Tunnel Electrical Power Systems Design

8/6/2019 Tunnel Electrical Power Systems Design

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Clem7 Tunnel - IEAUST PresentationElectrical Power Systems DesignJuly 2010



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Introduction – Tunnel Mechanical &

Electrical Services

UGL Limited Infrastructure (formally ALSTOM) has a long history in the

Design and Construction of the Mechanical & Electrical Services / Processes

for both Road and Rail tunnels in Australia

The D&C business started in 1988 with the establishment of the Sydney

Harbour Tunnel Project

In New South Wales to date:

– Sydney Harbour Tunnel – M5 Tunnel – Eastern Distributor – Epping toChatsworth Rail Line – Lane Cove Tunnel

In Queensland to date:

– The Inner City Bypass D&C – South Eastern Busway C – The InnerNorthern Busways 4 C & 5 D&C – Boggo Road Busway Design C

There has been projects in both Victoria and Western Australia as well.



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Presentation Contents

– Design Objectives

– Systems Overview

– Incoming Energex Supply

– LV Systems Design

– HV Systems Design

– Substation Arrangement

– Cross Passage Arrangements

– Design Documentation

– Electrical Equipment

– Electrical Materials



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Design Objectives

– Perform all Electrical Engineering design requirements to meet the M&EPerformance Specifications for successful tunnel operations

– Electrical Design Reports

– Design Calculations

– Electrical Design _ Detail Design 50% _ DD80_Final Design

– Electrical Drafting

– Equipment Specification

– Construction and Installation Methods and Inspection and Test

documents

– Equipment Factory Acceptance Tests

– Cable Schedules, Installation and Termination Sheets

– Commissioning Procedures and Records documentation



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Systems Overview

– 2 off Incoming Energex 33kV supply rated @ 22MVA

Supply A @ Woolloongabba, Supply B @ Bowen Hills

– HV Redundancy via dual 22kV supplies to each of the 7 off Projectsubstations

– 22kV stepped down locally at each substation to 690V & 433V

– Loads shared across A & B supplies with 690V & 433V switchboards ineach substation

– Dual 690V / 433V supplies to each 690V & 433V switchboard automaticchangeover



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Systems Overview

– 690V : directly supplies significant plant system motors in vicinity ofsubstation

– 433V : general light & power and small motors

Submains distribution to XPs in vicinity of substation

Lighting / power / communications then distributed to devices in vicinity ofXP (≈ 116m)

– Local Energex power supplies to RSCs for surface related works

– UPS system provides “essential” power to “life-safety” devices



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Systems Overview



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Incoming Energex Supply

Negotiations with Energex established that 25MVA of capacity at 33kV would beavailable from both the North and South sides of the Brisbane River - these suppliesare detailed below

33kV Supply, 25MVA Connected Capacity

– ‘Supply A’ : Wellington Rd Energex Substation

Connected to Substation #1 @ SVO Site (Woolloongabba)

Reticulated @ 22kV from Sub#1 to Sub #7 via 5 off tunnel substations

Transformed (stepped down) from 22kV at each substation to 690V & 433V

– ‘Supply B’ : Victoria Park Energex Substation

Connected to Substation #7 @ NVO / TCC Site (Bowen Hills)

Reticulated @ 22kV from Sub#7 to Sub #1 via 5 off tunnel substations

Transformed (stepped down) from 22kV at each substation to 690V & 433V



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LV Systems Design

There are three separate areas of LV reticulation required for tunnel

operation

– In Tunnel, Lighting, Ventilation and Pumping systems

– External Ventilation Outlets, Waste Water Treatment, Fire Systems,

and Tunnel Control Centre

– External Road Lighting and Traffic control systems

All of these systems require supervision from the Tunnel OperationsControl System, the details of which are not included in this presentation



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LV Systems Design - Lighting

The Tunnel Lighting System – 433V 50Hz Supply

– Is configure as 6 switchable levels with L1 the highest luminance

intensity and L6 the lowest

– The tunnel entry portals utilize the higher levels with the level at any

particular time automatically selected to equal the light level external

to the tunnel

– Internal tunnel lighting is switched between the lower levels of 5 and

6, with 6 selected during the quieter hours of the morning

– Tunnel lighting is designated either essential or non-essential,

essential being approximately 30% of the total installation

– The essential lighting is powered from UPS supplied distributionboards whereas the non-essential is powered from normal supply



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LV Systems Design - Lighting

– Lighting is configured as alternately supplied, that is every second

luminaire is supplied from the A Supply with the alternate luminairefrom the B Supply

– There is approximately 850 individual luminaires in each of the North

bound and South bound tunnels

– The luminaires range in size from 150W, 250W and 400W with the

higher capacity luminaires used in the portal areas



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LV Systems Design - Ventilation

The Tunnel Ventilation System – 690V 50Hz Supply

– In Tunnel Jet Fans are Strategically placed throughout the tunnel

mounted below the smoke duct (roadway ceiling)

– There are a combination of both 30kW and 45kW 690V drives for this

purpose

– The majority of drives incorporate Reversing DOL motor starting withelectronic motor protection relays to allow monitoring of the drive

condition by the tunnel control system with the direction of flowdetermined automatically

– Electrically actuated (240V 50Hz) Smoke Dampers are mountedthrough the smoke duct as the passage to draw smoke from thetunnel in an emergency, essential supply



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LV Systems Design - Pumping

The Tunnel Pumping System – 433V & 690V 50Hz Supply

– In Tunnel Pump Stations are located at the 2 low points of the roadway

– There are pump stations at the North Portal, the SVO and CC01

– The stations include both Storm Water and Ground Water Pumps thelargest drive being 250kW 690V, utilizing a Soft Starter module

– Smaller size drives operate at 433V

There are 2 external to the tunnel, Fire Pump Stations that supply water tothe tunnel deluge piping main

– There is a combination of both 690V and 433V pump drives for thispurpose

All pumping operates automatically through process control systems



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Electrical Power SystemLV Systems Design – Ventilation Outlet Stations

The Tunnel Ventilation Outlet Stations – 690V 50Hz Supply

– There are 2 ventilation outlets one on the North the NVO with the SVO

at the South

– Each of these stations have 5 – Vent Fans that draw out the general

roadway emissions and 5 - Smoke Fans that draw out smoke in an

emergency through the smoke duct

– The Vent Fan capacities are 400kW at the SVO and 450kW at the NVO

– Smoke Fan capacities are 650kW at both stations

– All of these drives are 690V Variable Frequency Drives.

Front End Harmonic Filters are included with these drive arrangements



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LV Systems Design – Electrical

Distribution

The LV Systems presented above are duplicated throughout the length ofthe tunnel (4.5km) with Electrical Distribution Substations established at

1km intervals approximately plus there are 2 above ground substationsassociated with each of the vent stations, a total of 2 above ground and 5 intunnel, having the following features

– An ‘A’ LV switchroom & ‘B’ LV switchroom is provided for each

substation

– Each switchroom has a 690V and 433V switchboard

– An ‘A’ & ‘B’ 690V (or 433V) redundant supply connects to eachswitchboard

– Switching of the ‘A’ & ‘B’ supplies to each board is electrically andmechanically Interlocked via an automatic changeover



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Distribution690V Motor Control Switchboard (MCS)

– The MCS powers significant motors in the respective area of the

substation

– This typically includes the tunnel jet fans, ventilation outlet axial fans

and large pumps

433V Low Voltage Switchboards (LVS) – The LVS provides power via distribution boards / panels to other

equipment

– A large part of the LVS distribution includes the distribution of power

(essential via an UPS & non-essential) to the tunnel



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DistributionThe distribution of the tunnel electrical load is shared by the 7 Substationseach substation distributes minor circuits via Cross Passage DistributionBoards – South to North across the Brisbane River

– #1 (surface) @ Woolloongabba / SVO Site

– #2 (tunnel) @ approx XP4 (cross passage 4)

– #3 (tunnel) @ approx XP15




– #7 (surface) @ Bowen Hills / NVO Site

There are 41 Cross passages through the tunnel





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LV Systems Design – ElectricalDistribution



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HV Systems Design

With the LV Supply Requirements established the Tunnel HV Supplypotential of 22kV was chosen to establish a potential separation withEnergex.

22kV Supply A:

– Sub#1 to Sub#2 to Sub#3 to Sub#4 to Sub#5 to Sub#6 to Sub#7

22kV Supply B:

– Sub#7 to Sub#6 to Sub#5 to Sub#4 to Sub#3 to Sub#2 to Sub#1

Supply ‘A’ equipment is physically fire separated from Supply ‘B’ equipment

Transformers:

– Oil type for surface substations

– Dry type for tunnel substations

HV Switchgear being non withdrawable is operated via 48V DC supplies



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HV Systems Design

22kV Switchboard

Sub03 HVS131

Transformer TRX132

22kV / 690V / 433V, 2MVA

22kV Switchboard

Sub04 HVS141

Transformer TRX142

22kV / 690V / 433V, 1.6MVA

22kV Switchboard

Sub05 HVS151

Transformer TRX152

22kV / 690V / 433V, 2MVA

22kV Switchboard

Sub06 HVS161

Transformer TRX162

22kV / 690V / 433V, 1.6MVA

22kV Switchboard

Sub07 HVS171

Transformer TRX172

22kV / 433V, 1MVA

Transformer TRX173

22kV / 690V, 5MVA

Transformer TRX122

22kV / 690V / 433V, 2MVA

22kV Switchboard

Sub02 HVS121

Energex 33kVSupply

Wellington RoadSubstation

33kV / 22kV 22MVATransformer

Sub01 TRX111

Transformer TRX112

22kV / 433V, 0.5MVA

Transformer TRX113

22kV / 690V, 5MVA

22kV SwitchboardSub01 HVS111

Transformer TRX212

22kV / 433V, 0.5MVA

Transformer TRX222

22kV / 690V / 433V, 2MVA

22kV Switchboard

Sub02 HVS221

Transformer TRX213

22kV / 690V, 5MVA

22kV Switchboard

Sub03 HVS231

Transformer TRX232

22kV / 690V / 433V, 2MVA

22kV Switchboard

Sub04 HVS241

Transformer TRX242

22kV / 690V / 433V, 1.6MVA

22kV Switchboard

Sub05 HVS251

Transformer TRX252

22kV / 690V / 433V, 2MVA

22kV Switchboard

Sub06 HVS261

Transformer TRX262

22kV / 690V / 433V, 1.6MVA

22kV Switchboard

Sub07 HVS271

Transformer TRX272

22kV / 433V, 1MVA

Transformer TRX273

22kV / 690V, 5MVA

22kV SwitchboardSub01 HVS211

Energex 33kVSupply

Victoria ParkSubstation

33kV / 22kV 22MVATransformer

Sub07 TRX271



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HV Systems Design



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HV Systems Design



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Substation Arrangement

Substation are located within the tunnel and above ground

Above Ground

– Substation 1 & 7



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Incoming Transformer 22MVA33/22kV

Above Ground

– Substation 1 & 7




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Below Ground

– Substation 3, 4, 5 & 6

Substation 6 – Southbound Tunnel



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Substation - HV Equipment

High Voltage Switchboard

Dry Type Transformer



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Substation - LV Equipment

Low Voltage Switchboard

Motor Control Switchboard

Automatic Changeover

Switchboard HMI



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Substation - LV ReticulationEssential Supply

Uninterruptible Power Supply

– A UPS system is an integral part of theLV distribution scheme providing battery

backed “essential” power to “life-safety”devices and control systems

– Life-safety devices are connected to“essential” distribution boards

– UPS battery capacity

30 mins : Every 3rd tunnel roadway light(for Level 6 lighting)

90 mins : tunnel signage, emergency

exit signage, communication systemequipment

240 mins : TCC OMCS equipment

UPS System



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Cross Passage - LV Reticulation

Cross Passage Power Supply

– Essential & Non-essential power is distributed from a tunnelsubstation to the cross passages in its vicinity

Tunnel Substation # 2 : XP01 to XP09

Tunnel Substation # 3 : XP10 to XP19, XP47 to XP50






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Cross Passage - LV Reticulation

Cross Passage Panels (combined panel consisting of)

– LV Essential Distribution Panel

– LV Non Essential Distribution Panel (some XPs have 2 off)

– PMCS Control Panel

– Ventilation Control Panel

– TTMCS Control Panel

– Provides a source of power and communications / controls to themajority of devices within the immediate vicinity of the XP

Other Electrical Panels

– Pump Station Control Panels

– Ventilation Outlet Variable Speed Drives



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Design Documentation

Electrical Design Reports

– LV Electrical Supply System – NSBT-2531-EL-RP-048225

– HV Electrical Supply System - NSBT-2501-EL-RP-047852

– Tunnel/Underpass Lighting Systems - NSBT-2560-LI-RP-049050

– Earthing Design Report - NSBT-2501-EL-RP-047864

Reports were issued to the Client and Independent Verifier for each of the 4

design phases



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Electrical Design Calculations

– LV Motor Equipment Power – Load Flow

– LV Lighting Power – Load Flow

– Electrical Equipment Heat Loss

– LV Maximum Demand Design Calculation - NSBT-2531-EL-CA-048225

– LV Fault Level Calculation Record - NSBT-2531-EL-CA-048203

– HV Fault Level Calculations Record - NSBT-2501-EL-CA-047872

– HV and LV Protection Schemes

– LV Cable Sizing

– HV Cable Sizing



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Electrical Equipment

Major Electrical Equipment Requirements

– 22MVA 33/22kV Auto Tap Change Incoming Transformer

– Neutral Earthing Resistor – 100A/12.7kV

– 5MVA (O), 2MVA (D), 1.6MVA (D), 1MVA (O) and 0.5MVA (O)Distribution Transformers

– HV Switchgear Vacuum Non Withdrawable

– MCS and LVS Switchboards

– UPS Systems plus UPS Power Distribution

– Variable Frequency Drives and Harmonic Filters

– Substation and Cross Passage Distribution Boards

– Pumping Motor Control Boards



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Electrical Materials

Electrical Cabling Requirements

– HV 22kV Cabling 10,733m

– LV Consumer Mains 2,149m

– LV Sub Mains 42,797m

– LV Fire Rated Cables/sub circuits 199,503m

– LV Control Cabling 108,210m

– Fibre Optic Cable 136,254m

– Earthing Cable 37,653m

– Special Motor Supply Cables 3,630m

In total there are 15,026 circuits for a total length of - 844km



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QUESTIONS

Documents

Tunnel Electrical Power Systems Design