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Project overview Maximum demand calculation Load flow studies Short circuit studies Protection Relay coordination
This Project is actually the brown field expansion of a 0.6 MTPA Pellet plant to 1.8 MTPA integrated steel plant. Existing Facilities include the following: 25 MW power plant 70 MW power plant 2 x 1.2 MTPA beneficiation plant 2x1.2 MTPA pellet plant 4 x 500 TPD DRI Plant A small capacity bar mill.
Expansion to 1.8 MTPA Integrated Steel Plant is planned in two stages of 0.9 MTPA each. The major units envisaged in Stage-I and Stage-II are as follows: 100T EAF/LF Oxygen Plant Sinter Plant Blast Furnace Coke Oven Bar Mill And Billet Caster
The existing plant receives power at 220 kV from nearby switching station, located approximately 17 kms away from the plant. In addition to the grid supply, in-house generation from 25 MW and 70 MW CPPs also caters to the load demand. Excess power generated after meeting the demand of the plant is exported to the Grid.
To cater to the increased demand of the power due to expansion of the plant , an additional capacity of 140 MW (2x70 MW CPPs) generation is also planned to be set up. For feeding the new plant units at 33 kV, a new 220/33 kV Main Receiving Substation (MRSS) is planned. The interconnection of the existing power system, CPPs and new MRSS and CPPS is planned through a number of interconnections considering various factors to ensure maximum availability and reliability.
Maximum demand calculations Transformer selection Load flow analysis Short circuit analysis Selection of Protective equipments Relay co-ordination
Shop/Unit
Production (Tonnes/yr)
W orking days/year
W orking hours/year
Load Factor
PHASE-1
To Unit
Raw Coal Sinter Lime stone RMHS Total Load BLAST FURNACE GHM COKE OVEN COKE SGP SLAG EAF/LF EAF/LF Auxillaries
8 8 8
B.F Output
910000
350
8400
175
159250000
18.96
0.8
23.70
CO Output
450000
350
8400
60
27000000
3.21
0.8
4.02
SGP
318500
365
8760
25
7962500
0.91
0.8
1.14
EAF/LF
1100000
320
7680
50
55000000
7.16
0.9
7.96
Step-1 Calculation of Annual Energy Consumption Step-2 Calculation of Average Load of each unit
Step-4 calculation of total maximum demand Step-5 calculation of simultaneous maximum demand considering 3% losses
Sum of Individual Maximum Demand (considering 3% losses) = 83.45MW Max. Demand (MD) (considering diversity factor of 1.25) = 66.76 MW Max. Demand (MD) (considering 5% contingency requirement) = 3.34 MW Total load demand =70.10MW Total EAF demand=106.0MW Total Energy consumption per annum (considering 3% losses) = 18089046.94kWh Total Energy requirement per annum = 621.06MkWh
Transformer selected will have the rating twice the calculated MVA for each load. For 70 MW plant loads, transformer selected is, 63/80 MVA For 106 MW EAF load, transformer selected is, 130/160 MVA
Load flow studies are carried out to determine the power flow in the system. Load flow studies helps in planning the operation of power system under existing conditions, its improvements and future expansion. The study also helps to identify Overloading of transmission lines Voltage limit violations at the buses
Case-1: Grid and 25MW CPP feeding existing loads Case-2: Grid and 95MW (1x25 & 1x70) CPPs feeding existing loads Case-3:Grid and 95MW (1x25 & 1x70) CPPs feeding existing loads and phase-1 loads. Case-4:Grid and 165MW (1x25 & 2x70) CPPs feeding existing loads, phase-1 and phase-2 loads. Case-5: Grid and 235MW (1x25 & 3x70) CPPs feeding existing loads, phase-1 and phase-2 loads.
DESCRIPTION
GENERATION
GRID
70 MW CPP-1 0 0
70 MW CPP-2 0 0
70 MW CPP-3 0 0
LOAD
CASE-1
MW MVAR
35.41 14.09
60.05 37.22
FROM NODE 1 4 2 2 7 12 8 12 1 20
FROM NAME Bus1 Bus4 Bus2 Bus2 Bus7 Bus12 Bus8 Bus12 Bus1 Bus20
TO NODE 2 3 5 6 8 8 14 14 19 2
TO NAME Bus2 Bus3 Bus5 Bus6 Bus8 Bus8 Bus14 Bus14 Bus19 Bus2
% LOADIN G 27.6 ^
-21.915 -12.477 0.0283 12.845 14.008 35.443 7.952 8.676 15.98 0.0243 0.0289 0.0482
LINE IS OPEN -4.661 2.32 -1.371 1.194 0.0025 0.0007 -0.0262 3.8 & -0.0275 2.1 &
! NUMBER OF LINES LOADED BEYOND 125%: @ NUMBER OF LINES LOADED BETWEEN 100% AND 125%: # NUMBER OF LINES LOADED BETWEEN 75% AND 100%: $ NUMBER OF LINES LOADED BETWEEN 50% AND 75%: ^ NUMBER OF LINES LOADED BETWEEN 25% AND 50%: & NUMBER OF LINES LOADED BETWEEN 1% AND 25%: * NUMBER OF LINES LOADED BETWEEN 0% AND 1%:
0 0 0 0 1 6 1
DESCRIPTION
GENERATION
GRID
70 MW CPP-1 70 25.85
70 MW CPP-2 0 0
70 MW CPP-3 0 0
LOAD
CASE-2
MW MVAR
60.05 37.22
FROM NODE 1 4 2 2 7 12 8 12 1 20
FROM NAME Bus1 Bus4 Bus2 Bus2 Bus7 Bus12 Bus8 Bus12 Bus1 Bus20
TO NODE 2 3 5 6 8 8 14 14 19 2
TO NAME Bus2 Bus3 Bus5 Bus6 Bus8 Bus8 Bus14 Bus14 Bus19 Bus2
FORWARD MW MVAR 34.476 34.75 12.85 14.012 -34.39 13.555 -1.559 7.952 8.675 6.838
LOSS MW 0.1446 0.051 0.0243 0.0289 0.0387 0 -8.123 7.5 0.0203 0.0144
% LOADING 28.9 ^ 4.3 & 11.9 & 12.9 & 15.9 & 0.0 * 10.8 & 9.1 &
! NUMBER OF LINES LOADED BEYOND 125%: @ NUMBER OF LINES LOADED BETWEEN 100% AND 125%: # NUMBER OF LINES LOADED BETWEEN 75% AND 100%: $ NUMBER OF LINES LOADED BETWEEN 50% AND 75%: ^ NUMBER OF LINES LOADED BETWEEN 25% AND 50%: & NUMBER OF LINES LOADED BETWEEN 1% AND 25%: * NUMBER OF LINES LOADED BETWEEN 0% AND 1%:
0 0 0 0 1 6 1
DESCRIPTION
GENERATION
GRID
70 MW CPP-1 70 25.35
70 MW CPP-2 70 2.50
70 MW CPP-3 70 2.5
LOAD
CASE-3
MW MVAR
69.85 43.3
FROM NODE
FROM NAME
TO NODE
TO NAME
FORWARD MW MVAR 13.339 -2.266 7.952 8.675 26.426 -14.312 IS OPEN IS OPEN -8.124 7.494
LOSS MW 0.144 0.0511 0.0243 0.0289 0.8468 0.0524 MVAR 0.1028 -0.0246 -0.006 -0.0018 1.6732 -0.0049
% LOADING
1 4 2 2 7 12 8 12 1 20
Bus1 Bus4 Bus2 Bus2 Bus7 Bus12 Bus8 Bus12 Bus1 Bus20
2 3 5 6 8 8 14 14 19 2
Bus2 Bus3 Bus5 Bus6 Bus8 Bus8 Bus14 Bus14 Bus19 Bus2
34.47 34.754 12.85 14.013 -163.08 129.549 LINE LINE -11.24 8.924
0.0202 0.0144
-0.0101 -0.0151
10.8& 9.1&
! NUMBER OF LINES LOADED BEYOND 125%: @ NUMBER OF LINES LOADED BETWEEN 100% AND 125%: # NUMBER OF LINES LOADED BETWEEN 75% AND 100%: $ NUMBER OF LINES LOADED BETWEEN 50% AND 75%: ^ NUMBER OF LINES LOADED BETWEEN 25% AND 50%: & NUMBER OF LINES LOADED BETWEEN 1% AND 25%: * NUMBER OF LINES LOADED BETWEEN 0% AND 1%:
0 0 0 2 1 5 0
DESCRIPTION
GENERATION
GRID
70 MW CPP-1 70 35.60
70 MW CPP-2 70 13.60
70 MW CPP-3 0 0
LOAD
CASE-5
MW MVAR
77.91 74.38
240.95 107.185
FROM NODE 1 4 2 2 7 12 8 12 1 20
FROM NAME Bus1 Bus4 Bus2 Bus2 Bus7 Bus12 Bus8 Bus12 Bus1 Bus20
TO NODE 2 3 5 6 8 8 14 14 19 2
TO NAME Bus2 Bus3 Bus5 Bus6 Bus8 Bus8 Bus14 Bus14 Bus19 Bus2
FORWARD MW 34.545 34.67 12.848 14.011 77.909 25.511 137.478 39.256 -11.32 8.917 MVAR 16.371 7.673 7.952 8.675 74.381 -2.3 75.849 5.293 -8.113 7.565
LOSS MW 0.154 0.0532 0.0243 0.0289 0.3656 0.0021 0.0079 0.005 0.0204 0.0145 MVAR 0.112 -0.0227 -0.006 -0.0018 -0.8488 -0.2645 0.0144 -0.2489 -0.0099 -0.015
% LOADING 29.9^ 4.4& 11.9& 12.9& 48.8^ 11.6& 70.9$ 17.9& 10.9& 9.2&
! NUMBER OF LINES LOADED BEYOND 125%: @ NUMBER OF LINES LOADED BETWEEN 100% AND 125%: # NUMBER OF LINES LOADED BETWEEN 75% AND 100%: $ NUMBER OF LINES LOADED BETWEEN 50% AND 75%: ^ NUMBER OF LINES LOADED BETWEEN 25% AND 50%: & NUMBER OF LINES LOADED BETWEEN 1% AND 25%: * NUMBER OF LINES LOADED BETWEEN 0% AND 1%:
0 0 0 1 2 7 0
DESCRIPTION
GENERATION
GRID
70 MW CPP-1 70 34.02
70 MW CPP-2 70 34.02
70 MW CPP-3 70 34.02
LOAD
CASE-4
MW MVAR
12.97 74.59
245.85 110.22
FROM NODE 1 4 2 2 7 12 8 12 1 20
FROM NAME Bus1 Bus4 Bus2 Bus2 Bus7 Bus12 Bus8 Bus12 Bus1 Bus20
TO NODE 2 3 5 6 8 8 14 14 19 2
TO NAME Bus2 Bus3 Bus5 Bus6 Bus8 Bus8 Bus14 Bus14 Bus19 Bus2
FORWARD MW 34.536 34.679 12.848 14.011 12.967 59.441 106.64 70.099 -11.31 8.918 MVAR 16 6.458 7.952 8.675 74.59 -2.078 75.626 5.498 -8.115 7.557
LOSS MW 0.1527 0.0525 0.0243 0.0289 0.184 0.0112 0.0054 0.0157 0.0204 0.0145 MVAR 0.1107 -0.0233 -0.006 -0.0018 -1.8226 -0.2169 0.0013 -0.193 -0.01 -0.015
% LOADING 29.7^ 4.4& 11.9& 12.9& 34.9^ 26.8^ 58.9$ 31.7^ 10.9& 9.2&
! NUMBER OF LINES LOADED BEYOND 125%: @ NUMBER OF LINES LOADED BETWEEN 100% AND 125%: # NUMBER OF LINES LOADED BETWEEN 75% AND 100%: $ NUMBER OF LINES LOADED BETWEEN 50% AND 75%: ^ NUMBER OF LINES LOADED BETWEEN 25% AND 50%: & NUMBER OF LINES LOADED BETWEEN 1% AND 25%: * NUMBER OF LINES LOADED BETWEEN 0% AND 1%:
0 0 0 1 4 5 0
Losses in the system are calculated. No buses or Lines are getting overloaded. No need for additional generation and inductive VAR support or placement of capacitors to maintain system voltages within specified limits is found.
Short circuit calculations provide currents and voltages on a power system during fault conditions. Short circuit study calculates the maximum available short circuit current at various points throughout the system and the calculated values are then used to evaluate the application of protective devices, and to develop circuit breaker trip settings.
Case-1: Grid and 25MW CPP & 70 MW CPP Case-2: with grid and all CPP sources (1x25 & 3x70MW)
BUS NUMBER Bus1 Bus2 Bus3 Bus4 Bus5 Bus6 Bus7 Bus8 Bus19 Bus20
MVA LEVEL 587.1 591.4 1013.5 1011.7 556.7 556.7 7267.9 3510.1 572.2 575.1
FAULT CURRENT (kA) 30.815 31.04 53.197 53.1 29.219 29.219 19.074 9.212 30.032 30.188
41
BUS NUMBER Bus1 Bus2 Bus3 Bus4 Bus5 Bus6 Bus7 Bus8 Bus9 Bus10 Bus12 Bus14 Bus15 Bus16 Bus17 Bus19 Bus20
MVA LEVEL 591.8 596.3 1028.1 1025.8 561 561 7641 3946.1 882.2 882.2 3842.9 3924.2 537.4 537.4 965.4 576.7 579.8
FAULT CURRENT(kA) 31.064 31.297 53.961 53.844 29.447 29.447 20.053 10.356 46.307 46.307 10.085 10.299 9.402 9.402 16.89 30.269 30.432
Short
circuit studies provide post fault bus voltages at different buses in the network for a fault at any location in the network. These results are typically given as fault MVA. Short circuit studies for minimum fault level condition is of interest in relay coordination to check whether relays can distinguish between the Maximum Load Currents and Minimum Fault Currents.
The purpose of an electrical power system is to generate and supply electrical energy to consumers. The system should be designed and managed to deliver energy to the utilisation points with both reliability and economy. Protection should be done to prevent the following: Prevent any disruption of supply Electrical equipment used is very expensive and we should prevent any damage to the equipment Power system should operate in a safe manner at all times Fault may represent a risk to life and property
Maximum
protection Minimum equipment cost Reliable protection High-speed operation Simple designs High sensitivity to faults Insensitivity to normal load currents Selectivity in isolating a minimum portion of the system
For attaining higher reliability, quick action and improvements in operating flexibility of the protection schemes, separate elements of a power system , in addition to main or primary protection , are provided with a back-up and auxiliary protection.
Protection Zone A To Zone A Relays Protection Zone B To Zone B Relays
Short-circuit protection includes two protection systems: primary and backup protection. Primary protection is the first line of defense. Back up protection gives back up to the main protection, when the main protection fails to operate or is cut out for repairs etc.
Relays
Current Transformers CTs Voltage Transformers VTs or PTs Circuit Breakers CBs etc.
Back up protection
(Over current and Earth Fault)
Application
The most commonly used protective relays are the instantaneous overcurrent relays. They are used as both primary and backup protective devices and are applied in every protective zone in the system.
Restricted earth fault protection is provided in electrical power transformer for sensing internal earth fault of the transformer
The current decreases as the distance increases, This indicates that the operation time of the relay will be larger as the current is farther from the RELAY source. This is one of the OPERATION advantages of inverse-type overcurrent relays. TIME Time (s)
Current (A)
Radial Line
Fault Load
Distance
protection uses current and voltage information to make a direct, or indirect, estimate of the distance to the fault. Application
Distance relays are widely used for primary and backup protection on transmission lines where high-speed relaying is desired. Other applications include generator backup protection for faults on the system and startup of large motors with high inertia.
Application
Synchronism check relays are applied when two or more sources of power are to be connected to a common bus.
The arrows shown in the figure are used to represent the protection tripping direction. Note that the relays are oriented towards the protected lines. This orientation divides the system protection into two independent groups: the relays looking to the right and those looking to the left. The directionality divides the coordination process into two independent processes. A relay only needs to be coordinated with the other relays in its group.
Application
Directional overcurrent relays are used to provide sensitive tripping for fault currents in one(tripping) direction and not trip for load or fault currents in the reverse (normal) direction.
Balanced CT Ratio CT
Protected Equipment
CT External Fault
If the primary and secondary currents at both sides of the protected equipment are equal. There will be no difference, and the relay will not operate.
50
IDIF = 0
CTR
50
For an internal fault, the secondary currents are 180 out of phase and produce a differential current through the overcurrent relay. If this differential current is larger than the pickup for the relay, the relay will trip both circuit breakers instantaneously.
Relay Operates
Bus protection Transformer protection Generator protection Line protection Large motor protection Reactor protection Capacitor bank protection Compound equipment protection
The
basic idea of coordination is that the backup relay should be slower than the primary relay, with a minimum separation of T between curves calculated as follows: tbackup = tprimary + T
Distance
} T
} T
Distance
For relay R1, CT chosen =1600/1A Maximum fault current(I) = 10.297kA Current setting(IS)=130% of 1600A = 2080A For t=0.15s, TMS=0.035
By performing various system studies using MiPower, the following things were concluded: From the results of Load flow analysis it is verified that: No bus or transmission line is getting overloaded. Real and Reactive power requirement or excess under various operating conditions is found. Loading of transformers is verified. From the results of Short circuit analysis following observations are made: Required rating of equipments and Interrupting capacities of breakers is found. No requirement for change in the existing system on account of expansion and capacity addition was found. Short circuit levels obtained at various buses is used as input for relay coordination. From the results of Relay Coordination following observations are made: Settings for over current relays at various feeders were given and coordination between them was verified.
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