who may come under the influence of the potential gradient due to severe earth faults. Reduction of the substations ground grid totals resistance also minimizes the effect of the ground potential rise to elements connected to the substations metallically but not in the fault current path.
7.2
General Requirements
A ground grid design has two primary objectives: To provide means for carrying electric currents into the earth under normal and fault conditions to maintain continuity of service and low impedance path for ground fault such that the equipment ratings are not comprised. To protect personnel within and in the vicinity of the substation, from the dangers of electric shock during a ground fault. In order to properly plan and design the grounding grid, the following parameters are calculated or defined: maximum fault current, grid resistance, grid current, safe touch and step voltages, ground potential rise, as well as expected touch and step voltage levels.
7.3
Design Specification
The grounding system grid shall consist of a network of bare conductors, the mesh buried in the earth to provide grounding connections to equipment ground terminals, equipment housing, and structures to limit the maximum possible shock current during fault conditions to safe values. If the determined step and touch voltages are below the maximum values for touch and step then the design is considered adequate. The ground grid should encompass all of the area within the substation fence and extend at least 3.0 feet outside the substation fence. The maximum single phase grid current during fault conditions has been determined to be: 20 kA. The tolerable touch and step voltages are to be determined using WinIGS for a shock duration of 0.25 seconds and must conform to IEEE Std80 (2000) safety standards.
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The equipment and grid ground conductor should be 4/0 soft drawn bare copper. The ground grid should consist of horizontal conductors placed in the ground to produce a square mesh. This can be visualized by a checkerboard pattern. Every grid conductor intersection should be bonded using exothermic welds. Vertical ground rods should be placed at grid corners and at junction points along the perimeter of the grid. Ground rods should be installed near major equipment, especially surge arresters. Vertical ground rods were specified to be 5/8 inch diameter and 10 foot long copper clad steel. All hand-crank switches require a 4 foot x 6 foot safety mat that is electrically connected to the switch and is placed directly below the switch crank. This will essentially prevent a potential gradient between the switch and the grid should a fault occur during switch operation. The entire area inside the fence and including a minimum of 3.5 feet outside the fence should be covered in 6 inches of crushed rock, possessing an approximate resistivity of 3,000 ohm-meters.
7.4
Design Criteria
The study shall be carried out in conformity with the design guidelines listed below and the computer software used for the design calculations shall take into account all of the factors listed:
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depth b. The voltage between the two inner (potential) electrodes is then measured and divided by the current between the two outer (current) electrodes to give a value of resistance, R. The current tends to flow near the surface for the small probe spacing, whereas more of the current penetrates deeper soils for large spacing. Thus, it is usually a reasonable approximation to assume that the resistivity measured for a given probe spacing a represents the apparent resistivity of the soil to a depth of a when soil layer resistivity contrasts are not excessive. A soil resistivity test has been accomplished starting at very small spacing a in order to determine upper layer characteristics and depth, the test results at different probe spacing are listed in table 1.0
Figure 1
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Upper layer resistivity calculated by computer software WinIGS = 320.14 ohmsmeters Upper layer depth calculated by WinIGS = 4.01 meters Lower layer resistivity = 48.17 ohms-meters
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capacitors, transformers, and, where appropriate, machine neutrals, lighting, and power circuits. Extra ground connections should be considered at all critical locations (such as at equipment neutrals, transformers, surge arrester grounds, operating handles and ground mats, etc.) To ensure an effective grounding capability even when one conductor is broken or a connection is improperly made. Do not assume equal division of currents between multiple ground connections. Oxidation or corrosion in the connection can create hot spots that can shorten the life of the connection. With the connection below grade, there is no visual way of knowing when the connection has failed. A properly installed exothermic connection is a molecular connection that eliminates the oxidation and corrosion in the connection and reduces the opportunity for hot spots. 7.4.7 - Addition of Surface Layer & Reduction Factor Additional surface A thin layer of highly resistive protective surface material such as crushed rock (approximately 3000 ohm.m in resistivity) spread above the earth grade at a substation can greatly reduce the available shock current at a substation. The surface material increases the contact resistance between the soil and the feet of people in the substation.
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The surface material is 6 inches in depth and extends to 4 feet outside the substation fence, however it can vary between 0.08 to 0.15 meter (3 to 6 inches) in depth and extends 0.91 to 1.22 meters (3 to 4 feet) outside the substation fence. If the surface material does not extend outside the substation fence, then the touch voltage may become dangerously high. Reduction Factor CS To be determined later.
7.5
Safety Considerations
Underground fault conditions, the portion of fault current flowing between a substation ground grid and the surrounding earth, IG, will result in potential gradients within and around the substation. Unless proper precautions are taken in design, the maximum gradients present can result in a potential hazard to a person in or near the substation. In addition to the voltage magnitude of the local gradients, such things as duration of the current flow, impedances in its path, body resistance, physical condition of the person, and probability of contact all enter into the safety considerations
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The threshold of perception for the human body is about one milliampere at commercial (50 or 60 Hz) frequencies. Currents of 1 to 6 mA, often termed let-go currents, though unpleasant to sustain, generally do not impair the ability of a person holding an energized object to control his muscles and release it. Higher currents (about 9 to 25 mA) can result in painful situations and affect the muscles so that the energized object is difficult if not impossible to release. Still higher mA currents can affect breathing and may cause fatalities if duration (usually on the order of minutes) is long enough. Further current increases (about 60 mA and above) can result in ventricular fibrillation of the heart. Sixty mA is approximately the current drawn by a 7.5 watt 120 V lamp. Currents above the level for ventricular fibrillation can cause heart paralysis, inhibition of breathing, and burns.
7.6
The grounding of the substation fence is critical because the fence is generally accessible to the public. The substation grounding design should be such that the touch potential on both sides of the fence is within the calculated tolerable limit of touch potential. The substation fence should be connected to the main ground grid by means of an outer grid conductor installed a minimum of 0.91 meter (3 feet) (approximately one arms length) outside the substation fence. Connections to the outer grid conductor should be made at all corner posts and at line post every 12.92 to 15.24 meters (40 to 50 feet). The gateposts should be securely bonded to the adjacent fence and the grid extended below the gate swing. It is recommended that all gates swing inward and be designed and installed to prevent an outward swing. If gates are installed with an outward swing, then the ground grid should extend a minimum of 0.91 meter (3 feet) past the maximum swing of the gate. The reasons to extend the ground grid to cover the swing of the gate are the same as the reason to install a ground conductor 0.91 meter (3 feet) outside the fence. The voltage above remote earth decreases rapidly as one leaves the substation grounding area. For example, if a person standing outside the substation grounding grid touches a fence or outward-
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swung gate under substation fault conditions, the resulting potential difference could be large enough to pose a serious danger.
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Appendices
Appendix A - Equations
Wind Loads:
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Grounding:
Step, Touch & reduction factor Calculations: Step & touch potentials were calculated using WinIGS : Permissible touch voltage = 1074.4V Permissible Step Voltage = 677.6V (Over Insulating Surface Layer) (Over Native Soil)
-They can also be calculated by hand using the following equations: Etouch = IB RB + 1.5 Cs Estep = IB RB + 6 Cs
Where:
RB is the resistance of the human body in , approximately=1000 IB : is the rms magnitude of the current through the body in A, IB = for 50kg body weight.
: is the resistivity of the earth beneath the surface material in m (= 320.1m) from soil data Cs : is the surface layer derating factor, determined using this equation:
Where
is the thickness of the surface layer (m) = 0.152 of crushed rock in my design. is the resistivity of the surface layer material (.m) = 3000 .m for crushed rock.
Cs = 1-
= 0.796
Etouch = IB RB + 1.5
Cs
Estep = IB RB + 6 Cs
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Momentary Current:
Formulas given below are based on IEEE C37.04-1999, and IEEE C37.09-1999 Below is my calculation: Iasymetrical = Isymetrical * =(
%dc = 100
@ 60 HZ , %dc = 100
)=(
) = 0.030357
= 33953.997
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Busbar Expansion
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Cantilever Strength:
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Center to Center Bus Spacing (Feet) Phase to Phase Fault Current (Amps) Total Bus Run (Feet) Three phase voltage (KV) Distance from center of bus to ground (Decimal Feet) BUS SUPPORT SPACING FOR 2 FIX ENDS. SPACING FOR ONE FIXED AND ONE PINNED VERSION 3.0 DATE: 7/19/1996
2 Fixed ends
REFERENCE: IEEE 605-1987 ALUMINUM ASSOCIATION HANDBOOK ANDERSON TECHNICAL DATA REFERENCE FOR THE ELECTRICAL POWER INDUSTRY
Calculated maximum span for conductor (FEET) Recommended number of bus supports needed Maximum allowable fault current for conductor (ACCEPTABLE / UNACCEPTABLE) Deflection (ACCEPTABLE / UNACCEPTABLE) Corona (ACCEPTABLE / UNACCEPTABLE) Damper cable (INSTALL IF UNACCEPTABLE / LEAVE OUT ACCEPTABLE) Number of expansion joints needed
GIVEN DATA CONSTANT BASED ON CONDUCTOR LOCATION (C/CS) 3 PHASE (B) MOUNTING FLEXIBILITY FACTOR (KF) FLANGE STEEL @ 16'-0" RADIAL ICE THICKNESS HEIGHT AND EXPOSURE FACTOR (Kz) EXPOSURE "C" @30 FEET GUST FACTOR (CF) EXPOSURE "C" @30 FEET WIND SPEED AT 30 FEET FORCE COEFFICIENT IMPORTANCE FACTOR FAULT DURATION FINAL CONDUCTOR TEMP. CONDUCTOR TEMP. AT FAULT INITIATION BAROMETRIC PRESSURE FOR 1257 FEET ABOVE SEA LEVEL BUS OPERATING TEMPERATURE FREQUENCY K FACTOR OVERLOAD FACTOR APPLIED TO THE WIND FORCES OVERLOAD FACTOR APPLIED TO THE SHORT CIRCUIT FORCES RECOMMENDED BUS SUPPORT SPACING IS SET FOR 2 FIX ENDS. RECOMMENDED SPACING FOR ONE FIXED AND ONE PINNED BASED ON INSTALLED TEMP. OF 20 DEG. C OR 68 DEG. F 0.866 1.00 0.5 IN 0.98 FT 1.26 FT 70 MPH 2.00 1.00 1 SEC. 90 DEG. /C 70 DEG. /C 72.62 CM OF HG 90 DEG F 1.22 2.00 1.60 CONDUCTOR 3.25" UABC 4" UABC 4" IWBC 6" IWBC 2" PIPE 2.5" PIPE 3" PIPE 3.5" PIPE 4" PIPE 5" PIPE 6" PIPE
INSULATOR INFORMATION TR-205 TR-216 TR-286 TR-287 TR-308 345KV-1 TR-369 HOR. VER. HOR. VER. HOR. VER. HOR. VER. HOR. VER. HOR. VER. HOR. VER. A A A A A A A A A A A A A A A A A A A A A A U A U A A A A A U U U U A A U U U U A U U U U U U U A U U U U U U U A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A U A A A A A A A A A A A U U U A A A U U U A A A A U U U U A U U U U U U U A U U U U U U U
BIL (KV)
95 110 150 200 250 350 550 550 650 750 850 900 950 1050 1050 1175 1300 1425 1550 1800 2050 2300
119
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DESCRIPTION: 3" IPS AL., 6063-T6, SCHEDULE 40 ITEM Short Circuit Current Unit Force Conductor Unit Weight Ice Unit Weight Unit Wind Force Total Unit Force On Conductor Maximum Allowable Fault Current For Conductor Maximum Allowable Fault Current Factor Maximum Bus Support Spacing Based on Deflection Maximum Bus Support Spacing Based on Fiber Stress Recommended Number Of Bus Supports Recommended Bus Support Spacing Bus Expansion Due to a Fault Recommended # Of Expansion Joints Per Phase Standard Maximum Allowable Deflection Actual Deflection per Recommended Bus Spacing Deflection Percentage Factor Per IEEE 605-1987 Allowable surface voltage gradient for conductor Equivalent Distance of Bus Height for 3 phase Average surface voltage gradient for needed operating voltage Maximum surface voltage gradient for conductor Check for Corona Natural Frequency of Bus Span Aeolian Frequency If acceptable, no need to add damper Maximum Allowable Conductor Amps INSULATOR INFORMATION HORZ. MT Effective span length Short circuit force transmitted to bus support Wind/gravitational force transmitted to bus support INSULATOR TR-205 15KV Wind force on insulator Total cantilever load acting at the end of support INSULATOR TR-216 69KV Wind force on insulator Total cantilever load acting at the end of support INSULATOR TR-286 138KV Wind force on insulator Total cantilever load acting at the end of support INSULATOR TR-287 138KV Wind force on insulator Total cantilever load acting at the end of support INSULATOR TR-308 230KV Wind force on insulator Total cantilever load acting at the end of support INSULATOR 345KV-1 345KV Wind force on insulator Total cantilever load acting at the end of support INSULATOR TR-369 345KV Wind force on insulator Total cantilever load acting at the end of support 31.25 248.98 181.40
7.9672 2.6210 2.4880 5.8049 14.6892 50,851.30 61% 31.21 41.96 5 25.00 1.93 1.00 1.500 0.852 43% 13.06 144.58 11.58 11.83 9% 1.91 13.97 93% 2272
UNITS LBS/FEET LBS/FEET LBS/FEET LBS/FEET LBS/FEET AMPS ACCEPTABLE Feet Per Span Feet Per Span Per Run Feet Inches Per Run Inches Per Run Inches Per Run ACCEPTABLE KV RMS/CM cm KV RMS/CM KV RMS/CM ACCEPTABLE HZ HZ UNACCEPTABLE Amps
17.1932 1054.280
65.2803 918.419
111.2182 933.699
111.2182 933.699
223.5110 1019.166
296.1521 1083.347
313.2378 1100.433
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Appendix E - Communications
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