upc 621.3114 OUTLINE OF 132kV SUBSTATION FOR UMM SAID INDUSTRIAL AREA DELIVERED TO M.E.W. STATE OF QATAR 1. FOREWORD ‘The recent industrial development of petrochemicals, steel, and other basic industries in the world’s oil producing countries, including the Middle East, has been noticeable and the expansion of power supply equipments to cope with the increasing demand for power accompanying this development is proceeding at a high pitch. ‘The main contents of this expansion are: (1) Construction of large power substation in industrial zones established by the country. (2) Construction of large power substation in industrial zones established by the country. (3) Constructuon of planned large power line networks for, future industrial zone development and city planning associated with (1) and (2). This construction is proceeding on a long-term plan as national policy. When these plants are purchased from oth- er countries, the electrical machinery manufacturer fre- quently receives orders only for delivery of equipment and despatching of engineers. However, the Middle East oil pro: ducing nations often make full tern key contracts with elec- trical machinery manufacturers that include civil works, site construction, site test, and maintenance for several years after start-up. When constructing such big procjects, the end user consigns basic planning, preparation of contract specifica tions, checking of approval drawings, attended inspection at product completion, site work inspection, and other user business to an American, European or other engineering company. Therefore, we electrical machinery manufactur- ers usually act through the engineering company from the beginning of negotiations to turning over of the plant after completion. The substation introduced here is one of the 132/33/11KV substations for industrial area ordered by the M.EW, state of Qatar, one of the oil producing nations on the Persia guif on the Arabian peninsula, and was con- structed at the center of the Umm Said industrial area being developed by the state of Qatar. ‘The user was represented by the consulting firm of “Kennedy and Donkin Consultant Engineers” in England from basic planning to commissioning test after site com- pletion, The contract was a full tern key contract covering 82 Tsuneo Ohkawara civil works, site construction, site test, and maintenance for one year after start-up. Although work based on an addi- tion to the contract is still progressing, the main substation and some of the local substations based on the original con- tract have already been operating favorably for a year. This substation consists of 132kV SF, gas insulated switchgears, main transformers, 33 kV metal clad switch- gears, and other main equipments. However, various unique concepts were employed at each facility to cope with the severe environment in which the substation is installed, facing the sea on one side and the desert on the other three sides, and the different technical customs requirements for safety design practice in the country ‘The following outlines this project. Hl, POWER LINE SYSTEM AND EQUIPMENTS Main power line system ‘The main power line system of this substation consists of a main substation having 132 kV bus bars, 33 kV bus bars, and 11 KV bus bars and a number of local substations supplied from the bus bars of the main substation. Since the power receiving lines are connected with two large net- ‘work substations by a 132 kV parallel connected transmis- sion lines. ‘The 132kV bus bar is the supply bus to large con- sumers and also plays an important part as a 132 kV power transmission network switching station. It is common to the power line system in that itis @ duplicate system such that, (1) 132 KV circuit, 33 kV circuit, 11 kV circuit bus bars are a double bus bar system or duplicate system with, ‘two single bus bars. (2) The main transformers consists of three SO% capacity, or two 100% capacity units, (3) Duplicate power line system to each consumer. is employed for high system reliability that permits im- mediate changeover at bus bar, equipment, or transmission cable trouble and maintenance and inspection ‘Two transformers having a 100% capacity are also in- stalled at the local substations installed at the entrance to each consumer (steel mill plant and ethylene plant) for any faults that may occur and for no-break maintenance andMan sutton eae Abu Fonts" ‘power ot 152A bus ca | ree OF abe oe i exams S38 bus ‘Stee! nln substation 2x 150A 2HV SL. cal 38 power suply i] L (NGL tne) Erlee pt substation 2x200A 2x 75M, UW bs or Fig. 1 Koy diagram for power inspection. There are three local substations (consumers) as shown in the figure. However, numerous full constructed stand-by feeder units are installed at each bus of the main substation ‘based on the future development plan as an industrial area. 2. Facility composition @ The main equipments of the main substation and each local substation are as follows 1) Main substation (1) Main switchgear room @ a) 132 KV SF gas insulated switchgear ot 2000/8004 32.8 kA double bus bar system (total 23 units) ‘Outline of 1928V Substation for Um Sali Industrial Area Delivered to MEW. jatrbution +b) 132/33 KV 40/20 MVA main transformer 3 sets Forced oil forced air (OFAF)/oil immersed self cooled (ONAN) with ondoad tap changer ©) 33 kV metal clad switchgear Lot 2,000/800A 26.3 KA double bus bar system (total 18) 4) Protection relay panels Lot for 132/33 kV feeders (total 38) and 132/33 KV bus bar protection (13 each) ©) 33 KV system earthing transformer 3 sets combined with L.V.A.C. power supply winding. 33 kV/V/3 600A 30 sec/380V 750 kVA continuous, f) 380/220V main L.V.A.C. panels lot 8) 110V DC power supply equipment 700 AH clad type storage battery 2eets 250A changer 2sets Charging switching panel, distribution panel 1 lot h) Fire extinguishing facility for main transformer/ earthing transformer Lot Water mist system, automatic extinguishing system with fire detectors Shunt reactor area, Outdoor oil immersed selfcooled three-phase shunt reactor 2 sets 132 kV 15 MVA, cable directly connecting system. 33/11 KV substation a) 33/11 KV 20/10 MVA transformer 2sets Oil immersed air cooled type (ON A F )/oil im- ‘mersed self-cooled type (ON A N) with onload tap tote of Gator 83changer. b) 11 KV metalelad switch gears Lot 1,200/600A 350 MVA ©) Protection relay panels for main transformer 1 lot 4) 380/220V AC and 110V DC distribution panel 1 lot ©) COz mist type automatic fire extinguishing equip- ment i lot (4) Control room. a) 132/33 KV circuits contro! panels, Lot ) Local substation mimic display panels (mosaic sys- tem) Lot ) Metering panels (for each consumer feeder) 1 lot, 4) Station power supply emergency Diesel engine gene- rator T set 380/220V 50 Hz 450 kVA power factor 0.8 €) SOV DC power supply equipment for remote con- trol/display 400 AH clad type storage battery 2sets 100A battery charger 2sets Charger switching panel, distribution panel 1 set £) 380/220V AC distribution panel lot 8) 110V DC distribution panel Lot h) Interface panels for power line carrier equipments for supervisory control lot 2) Steel mill plant substation ) 132/66 kV 150 MVA/75 MVA main transformer 2 sets OFAFJONAN with ondoad tap changer ) Main transformer protection relay panels. 1 lot ©) Main transformer local control panels lot 4) 132 kV cable protection relay panels Lot ¢) Water mist type automatic fire extinguishing equip- ment ot 1) 66RV/V3 100A 30 secs, NGR 2sets 8) 380/220V AC, 110V DC distribution panel 1 lot 3) Ethylene plant substation a) 132/33 KV 75 MVA/37.5 MVA main transformer 2 sets OFAF/ONAN with on-load tape changer b) Main transformer protection relay panels. 1 lot ©) Main transformer local control panels ot 4) 132 KV calbe protection relay panels Lot ) Water mist type automatic fire extinguishing equip- ‘ment Lot £) 33 KV/V3 750A 30 secs, earthing transformers 2 sets 8) 33 kV/V3 750A 30 secs, NGR 2 sets 4) NGL plant substation Cable protection relay pane! ot Ill, FEATURES OF FACILITY 1. Coping with special environmental conditions As previously mentioned, the installation site of this substation is a special region facing the ocean on one side and a desert on the other three sides, and the following environmental conditions had to be given to the design and 84 ‘manufacture of each facility. (1) Large effect of ocean breezes (salt damage). (2) Seasonal desert sand storms. (3) Maximum ambient temperature of 50°C. (4) Maximum relative humidity of 100% (dewy condition), To cope with these special environmental conditions, the parts of each equipment affected by the environmental conditions were checked by function, based on the custom- cr specifications for an indoor facility, and the following basic countermeasures were taken: 1) Indoor temperature rise and dustproofing ‘The required ventilation to suppress the indoor temper- ature rise caused by the calorific value of the equipment and the radiated heat from the sun entering the building through the roof and walls to the allowable value was cal- culated and forced ventilation equipments were installed, Good dust collecting performance, easy maintenance roll mat type filters were installed at the air inlets and special consideration was given to preventing clogging by raising the filter take-up speed especially in the dust storm season, ete. The pressure inside the building was made higher than the outside pressure by selecting a suitable in- take fan and exhaust fan air flow to prevent the entry of dust from outside, ‘The ventilation equipment is divided into a number of blocks by auxiliary power source system and special con- sideration was given to the fan layout and air flow to suppress the abnormal rise of the room temperature even if trouble should occur in the equipment. The transformer room was equipped with ventilation equipment independ- ent from the other rooms because of the telationship with the water mist type fire extinguishing equipment and the ventilation equipment are automatically stopped when a fire occurs The comfort of the maintenance personnel was taken into consideration and an air conditioner was added at the control room to maintain the temperature and humidity constant throughout the year. 2) High temperature countermeasures In regard to the maximum ambient temperature of 50°C, the following countermeasures were taken in the design and manufacture of the equipment based on basic policy of (1) the life of the equipment must not be shortened, (2) the performances of the control equipment, etc. must not be adversely affected. @ To lower the temperature rise value of the equip- ment by 10°C from the stipulated standard value, the radiators of the transformers, etc. were in- creased. Moreover, the current rating of the switchgear, cables etc. was raised one rank. @® The operation characteristics of the meters, relays, and other main control devices at 50°C were checked and operation without any trouble in the practical performances was confirmed. 3) High humidity countermeasures Since the temperature change under 100% humidity conditions is directly related to dewing. Continuously oper- FUJI ELECTRIC REVIEW Vol. 26 No.3. 1980ated space heaters were installed at high voltage switchgear, general purpose panels, terminal boards, and other equip- ‘ment that are easily affected by dewing. For design of the space heater, the heat balance of the calorific value from the heaters and the dissipated heat from the natural cooling ventilation ducts, and the temperature inside the panels was ‘maintained at a higher temperature than the ambient tem- perature and the relative humidity inside the panels was suppressed to below the ambient humidity. Heat resistance and moisture resistance tests by using a constant temperature tank were made on the meters, relays, and other control apparatus and their practical perform- ances, even in the frosted state, was guaranteed. 4) Corrosion countermeasures ‘The processing standards for each type used in the past were studied as countermeasures for tropical humid regision and uniform processing standards were prepared for this project to assure uniformity among factories from parts selection to plating material and painting of main equip- ments, Fig, 4 Overall view of 122 kV SF, go insulated switchgears Ab pet a factory completion, Fig. 4 shows an overall view of the switchgear after installation, and Fig. 5 is a sectional view of the switchgears room. The delivered SF, gas insulated switchgears are used as the 132 kV bus bar switchgear which is the most important part of the main circuit system shown in Fig. 1. A bus see- tion unit is provided between the double bus bar system, and the unit are installed in the center of double bus to divid the entire system into 4 bus bars so that each bus can be operated independently. The power transmission reliabil ity was made extremely high by means of power incoming from two independent systems, two independent distribu- tion systems to each consumer, bus protection relay equip- ment installed at each bus bar, etc. The following describes the additional main features of ‘this equipment. (A) Since all the units (total 23 units) are installed in a straight line facing the front as shown in Fig. 4, it has a pleasing appearance and onsite operation and mainten- ance are easy’ (2) Bach unit is attached to an independent base as shown in Fig. 3 and Fig. 5, and was shipped completly as- sembled, ‘The units were installed by laying two base channels and fastening the base of each unit to this base channel as shown in Fig. 5. This base channel supports the static load and dynamic load (vibration of breaker switching) of each unit, prevents the application of un- reasonable force against the floor, and shortened the installation time by serving as rails when the equip- ‘ments were carried into the room, (3) The same concepts were incorporated into the com- mon high voltage metal clad switchgear and the breaker body was the draw-out type and the breakers of all the units were interchangeable in case trouble should occur. The use of a ceiling crane to carry the breaker was con- sidered, but it was delivered with an “air pallet” cor- responding to a dolley, considering the economy of the 4 [- a N cube wom | Bae cha ee Fig. 5 Sectional view of 132 kV SF, 988 ineulated switchgears room uttne of 132kV Substation for Unm Said Industral Area Delivered 10 MEW. State of Gotor 85@ 6) © a Q) @) 86 lene sue ar charoer Fig, 6 Principle drawing of sir pal crane facility and building, The principles of this equipment resemble those of @ hovercraft. As shown in Fig. 6, the entire equipment is lifted by applying air pressure to the floor and the action of the thin air layer between the air chamber sliding face and the floor causes the floor to slide. When this air pallet is used, the floor finish must be air tight to @ certain extent, but concentrated load to the floor ean be avoided and the equipment easily moved by manpower by its use. To generate a low gas pressure alarm only at the neces- sary points even when the control power of each unit is interrupted for maintenance, a “portable gas alarm unit” for the maintenance personnel and a “remote gas alarm unit” for remote supervision were delivered as optional accessories. A isolator and earthing switches operating mechanism ‘was equipped with a interlock mechanism using an automatic reset type key switch at the manual operat ing section and a lock mechanism was installed at the ‘motor operating shaft and other safety design practices bbased on the users technical customs were followed. ‘The following SF, gas handling equipment requested by the customer, as well as normal gas recovery equip- ment, were delivered. ® Moisture meter ® Leakage detector © 0, gas analyzer ‘Main transformer All the main transformers are of the separately instal- Jed main tank and radiator type and have forced oil, forced air self-cooling double ratings (100%/50%). All the things connected to the bare conductors by air bushings were housed in the building to prevent salt damage. To avoid local overheating of the core by eddy current, the core was separated from the tank and frame and grounded at one point. However, a handhole was pro- vided at the ground connection section to permit megger testing from the outside, This was based on the customer's design concept of checking for core damage during shipment and checking of the insulation after Fig, 7 150 MIVA power transformer under shipping the start of operation. (4) A sequential starting circuit and resistance starting cir- cuit was provided at each oil pump to alleviate the oil level variation at pump starting and to prevent errone- cous operation of the Buchholtz relay. This was based on the design concept that the protection relay must not lock even at instush (5) Winding temperature monitoring equipment was instal led to automatic operation of the cooling equipment and for back-up tripping at an overload. 4, 33KV metal clad switchgears Each metal clad switchgear employs a JEM-F2 class double bus bar system and each unit consists of a bus bar selection disconnecting switch, 1500 MV minimum oil cir- cuit breatker, bushing feedthrough type CT, moulded PT, and earthing switch, Fig. 8 is 2 sectional view of the switchgear under as- sembling and Fig. 9 is an exterior view of the switchgear under assembling, As shown in the sectional view of Fig. 8, the discon- necting switch and other equipments, including each bus Fig. 8 Sectional view of 33 kV switchgear under assembling Vol. 26 No.3 1980 FUJI ELECTRIC REVIEWbar, are arranged for simple maintenance and inspection. ‘The insulation barrier of each partis constructed to be easy to remove to facilitate inspection. The shutter in the circuit breaker room can be opened at both the bus bar side and circuit side, even when the cir cuit breaker is drawn out, and it is equipped with a safety lock. The earthing switch and bus bar selection disconnect- ing switch are equipped with the same operation interlock mechanism as the 132 kV SF gas insulated switchgear and the earthing switch also has a mechanical interlock with the breaker drawer mechanism. In the case of the power side circuit, installation of an electric interlock with the re- mote end switch or installation of a nameplate, and other considerations were taken to prevent earthing of not line by erroneous operation. 5.11 KV metal clad switchgear The 11 kV metal clad switchgear is needed to be inter changeable with that used by the customer at each place, Metal clad switchgears made by Reyrolle (England) was purchased and delivered as specified by the customer. The circuit breaker is the bulk oil type, so-called OCB, and to also use it as an earthing switch, it was constructed so that circuit breaker can be inserted and closed at the bus earth, operation, and circuit earth positions. An exterior view of the switchgear is shown in Fig. 11 Fig, 11 Exterior view of model "LMT2” 11 kV switchgears supplied by Reyrolle Lad. Fig, 12 Relay room for main substation 6. Protection relay system ‘As shown in Fig. 12, the protection relay system con- sists of rows of panels separated into the following four groups and housed in the relay room of the main switchgear building. (1) 132 KV bus bar protection panels (2) 33 kV bus bar protection panels (3) 132 kV circuit protection panels (4) 33 KV circuit protection panels The bus bar protection relay system provides dis- criminating protection of each bus bar by combining check relays and discriminating relays for both 132 kV and 33 kV bus bar systems. Both the check relays and discriminating relays incor- porate an exclusive CT and can also detect CT open circuit. Biased current differential electromagnetic type relays are used as the check relays and similar biased current dif- ferential transistor type relays (with checking device) are used as the discriminating relays. ‘A test CT having the same characteristics as the actual CT was manufactured for the bus protection relays and its operating characteristics were confirmed by conducting (Outline of 1328V Substation for Umm Said Industrial Arga Delivered to MEW. State of Qotor 87Fig, 14.18 kV insulation junction box for pilot/telephone cable tests (dynamic test) by combining it with a short circuit generator. ‘The following were used as the main protection relays for each circuit 1) 2) Long distance fine Distance relay (with carrier acceleration) Short distance line 15 kV insulation, 2-wire pilot wire relay with intertrip and pilot supervision equipments. 3) 4) Main transformer circuit Biased differential type (layer faulty detection) Restricted earth faulty relay (earth fault detection) Shunt reactor circuit Current balance type (cable faulty detection) Restricted earth faulty relay (winding earth fault detec- tion) Instantaneous type overcurrent relay (overcurrent detection) (with delay timer) 7. Control system (1) Normally, supervision and control is performed from the control panel installed in the control room. Con- sideration has been given so that supervisory control can be performed from a supervisory control room about 50km from this substation through power line carrier equipments. (2) A portable type synchronizing check equipment hous- ing synchronizing check relays is provided and each cir- cuit breaker of the 132 KV and 33 KV systems can be closed through the synchronizing check circuits (3) To supervise the state of the local substation installed in each consumer at the main substation, mosaic type supervisory panels are installed in the main substation control room and main circuit breaker switching dis- play and trouble display are performed, (4) Multiconductor type “pilot/telephone cable” (15 kV insulated) was layed between each local substation and the main substation. This cable is used for transmission of the previously mentioned pilot wire relay signals, local substation status display and asa direct telephone cireuit (S) A two motion type “discrepancy control switch” which can also serve for performing switching display at the normal switch handle position is installed at the 132. KV and 33 kV systems control panel in the m: substation as the circuit breaker and disconnecting switch operation switch, and an “automatic semaphore indicator” that performs mechanical indication instead of a lamp is installed at point which only performs switching display to conserve battery current and for matching to the mimic bus. (6) A lamp cabinet containing “alarm stop, reset, lamp test” pushbuttons is provided at each feeder panel as fault display equipment, and all the power supply equipment and annuciator relays, etc. needed by the display system are made electronic and are housed in a separate type “logic panel” “Repeat contact equipment” to send contacts of the same nature as the site trouble contacts to a remote site is also provided at this logic panel 8. Control and auxiliary power supply equipments 1) LV.AC. power supply equipment ince the voltage of the auxiliary power used at this station is 3-phase 380 V for general auxiliary machines and single-phase 220 V for lighting and space heaters, a 3-phase, 4-wire (380-220 V) power supply system was adopted. As shown in Fig. 15, the power bus bars are divided into “a nonessential bus,” “essential bus,” and “emergency bus” corresponding to the importance of the load. In addition, ‘an emergency diesel engine-generator which automatically starts when the commercial power is interrupted is provided to supply a safety power source (battery charging, emergen- cy lighting, SF gas insulated switchgear hydraulic pump, fire extinguishing pump, control room ventilation equip Vol. 26 No.3 1980 FUJI ELECTRIC REVIEWwar Erorgoncy goertor —O Fig. 18. Key diagram for low voltage AC auxiliary power supply equipment nat toy Fig. 16 Key diagram for 110 V DC and 0 V DC control power supply equipment ‘ment load, ete.) at a total power failure. Two of the three station transformers are for main use and the remaining transformer is for standby use. If trouble Cutie of 1324Y Substation for Umm Said Industrial Area Delivered to MEW. State of Gotor fcccurs at one of the amin transformers, operation is auto- matically switched to the standby transformer. A control circuit that automatically switches the circuit so that the remaining transformer is connected to the essential bus side when both of the main transformers stop is provided. 2) DC power supply equipment In addition to the 110 V power supply for general con- ‘trol and protection relay circuit use, this substation is equipped with a DC 50 V power supply for control display and telephone in the central control room. ‘The main circuit of both the 110 V and 50 V systems consists of two storage batteries, two chargers and their switching equipment as shown in Fig. 16. The equipment is constructed so that quick charging and maintenance and in- spection can be performed independently from each circuit, 9. Master key systems For erroneous operation prevention, locks with indi- vidural keys are provided at the transformer valves, panel doors, main changeover switches, and other main operating parts. However, the construction of all the locks of the main equipments has been made uniform to provide @ common key (master key) for all the equipments in addi- tion to the individual keys, IV. CONCLUSION An outline and the special features of the 132 kV sub- station equipments delivered to M.E.W. state of Qatar were siven above. There are many other points processed to meet the technical customs of the customer not seen in products for domestic use, but these had to be omitted because of space considerations, The authors will be happy if this article serves as re- ference for fuller technical planning when holding business for the same kind of substation for export in the futur.