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n° 169

HV industrial
network design

Georges THOMASSET

Graduated as an engineer from the


IEG (Grenoble Electrical Engineering
Institute) in 1971.
Since then, he has been designing
complex industrial networks in the
framework of Merlin Gerin
company's Technical Division.
After having headed the "Medium
Voltage public distribution and
hydroelectric installations"
engineering department, he has
been in charge of the engineering
section of the Contracting
department's industrial unit since
1984.

E/CT169 first issued october 1994


lexicon

flicker: periodic fluctuations the light range A = 1 kV < U < 52 kV, protection system used, the choice of
output of lamps. range B = 52 kV ≤ U < 300 kV, devices and device settings.
HTA and HTB: categories of medium range C = U ≥ 300 kV. network structure: overall network
voltage defined by a French decree A revision is pending, which will include arrangement, often represented in a
dated 14 November 1988. only two ranges: single-line diagram, which indicates the
Voltage levels are classified by different range I = 1 kV < U ≤ 245 kV, relative arrangement (interconnections,
decrees, standards and other particular range II = U ≥ 245 kV. separation of circuits, etc.) of the
specifications such as those of utilities. ■ the French national utilities EDF now different sources and loads.
AC voltages greater than 1000 V are uses the classification given in the
decree cited above. plant: grouping (in a location) of
defined by:
■ the French decree of 14 November several energy consumers.
network dynamic stability: the
1988 which defines two categories of capacity of a network, which includes private network: electrical network
voltage: several synchronous machines, to which supplies power to one or more
HTA = 1 kV < U ≤ 50 kV, return to normal operation after a user sites (plants) which generally have
HTB = U > 50 kV. sudden disturbance that has caused a the same owner.
■ CENELEC (European committee for temporary change (i.e. short-circuit) or utility supply: electrical network which
electrotechnical standardisation), in a permanent change (line opening) in the belongs to the national or local energy
circular dated 27 July 1992, specifies:
network configuration. distributor and serves several
MV = 1 kV < U ≤ 35 kV,
network protection plan: overall independent consumers.
HV = U > 35 kV.
■ the IEC publication sets forth the organization of electrical sensitive loads: loads for which no
highest voltage ranges for equipment: protection gear, including: the absence of power supply is tolerated.

appendices
appendix 1: extension of an hypotheses p. 19
existing industrial network approximate calculation of a p. 19
current limiting reactor
appendix 2: computerized means calculation software programs p. 20
used for network analyses expert system for evaluating p. 20
electrical network design quality
appendix 3: general principle of compensation p. 20
appendix 4: choice of the earthing system for a HV industrial network p. 21
appendix 5: network voltage drops p. 22
appendix 6: stages in industrial network design p. 22
appendix 7: bibliography p. 24

Cahier Technique Merlin Gerin n° 169 / p.2


HV industrial network design Faced with increasingly fierce
competition, industrialists must employ
highly rigorous management and their
production facilities must have a high
level of availability.
Electrical networks supply the energy
required to run the production facilities.
The provision of a continuous power
supply to loads is strived for from the
start of the network design, in particular
contents during preliminary choices in the single-
line diagram.
Reductions in electrical installation and
1. needs and main constraints to be met needs to be met p. 4 operating costs, together with reliable
main constraints p. 5 failure-free operation, are vital
conditions for profitability. This
2. main rules of industrial network load survey, load and diversity p. 7 technical and economic optimization
design factors calls for detailed and global preliminary
choice of voltages p. 7 analyses, which include:
reactive power compensation p. 7 ■ specific needs and constraints
backup and replacement sources p. 7 related to the type of industry,
■ integration of the limits and
autonomous electrical energy p. 7 constraints of the public distribution
production network,
division of sources p. 7 ■ standards and local practices,
overall electrical diagram p. 8 ■ particularities of the operating
3. validation and technical and choice of the earthing system p. 9 personnel, facilities manager and
economic optimization maintenance personnel.
feeder definition p. 9
The scope of this study is limited to the
insulation coordination analysis p. 9 analyses involved in the design of High
protection system definition p. 9 Voltage ("HTA" and "HTB") high power
short-circuit currents calculation p. 10 industrial installations which have the
calculation of voltage fluctuations p. 11 following main characteristics:
under normal and disturbed ■ installed capacity in the 10 MVA
operating conditions range,
■ autonomous electrical energy
choice of motor starting method p. 11
production (when applicable),
network dynamic stability p. 12 ■ power supplied by a national
synthesis p. 13 transmission or distribution network
4. choice of optimal network structure standard network structures p. 14 (≥ 20 kV),
and operation ■ private Medium Voltage distribution.
concrete example of a structure p. 16
choice of equipment p. 16
optimal operation p. 16
5. conclusion p. 18
appendices see page on left

Cahier Technique Merlin Gerin n° 169 / p.3


1. needs and main constraints to be met

Industrial electrical networks must ■ overcurrent (short-circuits and ■ initial investment cost,
supply power to all the plant loads, at overloads), ■ operating and maintenance costs,
optimal investment, operating and loss ■ overvoltage. ■ cost of production losses associated
of production costs, taking into account: The solutions that are used must with the network design and protection
■ the needs to be met: ensure at the least the following: plan (protection system used, choice of
■ safety of people, ■ quick fault clearance and continued devices and settings).
■ safety of property, power supply to the fault-free sections Optimization of electrical energy
■ continuous power supply, of the network (discrimination), When a plant includes electrical energy
■ network operating ease, ■ supply of information on the type of generators, it is necessary to manage
■ minimum installation cost, initial fault, for quick servicing. the energy supplied by the utility and
■ optimization of electrical energy the energy produced locally in the best
(cost / quality), Continuous power supply to loads
Continuous power supply to the loads manner possible.
■ network changes and future A control and monitoring system makes
extensions, is necessary for the following reasons:
■ safety of people, e.g. lighting; it possible to optimize the cost of plant
■ network upgrading; power consumption in accordance with:
■ constraints linked to: ■ sustained production performance,
e.g. glass wire drawing; ■ the contract with the utility (billing
■ the industrial process, rates according to the time, day and
■ the electrical process, ■ productivity;
■ operating convenience, e.g. season);
■ the utility, ■ the availability of the plant
■ the climate and geography of the site, simplified machine or workshop restart
procedure. generators;
■ standards, regulations and local ■ industrial process requirements.
practices. Loads are divided into three groups
according to their operating Network changes and future
It is clear that not all the needs can be
requirements: extensions
optimally met, which means that the
network designer must endeavour to ■ "normal" loads, When designing an industrial network,
find the best compromise. ■ "essential" loads, it is of primary importance to make a
■ "sensitive" loads for which no careful assessment of the future
absence of power supply is tolerated. development of the plants, especially
needs to be met when extensions are foreseeable.
Network operating ease Changes that are liable or due to be
Safety of people In order to carry out their tasks safely made in the future should be taken into
Even if not all countries have standards and reliably, network facilities operators account:
and rules, certain obvious principles need the following: ■ in sizing the main power supply
must be adhered to: ■ a network that is easy to operate in components (cables, transformers,
■ prohibiting access to energized parts order to act correctly in the event of a switching devices),
(protection against direct contact), problem or a manoeuvre; ■ in designing the distribution diagram,
■ a system to protect against the rise in ■ sufficiently sized switchgear and ■ in calculating the areas to be set
potential of metal structures (protection equipment, which require little aside for electrical rooms.
against indirect contact), maintenance and are easy to repair This forward planning will result in
■ prohibiting on-load line disconnecting (maintainability); increasingly flexible energy
switch operations, ■ efficient means of control and management.
■ prohibiting earthing of live conductors monitoring which facilitate remote Network upgrading
■ quick fault clearance. control of the network by real time Electrical energy consumption
centralization in a single location of all increases as extensions are made to
Safety of property
the information relating to the state of meet the needs of new types of
Electrical installations should not be
the "electrical process", under normal manufacturing and ever more powerful
submitted to stress that they are not
and disturbed operating conditions. machines. This makes it mandatory to
able to withstand. The choice of
materials and equipment is therefore of Minimum electrical installation cost upgrade and/or restructure the network.
prime importance. Two electrical The minimum electrical installation cost Greater care must be taken in network
phenomena are to be considered in does not necessarily mean the upgrading analyses than in analyses of
order to avoid fire and to limit minimum initial cost, but the sum of new installations since additional
destructive effects: three costs: constraints are involved, i.e.:

Cahier Technique Merlin Gerin n° 169 / p.4


■ insufficient electrodynamic and In addition, some industrial processes system (central computers, PLCs), and
dielectric strength of existing devices or pollute their environment. They produce management control system as well as
equipment; substances (dust, gas) that are scientific calculation errors.
■ capacity to supply power to large sometimes corrosive and can jam ■ mechanical destruction of motors,
loads (starting current, dynamic mechanisms or degrade the motor coupling and/or the driven
stability, etc.); performance of electrical devices machines. This occurs during
■ area and height of existing electrical (e.g. dielectric strength) or even cause momentary dips (re-energizing of
rooms that cannot be changed; explosions in the presence of electric motors that are still in motion), since
■ imposed geographical location of coupling may take place with phase
arcs.
equipment and loads. opposition between the mains voltage
Constraints linked to the electrical and the residual voltage generated by
Example of upgrading with the addition
process the motor, this resultat in motor
of a new transformer: the installation of
During the analysis, it is necessary to currents being very high , i.e. 4 to
a three-phase reactor between the old
take into consideration various 5 times the rated current, and cause
installation and the transformer makes
"electrotechnical" conditions that all excessive electrodynamic stress.
it possible to limit the increase in short-
circuit current and therefore to continue electrical networks must fulfil, in ■ overvoltage of external origin, in
using the existing equipment (see particular: particular lightning strokes (refer to
appendix 1). ■ limitation of short-circuit currents and "Cahier Technique" n°168).
their duration ■ value and quality of the supply
Quality of analyses ■ starting or restarting of large motors voltage:
The design analysis and detailed without excessive voltage drops, ■ the value of the supply voltage
analysis must be carried out ■ stability of alternators after a dictates to a certain extent the
methodically and precisely. ISO 9001 disturbance has occurred. organization of private network
certification entails setting up voltages. If the power supply is in High
procedures which describe the Constraints imposed by the utility
Voltage, it may be of benefit to use that
essential steps involved in design and electrical power distribution network
voltage level for the plant's main
detailed analyses in the view of ■ short-circuit capacity distribution system;
mastering these analyses and meeting The short-circuit capacity of the ■ the quality of the supply voltage.
the clients' needs in the best way upstream network supplying the private Various voltage fluctuations may bother
possible. network is a decisive element when or even prevent production equipment
Merlin Gerin's Contracting Department choosing: operation. The chart in figure 1 shows
was granted ISO 9001 certification ■ the structure of the private such faults, the causes and
in 1992. distribution network, consequences, as well as the main
■ the maximum load, remedies.
■ particular loads that are sensitive to Remarks:
main constraints voltage drops. In terms of supply voltage quality,
Constraints linked to the industrial ■ utility earthing system frequency deviations must be
process The same type of earthing system, as within ± 2% and harmonic voltages
Apart from the need for a high level of used by the utility, is often used for the must be less than 3%.
continuous power supply in certain private network but it is sometimes not A major European national utility has
industrial processes, those very compatible with particular loads. In installed more than 2000 recording
processes also impose constraints: such cases, it is necessary to create a devices on the power supply system for
■ power supply and, in particular, separate system with: major industrial sites in order to assess
starting of very large motors which ■ a type of electrical protection for the quality of the electrical power being
drive crushers, grinders, fans, pumps phase-to-earth faults, supplied.
and conveyor belts (a major cause of ■ a special network operating method The devices measure:
voltage drops during starting); (fault tracking and/or clearing by ■ rms voltage and current;
■ power supply to arc furnaces, the arc operating personnel in the case of ■ active and reactive power,
often being unstable, which causes isolated neutral systems). ■ short and long power outages,
brief but repeated unbalanced voltage ■ voltage dips,
drops (resulting in flicker), and can ■ momentary dips or substantial ■ harmonic voltages and currents,
create harmonics; transient single-phase or multiphase ■ voltage unbalance.
■ power supply to high capacity voltage drops. They also detect 175 and 188 Hz
electronic devices (rectifiers, thyristors, The presence of such phenomena can remote control signals.
etc.) which create major voltage wave cause disturbances, or even production Climatic and geographical
deformations (harmonics) in the shutdowns and machine destruction. constraints
network and lower the power factor; These phenomena may result in: In order to determine the best
this is the case for potlines, DC electric ■ operating errors and/or the loss of specifications for equipment and
furnaces and variable speed drives. data of the industrial process computer devices according to the types of

Cahier Technique Merlin Gerin n° 169 / p.5


voltage fluctuations a few % 5 to 25% 5 to 25% 100%
duration 1/100 to 1 s 0.5 to 20 s 20 s to 1 hour 0.1 to 0.3 s or 10 to 30 s
periodicity YES NO NO NO
causes presence of electric ■ starting of large motors absence of voltage fast and/or slow HV line
arc furnace ■ single- or multiphase regulation in primary reclosing system
fault substations
consequences variations in incandescent ■ risk of network instability ■ motor overload momentary suspension of
lighting (Flicker) ■ high risk of network power supply to all loads
instability
main remedies use static var ■ change the starting equip the transformers use shunt circuit breakers
compensation equipment method with on-load tap changers
■ increase protection
plan rapidity

fig. 1: voltage fluctuations, causes ,consequences and main remedies

installations, it is necessary to know the ■ environment (corrosive atmosphere Compliance with standards and local
following: or risk of explosion), practices
■ average and maximum daily ■ altitude, In this regard, it is especially important
temperatures, to be familiar with:
■ frequency of lightning strokes in the
■ relative humidity rate at maximum ■ national and/or international
temperature, region,
switchgear and installation standards,
■ maximum wind speed, ■ difficulties in gaining access to the ■regulations and rules which apply
■ presence of frost, ice, sand-bearing site (for the transport of materials and specifically to the industrial complex,
winds, also for maintenance). ■ local practices.

Cahier Technique Merlin Gerin n° 169 / p.6


2. main rules of industrial network design

The aim of this chapter is to explain from the main substation, even if the operation or to provide greater
how the industrial network design ten largest motor loads require a operating flexibility.
process takes into consideration all the nominal voltage of 6.6 kV.
obligations (needs and constraints)
described in the previous chapter.
autonomous electrical
Since plants are designed to operate reactive power energy production
non-stop, any break in the electrical compensation A plant may have its own means of
power supply should be assessed The local utility generally establishes generating electrical power to supply its
during the analysis phase and the the minimum power factor (p.f.) for the "sensitive" loads, for electricity billing
consequences examined in order to client's supply point. rate reasons or when the plant's
determine the measures to be taken. Reactive power compensation is often manufacturing process produces
The method put forth in this chapter necessary to meet this requirement and energy (thermal or mechanical), e.g. in
comprises two phases: may be carried out at two levels: the form of vapour.
- 1 - endeavouring to achieve an ■ at the substation (or main If the utility network has a sufficient
appropriate technical balance between switchboard) level: global short-circuit capacity and voltage and
needs and constraints (see chapter 1), compensation; frequency quality, it is preferable to
- 2 - technical and economic ■ at the load level: distributed operate the autonomous sources and
optimization through the correct use of compensation. the mains in parallel, since the mains
certain calculations and the concepts The general principle of compensation help to stabilize the performance of the
presented below. using capacitors is presented in plant's alternators (voltage and speed).
Appendix 2, without being exhaustive, appendix 3. When parallel operation is used, a
lists the main calculation software Remark: strong compensation by system for distributing active and
programs that are used by specialized means of fixed capacitor banks may reactive power between the different
network analysis engineers. cause overvoltage. A particular case of alternators and the mains should be
this is the phenomenon of the self- included.
excitation of asynchronous machines: When serious electrical problems occur
load survey, load and the capacitors that are associated with in the private network, or in the utility
diversity factors an asynchronous motor (distributed network near of the plant, instability
compensation) may give rise to very may result. It may be necessary to
This is the first essential step in high overvoltage when there is a break separate the private network from the
designing a network. in the power supply. This phenomenon utility network (creation of an isolated
It should define and geographically can occur when compensation is network supplied by the alternators)
locate the power requirements. greater than 90% of the magnetizing within an extremely short time (about
Load survey current, which is approximately equal to 0.2 seconds) so as not to risk a full
It is necessary to: motor no-load current. facilities shutdown. Separation of the
■ distinguish active, reactive and networks is generally accompanied by
apparent power; the disconnection of non-essential
■ group the power demands by backup and replacement loads from the private network in order
geographical area (3 to 8 areas) sources to avoid overloads.
according to the size of the site; Backup sources are installed to protect
■ identify, for each area, the "normal" - people (standards and laws),
"essential" and "sensitive" loads. e.g. emergency exit route lighting. division of sources
Load and diversity factors (see fig. 2) Replacement sources are installed in Certain loads cause a high degree of
order to maintain production facilities interference in the utility supply

choice of voltages
The choice of voltages is determined by motors lighting power
the function that is to be performed: heating outlets
transmission, distribution or
load factor 0.75 1 (**)
consumption. In HV, the distribution
voltage is not necessarily the same as diversity factor 0.70 (*) 1 0.1 to 0.3
the consumer voltage. For example, * Depends on the process
20 kV may be the optimal distribution ** Depends on the destination
voltage in a plant in view of the power fig. 2: general indication of load and diversity factors.
flow and the distance of workshops

Cahier Technique Merlin Gerin n° 169 / p.7


network. The division of sources (see
fig. 3) is used to isolate the fluctuating
loads and it offers two additional
advantages as well:
■ improved discrimination between the
protection devices, thereby increasing
continuous power supply to the other
loads;
■ adaptation of the earthing system to
suit the loads.

overall electrical diagram


The network designer uses the various M M M
elements described earlier in this
chapter to establish a preliminary
structure, which he then fine-tunes in
accordance with the constraints of the lighting high power variable
industrial site to obtain the "overall computers motors speed motor
single-line diagram" of the plant's
electrical distribution system. This is the normal "sensitive" "fluctuating" loads
starting point for technical and loads loads
economic network optimization.
The next chapter presents the different
choices that are available and the fig. 3: the division of sources is a means of separating the "fluctuating" loads from the other
calculations that are required to find the loads.
optimal solution.

Cahier Technique Merlin Gerin n° 169 / p.8


3. validation and technical and economic optimization

choice of the earthing ■ atmospheric overvoltage (lightning information, geographical


strokes). arrangements, etc.
system
Insulation coordination contributes to Current discrimination
Standards and regulations make
obtaining greater electrical power Used (in Low Voltage) when short-
protection against direct and indirect
availability. Correct insulation circuit current decreases rapidly as the
contact compulsory for all electrical
coordination entails: distance increases between the source
installations. In general, protection
■ knowing the level of overvoltage that and the short-circuit point being
functions automatically interrupt the
is liable to occur in the network; examined, or between the supply and
power supply (upon the first or second
■ specifying the desired degree of load sides of a transformer.
phase-to-earth fault according to the
performance or, more explicitly, the Time discrimination
earthing system used). There are also
acceptable insulation failure rate; Used in Low Voltage and very often in
special protection devices designed for
■ installing protection devices that are High Voltage as well. Protection device
specific situations. High Voltage
suited to both the network components (circuit breaker) tripping time delays are
network earthing systems may be
(insulation level) and the types of increased as the devices become
chosen according to the criteria given in
overvoltage; closer to the source. In order to
appendix 4.
■ choosing the various network eliminate the effects of transient
However, it is very often of benefit to
components based on their level of currents , the minimum time delay at
use different earthing systems in the
overvoltage withstand, which must the furthest point from the source
same industrial network, each of which
meet the constraints described above. (directly upstream from the load) is
provides a predominant advantage.
"Cahier Technique" n° 151 describes 0.2 s or even 0.1 s if the current setting
voltage disturbances, ways of limiting is high, with a maximum time delay
feeder definition them and the measures set forth in the of 1 s at the starting point of the private
Feeders account for a large portion of standards to ensure dependable, network.
electrical installation investment. It is optimized electrical energy distribution, These time delays may be definite time
therefore important, for safety and cost thanks to insulation coordination. or short-circuit current dependent.
reasons, to: Discrimination by logical data
■ choose the best type of equipment transmission, or logical
(cables), protection system discrimination
■ make the most accurate calculations definition This type of discrimination consists of
of the minimum cross section, while When a fault appears in an electrical the transmission of a "blocking signal"
taking into account short-circuit and network, it may be detected of a limited duration, by the first
starting currents, voltage drops, losses, simultaneously by several protection protection unit situated directly
etc. devices situated in different areas of upstream of the fault, and which is
the network. The aim of selective supposed to open the circuit, to the
tripping is to isolate as quickly as other protection units situated further
insulation coordination possible the section of the network that upstream.
analysis is affected by the fault, and only that This technique, which has been
The coordination of insulation provides section, leaving all the fault-free developed and patented by Merlin
the best technical and commercial sections of the network energized. The Gerin, is described in detail in "Cahier
compromise in protecting people and network designer must first of all select Technique" n° 2.
equipment against the overvoltage that a protection system that will enable him The tripping time delay is short and
may occur in electrical installations, to specify the most suitable protection definite, wherever the fault may be
whether such overvoltage originates devices. He must also create a relay situated in the network. This helps
from the network or from lightning. tripping plan, which consists of increase to the dynamic stability of the
Three types of overvoltage may cause determining the appropriate current and network and minimizes the damaging
flashovers and hence insulation faults, time delay settings to be used to obtain effects of faults and thermal stress.
with or without destruction of the satisfactory tripping discrimination. Discrimination using directional or
equipment: Different discrimination techniques are differential protection
■ power frequency overvoltage (50 to currently implemented, which use or This type of discrimination provides
500 Hz), combine various data and variables specific protection of a portion or
■ switching surges, such as current, time, digital particular element of the network.

Cahier Technique Merlin Gerin n° 169 / p.9


Examples: transformers, parallel
cables, loop systems, etc.
Discrimination using distance
protection
This type consists of splitting the
network into zones. The protection 0.5 s
units locate the zone area in which the discrimination by data
fault is situated by calculating the circuit transmission
impedance.
This technique is seldom used except 0.5 s
when the private HV network is very
widespread.
An example of a protection system that
uses several discrimination techniques
is given in figure 4. time discrimination
N.B. The criteria used for selecting
protection systems, relays and
protection settings are not discussed in
this section. A number of other
publications deal with those matters,
e.g. "Cahiers Techniques" n° 2 and
158. 0.2 s

pilot wire
short-circuit current
0.2 s
calculation
In order to find the best technical and discrimination by data
pilot wire
economic solution, it is necessary to transmission
know the different short-circuit values
so as to determine:
■ making and breaking capacity
according to the maximum peak and 0.2 s
rms short-circuit current;
■ equipment and switchgear resistance
to electrodynamic stress, according to
the maximum peak short-circuit current;
■ protection tripping settings in
discrimination analyses according to
the maximum and minimum rms short-
current discrimination
circuit current.
"Cahier Technique" n° 158, after
reviewing the physical phenomena to
be taken into consideration, reviews the
calculation methods set forth in the
standards.
When rotating machines (alternators or
motors) are included, the form of short-
circuit current can be broken down into fig. 4: protection system using several discrimination techniques: current, time and logic.
three portions:
■ subtransient,
■ transient, built up in the synchronous and asymmetrical component, also referred
■ steady state. asynchronous rotating machines. to as a DC component, the damping of
The subtransient and transient stages In both of these stages, it is necessary which depends on the R/X ratio of the
are linked to the extinction of the flux to deal with the aspect of an upstream network and the timing of the

Cahier Technique Merlin Gerin n° 169 / p.10


fault with respect to the phase of the choice of motor starting dω
T'm - Tr = J
voltage. dt
In addition, it is necessary to take into
method T'm = motor torque when energized at
account motor contribution to short- The starting method used (delta-star, actual supply voltage (Ur),
circuit current. When a three-phase autotransformer, resistors or stator Tr = braking torque of the driven
short-circuit occurs, asynchronous reactors, etc.) must obviously provide machine,
machines are no longer supplied with sufficient accelerating torque J = inertia of all the driven masses,
power by the network, but the magnetic (accelerating torque is generally greater dw/dt = angular acceleration,
2
flux of the machines cannot suddenly than 0.15 times the rated torque), and, Ur
in addition, must only cause acceptable T'm = Tm
disappear. Un
The extinction of this flux creates a voltage drops (< 15%). Tm = motor torque when energized at
subtransient and then transient current Reminder: the equation governing the rated voltage (Un).
which intensify the short-circuit current interaction of the motor with the driven Ta = T'm - Tr
in the network. mechanism is: Ta = accelerating torque.
The total short-circuit current is the
vectorial sum of two short-circuit
currents: source short-circuit current
and machine short-circuit current.
Un = 60 kV

calculation of voltage
fluctuations under normal
and disturbed operating
conditions 30 km line

Normal operating conditions I Start


The calculation of voltage fluctuations
under normal operating conditions is a
design task which serves to verify the
voltages throughout the network.
If the voltages are too low, the network
designer should verify whether:
Un = 60 kV 57 kV
■ the active and reactive power flows
are normal,
■ the feeders are correctly sized,
■ the transformer power ratings are
sufficient, I Start
■ the reactive power compensation
scheme is appropriate,
■ the correct network structure is being
used. Un = 5 kV 4.75 kV Un = 5 kV 4.5 kV
Disturbed operating conditions
It is necessary to calculate voltage I Start
fluctuations under disturbed operating
conditions in order to verify whether the plant network 1200 kW
following phenomena will result in I Start = 5 I n
excessive voltage drops or rises: motor during
■ starting of large motors (see fig. 5), starting phase
■ downgraded network operation (e.g.
2 transformers operating instead of the
3 intended for normal operation),
fig. 5: example of the determination of voltage dips during motor starting for the installation of a
■ no-load network operation, with or
1200 kW motor supplied by a 30 km long, 60 kV line. It should be noted that separation of the
without reactive power compensation. "plant network" power supply and the motor power supply have made it possible to have a
Appendix 5 gives the mathematical voltage drop of only 250 V in the "plant network".
expression and vector diagram of a xx kV = voltage during motor starting
network voltage drop.

Cahier Technique Merlin Gerin n° 169 / p.11


The curve showing Ta as a function of ■ the motor torques are greater than ■ motor accelerating torque, and hence
speed is given in figure 6 below. the braking torques, in which case the voltage drop,
The chart in figure 7 shows the most motors can reaccelerate and return to ■ rotating machine inertia.
frequently used starting methods (for their stable state; Calculation software may be used to
further details, please refer to "Cahier ■ the motor torques are less than the simulate the dynamic performance of
Technique" n° 165). braking torques, in which case the electrical networks, making it easier to
motors continue to slow down, drawing
large currents which are detected by
network dynamic stability the motor and/or network protection
Under non-disturbed operating devices, which trip the related circuit
conditions, all the rotating machines breakers.
(motors and alternators) included in the
Motor reacceleration, and hence
installation form a stable system with
network dynamic stability, are favoured
the utility network.
by:
This equilibrium may be affected by a
■ a suitable load shedding plan
problem in one of the networks (utility
or private), such as: major load (tripping of normal, non-essential three-phase fault
fluctuation, change in the number of motors in the event of serious faults);
transformers, lines or supply sources, ■ a powerful network (correctly
multiphase fault, etc. regulated alternators and low voltage
drop); voltage drop
This results in either short-lived
instability, in the case of a well- ■ fast-acting protection systems which
designed network, or a loss of stability reduce the duration of motor slowdown
(e.g. logical discrimination); increase decrease in
if the disturbing phenomenon is very motor torque
serious or if the network has a low ■ a suitable network structure with: in current
(proportional to
recovery capacity (e.g. short-circuit ■ separation and regrouping in consumed
voltage
separate circuits of normal, non- by motors squared)
capacity too low).
Asynchronous motor performance in essential loads and essential and
the presence of a three-phase fault sensitive loads, which facilitates load
shedding, slowing down
Here, as an example, is the analysis of of all motors
asynchronous motor performance in ■ minimal impedance connections for
the presence of a three-phase fault essential and sensitive loads so as to
(see fig. 8). limit voltage drops.
After the fault has been cleared, two The duration of the return to normal fig. 8: performance of asynchronous motors
situations may occur: motor speed depends on: in the presence of a three-phase fault

torque application application starting advantages


T Tm needs characteristics method drawbacks
Tn Tr
continuous or virtually machines that require direct simplicity, reduced
T'm continuous process strong starting torque investment.
Ta Tn starts ≤ 1 per day upon starting:
1
■ strong torque,
0.6 frequent motors with low inrush direct ■ high inrush current,
starts > 1 per day current or low power ■ strong mechanical stress.
0
0 speed (ω ) pumps, fans, machines that start with stator- reactor reduction of torque and
compressors, weak torque inrush current upon starting
T'm = motor torque when energized at the frequent starts (adjustment possible).
actual supply voltage (Ur),
Tr = braking torque of the driven machine optimization of when starting current stator - optimization of torque
Tm = motor torque when energized at the starting needs to be reduced autotransformer (reduced) and inrush current
rated voltage (Un) characteristics while maintaining the upon starting (adjustment
Ta = accelerating torque torque needed for possible).
starting
fig. 6: diagram of different motor torques
according to speed, with a voltage drop of optimization of strong the most difficult starts rotor low inrush current and
about 15% (hence T'm = 0.7 Tm) and torque starting strong starting torque.
braking torque TR = 0 during starting. characteristics
It should be noted that this voltage drop
would not allow the motor to be started with
a Tr > 0.6 Tn when started, since Tr > T'm. fig. 7: the most commonly used starting methods

Cahier Technique Merlin Gerin n° 169 / p.12


make the correct choices, in particular, To summarize: as to sustain it (load shedding) and
when establishing the procedures to be If the disturbance is minor (two-phase avoid the risk of a complete installation
used to separate power supply sources short-circuit far from the load), stability shutdown (see fig. 9).
(creation of "isolated systems"), non- is restored by speed and voltage
essential load shedding plans and
regulators. When there is a high risk of
protection systems (logical
instability, it is necessary to include a
synthesis
discrimination for very short tripping
protection device that will clear the fault All of the information presented in this
times). All of these factors contribute to
maintaining the dynamic stability of the within a very short time (0.2 to 0.3 s) chapter is summarized in a logic
network when disturbances occur. and/or a device to divide the network so diagram in appendix 6.

ω
G (rad/s)
alternator G

300

shed circuit 250 motor M1, with load shedding

motor M1, without load shedding


M1 M2 M3 M4 M5
0.15 1 2 3 t (s)

clearing of the short-circuit

fig. 9: presentation of the dynamic performance of a network with and without load shedding

Cahier Technique Merlin Gerin n° 169 / p.13


4. choice of optimal network structure and
operation

Different network structures are


possible, the most common of which
are described in this chapter together
with the main areas in which they are
used.
The choice of a network structure, HV
which is always a decisive factor in
terms of energy availability, is often a
difficult one to make.
The most rational method consists of
making a quick comparison of the
unavailability of voltage at a particular
point in the network for different
structures and using a very interesting
expert system (see appendix 2).

standard network
structures
Open or closed loop, also called
"primary loop system" LV LV LV
(see fig. 10)
Recommended for very widespread fig. 10: diagram of a primary loop.
networks, with major future extensions.
Open loop operation is advisable.
Double radial feeder, also called
"primary selective system" (manual
or automatic)
(see fig. 11)
HV
Recommended for very widespread
networks with limited future extensions
and which require a high level of
continuous power supply.
Radial feeder, also called "single
power supply" LV
(see fig. 12 on the opposite page)
Recommended when continuous power
supply requirements are limited. It is
often used for cement plant networks. LV
Dual power supply
(see fig. 13 on the opposite page)
Recommended when a high level of
continuous power supply is required or LV
when the operating and maintenance
teams are small.
It is very often used in the steel and fig. 11: diagram of a primary selective network.
petrochemical industries.

Cahier Technique Merlin Gerin n° 169 / p.14


Dual busbar fluctuations. The loads may be With replacement source and load
(see fig. 14) distributed between the two busbars shedding
Recommended when a very high level without any break in the power supply. (see fig. 16)
of continuous power supply is required This is the typical case for an industrial
With energy generating sets network in which a very high level of
or when there are very strong load
(see fig. 15) continuous power supply is required
This is the simplest structure, and is using a single power supply source,
very often used. i.e. the utility.

incomers
HV

busbar A
busbar B
HV
subdistribution
board

LV LV
feeders
fig. 12: diagram of a single power supply
network. fig. 14: diagram of a dual busbar network.

HV

fig. 15: diagram of a network with local generation.

main replacement
source G source

HV

non-essential essential
loads loads
LV (network with backup)
fig. 13: diagram of a dual power supply
network. fig. 16: diagram of a network with a replacement source and load shedding.

Cahier Technique Merlin Gerin n° 169 / p.15


concrete example of a
structure
The diagram in figure 17 was designed
and developed for a multi-metal mine in
Morocco. It includes different network 63 kV
structures that were described earlier.
The power supply to the various
workshops is provided by a loop, a replacement source
duplicate feeder, or a main source and
replacement source. G

choice of equipment 10 MVA 2 MVA 10 MVA


Whatever the structure that is used, the
equipment must comply with:
■ standards in effect;
■ network characteristics: 20 kV
■ rated voltage and current,
■ short-circuit current (making and
breaking capacity, electrodynamic and
thermal withstand);
■ the required functions (fault breaking,
breaking in normal operation, frequency
control, circuit isolation, etc …);
■ continuous power supply
requirements (fixed, disconnectable,
withdrawable switchgear); pit head crushing
■ operating and maintenance staff
qualifications (interlocks, varying
degrees of automatic control, breaking
technique requiring maintenance or
maintenance-free); 5 kV
■ requirements related to maintenance
and possible extensions (extra space treatment grinders
for future use, modular system, etc.).
N.B. At this stage of the analysis, all
the network characteristics result from
calculations that are often carried out
using scientific calculation software.

optimal operation
Optimal electrical distribution system
operation means finding:
■ the best level of continuous power
supply,
■ minimum energy consumption cost, LV LV 5 kV
■ optimization of the operating and
level - 300
maintenance means which contribute to
pit n° 1
correct network operation, both steady
state and transient, and in the presence
of a fault.
The solution lies in the implementation
of an electrical Energy Management
System for the entire network. level - 500
pit n° 2
The Energy Management Systems that
are currently offered by manufacturers,
such as Merlin Gerin, make full use of fig. 17: structure of the electrical network of a Moroccan mine (Merlin Gerin).
microprocessor performance. These

Cahier Technique Merlin Gerin n° 169 / p.16


components, integrated in local and Description of an Energy buses (networks via which the
remote management centres, and in Management System information is conveyed).
the protection and control gear installed (see fig. 18) Assignments carried out by Energy
at the actual energy consumption sites, Energy Management Systems are set Management Systems
are at the origin of the concept of up in four levels: ■ managing energy supply and
"decentralized intelligence". The term ■ level 0: sensors (position, electrical consumption according to:
"decentralized intelligence" means that
variables, etc.) and actuators (trip units, ■ subscribed power,
the control centres and devices
coils, etc.); ■ utility billing rates,
autonomously carry out their
assignments at their levels (without any ■ level 1: protection and control units, ■ availability of the private generating
human intervention) and do not call e.g. HV cubicle; station,
upon the "upper" level except when ■ level 2: local control, e.g. a HV/LV ■ industrial process requirements.
failures occur. The remote monitoring substation of a plant or LV switchboard ■ maintaining continuous power supply
and control system continuously in a workshop: through:
informs the network manager or user of ■ level 3: remote control of an entire ■ quick, discriminating protection (e.g.
changes. private network. logical discrimination system),
This explains the importance of clearly All this equipment, particularly levels 1 ■ automatic power supply source
specifying the network architecture. to 3, is linked by digital communication changeover,

control-monitoring station control-monitoring station


level 3 n°1 n°2
remote control of the entire
private electrical network
(remote control and
monitoring system and
data loggers)

level 2
Welding works branch: intensity 32A er 2: Overload 150A, Load shedding feeder 2: trigged, ground fault
local management of
"plant-substation" networks
(network control centre)

level 1
Def A1
protection and control units I 1 = 96 A I 1 = 136 A
(HV cubicles, workshop main
LV switchboards)

level 0
sensors and actuators
(trip units, limit switches,
instrument transformers, etc.)

fig. 18: example of Energy Management System architecture.

Cahier Technique Merlin Gerin n° 169 / p.17


■ efficient load shedding/reconnection, All this data is used, in particular, to of level 2 hardware and software
the parameters of which can be set via organize preventive maintenance. provide industrialists with technical and
the man/machine interface with the ■ drawing up "User Guide" procedures economic benefits, in particular:
establishment of load shedding criteria which, for example: ■ increased operating dependability;
(load shedding/reconnection plan); ■ prohibit the starting of particular ■ a broader range of accessible
■ sequential workshop restarting, motors according to the power functions, especially data logging,
■ adjustment of voltage, power factor, available from the generating station, preventive maintenance and remote
etc. the time, or the degree of priority of the control,
■ maintaining power supply to motors, ■ easier commissioning and more
essential loads during outages of the ■ prohibiting the use of particular High efficient operation.
utilily supply the local alternators. Voltage switchboard power supply The richness of the functions that are
■ enabling man/machine dialogue: configurations (paralling of supplies), offered by these systems, new
■ real time display of network and ■ proposing the most suitable backup possibilities for self-testing or even self-
equipment status via mimic diagrams arrangement for serious faults in a main diagnosis and monitoring, as well as
(single-line diagrams, detail diagrams, feeder or a generator, the user-friendliness of the user
curves, etc.); ■ proposing operating instructions and dialogue interfaces, naturally make the
■ remote control of switching devices; maintenance operations (electrical, facilities manager's role more effective
■ data and measurement logging, mechanical, etc.). and interesting. The facilities manager
■ chronological recording of faults and Advantages of an Energy is better able to assess the operation of
alarms (10 ms), Management System his network and to optimize, apart from
■ filing of events, The development of level 1 digital remote monitoring and control,
■ metering, statistics, protection and control systems and the maintenance and renewal of his
■ archiving. rapid rise in the performance/cost ratio electrical equipment.

5. conclusion

Well-mastered electrical network investment, operating costs and The new generations of electrical
design makes it possible to ensure production losses. switchgear and equipment are
optimal operation under normal and The best operating conditions provide a designed to communicate, via digital
disturbed network operating conditions. level of continuous power supply to communication buses, with one or
more control centres. And it is the
The best cost does not necessarily loads which is compatible with
combination of both networks, the
mean the minimum initial investment, installation requirements, in the aim of energy network and the information
but rather the design of an electrical obtaining maximum productivity and network, at an acceptable investment
network which proves to be the most maximum safety of people and cost, which provides optimal fulfilment
economical from the viewpoint of initial property. of users' needs.

Cahier Technique Merlin Gerin n° 169 / p.18


appendix 1: extension of an existing
industrial network

The extension of an existing industrial


network by adding a transformer that
can be connected parallel to the
existing transformer has the drawback limiting new
of increasing short-circuit current 36 MVA reactor 20 MVA
strength and also of making it Ucc = 12% transformer
necessary to increase: 17 kA Usc = 12%
■ the breaking and making capacity of X = 0.81 Ω
I sc 1
the existing devices, 10 kV 10 kV
■ the old installation's resistance to
electrodynamic stress. 4 kA
The installation of a three-phase 21 kA
existing installation new installation
reactor between the old and new
facilities eliminates these difficulties
(see fig. 19). fig. 19: extension of an existing industrial network by addition of an extra transformer.

hypotheses
■ short-circuit current of the existing 21 - 17 = 4 kA = IscL
installation: 17 kA (Isc1), ΙscL = current limited by the reactor
■ short-circuit current in the existing V
busbar must be limited to 21 kA (Isc2), =
X
XTr = 0.63 Ω.
X = total reactance (20 MVA
transformer and limiting reactor)
approximate calculation of V 10,000
X= = = 1.44 Ω
a current limiting reactor IscL 3 x 4,000
(resistors neglected) X = Xreact + XTr
The current flowing through the reactor XTr = 0.63
should be equal, in the first X react = 1.44 - 0.63
approximation, to: X react = 0.81 Ω

Cahier Technique Merlin Gerin n° 169 / p.19


appendix 2: computerized means used for
network analyses

Here is a list of the main software ■ harmonic currents and voltages, Merlin Gerin. It is used to make a quick
programs used in Merlin Gerin's ■ lightning and switching voltage comparisons of the unavailability of
different departments that are surges, voltage at a particular point in the
responsible for analyzing and/or ■ transformer and capacitor switching, network using distribution schemes.
designing electrical networks. ■ unavailability of electrical power
It offers the advantage of requiring
supply.
fewer calculations than the Markov
calculation software graph method, and also of providing
programs expert system for both qualitative information (graph of
■ load flow study,
evaluating electrical combinations of events which lead to
■ short-circuit currents, network design quality system failures), and quantitative
■ voltage drops, An expert system called ADELIA has results (network unavailability
■ network dynamic stability, been developed and is used by calculations).

appendix 3: general principle of


compensation

The principle of compensation using installlation output is thereby improved


capacitors may be illustrated by the two since losses due to the Joule effect are
figures opposite. proportional to the square of the before after
■ figure 20 shows the vectorial current. compensation compensation
composition of the different currents
and for a given active current, the increased
reduction in the total current in the available
conductors. power
Ia
Ia = active current consumed ϕ1 ϕ2
It1 = total current prior to compensation active
Ir1 = reactive current supplied via the power
transformer prior to compensation
It2 = total current after compensation
Irc = reactive current supplied by the Ir2 It2
capacitor
Ir2 = reactive current supplied by the reactive reactive
transformer after compensation Irc power power
(Ir2 = Ir1 - Irc) output by the supplied by
■ figure 21 illustrates the local It1 transformer the capacitor
Ir1
exchange of reactive power which fig. 21: diagram depicting the energy
takes place between the load and the fig. 20: phasor diagram of the different exchange in a consumer circuit and the
capacitor. The total current supplied by currents and the effect of compensation. advantage of compensation.
the network It2 is reduced and the

Cahier Technique Merlin Gerin n° 169 / p.20


appendix 4: choice of the earthing system
for a HV industrial network

The choice of the earthing system for a ■ constraints related to the type of ■ isolated neutral.
High Voltage industrial network loads, Each of them offers advantages and
involves the following criteria: ■ etc. drawbacks with which the network
■ general policy, Five diagrams may be considered: designer should be familiar before
■ legislation in effect, ■ directly earthed neutral,
making his final choice. They are listed
■ constraints related to the network, ■ reactance- earthed neutral,
in the chart below (see fig. 22).
■ constraints related to network ■ resonant- earthed neutral,
operation, ■ resistance- earthed neutral,

directly earthed neutral advantages drawbacks in practice


diagram
directly earthed neutral ■ facilitates earth fault causes high earth fault currents not used
detection and protection (dangerous for personnel and risk
discrimination, of major equipment damage)
■ limits overvoltage
reactance-earthed limits earth fault currents ■ requires more complex protection applicable without any particular
than direct earthing, precautions only if the limiting
■ may cause severe overvoltage, impedance is low with respect to
depending on installation configurations the circuit's earth fault resistance
resonance-earthed is conducive to self-extinction requires complex protection ■ sometimes used in Eastern
(Petersen coil) of earth fault current (directional devices that are difficult countries
to implement) ■ not used in France
resistance-earthed ■ limits earth fault currents, the most beneficial for industrial
■ facilitates earth fault current distribution: it combines all the
detection and protection advantages
discrimination,
■ limits overvoltage
isolated from earth limits earth fault currents ■ risk of overvoltage no tripping when the first earth fault
■ requires the use of over-insulated occurs entails:
equipment (line voltage between phase ■ being granted special
and earth when a zero impedance dispensation (French law)
fault occurs), ■ that the capacitance between
■ overvoltage protection advisable, active network conductors and
■ insulation monitoring obligatory earth do not cause earth fault
(French law), current that is dangerous for
■ complex discrimination between personnel and machines.
earth fault protection devices

fig. 22: advantages and drawbacks of the different earthing diagrams used for a HV industrial network.

Cahier Technique Merlin Gerin n° 169 / p.21


appendix 5: network voltage drops
(mathematical expression and vector diagram)

Voltage drops in a network may be


calculated using the following Lω
mathematical expression: source R
∆V = R I cos ϕ + X I sin ϕ I

load
The electrical diagram and vector Va
Vd AD = RI cos ϕ
diagram which correspond to this
equation are given in figure 23. DE = BC sin ϕ + CF sin ϕ
DE = BF sin ϕ = XI sin ϕ
cable

Vd
XI
Va A D C θ
ϕ ϕ E

I RI B

fig. 23: phasor diagram of network voltage drop

appendix 6: stages in industrial network


design

This logic diagram comprises two organization of a network structure in analysis and selection loop
loops: an "Overall single-line diagram"; leading to the organization of
■ the first one, the analysis and ■ the second is aimed at optimization a structure
selection loop, starts at "Needs and of the structure. structure optimization loop
constraints to be met" and leads to the

Cahier Technique Merlin Gerin n° 169 / p.22


Needs and
constraints to
be met

Major needs
met and/or
load survey constraints Choice of the motor starting method
$ active This depends on:
$ reactive mastered $ permissible network voltage drop
based on
NO $ braking torques and motors
$ load factors $ inertia of rotating machines
$ diversity factors
N.B. The maximum voltage drop and starting time
values currently encountered are:
$ voltage drops = 10 to 15% of rated voltage
Choice of voltages
YES $ starting times:
£ pumps = 0.5 to 2 s
According to: £ grinders = 5 to 10 s
$ the function to be performed: £ conveyor belts = 5 to 30 s
£ transmission £ fans = 10 to 200 s
£ distribution
£ consumption
$ power available and power
to be supplied
$ the distance between sources Calculation of voltage fluctuations under normal
and loads and disturbed operating conditions
$ local practices and habits

Reactive energy compensation Short-circuit current calculation


Using the following main criteria
for choosing the type of
compensation:
$ feeder length and cross
section Protection system definition
$ desired increase in available
active power

Backup sources Insulation coordination analysis


$ standards
$ laws
Replacement sources
$ maintaining of production facilities Feeder definition
operation Main criteria to be used:
$ power supply convenience $ steady state current (or equivalent)
$ installation method
$ exposure to sun
$ ground temperature
$ air temperature
Autonomous electrical power $ ground conductivity
production $ permissible voltage drop under normal and disturbed
If the industrialist: operating conditions
$ has available vapour produced $ short-circuit current withstand
by the process $ cable screen withstand to single-phase and/or
$ has fuel available at a low cost multiphase faults
$ is unable to obtain a strong or $ contact voltage
reliable utility supply $ etc.

Choice of earthing systems


Division of sources among the following possible diagrams:
To delimit areas disturbed by: $ isolated neutral
$ starting of large motors $ directly earthed neutral
$ power electronic systems $ neutral earthed via a reactor or Petersen extinction coil
$ etc. Overall $ neutral earthed via a resistor
single-line
diagram

Cahier Technique Merlin Gerin n° 169 / p.23


appendix 7: bibliography

Merlin Gerin Cahiers Techniques


■ Protection of electrical distribution
networks by the logic selectivity system
Cahier Technique n° 2
F. SAUTRIAU
■ Mise à la terre du neutre dans un
réseau industriel haute tension
Cahier Technique n° 62
F. SAUTRIAU
■ Gestion de l'énergie dans les
processus industriels
Cahier Technique n° 133
C.G. POUZOLS
■ Surtensions et coordination de
l'isolement,
Cahier Technique n° 151
D. FULCHRION
■ Calcul des courants de court-circuit,
Cahier Technique n° 158
R. CALVAS, B. DE METZ NOBLAT,
A. DUCLUZAUX and G. THOMASSET
■ Lightning and HV electrical
installations,
Cahier Technique n° 168
B. DE METZ NOBLAT
Miscellaneous publications
■ Overvoltage when clearing short-
circuits from networks with a reactance-
earthed neutral system.
Bulletin de la société Française des
Electriciens, series 8, Volume 1, n° 4
(April 1960)
LE VERRE

Réal.: Sodipe - Valence


Edition: DTE - Grenoble
10/94 - 2500 - Printing: Leostic - Seyssinet - Pariset
Cahier Technique Merlin Gerin n° 169 / p.24 Printed in France

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