Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
HV industrial
network design
Georges THOMASSET
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
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.:
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.
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
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
calculation of voltage
fluctuations under normal
and disturbed operating
conditions 30 km line
ω
G (rad/s)
alternator G
300
fig. 9: presentation of the dynamic performance of a network with and without load shedding
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.
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
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.
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
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.)
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.
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
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).
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,
fig. 22: advantages and drawbacks of the different earthing diagrams used for a HV industrial network.
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
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
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