Basic Design Report - Part 2 Rev 1 Oct 2007 PDF

Design Report
300927.01 October, 2007 Revision 1
Electricidad Andina S.A. Santa Rita Hydroelectric Project, Peru

Basic Design Report Part 2 Electromechanical Equipment
PYRY ENERGY LTD. Ref. No 300927.01 Date March, 2007 Page 2 (49)
Copyright Pyry Energy Ltd. All rights are reserved. This document or any part thereof may not be copied or reproduced without permission in writing from Pyry Energy Ltd.
Copyright Pyry Energy Ltd.
Preface
Contact: Martin Nater Project Manager E-mail: martin.nater@poyry.com Siegfried Schwarz Senior Electrical Engineer E-mail: siegfried.schwarz@poyry.com Christian Schiess Senior Mechanical Engineer E-mail: christian.schiess@poyry.com
Pyry Energy Ltd. Hardturmstrasse 161, P.O. Box CH-8037 Zurich/Switzerland Tel. +41 44 355 5554 Fax +41 44 355 5564 www.poyry.com
Contents 1 2 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 2.12 3 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 3.12 3.13 3.14 3.15 3.16 3.17 3.18 3.19 GENERAL ............................................................................................................................ 7 MECHANICAL WORKS ................................................................................................... 8 Scope of mechanical works.................................................................................................... 8 Turbine with auxiliary equipment .......................................................................................... 8 Main inlet valve.................................................................................................................... 10 Emergency Diesel generator set(s)....................................................................................... 11 Cooling water system ........................................................................................................... 12 Drainage and dewatering system.......................................................................................... 13 Low pressure compressed air system ................................................................................... 13 Fire detection, alarm and fighting system ............................................................................ 14 Air conditioning and ventilation system .............................................................................. 14 Oil treatment plants .............................................................................................................. 17 Electric overhead travelling crane for cavern ...................................................................... 17 Mechanical workshop .......................................................................................................... 17 ELECTRICAL WORKS ................................................................................................... 18 Scope of electrical works ..................................................................................................... 18 Generator with auxiliary equipment..................................................................................... 19 Isolated Phase Bus Duct (IPB) ............................................................................................. 21 Generator neutral grounding ................................................................................................ 22 Static excitation system with automatic voltage regulator (AVR)....................................... 23 Generator circuit breaker with isolator................................................................................. 25 Current and voltage transformers for protection, measuring & metering, synchronisation. 26 Synchronisation and measuring & metering system ............................................................ 27 Unit transformer with on load tap changer (OLT) ............................................................... 28 Generator and transformer protection system ...................................................................... 28 Auxiliary transformers ......................................................................................................... 30 Low voltage 400 VAC switchgear ....................................................................................... 32 Batteries A+B 220 VDC with battery chargers and DC switchgear .................................... 34 Uninterrupted power supply (UPS) with static bypass system ............................................ 36 Lighting system for power house, transformer niches and control building........................ 36 Power plant grounding and lightning system ....................................................................... 38 Cabling (power and signal connections) .............................................................................. 40 Distributed control system (DCS) for power plant and high voltage switchgear ................ 42 High voltage switchyard 230 kV.......................................................................................... 48
Annexes
Drawings Electromechanical works Schematic diagram cooling water system Schematic diagram fire fighting water system Schematic diagram HVAC system 410-DB-010 B: Electrical Single Line Diagram, Sheet 1 410-DB-011 B: Electrical Single Line Diagram, Sheet 2 Civil / hydromechanical works 100-TD-001: General layout, plan view 130-TD-001: Low pressure tunnel, longitudinal profile 130-TD-002: Headworks, geology, plan view I 130-TD-003: Headworks, geology, plan view II 130-TD-004: Powerhouse area, geology, plan view 200-TD-001: Headworks, general layout, plan view 210-TD-001: Headworks, river diversion, plan view 220-TD-001: Headworks, river realignment, plan view 220-TD-002: Headworks, river realignment, longitudinal profile 220-TD-003: Headworks, river realignment, blockramp, longitudinal profile 220-TD-004: Headworks, river realignment, typical cross section 220-TD-005: Headworks, river realignment, riverbank, sections 220-TD-006: Headworks, river realignment, downstream, sections 0+052 to 0+750 220-TD-007: Headworks, river realignment, downstream, sections 0+850 to 1+550 220-TD-008: Headworks, river realignment, upstream, sections 0+050 to 0+450 230-TD-001: Headworks, diversion weir, plan view level 758.00 230-TD-002: Headworks, diversion weir, plan view level 753.00 230-TD-003: Headworks, diversion weir, longitudinal sections 1-1 & 2-2 230-TD-004: Headworks, diversion weir, longitudinal sections 3-3 230-TD-005: Headworks, diversion weir, longitudinal sections A-A, B-B, 5-5, 6-6 230-TD-006: Headworks, diversion weir, longitudinal sections C-C, D-D, 4-4 250-TD-001: Headworks, sand trap, plan view & sections 250-TD-002: Headworks, sand trap, sections & details 250-TD-003: Headworks, sand trap, sections & details 260-TD-001: Headworks, spillway, plan view 260-TD-002: Headworks, spillway, sections 1-1 to 3-3 260-TD-003: Headworks, spillway, sections 4-4, 5-5 270-TD-001: Headworks, daily regulating reservoir, plan view 270-TD-002: Headworks, daily regulating reservoir, profile, sections 0 to 300 270-TD-003: Headworks, daily regulating reservoir, sections 400 to 800, outlet 270-TD-004: Headworks, daily regulating reservoir, typical sections & details 274-TD-001: Headworks, reservoir inflow structure, plan view 274-TD-002: Headworks, reservoir inflow structure, sections 276-TD-001: Headworks, reservoir outflow structure, plan view 276-TD-002: Headworks, reservoir outflow structure, sections & details 278-TD-001: Headworks, reservoir flushing structure, plan view & detail 278-TD-002: Headworks, reservoir flushing structure, sections & details 280-TD-001: Headworks, slope stabilization overview, plan view 280-TD-002: Headworks, slope stabilization sector 1, plan view 280-TD-003: Headworks, slope stabilization sector 1, sections Copyright Pyry Energy Ltd.
280-TD-004: Headworks, slope stabilization sector 1, details 280-TD-005: Headworks, slope stabilization sector 2, plan view 280-TD-006: Headworks, slope stabilization sector 2, sections 280-TD-007: Headworks, slope stabilization sector 3, plan view 280-TD-008: Headworks, slope stabilization sector 3, sections 280-TD-009: Headworks, slope stabilization sector 4, plan view 280-TD-010: Headworks, slope stabilization sector 4, sections 280-TD-011: Headworks, slope stabilization valley, plan view & details 280-TD-012: Headworks, slope stabilization sector 5, plan view 280-TD-013: Headworks, slope stabilization sector 5, sections & details 300-TD-001: Waterways, low pressure tunnel, plan view & longitudinal profile 310-TD-001: Waterways, low pressure tunnel, typical D&B cross sections 310-TD-002: Waterways, low pressure tunnel, typical TBM cross sections 320-TD-001: Waterways, adit 1 & adit 2, plan view 320-TD-002: Waterways, adit 3 & adit 4, plan view 330-TD-001: Waterways, surge shaft, cross sections 330-TD-002: Waterways, lower surge shaft, cross sections 340-TD-001: Waterways, pressure shaft, cross sections 350-TD-001: Waterways, pressure tunnel, cross sections 350-TD-002: Waterways, 2 units manifold, cross sections 350-TD-003: Waterways, 1 unit manifold, cross sections 360-TD-001: Waterways, tailrace tunnel, cross sections I 360-TD-002: Waterways, tailrace tunnel, cross sections II 400-TD-001: Powerhouse area, general layout, plan view 400-TD-002: Powerhouse area, layout, plan view & sections 400-TD-003: Powerhouse area, surge shaft, pressure shaft & pressure tunnel, profile 1-1 400-TD-004: Powerhouse area, tailrace tunnel & outlet structure, profile 2-2 400-TD-005: Powerhouse area, access tunnel, profile 3-3 400-TD-006: Powerhouse area, cable tunnel, profile 4-4 420-TD-001: Powerhouse, machine floor, plan view 420-TD-002: Powerhouse, generator floors, plan view 420-TD-003: Powerhouse, turbine floor, plan view 420-TD-004: Powerhouse, spiral case floor, plan view 420-TD-005: Powerhouse, section A-A, section 420-TD-006: Powerhouse, section B-B, section 420-TD-007: Powerhouse, section C-C, section 420-TD-008: Powerhouse, section D-D, section 420-TD-009: Powerhouse, excavation, sections 420-TD-010: Powerhouse, metallic roof structure, plan view section & details 440-TD-001: Powerhouse area, switchyard, general layout
GENERAL The present design report for the Santa Rita Hydroelectric Project (Peru) substantiates the selected design of the electromechanical equipment. With this report the type of equipment and its main features shall be defined. The Santa Rita plant is designed for: Safe and reliable operation Good maintainability High cost benefit ratio For the sake of competitive cost for the plant the following equipment and services by contractors are not foreseen for the Project Santa Rita: Model test of turbine Elevator in cavern
2 2.1
MECHANICAL WORKS Scope of mechanical works The scope of the mechanical work is as follows: Turbine with auxiliary equipment (hydraulic power unit, speed governor, etc.) Main inlet valve Draft Tube Gates Emergency Diesel generator set(s) Cooling water system Drainage and dewatering system Low pressure compressed air system Fire detection, alarm and fighting system Air conditioning and ventilation system Oil treatment plant Electric overhead travelling crane Mechanical workshop
2.2 2.2.1
Turbine with auxiliary equipment Design requirements and assumptions For the present condition regarding net head and flow rate it was decided to select 3 Francis turbines. The type of turbine is implied by the specific speed and will result in the highest turbine efficiency for the plant. The following table presents the main data of the turbine: Number of Francis turbines Nominal speed Spiral Case Centre Line Fly wheel effect GD
2
3 360 or 400 rpm 486.0 m.a.s.l To be defined later <40% nominal speed 752.0 m.a.s.l.
Transient speed rise on load throw from full load Max Head Water Level Copyright Pyry Energy Ltd.
Min Head Water Level Max static pressure on Centre Line Distributor Outlet invert elevation Tail Race Tunnel TWL (20m /s) TWL (40m3/s) TWL (120m /s) Max Net Head (20m /s) Max Net Head (40m /s) Max Net Head (120m /s) Min net Head (20m /s) Min net Head (40m /s) Min net Head (120m3/s) Rated net head Qmax Max Power output per unit (Hmax, 40m3/s) Runner material Shaft material Bearing arrangement
3 3 3 3 3 3 3
738 m.a.s.l. 266m 489.0m.a.s.l. 492.8 m.a.s.l. 493.7 m.a.s.l. 495.3 m.a.s.l. 258.36m 255.40m 234.05m 244.36m 241.40m 220.05m 243.56 m 3 x 40m3/s 95.2MW Stainless steel (1.4113) Ck35 W41, IM8421 (DIN42950, IEC 14-7)
Vibrations in continuous operation range have to be within limits given by ISO 10816-5 and ISO 7919-5. 2.2.2 Detailed scope and description of equipment The turbine shall be provided with: Shaft seal of water lubricated type Means for aeration Electronic Governor and automatic turbine controller for start and stop sequences, frequency-, power- and flow regulation Hydraulic power units for governors Two independent speed sensing devices based on generator VTs and inductive transducer on toothed wheel. Creeping detection device For the governor of each unit a hydraulic power unit (HPU) shall be foreseen. Oil / air pressure accumulator sized for three entire strokes (closing and opening) of the wicket
gate servo motor, in case of failure of HPU when the level of pressure is at the lower threshold (level for starting the pumps). For each HPU one stand by pump is required. The contractor shall perform after the commissioning of the turbine a field acceptance test according to IEC 60041, in order to demonstrate the guaranteed efficiency of the equipment. On the Turbine installation all provisions shall be taken in order to allowing index testing. The operating points in the following table outline the Continuous Normal Operating Range as per IEC60609.
Net Head [m] 220.05 250.73 253.69 244.36 225.26 Flow Rate [m /s] 40 40 20 20 25
3 3
Operation of 3 units 40m /s each, at Min Head Water Level 3 1 unit 40m /s Head Water Level 2/3 3 1 unit 20m /s, Head Water Level 2/3 3 1 unit 20m /s, Min Head Water Level 3 3 2 units 40m /s + 25m /s
The two following Operating Points one unit 40m3/s at Max. Head Water Level (HNetto = 255.4m) one unit 20m3/s at Max. Head Water Level (HNetto = 258.36m) shall be within the temporary operating range to be defined by ETU, ECU, ETL, ECL, PTU, PCU, PCL, PTL, as per IEC60609. Further, the following criteria shall be fulfilled: The Turbine shall have in the entire range given by the above table an Efficiency of at least 85%. Over the entire Range of Net Head, at 40m3/s the Turbine Efficiency shall be at least 93.5%. 2.3 2.3.1 Main inlet valve Description of equipment
Number of main inlet valves Type Nominal Diameter Max Static Pressure Design Pressure Test pressure Copyright Pyry Energy Ltd.
3 Spherical Valve 2.2 m 266 mWS 372.4 mWS 558.6 mWS
Actuation shall be by two servo motors arranged on both sides of the valve. The rods of the servomotor have to be hard chromium plated. Provided with closing weight, capable to close the valve under worst operating condition (max possible flow rate, including exceptional conditions such as runaway, Pmax, etc.). During closure the servo motor shall act as brake. Main inlet valve provided with Bypass with needle type valve for filling purposes. Pressure equalization shall be possible with worn out wicket gates. Inlet pipe shall be provided with drainage pipe, connected to draft tube equipped with regulating valve. Outlet pipe provided with dismantling joint of expansion type, for compensation of thermal growth and axial movements. For each main inlet valve a pressure oil system with pressure accumulators shall be provided. Each pressure oil system has to be provided with one stand by pump. 2.4 Draft Tube Gate The draft tube gate shall be designed to withstand all static and dynamic forces acting by the water, the operation of the equipment and any other load in line with DIN19704 and the General Technical Specification. The Leakage of the Draft Tube Gate under any head and without the use of any additional sealing materials shall be per m length of gasket not more than 0.1 l/s. The following tables list the main dimensions and data of the Draft Tube Gate. Gate type Gate width, nominal Gate height Gate area Elevation of channel invert Elevation of top of gate Nominal pressure (at max TWL = 495.30) Normal position Actuation Mode Bonneted Slide gate 5.4 or 2 x 2.7 m
1)
3.4 1) m ~18 m2 approx.475.5 m asl approx.478.9 m asl 19.80 m WC Open Hydraulic or Electro Motor Closing / opening under balanced condition. Closed exposed to unilateral DS pressure Local/manual 1 or 2
Control Quantity Copyright Pyry Energy Ltd.
To be coordinated with dimensions of Draft Tube outlet section and pier thickness if any.
2.5 2.5.1
Emergency Diesel generator set(s) Description of equipment To ensure the safe operation of the plant under any circumstances, for the vital components redundancy shall be provided by power supply from an emergency Diesel. Number of Diesel set One (1) set at diversion weir: Capacity One (1) set at Powerhouse cavern: Capacity 2 100 kVA 600 kVA
For each diesel set a tank shall be provided for operating the engine at least 48h. The diesel set shall be provided with cooling air supply, exhaust air system, battery starting system, fuel oil system, protection and monitoring system, etc. 2.6 2.6.1 Cooling water system Description of equipment For each unit a dedicated cooling system shall be provided. The corresponding scheme is depicted on the Drawing Schematic Diagram Cooling Water System. Type Water temperature in tail race Twin circuit ~20C
The twin circuit cooling water system shall provide cooling water to the following systems: Generator air coolers Coolers of bearings Coolers of governor oil Cooling for the air circulation units (Transformer gallery) Connection for the Shaft seal on the secondary side The cooling water system is provided with pumps (one on duty, one stand by), booster pump, plate heat exchanger, self cleaning filters, valves, pressure switches, etc.
The water is taken in the tail race bay or draft tube, further downstream the return line is drained back to the tail race. The maximum water temperature of the water leaving the heat exchanger on the secondary side shall be <30C. For the HVAC system a separate cooling system shall be provided.
2.7 2.7.1
Drainage and dewatering system Design requirements and assumptions The amount of water and rain and the area which will be drained to the access tunnel and the cable gallery has to be determined later. The data indicated below are based ob rough estimations.
2.7.2
Description of equipment Capacity Dewatering system Capacity Drainage system ~ 25 l/s ~ 20 l/s
A drainage system for all the tunnels, galleries and the power house cavern shall be provided. The sump and the corresponding pumps shall be designed for the worst possible down pour in the Santa Rita area. The dewatering system shall be sized in order to empty one unit entirely in at least 15 hours. Each sump, the drainage and the dewatering sump shall be equipped with at least 3 submergible pumps, two on duty and one stand by. 2.8 2.8.1 Low pressure compressed air system Description of equipment Number low pressure compressed air systems capacity Number of compressors Nominal pressure Air receiver volume 1 ~ 100Nm3 / h 2 8 bar 4m3
The low pressure compressed air system shall be provided for the powerhouse cavern. It is foreseen to provide oil free compressed air to the following purposes:
3 air accumulators for generator brakes and inflatable maintenance seal 3 tapping points on each elevation 3 tapping points for erection bay 4 tapping points for workshops
2.9 2.9.1
Fire detection, alarm and fighting system Description of equipment The fire fighting system shall consist in: Smoke and heat detectors spread over the entire power cavern area, access tunnel, cable gallery and control room area. Automatic fire alarm system CO2 extinguishing system for generators Automatic high velocity water spray system for transformers Fire hydrant in power house area Portable fire extinguishers, on each floor at the stair case and nearby hazardous equipment. The water spray system shall be provided with fire fighting water either from an elevated tank, or from pressure accumulators. The amount of water shall be enough to extinguish and cool one transformer, according to the NFPA standard.
The corresponding pumps shall be driven from two independent power sources. All equipment for the fire fighting system shall be in full accordance to the regulation given by NFPA.
2.10 2.10.1
Air conditioning and ventilation system Climatic condition Climatic conditions provided by SENAMHI (Oficina General de Estadsticas e Informtica) show the following values for the station Tembladera, which is meteorological comparable to the Santa Rita site:
Relative humidity at 7 am: Jan Max min 98 90 Feb 98 91 Mar 98 92 Apr 98 92 May 98 91 Jun 98 91 Jul 98 93 Aug 97 93 Sep 97 91 Oct 96 na Nov 97 91 Dec 97 91
Relative humidity at 1pm: Jan Max min 92 66 Feb 89 72 Mar 90 71 Apr 90 72 May 94 71 Jun 94 63 Jul 92 65 Aug 89 63 Sep 89 66 Oct 89 na Nov 87 68 Dec 89 71
Monthly average temperature: Jan Max min 30.2 19.1 Feb 30.1 19.6 Mar 30.3 19.9 Apr 31.2 18.2 May 30.9 15.4 Jun 30.1 14.3 Jul 29.1 12.5 Aug 28.6 12.9 Sep 29.0 14.0 Oct 30.1 14.8 Nov 30.0 15.7 Dec 30.7 17.8
For the design of the air conditioning and ventilation system the following design data shall be used: Ambient Temperature to be considered: 10C - 32C Required Temperature in Cavern: Required rel. Humidity of supply air: 2.10.2 Min 18C Max 26C 70%
Detailed scope and description of equipment The capacity of the air handling unit shall be ~100000m3/h. The air handling unit consists in the outside air duct through the access tunnel, mixing box, filter unit, compressor type air cooler, fresh air fan, exhaust air fan, air distribution system with all required ductwork, fire dampers, louvers, grills, etc. The battery room shall be provided with an exhaust system, directly carrying the exhaust air to the outside.
The Cavern shall be provided with a forced, reciruclating exhaust ventilation system. Recirculation rate shall be adjustable in order to minimize energy consumption. The generator pit shall be provided with an evacuation system, to be used after having released the CO2 extinguishing system. In the transformer niches air circulation units with air/water heat exchangers shall be provided. A heat and smoke ventilation system shall be provided for the power house cavern. A separate smoke and heat ventilation fan plus the ducts through the cable gallery shall be provided, designed for 2-hours resistance to temperatures up to 600C. The capacity of the ventilator shall be 50000m3/h. In connection with the fire fighting system the cavern area shall be divided into fire compartment. Wherever ducts are crossing segregation walls in between fire compartments fire dampers need to be provided. The access tunnel shall be built as fire compartment, properly isolated from the cavern in order to use it as escape route. For the same reason stairwell(s) used as escape route shall be pressurized. All equipment for the fire fighting system shall be in full accordance to the regulation given by ASHRE. 2.10.3 Reference Value for Air Handling Unit To be included in the offer, according to ASHRE Standard: Air flow capacity Main Air handling unit Filter according to Eurovent-Standard Capacity cooling coil fed with cooling water 95'000m3/h G3 and F5 ~150kW
Capacity cooling coil fed with approved non Ozone depleting ~200kW refrigerant for dehumidification Heating coil for recuperation of condenser waste heat heating coil Fire compartment shall be: Access tunnel, cable gallery, Transformer niches, Diesel, Battery room, Workshop, Oil depot, etc. ~70kW
2.11 2.11.1
Oil treatment plants Description of equipment For the filtration of the transformer oil, governor and bearing oil, suitable treatment facility shall be provided. It shall be mobile and equipped completely, with oil evacuation pumps, degasser, heaters, filters, connecting hoses, corresponding tank, etc. Capacity for transformer oil treatment: ~1000 l/hour Capacity of bearing oil and governor oil treatment plant: ~250 l/hour
2.12 2.12.1
Electric overhead travelling crane for cavern Description of equipment The lifting capacity of the main hook is given by the heaviest part of the generator. Type Capacity main hook Capacity auxiliary hook Electrical overhead travelling crane ~ 250t ~ 20t
The overhead travelling crane shall be a double girder bridge crane provided with portable radio control unit. Auxiliaries necessary for lifting, such as lifting beam are part of the scope of supply. The crane shall be fully in accordance with the regulation given by FEM. 2.13 2.13.1 Mechanical workshop Description of equipment The mechanical workshop shall be equipped in order to allow doing all regular maintenance jobs.
3 3.1
ELECTRICAL WORKS Scope of electrical works The scope of the electrical work is as follows: Generator with auxiliary equipment Isolated phase bus duct (IPB) Generator terminal and neutral grounding equipment Static excitation system with automatic voltage regulator (AVR) Generator circuit breaker with isolator Current and voltage transformers (CTs, VTs) for protection, measuring & metering and synchronisation Synchronisation equipment for generator circuit breaker and high voltage breaker Measuring & metering system Unit transformer with on load tap changer (OLT) Generator and transformer protection system Medium and low voltage auxiliary transformers for power house and remote service area Medium voltage distribution system to remote service area Medium and low voltage switchgear with associated distribution systems Battery with battery chargers and DC switchgear Uninterrupted power supply (UPS) with static bypass system Lighting system for power house and control building Power plant grounding and lightning system Cabling (power and signal connections) Distributed control system (DCS) for power plant and high voltage switchgear with HMI/SCADA and communication equipment High voltage switchyard 230 kV
3.2 3.2.1
Generator with auxiliary equipment Design requirements and assumptions The power and speed of the generators are dictated by the turbine and the hydraulic conditions. The generators shall be designed, manufactured, erected and tested according to IEC 60034 standard.
3.2.2
Scope and description of equipment Number of generators Type Rated capacity Power factor Rated generator voltage No. of phases Frequency Nominal speed Insulation class for stator and rotor Permissible temperature rise Efficiency Generator grounding 3 Vertical Synchronous 110 MVA 0.85 13.8 kV 10% 3 60 Hz 3% 360 or 400 rpm class F according to class B > 98% Star point grounded through grounding transformer or alternatively through resistor
Cooling system The generator ventilation system shall be of closed air circuit type. The whole generator shall be enclosed in an airtight housing. Braking system The system shall enable braking in order to quickly slow down the rotating parts from 20-30 % of rated speed during shutdown sequences. This quick slowdown shall ensure protection of the thrust bearing by limiting the duration of critical load on the oil film. Insulation and temperature rise limits The stator and rotor pole windings shall be of epoxy resin impregnated type pertaining to class F insulation.
At rated output the generator stator and rotor winding temperature rises shall not exceed the limits for class B insulation, while at overload conditions (107% of rated output) maximum generator stator and rotor temperature rises shall not exceed the limits according to class F insulation. Short-circuit withstand capability The generator shall be capable of withstanding a three phase short circuit test at the generator terminals when operating at rated MVA and power factor with 5% over voltage for a period not less than 3 sec. Quality of stability and performance The generator shall operate satisfactorily in parallel with each other and with other machines connected to the grid. The generator shall be able to operate on sudden application/or loss of maximum load and during momentary short circuits and sustained ground faults without causing any abnormal vibration or resonant conditions. The generator shall be capable of operating continuously on an unbalanced system such that with none of the phase currents exceeding the rated current, the ratio of negative sequence component of current (I2) to the rated current (In) does not exceed 0.08 and under fault conditions shall be capable of operation with the product of (I2/In)2 and time in seconds (t) not exceeding 20. Runaway speed withstand capability The generator shall be designed and constructed to be capable of operating for a period of fifteen (15) minutes at runaway speed (with cooling water flow intact). Guarantees on efficiency The rated and maximum output of the generator shall be guaranteed (within the limits of temperature rise specified) at rated power factor and at any voltage and frequency in the specified operating range. Also, the efficiencies of the generator shall be guaranteed at specified output levels up to the maximum continuous overload output. Individual losses shall be established using suitable method as per IEC 60034-2 and the efficiencies shall be determined according to IEC 60034-2. Standards The generators covered under these specifications shall conform to the applicable, latest edition of the following standards: International Electro technical Commission IEC particularly IEC 60034 Rotating electrical machines
Alternatively, applicable standards from one of the following standards agencies may be substituted: ANSI IEEE ISO American National Standard Institute Institute of Electrical and Electronics Engineers International Organization for Standardization, particularly
ISO 10816-1 and 7919-5 regarding mechanical vibration NFPA National Fire Protection Association, particularly for fire protection system.
3.3 3.3.1
Isolated Phase Bus Duct (IPB) Design requirements and assumptions The buses shall be isolated phase type, with each phase conductor and all other components of each phase completely enclosed in a metallic enclosure separate from the enclosures of the other two phases. Each phase conductor and its enclosure shall be arranged concentrically round in the form of aluminium tubes, insulated from each other by air and moulded resin/porcelain insulators. The buses will serve as the connections among the circuit equipment at generator voltage, including the generator circuit breaker, the main transformers, the potential transformer and surge protection groups; station service transformer and excitation transformer. The buses and all the circuit components shall meet the continuous overload rating of the connected generators. The enclosures of each phase bus should be short circuited across the three phases at both ends of the bus run. This will facilitate current flow (in the opposite direction to the conductor current) in the enclosure with magnitudes running as high as 95 % of the conductor current, depending on the system configuration and the impedance of the short circuit connections between the enclosures. All equipment shall be designed and tested to satisfy the requirements of the latest applicable IEC- and ANSI/IEEE-Standards.
3.3.2
Description of equipment Number of systems Rated voltage Maximum voltage 3 13.8 kV 17.5 kV
Power frequency withstands voltage Lightning impulse withstands voltage (1.2/50 s) No. of phases Rated current Temperature rise for conductor Temperature rise for enclosure Layout of bus ducts and associated equipment
38 kV 95 kV 3 5 000 A 65 oC 40 oC
Isolated phase bus ducts through seal off bushings will run from generator terminals to the transformer terminals. Current transformers for metering and protection will be mounted in the run of bus ducts from generator to the transformers or alternatively in the generator circuit breaker enclosure. Isolated bus ducts through seal off bushings will emanate from neutral terminal cubicle and will be connected to neutral grounding cubicle after forming the neutral. CTs for protection and metering will be mounted in the run off bus duct before formation of neutral. Surge arrester and VT cubicles (LAVT cubicle) This cubicle would house equipment for surge protection of the generator and other equipments. Alternatively the surge arrestors and VTs can be fitted inside the generator breaker enclosure. Excitation transformer cubicles This cubicle is included in the section on generators and excitation system as a part of the static excitation scheme. The tap off bus ducts for connection to excitation transformer cubicle will be provided together with the main bus ducts. Station service transformers and its cubicle The station service transformers, connected to the isolated phase bus ducts of Unit 1 and Unit 3, and their metallic cubicles will be provided together with the isolated phase bus bars, including the necessary tap offs.
3.4 3.4.1
Generator neutral grounding Design requirements and assumptions The generator neutral shall be grounded either via a dry type single-phase power transformer or via grounding resistor.
3.4.2
Description of equipment If a transformer is used, the secondary winding of this transformer shall be loaded with resistors. The following design parameters shall be considered: The knee point primary voltage shall be not less than 130% rated system voltage. The insulation level shall be adequate for rated system voltage. The grounding current shall be limited to approximately 10A. The short time rating shall be 30 sec. The transformer capacity shall be based on maximum voltage and maximum possible current with the secondary loaded as specified. The continuous transformer rating shall match with the maximum possible star point current at normal operation. If the generator neutral is grounded via resistor, the rating shall be approximately 850 for grounding current of approximately 10A. The short time rating shall be 30seconds. The following requirements are valid for both options. All additional equipment as required to enable 100% and 95% stator ground fault protection shall be coordinated with the supply of the protection equipment and shall be installed in the neutral grounding cubicle. Steel sheet cubicle for accommodating the neutral isolating link, distribution grounding transformer and secondary loading resistor, etc. or grounding resistor shall be supplied.
3.5 3.5.1
Static excitation system with automatic voltage regulator (AVR) Design requirements and assumptions The excitation system shall be capable of continuously supplying the maximum excitation power required to produce 107% of rated output, at rated generator voltage, rated power factor and 48.5 Hz frequency, plus an additional capacity of ten (10) percent. With 80% generator voltage, the excitation system shall be capable of providing a current, to the field, of not less than 1.6 times, the rated field current, for at least 10 seconds. The excitation system shall use AC power directly from the generator output leads through a high performance dry type transformer. The system shall be able to control the generator terminal voltage under all operating conditions and facilitate joint control.
The excitation system shall be capable of reversing its output voltage in response to a control signal in order to minimize generator iron burning in the event of generator fault. The equipment shall be capable of withstanding lightning and switching surges and dynamic over voltages to which they may be subjected to and shall conform to the latest issue of IEEE 421 or equivalent standard. Over voltage protection shall be by means of crowbar type. The excitation system shall provide suitable local indication of the main variables and shall contain all necessary protection and limiting functions, such as loss of excitation, minimum field current, maximum stator current and maximum field current. 3.5.2 Description of equipment Excitation transformers Three phase power shall be obtained through a three phase, self cooled, indoor, metal cubicle enclosed, cast resin type transformer connected to the isolated phase bus ducts. Full rated capacity taps on the high voltage winding shall be provided to accommodate the complete range of operation. Segregation between the HV terminals in the cabinet shall be provided. Power rectifier Power rectifier bridges shall be silicon controlled type and the number of bridges shall be such that one bridge is always available as redundant (n-1 configuration). Field flashing equipment The power for field flashing equipment shall be taken from 400 V, 3 phase, 60 Hz auxiliary supply and alternatively from the station 220 V DC supply. Voltage regulator The excitation equipment shall be provided with a complete system for manual and automatic voltage regulation (AVR), excitation control and indication. The excitation system shall be controlled by fully redundant, dual channel; micro processor based digital Automatic Voltage Regulators. The voltage regulator shall have following additional features: Reactive power control function devices to ensure satisfactory load sharing during parallel operation of the generators, alternatively a power factor regulator must be selectable. An adjustable minimum excitation limit device having characteristics to closely match the generator capability curves (rotor angle limiter or P/Q-limiter).
An adjustable maximum excitation limiter device (field current limiter). An adjustable maximum stator current limiter. Adjustable V/Hz limiter, preventing over fluxing of unit transformer and connected VTs and CTs. Follow up circuit for bump less changeover from "Auto" to "Manual" mode and viceversa. Line drop compensation. Power system stabilizer. Excitation control. The voltage regulating and excitation control equipments shall be suitable for local, manual and automatic control. Interfacing with control and monitoring system. The microprocessor voltage regulating and excitation control equipment shall be capable to communicate via serial interface with the unit control computers. Cooling of thyristors The equipment shall be cooled by forced air. For this purpose, 100% capacity reserve fans shall be supplied. Protection of static excitation equipment The excitation equipment shall be protected against internal faults, failure of thyristor bridges, cooling fans etc., for which signals shall be provided for alarm and shut down of the unit.
3.6 3.6.1
Generator circuit breaker with isolator Design requirements and assumptions Circuit breakers of SF6-gas or vacuum type, 3-phase, segregated poles, shall be used. The circuit breaker shall be trip-free and anti-pumping and shall be capable of operating under the range of ambient temperatures in the powerhouse. Only three phase operation shall be allowed. A stored-energy mechanism including two 220 VDC trip coils shall be furnished for each circuit breaker complete with all control equipment, inter phase pipe work (as far
as applicable) and internal wiring. The only external requirement for operation shall be electrical auxiliary supplies of 220 VDC and 400 VAC. For purposes of inspection and adjustment, means shall be provided to permit local operation of the circuit breaker. The disconnecting switch shall be air-insulated, motor operated and enable mechanical operation by hand. Each phase assembly shall be integrated with the specified circuit breaker into the enclosure forming a section of the isolated phase bus. The disconnecting switch shall be remote and local controlled and shall be interlocked with the circuit breaker. The grounding switches shall be rotary blade types, air-insulated, motor operated, enable mechanical operation by hand and shall also be integrated with the circuit breaker and the disconnect switch into the same enclosure. Grounding switch operation shall be remote and local controlled and interlocked with the generator circuit breaker and the disconnect switch. The grounding switch shall be of the quick acting type, capable for making current. Voltage and current transformers can be installed in the generator circuit breaker cubicle if required. 3.6.2 Description of equipment Number of circuit breakers Rated continuous current Rated symmetrical interrupting capability (minimum) Rated asymmetrical interrupting capability No. of phases Type of cooling Ratings of disconnecting and grounding switches 3 5 000 A to be defined later to be defined later 3 air, natural consistent with circuit breaker ratings
3.7
Current and voltage transformers for protection, measuring & metering, synchronisation Design requirements and assumptions Cast resin type current and voltage transformers shall be provided as shown on the single line diagram. The current transformers shall be mounted in the run of bus ducts and tap of buses. The transformers shall conform in all respects to the requirements of IEC 60044.
3.7.1
3.7.2
Description of equipment Current transformers The primary winding shall be adapted to the actual design of the circuit and shall withstand the specified through fault current without damage. The secondary terminals shall be brought out in a separate compartment for easy access and provision shall be kept for shorting the current transformers secondary terminals. The assignment of the current transformers is shown in the generator and transformer protection and measuring scheme. Voltage transformers Miniature circuit breakers MCB for the protection of the secondary circuits shall be provided and installed in the terminal boxes. The MCBs shall be equipped with auxiliary contacts for signalization of tripped and manually opened MCB.
3.8 3.8.1
Synchronisation and measuring & metering system Design requirements and assumptions Synchronisation and measuring and metering systems can be delivered as one system (cubicle) in order to reduce wiring from and to VTs.
3.8.2
Description of equipment The synchronizing device has to be a dual channel system. The dual channels have been configured such that each channel can operate as an automatic synchronizer. Normally both channels operate in parallel and compare their operational status. In case of discrepancies between the two channels, synchronizing is interrupted. After locating the fault locally, it is possible to continue synchronizing with the correct functioning channel (switchover has to be carried out locally). For synchronisation the voltages before and after the breaker which has to be synchronised are measured and fed to synchronising unit. The synchronisation is carried out when the required criteria for e.g. actual slip and variation, voltage difference, closing angle, system voltage and frequency variation are satisfied. During synchronisation process, the synchronisation process send raise/lower commands to the governor of turbine and raise/lower commands to the AVR of generator. Each unit is equipped with its own synchronization unit which allows synchronizing alternatively the generator circuit breaker or the associated HV breaker.
The measuring & metering system serves for data acquisition of all electrical signals as generator voltage, generator current, frequency, power factor, imported and exported active and reactive power.
3.9 3.9.1
Unit transformer with on load tap changer (OLT) Design requirements and assumptions Three 3 phase, two windings, oil-immersed transformers will be used as unit transformers. The transformers will be installed in separate niches inside the powerhouse; therefore they will be cooled by an oil-forced, water-forced (OFWF) cooling system.
3.9.2
Description of equipment Number of unit transformers Cooling system Rated capacity Rated voltage On load tap changer Frequency Impedance voltage at main tap Type of connection 3 Oil forced-water forced (OFWF) 110 MVA HV - 240 kV LV - 13.8 kV
5
2.5%
60 Hz 12 % Ynd1
3.10 3.10.1
Generator and transformer protection system Design requirements and assumptions The electrical protection for the generating unit shall trip the generator breaker, the main breaker, the excitation/field breaker and shut down the generating unit, according to the sequence as applicable (quick shutdown, emergency shutdown). The protection shall give alarm and tripping indications to the alarm annunciation system. In order to ensure the reliability the protection is divided in a primary and a backup system. The protection functions are divided in such a way that one system covers the primary functions while the relevant backup functions are covered in the other system and vice versa. Each system has its own electronic modules installed. The two systems
are designated as 'System A' and 'System B' and have separate setfiles. In case of failure or disturbance of one system an alarm signal will be sent to the control system and a new start of the turbine is blocked. It is recommended to shut down the turbine as soon as possible. If both systems fail a GCB trip resp. HVCB trip will be initiated by the control system. The protection relay scheme shall consist of two separate groups, Main Protection I and Main Protection II. Each group shall be supplied from a separate DC feeder. The relays of each group shall be placed in separate cubicles. 3.10.2 Description of equipment Generator protection system The following protection relays or protection functions shall be provided as indicated in the protection single line diagram and enlisted hereafter: Generator under impedance protection Generator reverse power protection Generator loss of excitation protection Generator negative phase sequence protection Generator overload protection 21 G 32 40 46 49 G
Generator undervoltage controlled definite time overcurrent protection 51 Generator excitation transformer overcurrent protection Generator under-/overvoltage protection Generator rotor ground fault protection Generator stator ground fault 95% protection Generator stator ground fault 100% protection Generator differential protection Generator-transformer block differential protection (3 leg) Generator breaker failure protection 51 EXC 59/27 64 R 64 S - 95% 64 S - 100% 87 G 87 B 50 BF
Unit transformer protection system The following protection relays or protection functions shall be provided as indicated in the protection single line diagram and enlisted hereafter:
Transformer overload protection under impedance protection Transformer restricted earth fault protection Transformer differential protection Transformer Buchholz protection
49 T 64 T 87 T 63
Medium voltage auxiliary transformers The protection of the auxiliary transformers shall be integrated in the main transformer protection and shall comprise the following protection functions: Transformer instantaneous overcurrent/ground overcurrent protection 50/50N Transformer time delayed overcurrent/ground overcurrent protection 51/51N
3.11 3.11.1
Auxiliary transformers Design requirements and assumptions Medium voltage auxiliary transformers for powerhouse auxiliaries Two 3000 kVA, 13.8/0.4 kV, 3 phase indoor, cast resin type auxiliary transformers shall be provided for the generating units 1 and 3. The winding material shall be electrolytic copper and full capacity off circuit taps shall be provided for each transformer for + 5% voltage variation in steps of 2.5% each. The transformer shall comply with IEC 60726. Steel sheet cubicle for accommodating the auxiliary transformers shall be provided. Medium voltage auxiliary transformers for remote area auxiliaries One 100 kVA, 0.4/13.8 kV and one 100 kVA, 13.8/0.4 kV 3 phase indoor, cast resin type auxiliary transformers shall be provided to supply the consumers on the 400 VAC level at the weir and intake. One of them is located in the powerhouse, the second is located at the remote service area.
3.11.2
Description of equipment Medium voltage auxiliary transformers for powerhouse auxiliaries Number of unit transformers Cooling method 2 Air
Rated capacity Rated voltage Off load tap changer Frequency Type of connection
3.0 MVA HV 13.8 kV LV - 0.4 kV

2
2.5%
60 Hz Dyn1
Medium voltage auxiliary transformers for remote area auxiliaries Number of unit transformers Cooling method Rated capacity Rated voltage Off load tap changer Frequency Type of connection 1 Air 0.1 MVA Primary 13.8 kV Secondary - 0.4 kV
2
2.5%
60 Hz Dyn1
Number of unit transformers Cooling method Rated capacity Rated voltage Off load tap changer Frequency Type of connection
1 Air 0.1 MVA Primary 0.4 kV Secondary 13.8 kV

2
2.5%
60 Hz Dyn1
3.12 3.12.1
Low voltage 400 VAC switchgear Design requirements and assumptions The switchgear system shall be solidly grounded, five wires (3 phases +N +PE). Each distribution board shall have at least two fully wired spare feeders of various standard current ratings. For local instrumentation voltmeter (busbar) and ammeters for infeeds and main outgoing feeders shall be incorporated. In the main distribution board all outgoing feeders shall be equipped with ammeters. Main distribution board The LV distribution board shall be divided into the following four sections: Bus 1N (normal supply) Bus 2N (normal supply) Bus 1E (essential supply) Bus 2E (essential supply) Each of the buses 1N and 2N will be connected to one low voltage auxiliary transformer. The bus 1E and 2E will be connected to bus 1N/2N and the emergency diesel generator in the powerhouse. The single buses for normal and essential supply can be connected via tie breakers. Each one of the important distribution boards / motor control centres (MCC) for the units, powerhouse services, lighting and small power, cooling water systems, drainage and dewatering, low pressure compressed air system, fire fighting, ventilation and air condition, switchyard, shall be connected to bus 1N or 2N as well as to bus 1E respectively 2E through withdrawable remote controlled circuit breakers. Less important distribution boards such as the workshops may be connected to busbar section 1N and / or 2N only. For the double supplied distribution boards / MCC interlocks between the respective feeding circuit breakers shall prevent paralleling of the bus sections. Each busbar section shall be equipped with at least two spare feeders. Unit Distribution Boards / Motor Control Center (MCC) Each generating unit shall receive its own distribution board UDB, located at the generator floor. The UDB shall supply the 400 VAC consumers such as hydraulic turbine governor, cooling water pumps, high pressure lubrication oil pump, start
excitation, air dryers, brake dust collection, brush gear dust collection, main transformers, etc. Powerhouse Service Distribution Board The common consumers in the powerhouse such as the chargers of 220VDC, Uninterrupted Power Supply, powerhouse crane, oil purification, workshop etc. shall be supplied through the powerhouse service distribution board. Remote Area Service Distribution Board At the remote service area (reservoir) a distribution a 400 VAC indoor switchgear must be foreseen in order to supply all electrical consumers such as radial gates, intakes desanders etc. The equipment under this section shall comply with the provisions and requirements of the latest approved recommendations of the International Electromechanical Commission (IEC), each as they apply.
3.12.2
Description of equipment The rating, insulation levels and test voltages of equipment and devices in the system shall be as follows: Nominal voltage Rated frequency Rated power frequency withstand voltage 60 s Rated current of distribution boards 400 V 60 Hz 2500 V 3600 A 630 A The actual value may be adapted during detail design 35 kA 40 kA 90 kA 40 kA 90 kA
Rated short time withstand current busbar 1 s and boards Rated circuit breaker short circuit breaking capacity Rated circuit breaker peak short circuit current Rated MCCB short circuit breaking capacity Rated MCCB peak short circuit breaking capacity
55 kA 80 kA 135 kA 80 kA 135 kA
3.13 3.13.1
Batteries A+B 220 VDC with battery chargers and DC switchgear Design requirements and assumptions The 220 V DC systems shall mainly supply the control circuits (e.g. switching function), protection circuits (e.g. tripping function) in the powerhouse, generator field flashing equipment (if not AC supplied), main transformers and the uninterrupted power supply (UPS). All relevant equipment feed from the powerhouse 220 V DC system shall be connected to the distribution board by two parallel cables. For decoupling of the two circuits isolating diodes shall be installed at equipment side. The 220 V DC system shall be fed from the powerhouse essential distribution board. Each battery assembly shall be capable of supplying successfully the load connected to it, at maximum load, for at least 10 hours without recharge. In case of failure of one rectifier or one battery, the remaining rectifier and battery shall supply the total power which might be necessary within tolerable voltage and ripple limits. The capacities of the batteries and the ratings of the given in this specification are estimated values. The Contractor shall make detailed calculations based on the actual power consumption of the connected equipment. The final allocation of the consumer to DC feeders shall be realized during detail design. Ratings, characteristics, tests and test procedures, etc. concerning the 220 V DC systems, shall comply with the provisions and requirements of the latest IEC Publications, each as they apply.
3.13.2
Description of equipment Batteries The batteries shall be of the totally sealed and maintenance-free lead acid type. Each 220 V DC battery assembly shall consist of 108 battery cells. The battery shall be designed for maintaining the charging voltage at 2.23V per cell. Each battery assembly shall be complete with racks, connections between the cells and a cable terminal box containing the battery fuses (2 poles). Adequate alarm devices (with auxiliary contacts for remote indication) shall be provided with the battery fuses in order to indicate the blow of a fuse. For each battery room an eye washing station shall be included in the scope of supply.
Battery chargers The battery chargers shall comply with the following technical requirements: Dry type transformers and static type rectifiers shall be used throughout. Each battery charger shall be fed from the 400 VAC service distribution board by means of a separate cable. On DC side the battery chargers shall be connected with the corresponding battery in parallel to the respective DC distribution busbar. The chargers shall be completely equipped for a fully automatic and controlled charging and floating charge of the batteries, and shall be of the constant voltage type with current limiting devices (IU-characteristic). The chargers shall be suitable for supplying the load and charging the battery simultaneously. The chargers shall be suitable for supplying the load within their capacity, without having to rely on the battery and within tolerable voltage and ripple limits. Complete control and supervision equipment such as circuit breakers, ampere and voltmeters shall be incorporated with each charger. Adjustable alarm devices shall be provided with potential free contacts wired to terminals for overvoltage, undervoltage, ground fault, availability etc. Distribution boards Sectionalized DC distribution boards with each section connected to one battery and one charger shall be provided for the systems. All main DC loads are connected to one common distribution board which will be fed via diodes from both battery systems. The distribution boards shall be metal-clad indoor cubicle of the withdrawable unit design. It shall be provided with separate base frame fixed to the concrete. The high of the frame shall be adapted to the individual design of the floor, e.g. directly mounted on the concrete or with a higher frame in connection with sub floors. The distribution boards shall be equipped with load break switches, circuit breakers and miniature circuit breakers as required for the incomings as well as for the outgoing feeders to supply the various DC power requirements. No fuses shall be used. Tripped breakers shall generate grouped alarm for indication in the plant control and monitoring system. All feeders to and from the cubicle assemblies will be cables. The assemblies shall be accessible for the cables from above or from the bottom to each feeder via separate cable compartment. If cables are mounted from above, dust protection shutters shall be provided. Each distribution board shall have at least two fully wired spare feeders of various standard current ratings.
For local instrumentation voltmeter (busbar) and ammeters for infeeds and main outgoing feeders shall be incorporated.
3.14 3.14.1
Uninterrupted power supply (UPS) with static bypass system Design requirements and assumptions The UPS system consisting of a static inverter connected to the 220 V DC system with an electronic by-pass and a service by-pass from the 400 V AC powerhouse service distribution board. The UPS system serves essential consumers in the power house mainly of the control system (such as PC's, monitors, printers, etc), motor-pumps and emergency lighting. The final allocation of the consumer to UPS feeders shall be realized during detail design. Ratings, characteristics, tests and test procedures concerning the UPS system, shall comply with the provisions and requirements of the latest IEC Publications, each as they apply.
3.14.2
Description of equipment The static inverter shall be suitable to feed continuously the essential 400/230 V AC consumers. The inverter shall be equipped with an electronic by-pass and a service by-pass and all accessories for uninterrupted power supply. The inverter panel shall also include: Instruments for output voltage, current and frequency Alarm indication on the panel front. Complete control and supervision equipment such as circuit breakers and instruments for current, voltage and frequency shall be incorporated in the system. Adjustable alarm devices for availability etc. shall be provided with potential free contacts wired to terminals.
3.15 3.15.1
Lighting system for power house, transformer niches and control building Design requirements and assumptions Indoor lighting shall mainly cover the following areas:
Powerhouse cavern Transformer niches Access gallery Cable gallery Switchyard control building Outdoor lighting system shall cover the following areas: Outside area of underground power station, switchyard, walkways, approach road to power station up to 500 m Outdoor area at power intake structure The supply for the illumination system for power station and outside area thereof shall be taken from the main lighting board. The supply for the illumination for outdoor area at power intake structure shall be taken from the local 400 V AC supply of remote service area. Emergency lighting DC system should be supplied through emergency lighting panel. Emergency lighting board shall be fed from DC distribution board. 3.15.2 Description of equipment All apparatus and materials supplied and all works carried out under this contract shall comply in all respect with the requirements of the IEC regulations. Service voltages: Normal lighting system Emergency lighting system AC socket outlets Power socket outlets Minimum Lux levels: General areas: Storage rooms Canteen Recreation and rest areas Changing rooms, washrooms and toilets Staircases Copyright Pyry Energy Ltd. 100 Lux 200 Lux 100 Lux 100 Lux 100 Lux three-phase, five wire, 400/230 V, 60 Hz two wire, 220 (48) V DC single-phase, three pins, 230 V, 60 Hz three-phase, five pins, 400/230 V, 60 Hz
Traffic routes for people in building Galleries Office areas: Offices Conference room (if applicable) Data processing area Equipment areas: Power station machine hall High and low voltage switching installations in building Mechanical equipment areas Control room Outdoor areas: Approach roads Dam crest Power intake Spillway gates Water storage reservoir for fire fighting
100 Lux 30 Lux 500 Lux 400 Lux 500 Lux 400 Lux 100 Lux 100 Lux 400 Lux 5 - 10 Lux 5 - 10 Lux 20 Lux 20 Lux 5 - 10 Lux
3.16 3.16.1
Power plant grounding and lightning system Design requirements and assumptions The design of the grounding system and of the lighting protection will be based on the following rules and standards: ANSI/IEEE Std. 80-1986 IEE Guide for Safety in AC Substation Grounding British Standard BS 6651: Protection of Structures Against Lighting and BS 7430: Requirements for Electrical Installations
3.16.2
Description of equipment Grounding system The primary grounding system required for the sound operation of the hydroelectric power project will include three main locations where local grounding grids shall be provided and all shall be solidly interconnected:
The underground powerhouse, consisting of the main cavern and the transformer niches, together with two adequately sized copper cables along the 230 kV cable gallery to the 230 kV Substation. The 230 kV Substation where the 230 kV cables will be connected and from where the 230 kV transmission lines will leave. The remote service area with intake, diversion weir and reservoir. Powerhouse and transformer niches Direct connection to the "neutral" superficial earthing does not exist in the underground works. However, the construction of a reinforcement cage in the concrete shall enable to built-up an "artificial" grounding system. For this purpose a mesh of interconnected reinforcement steels shall be constructed on each level of the main and the transformer niches, in the cable gallery, in the access gallery and in the draft tubes and tailrace tunnel. Each level will be interconnected by several raising reinforcement bars. On each level a sufficient number of connecting wall plates shall permit the connection of the interior secondary grounding ring system to the primary reinforcement grounding cage. All metallic parts shall then be connected to this secondary grounding system. The neutral points of the transformers and the HV cable shields shall be connected to the mesh below the transformers. 230 kV switchyard The grounding grid systems of the switchyard shall ensure low resistance grounding. The grounding grid for switchyard will have its conductors spaced approximately 6 meters apart in both directions. All embedded or buried intersections or tee connections in the grounding system will be solidly fused by an exothermic weld. All connections outside of earth will be screwed and easily accessible for control. All connections will be protected against corrosion. Wherever necessary, conductors for potential grading will be provided according to the applicable Standards. All ground cables shall be annealed bare copper cables, concentric stranded and in accordance with an acceptable Standard (ANSI/ ASTM B8, Class B or equivalent). Remote service area An embedded copper ring shall be installed around the location where the distribution transformer will be installed, providing at least two tails to/form a secondary grounding ring and to provide a grounding point for the equipment installed and all metallic parts.
Lighting protection For the underground powerhouse no means for lighting protection will be provided. For the 230 kV switchyard and for the remote service area all structures and buildings shall be provided with lighting protection by means of air termination network provided on the roofs, and on top of the concrete and steel structures. The 230 kV switchyard lightning protection shall be done through overhead earth wires. Same material (copper) as for the grounding system shall be used, as far as possible, for the lightning protection, unless there is potential hazard of electro-galvanic corrosion.
3.17 3.17.1
Cabling (power and signal connections) Design requirements and assumptions Voltage drops All power cables shall be dimensioned to stay below a 3 % voltage drop at nominal operating current. All cables will be laid on cable trays or in cable ducts, cable conduits, in ground, or properly attached with clamps to building structures. Cable trays The cable trays shall be designed to allow the laying of the cables on the trays from the side, without pulling through. All cable trays and fixing material shall be hot dip galvanized. All cable trays shall be properly grounded. Cable conduits Where cables are in danger of being mechanically damaged after installation or where the cable laying may present difficulties, ample sized cable conduits shall be used. Cable laying in general All cables shall in principle be laid in one single length. If it is not practicable to lay power cables in one length, approved connections shall be used. The cable routing shall be selected in a way to allow a complete segregation of high voltage power cables, of low voltage power cables and of control, measuring and signal cables. High voltage power cables of different systems shall be segregated in order to minimize mutual effects of short-circuits. Cable crossings in the same plane shall be avoided.
3.17.2
Description of equipment Minimum cross-sections/area All cables shall be designed to cope with the short circuit conditions, the applied protective system in respect to cross-section and number of strands. For mechanical reasons the cross-sectional area of cable conductors from E-copper shall not be less than: for measuring, control and communication cables secondary power cable main power cables 0.5 mm2 1.5 mm2 2.5 mm2
The cross-sectional area of the neutral and protective earth conductors in percentage of the phase conductor of all power cables shall be as follows: Phase conductor 1.5 - 16 mm2 > 25 mm2 Rated voltages and test voltages The rated voltage of the AC and DC power cables shall be 1/0.6 kV. The test voltages shall be as follows: Power frequency withstand voltage (factory test) Power frequency withstand voltage (site test) 3.5 kV 2.0 kV N-conductor 100 % 50 % PE-conductor 100 % 50 %
The rated voltage of the control, measuring and signal cables shall be 500/300 V. The test voltages shall be as follows: Power frequency withstand voltage (factory test) 2.0 kV
Standardization In order to minimize the required number of type of cables, all cables shall be standardized regarding their cross-sectional area, number of strands and marking of strands. Insulation materials All cables shall be at least flame retardant according to IEC Publication 60331 and 60332.
Armouring, shielding All cables and multiple-conductor control cables running outside of buildings shall be steel tape or flat steel wire armoured each as they apply considering also the mechanical forces for the cable laying. All armoured cables shall have an outer thermoplastic sheathing to prevent the armouring from corrosion. The armouring is also intended to avoid damages caused by rodents. All control and measurement cables shall be adequately shielded to avoid interference by parasite voltages.
3.18 3.18.1
Distributed control system (DCS) for power plant and high voltage switchgear Design requirements and assumptions This chapter specifies the requirements of all local and remote control systems in the powerhouse, the 230 kV switchyard and the ancillary plant areas which shall be suitable for manual and automatic start-up, running and shut-down of the generating units, the station auxiliary systems and the plant building systems. To achieve operation centralisation a Central Control Room (CCR) in the 230 kV switchyard is foreseen, from where all units and ancillary plant systems shall be operated and supervised. In the central control room data acquisition and visualization, event/alarm recording, trend data logging, generation of reports, data archiving, etc. shall be installed. In addition, it must be possible to transmit superposed signals to/from a National Control Centre (NCC) and/or a Regional Control Centre (RCC). The superior plant management will primary occurs by the NCC and RCC. The control and monitoring system shall be based on the decentralised intelligent principle. Control functions, supervisory functions, limiting functions and as far as appropriate alarm handling, event handling, data acquisition, trend data logging, etc. shall be executed by the local controllers. The control and monitoring system shall be built hierarchically. Malfunctions of upper systems must not influence subordinate systems. The software shall be accessible by the owner, modifications and parameter setting can be made at site as required. For operating principle shall be such that the nearer the operator is to the process, the superior is its operating priority. All control and communication devices shall be energised with two independent power supply modules each. They shall be fed by individual DC sources.
All software shall be safe on the controllers memory card (control program and all parameters for process control). In addition, safety copies of the latest updates shall be created and stored at the power plant. The control and monitoring system shall be designed for self supervision. Failures of local controllers or in the communication network shall be indicated in the SCADA system. The control of the units and unit ancillary systems shall be executed by the unit control boards (UCB). Local control from the UCB through push buttons (except for emergency shut-down) and / or touch screen is not envisaged. However, an interface shall be provided at each location of controllers and of turbine governor for plug-in of the mobile engineering/service station. Local control for tests and in case of disturbances shall be possible from this station, applying the same visualization pictures as at the operator workstations. All the rules for access through operator (log-in) and control hierarchy (local/remote) shall be realized by password according to the state-of-the-art. Control of individual equipment / components shall also be possible locally (through mobile station) as well as remotely (through operator workstation). The control and monitoring system, in particular the communications shall be of an open, non proprietary standard and comply with the latest International Standards. The signal transmission shall be redundant via a fibre optic cable ring. In addition to the interfaces at the respective control units, the design of the fibre optic bus shall enable the connection of the mobile engineering / service station at all relevant locations such as machine hall floor, generator floor, turbine floor, etc. All equipment provided and connected to the control and monitoring system shall be equipped with the necessary interfaces (communication port, remote terminal unit, I/O module, smart terminator, etc.). The type of interface shall be to best fulfil the respective requirements with regard to signal volume, reliability, maintainability, extendibility, etc. 3.18.2 Description of equipment The configuration of the distributed control system as well as the locations for the equipment will be defined during detail design. The Contractor may supply a control system according to his standard varying in certain details from the proposed design, if the main aspects of this specification are fulfilled. Unit control system The unit control system shall comprise: Synchronizing equipments Temperature measurement equipment,
and interface / incorporate the following systems: Excitation system Protection system Turbine governor Main inlet valve Hydraulic quantities measurement system Turbine and generator vibration monitoring Cooling water system Unit specific auxiliary systems Generator bus Main transformer AVRs / Tap changer control systems Station control system The station control system shall comprise: Automatic reservoir measuring and control system Joint active and reactive power control and interface / incorporate the following systems AC, DC and uninterrupted power supply systems including diesel generator set Communication system Drainage and dewatering system Low pressure compressed air system Fire fighting system Air-conditioning and ventilation system Draft tube gates Water measuring system
Switchyard control system The switchyard control system shall be completely integrated in the SCADA system in the central control room. The control system at the switchyard will interface / incorporate the following equipments: Switchyard control Switchyard protection Measuring systems Electric auxiliary AC and DC equipment Control system for remote service area The control system for the power intake, diversion weir and reservoir shall interface / incorporate the following equipment: Water measuring system Intake gates Spillway gates Electrical auxiliary AC and DC systems of power intake including diesel generator set Gateway for data exchange The Gateway shall serve as an interface between the power plant control and monitoring system (SCADA) and the superposed dispatch centre for control and data transfer. The capacity of the gateway shall enable the transfer of the most important data for the monitoring of the plant and for the setting of the superimposed control. Central control room (CCR) The normal operation of the power plant shall be executed from the central control room. All plant operations related to the power production, transformation, switchyard, transmission and the ancillaries shall be operated from video display units (VDU) associated with the fully redundant operator workstations. At each time both of the operator workstations shall have 100% the same information content allowing a take over of the control by the redundant unit without any disturbances, should one of the units fail.
Telephone system The entire power plant shall be equipped with a telephone system consisting of a main exchange and a sub exchange. This system shall take over the internal and external telephone traffic of the powerhouse, switchyard control building, remote service area etc. For the interconnection between telephone exchange in powerhouse and the communication facilities and all other locations, fibre optic cables shall be used where appropriate. All necessary modems, protection and other equipment shall be included in the supply. The individual types of extensions shall be as follows: Desk type for offices Wall mounted type for inside areas Heavy duty wall type for external areas Desk built-in types for control room and unit control boards The plant shall be equipped with one (1) telephone switchboard located in the central control room. This switchboard shall handle the complete telephone traffic. Every call from outside to an extension and vice versa shall be transferred via the switchboard. The switchboard shall contain, but not be limited to: Extension to switch into lines Call indicators Internal call indicators Meters for outside calls) Switching facilities Conference call establishing facilities Separate extension lines shall be reserved for the fax transmission. The fax units enable transmission of A3 and A4 size pictures. Sound hoods shall be installed for the wall mounted telephone extensions in the workshop and other noisy areas. The sound hoods shall be equipped with beacon lights for call receiving.
Clock system GPS clock system shall continually synchronize slave clocks throughout the power plant, and shall be capable of clock readouts in multiple time zones where desired. The system shall synchronize all clocks to each other. The system shall utilize GPS technology. The clocks shall be synchronized at least 6 times per day, and the system shall have an internal oscillator that maintains plus or minus one second per day between synchronizations, so that clock accuracy shall not exceed plus or minus 0.2 seconds. The system shall include an internal clock reference so that failure of the GPS signal shall not cause the clocks to fail in indicating time. The system shall be battery powered for at least 10 hours. The system shall incorporate a "fail-safe" design so that failure of any component shall not cause failure of the system. Upon restoration of power or repair of failed component, the system shall resume normal operation without the need to reset the system or any component thereof. Clock locations and types shall be as follows: Analogue type 1 2 1 Data (digital) type 1 The types of slave clocks are as follows: Analogue type with dial approximate 300 mm, one side indication, black figures on white ground, figures for hours, minutes, with pointers for hours, minutes and seconds. Data type with rectangular casing approximate 600x200 mm, one side indication, figures for days, months, hours and minutes, colour white. Arrangement of figures shall be preferably in two rows. Analogue type, big size, approximate 1200x1000 mm case dial approximate 900 mm, one side indication, flack figures on white ground, figures for hours, minutes, with pointers for hours, minutes and seconds. Radio communication system The walkie-talkie units shall be capable for direct two-way communication over a distance of at least 20 km and for communication via the telephone system. Copyright Pyry Energy Ltd. Location Machine hall floor (both ends) Office rooms Communication room Location Control room
The radio communication system shall cover the entire power plant area including powerhouse, switchyard and remote service area. The system shall operate on the basis of three frequency channels distributed from several stations and wire as antenna wire (support cable/antenna). The batteries shall be reloaded in reloading stations where the walkie-talkie units and/or the batteries shall be plugged-in to be recharged. To transmit the signals within the powerhouse and to the outside or vice versa, antenna rings shall be installed as required. The ring shall work as extended antenna for the walkie-talkie signals, necessary receiver/transmitter units shall be connected onto the ring according to the requirements of the system selected. The system shall be connected via an interface to the telephone system in the powerhouse. It shall be possible to dial a number code for the particular walkie-talkie and the system shall connect the telephone extension with the called walkie-talkie for a two-way communication. The control station and antenna shall be placed in the powerhouse. Video supervision system A video supervision system for the control room with cameras in the power house and at the reservoir shall be included in the scope of control system. The cables for the transmission of the video signals must be part of the scope. 3.19 3.19.1 High voltage switchyard 230 kV Design requirements and assumptions The switchyard will be located on a suitable flat area approximately 600m away from the power plant. The connection between the main transformers and the switchyard is made by three high voltage power lines, each circuit dedicated to one generating unit. Based on the solution of an underground powerhouse a surface type substation / switchyard is proposed The operation and control building is located at the 230 kV substation. The operator should have a complete view of the station from the control room. This building is equipped with all necessary facilities for the stations good functioning. 3.19.2 Description of equipment Nominal system voltage between phases Maximum system voltage between phases Rated short duration power frequency withstand voltage Copyright Pyry Energy Ltd. 230 kV 245 kV 850 kV
Rated lightning impulse withstand voltage Rated frequency
950 kV 60 Hz

Basic Design Report - Part 2 Rev 1 Oct 2007 PDF

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Basic Design Report - Part 2 Rev 1 Oct 2007 PDF

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Design Report

300927.01 October, 2007 Revision 1

Electricidad Andina S.A. Santa Rita Hydroelectric Project, Peru

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3 Spherical Valve 2.2 m 266 mWS 372.4 mWS 558.6 mWS

Control Quantity Copyright Pyry Energy Ltd.

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3.0 MVA HV 13.8 kV LV - 0.4 kV

1 Air 0.1 MVA Primary 0.4 kV Secondary 13.8 kV

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Rated lightning impulse withstand voltage Rated frequency

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