Clem7 Tunnel - IEAUST Presentation Electrical Power Systems Design

July 2010

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 to Chatsworth Rail Line Lane Cove Tunnel

In Queensland to date: The Inner City Bypass D&C South Eastern Busway C The Inner Northern Busways 4 C & 5 D&C Boggo Road Busway Design C

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

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

Design Objectives
Perform all Electrical Engineering design requirements to meet the M&E Performance 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 Project substations 22kV stepped down locally at each substation to 690V & 433V Loads shared across A & B supplies with 690V & 433V switchboards in each substation Dual 690V / 433V supplies to each 690V & 433V switchboard automatic changeover

Systems Overview
690V : directly supplies significant plant system motors in vicinity of substation 433V : general light & power and small motors Submains distribution to XPs in vicinity of substation Lighting / power / communications then distributed to devices in vicinity of XP ( 116m) Local Energex power supplies to RSCs for surface related works UPS system provides essential power to life-safety devices

Systems Overview

Incoming Energex Supply

Negotiations with Energex established that 25MVA of capacity at 33kV would be available from both the North and South sides of the Brisbane River - these supplies are 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

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 Operations Control System, the details of which are not included in this presentation

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 distribution boards 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 luminaire from 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 with electronic motor protection relays to allow monitoring of the drive condition by the tunnel control system with the direction of flow determined automatically Electrically actuated (240V 50Hz) Smoke Dampers are mounted through the smoke duct as the passage to draw smoke from the tunnel 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 the largest 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 to the tunnel deluge piping main There is a combination of both 690V and 433V pump drives for this purpose

All pumping operates automatically through process control systems

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Electrical Power System LV 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 of the tunnel (4.5km) with Electrical Distribution Substations established at 1km intervals approximately plus there are 2 above ground substations associated with each of the vent stations, a total of 2 above ground and 5 in tunnel, 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 each switchboard Switching of the A & B supplies to each board is electrically and mechanically Interlocked via an automatic changeover

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LV Systems Design Electrical Distribution

690V 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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LV Systems Design Electrical Distribution

The distribution of the tunnel electrical load is shared by the 7 Substations each substation distributes minor circuits via Cross Passage Distribution Boards South to North across the Brisbane River #1 (surface) @ Woolloongabba / SVO Site #2 (tunnel) @ approx XP4 (cross passage 4) #3 (tunnel) @ approx XP15 #4 (tunnel) @ approx XP23 #5 (tunnel) @ approx XP30 #6 (tunnel) @ approx XP38 #7 (surface) @ Bowen Hills / NVO Site

There are 41 Cross passages through the tunnel

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LV Systems Design Electrical Distribution

B SUPPLY
415V Switchboard
Transformer TRX212 22kV / 433V, 0.5MVA

A SUPPLY
Sub01 LVS211 415V Switchboard 660V Switchboard Sub01 LVS111
Transformer TRX113 Transformer TRX112 22kV / 433V, 0.5MVA

Transformer TRX213 22kV / 690V, 5MVA

Sub01 MCS211 660V Switchboard Sub01 MCS111

22kV / 690V, 5MVA

Transformer TRX222 22kV / 690V / 433V, 2MVA

Transformer TRX122 22kV / 690V / 433V, 2MVA

Transformer TRX232 22kV / 690V / 433V, 2MVA

415V Switchboard Sub04 LVS241 415V Switchboard

Transformer TRX132 22kV / 690V / 433V, 2MVA

Transformer TRX242 22kV / 690V / 433V, 1.6MVA

Sub04 LVS141 660V Switchboard Sub04 MCS241 660V Switchboard Sub04 MCS141

Transformer TRX142 22kV / 690V / 433V, 1.6MVA

Transformer TRX252 22kV / 690V / 433V, 2MVA

Transformer TRX152 22kV / 690V / 433V, 2MVA

Transformer TRX262 22kV / 690V / 433V, 1.6MVA

Transformer TRX162 22kV / 690V / 433V, 1.6MVA

Transformer TRX272 22kV / 433V, 1MVA Transformer TRX273 22kV / 690V, 5MVA

Transformer TRX172 22kV / 433V, 1MVA Transformer TRX173 22kV / 690V, 5MVA

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LV Systems Design Electrical Distribution

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LV Systems Design Electrical Distribution

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LV Systems Design Electrical Distribution

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LV Systems Design Electrical Distribution

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HV Systems Design
With the LV Supply Requirements established the Tunnel HV Supply potential of 22kV was chosen to establish a potential separation with Energex. 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

Transformer TRX212 22kV / 433V, 0.5MVA

Transformer TRX112

22kV Switchboard
Transformer TRX213 22kV / 690V, 5MVA

33kV / 22kV 22MVA Transformer Sub01 TRX111

22kV / 433V, 0.5MVA

22kV Switchboard Sub01 HVS111

Transformer TRX113 22kV / 690V, 5MVA

Sub01 HVS211

Transformer TRX222 22kV / 690V / 433V, 2MVA

22kV Switchboard Sub02 HVS221

22kV Switchboard Sub02 HVS121

Transformer TRX122 22kV / 690V / 433V, 2MVA

Transformer TRX232 22kV / 690V / 433V, 2MVA

22kV Switchboard Sub03 HVS231

Energex 33kV Supply Wellington Road Substation

22kV Switchboard Sub03 HVS131

Transformer TRX132 22kV / 690V / 433V, 2MVA

Transformer TRX242 22kV / 690V / 433V, 1.6MVA

22kV Switchboard Sub04 HVS241 Energex 33kV Supply

22kV Switchboard Sub04 HVS141

Transformer TRX142 22kV / 690V / 433V, 1.6MVA

Transformer TRX252 22kV / 690V / 433V, 2MVA

22kV Switchboard Sub05 HVS251

Victoria Park Substation

22kV Switchboard Sub05 HVS151

Transformer TRX152 22kV / 690V / 433V, 2MVA

Transformer TRX262 22kV / 690V / 433V, 1.6MVA

22kV Switchboard Sub06 HVS261

22kV Switchboard Sub06 HVS161

Transformer TRX162 22kV / 690V / 433V, 1.6MVA

Transformer TRX272 22kV / 433V, 1MVA Transformer TRX273 22kV / 690V, 5MVA

Transformer TRX172

22kV Switchboard Sub07 HVS271

33kV / 22kV 22MVA Transformer Sub07 TRX271

22kV Switchboard Sub07 HVS171

22kV / 433V, 1MVA Transformer TRX173 22kV / 690V, 5MVA

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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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Substation Arrangement
Incoming Transformer 22MVA 33/22kV Above Ground Substation 1 & 7

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Substation Arrangement
Below Ground Substation 3, 4, 5 & 6

Substation 6 Southbound Tunnel

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Substation - HV Equipment

Dry Type Transformer

High Voltage Switchboard

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Substation - LV Equipment

Automatic Changeover

Motor Control Switchboard

Switchboard HMI Low Voltage Switchboard

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Substation - LV Reticulation Essential Supply

Uninterruptible Power Supply A UPS system is an integral part of the LV 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 system equipment 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 tunnel substation to the cross passages in its vicinity Tunnel Substation # 2 : XP01 to XP09 Tunnel Substation # 3 : XP10 to XP19, XP47 to XP50 Tunnel Substation # 4 : XP20 to XP26 Tunnel Substation # 5 : XP27 to XP34 Tunnel Substation # 6 : XP35 to XP41

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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 the majority 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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Design Documentation
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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Design Documentation

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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 LV Consumer Mains LV Sub Mains 10,733m 2,149m 42,797m 199,503m

LV Fire Rated Cables/sub circuits LV Control Cabling 108,210m Fibre Optic Cable Earthing Cable 136,254m 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

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