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DEC-2012
REPORT ON
P O W E R R E T I C U L AT I O N S Y S T E M
A B B O T P O I N T C O A L T E R M I N A L T- 0 E X PA N S I O N
DRAFT REPORT
12-DEC-12
REV:0
TABLE OF CONTENTS
1.0 INTRODUCTION ....................................................................................................................................................... 3
2.0 EXECUTIVE SUMMARY ............................................................................................................................................ 3
2.1 DOCUMENT PURPOSE ................................................................................................................................... 3
2.2 EVALUATION / STUDY .................................................................................................................................... 3
2.3 CONCLUSION .................................................................................................................................................. 3
LIMITATIONS ............................................................................................................................................................ 4
3.0 SYSTEM INTRODUCTION ......................................................................................................................................... 5
4.0 OPTION-I AS PER BASIC ENGINEERING .................................................................................................................. 6
3.1 CONCEPT NOTES ............................................................................................................................................ 6
3.2 QUANTIFICATION OF ELECTRICAL ITEMS/EQUIPMENTS ............................................................................ 7
3.3 MERITS & DEMERITS OF PROPOSED SCHEME ............................................................................................. 7
3.4 BULLET POINT ................................................................................................................................................ 8
5.0 OPTION-II SUGGESTED BY BMT WBM ASSOCIATES .............................................................................................. 9
4.1 CONCEPT NOTES ............................................................................................................................................ 9
4.2 QUANTIFICATION OF ELECTRICAL ITEMS/EQUIPMENTS .......................................................................... 11
4.3 MERITS & DEMERITS OF PROPOSED SCHEME ........................................................................................... 11
4.4 BULLET POINT .............................................................................................................................................. 11
6.0 AN ALTERNATE, OPTION-III................................................................................................................................... 12
5.1 CONCEPT NOTES .......................................................................................................................................... 12
5.2 QUANTIFICATION OF ELECTRICAL ITEMS/EQUIPMENTS .......................................................................... 13
5.3 MERITS & DEMERITS OF PROPOSED SCHEME ........................................................................................... 13
5.4 BULLET POINT .............................................................................................................................................. 14
7.0 VFD SCHEME SELECTION ...................................................................................................................................... 15
6.1 CONCEPT NOTES ......................................................................................................................................... 15
6.1 BULLET POINTS............................................................................................................................................ 15
8.0 SUMMARY................................................................................................................................................................ 2
9.0 RECOMMENDATION ............................................................................................................................................... 3
1.0
INTRODUCTION
Abbot Point Coal Terminal is situated at Queensland state on east coast of Australia.
Adani Abbot Point Coal Terminal (AAPCT) Pty Ltd is intended to create certain Common User Facilities,
Common Maneuvering Area, facilities for Material Handling System and facilities specific for handling
Bulk cargo carriers on Berth-3 under T0 expansion at AAPCT (QLD).
2.0
EXECUTIVE SUMMARY
2.1
DOCUMENT PURPOSE
The purpose of this document is to evaluate overall Electrical reticulation system most suitable in
terms of technical reliability as well as overall economics for T0 expansion at AAPCT.
There are 3 (Three) options available for proposed Electrical reticulation system out of which one is to
be finalized that can fulfill above mentioned aspects.
a) Option - I
b) Option - II
c) Option - III
This document details high level Schematic Description, Quantifications, Advantages and
Disadvantages of all three available options.
2.2
EVALUATION / STUDY
2.3
Installation feasibility
System reliability
Operation & Maintenance convenience
Economics involved
CONCLUSION
PARAMETER
Installation cost /
feasibility
Reliability of electrical
system
Reliability of continuity of
port operation.
REMARK
Option-III
Option-II
Cost of installation
Convenience of
installation
Option-III
Option-III
Looking at the overall comparison between various options, we recommend option-III for proposed
power reticulation system.
LIMITATIONS
3.0
SYSTEM INTRODUCTION
The project shall include 1 (one) dedicated berth capable of handling of dry bulk/coal with necessary
back up yard and facilities. The main elements/facilities of proposed terminal project under phase-I
are;
The installation of Electrical & Instrumentation system facility for above mentioned elements/facilities
is to be carried out in accordance with applicable codes, standards, acts & regulations.
Power supply at 66kV (primary source voltage) shall be tapped from nearest source of power from the
network governed by Local power supply authority/network operator and shall be brought at 66kV
Switchyard (AIS).
Power shall be stepped down at required voltage level through Main Power Transformers for further
distribution at Main substation located adjacent to 66kV Switchyard.
The options for Electrical reticulation system proposed by various parties need to be evaluated from
the point of stepped down voltage level.
4.0
3.1
VOLTAGE LEVEL
66kV
11kV
3.3kV
11kV
11kV
3.3kV/3.3kV
3.3kV
0.415kV
REMARK
At Switchyard
From Main S/S to area S/S
Distribution for conveyor motors
CONCEPT NOTES
MAIN SUBSTATION
RAIL
RECEIVING
SUBSTATION-1
STACKING
SUBSTATION
OUTLOADING
SUBSTATION
INLOADING
SUBSTATION
Phase-I (11kV)
Final Phase (11kV)
RAIL
RECEIVING
SUBSTATION-2
WHARF
SUBSTATION
11/0.433 kV
TX-1
11/3.3 kV
TR
11/0.433 kV
TX2
11/3.3 kV
TR
LV PANEL
FIG 3.2
VFD
VFD
VFD
VFD
VFD
VFD
3.3.1 Merits;
Replication of power reticulation system of existing T1 terminal and working satisfactorily.
Simple & proven. Widely accepted power reticulation system.
Type of operation-wise substation that makes operation and maintenance of electrical system
easier.
E.g. Stacking substation for Conveyors/Machines involved in stacking operation,
Out-loading substation for Conveyors/Machines involved in out-loading operation.
No. of location of major electrical installation is less. Hence higher electrical system reliability.
Full redundancy in both system of HV & LV.
Less manpower required for operation and maintenance of electrical system.
3.3.2 Demerits
If one area substation goes down due to any hazard, entire port operation will be affected.
E.g. If Stacking substation goes down, all Conveyors/Machines involved in stacking operation shall
stop working.
Complete isolation of any conveyor needs actions at multiple panels of HT & LT. However, single
click isolation can be achieved but this solution is complicated.
LV cabling is much higher.
Larger size prefabricated substation building required.
Existing T1 terminal power reticulation system was of conveyor motors without VFD. Basic
engineering design does not describe type of VFDs to be used for Conveyor motors.
Handling facility of large size prefabricated substation to be considered at project site.
5.0
4.1
VOLTAGE LEVEL
66kV
22kV
6.6kV
22kV or 6.6kV
22kV or 6.6kV
6.6kV
6.6kV
0.415kV
REMARK
At Switchyard
From Main S/S to area S/S
Distribution for conveyor motors
CONCEPT NOTES
PDC Nr TT-15A
PDC Nr TT-24
PDC Nr TT-18
PDC Nr TT-22
PDC Nr TT-14
Detail Fig 4.2
FIG 4.1
9
PDC Nr TT-12
Phase-I (22kV)
Final phase (22kV)
VFD
LV PANEL
PLC
RI/O
110V
Supply
FIG 4.2
10
4.2
4.3.1 Merits:
Single point isolation can be achieved for each conveyor / machine of the plant. Hence
conveyor/machine maintenance can be carried out very easily.
Hazard / fault on one switchroom or fault at LV system to affect operation of one particular
conveyor. Hence less effect on overall plant operation.
LV cabling & cable tray reduces considerably and becomes simple.
Transportation and handling of prefabricated substation building at project site is convenient as
building sizes smaller.
Immediate isolation of particular conveyor can be performed in case of emergency when
centralized control system gets failed.
Saving in HV cable as 22kV distribution to require less sizes of MV cable to cater same amount of
load than 11kV distribution.
4.3.2 Demerits:
Supply & Installation cost is higher than other reticulation options in terms of No of prefabricated
substations, No. of HT Switchgears, No. of Transformers, PLC-RIO and HV cables.
Unavailability of LV power to be observed on complete isolation of Conveyor system for
maintenance. Incomer breaker for LV transformer has to be kept on for availability of LV power for
conveyor system maintenance then Option-II scheme is no different than other reticulations system
proposed as per Option-I. This case diminishes advantage in Option-II regarding complete isolation
of Conveyor up to much extent.
No redundancy of LV system
Maintenance and operation of electrical system to become difficult as number of Major electrical
equipment installation is much higher. Hence, more manpower required for operation and
maintenance.
Frequency of occurrence of fault likely to increase due as number of Major electrical equipment
installation is much higher.
Absence of mechanical brakes limits VFD options available. Hence, it is observed that proposed
Option-II scheme not to perform any value addition in VFD system by putting VFDs nearer to Motor.
4.4
BULLET POINT
Option-II suggested by BMT WBM scheme does not describe type of VFDs to be used for Conveyor
motors.
Possibility of entire port operation to be on stop in case of outing of any area substation due to any
hazard in reticulation scheme proposed as per Option-I. Similar situation may arise with scheme
proposed in Option-II in case of outing of any PDC or Main substation.
11
6.0
AN ALTERNATE, OPTION-III
Electrical reticulation system proposed in Option-III is illustrated as shown in block diagram.
Refer Fig 5.1
In scheme proposed in Option-III, power is being stepped down to 11kV for further distribution.
DESCRIPTION
Incoming power
Primary distribution
Secondary distribution
Stacker re-claimer
Ship loader
VFD input/output voltage
Conveyor motors
LV distribution
5.1
VOLTAGE LEVEL
66kV
11kV
11kV
11kV
11kV
11kV/3.3kV
3.3kV
0.415kV
REMARK
At Switchyard
From Main S/S to area S/S
For conveyor motors (VFDs)
CONCEPT NOTES
SUBSTATION-D
SUBSTATION-E
SUBSTATIONA
SUBSTATIONB
SUBSTATION
-C
12
11/0.433 kV
TR
VFD
VFD
VFD
VFD
VFD
VFD
11/0.433 kV
TR
LT PANEL AT SUBSTATION-A
LV LOAD
ENGAGED
WITH CONV-1
LV LOAD
ENGAGED
WITH CONV-2
LV LOAD
LV LOAD
ENGAGED
ENGAGED
WITH CONV-3 WITH CONV-4
5.2
5.3.1 Merits;
Simple & proven. Widely accepted power reticulation system.
Reduced number of substation building, elimination of 11/3.3kV transformer and other electrical
installation keeps overall system installation cost lower.
Full redundancy in system of HV & LV.
No. of location of major electrical installation is less. Hence higher electrical system reliability.
Easy in maintenance and operation of electrical system.
Less manpower required for operation and maintenance of electrical system.
13
5.3.2 Demerits
If one area substation goes down, entire port operation will be affected.
Single point isolation is not available. However, Single LV cubicle is placed to supply LV load engaged
with that conveyor. Hence, isolation can be achieved with reasonably easy interlocking.
LV cable requirement is higher than scheme proposed in Option-II.
Larger size prefabricated substation building required.
5.4
BULLET POINT
14
7.0
6.1
CONCEPT NOTES
6.1
BULLET POINTS
Max distance between VFD and Motor for various scheme proposed by various agencies are as
below;
Option-I
: 1200 Mtr (Approx)
Option-II
: 150 Mtr (Approx)
Option-III
: 900 Mtr (Approx)
Option-I (Basic engineering) and Option-II input documents do not describe type of VFD system to
be used that is suitable to its power reticulation system.
15
Table 6.1: 12 PULSE VFD WITH OUTDOOR INVERTER TRNAFORMER (OIL COOLED)
DESCRIPTION
Cost
Distance limitation between VFD and motor
OPTION-I
OPTION-II
OPTION-III
REMARK
Favorable
Favorable
Favorable
Unfavorable
Favorable
Unfavorable
Unfavorable
Unfavorable
Unfavorable
Unfavorable
Unfavorable
Unfavorable
Unfavorable
Unfavorable
Unfavorable
Favorable
Favorable
Not
recommended
Favorable
Favorable
Not
recommended
Favorable
Favorable
Not
recommended
Dynamic braking.
Additional cost for installation
Availability in market
Space requirement inside substation
CONCLUSION
Table 6.2: 12 PULSE VFD WITH IN-BUILT INVERTER TANSFORMER (DRY TYPE)
DESCRIPTION
Cost
Installation and maintenance
Distance limitation between VFD and motor
OPTION-I
Favorable
Favorable
OPTION-II
Favorable
Favorable
OPTION-III
Favorable
Favorable
Unfavorable
Favorable
Unfavorable
Unfavorable
Unfavorable
Unfavorable
Unfavorable
Unfavorable
Unfavorable
Favorable
Favorable
Unfavorable
Not
recommended
Favorable
Favorable
Unfavorable
Not
recommended
Favorable
Favorable
Unfavorable
Not
recommended
Dynamic braking.
Additional cost for installation
Availability in market
Space requirement inside substation
CONCLUSION
ii
REMARK
Lowest compared to other options
Maximum allowable distance between VFD
& Motor is approx. 300 Mtr (Max.)
Sine wave filter: Issue related to design &
rating, life cycle, uncertainty of proper
working.
Additional circuits & Resistor bank required
achieving dynamic braking.
OPTION-I
Unfavorable
Favorable
OPTION-II
Unfavorable
Favorable
OPTION-III
Unfavorable
Favorable
Favorable
Favorable
Favorable
Partially
Favorable
Unfavorable
Favorable
Partially
Favorable
Unfavorable
Favorable
Partially
Favorable
Unfavorable
Favorable
Recommended
Partially
Recommended
Recommended
REMARK
* No braking circuit & resistor bank required in some drives available in market to achieve dynamic braking by dual frequency brake.
iii
iv
OPTION-I
Unfavorable
Unfavorable
OPTION-II
Unfavorable
Unfavorable
OPTION-III
Unfavorable
Unfavorable
Favorable
Favorable
Favorable
Favorable
Favorable
Favorable
Not
Recommended
Favorable
Favorable
Favorable
Favorable
Favorable
Favorable
Not
Recommended
Recommended
REMARK
No distance limit
No additional component required to
increase distance limit.
CONCLUSION:
From Above description in table 6.1, 6.2, 6.3 & 6.4, it may be observed that;
VFD with multilevel output seems only option available that is suitable for Power reticulation scheme proposed Option-I &
Option-III.
VFD with multilevel output may be recommended for Power reticulation scheme proposed Option-II as it does not perform
any value addition to system by keeping VFDs near to conveyor motors. Hence, VFD with active front end is suitable for power
reticulation scheme proposed in Option-II.
8.0
SUMMARY
The report shows that scheme proposed for power reticulation is dependent on reliability of electrical system / reliability of port
operation, Installation cost / feasibility, ease of operation & maintenance of Electrical system including VFDs, type of VFD
system,.
Overall summary of the report is illustrated in table 7.1
7.1
7.2
7.3
AN ALTERNATE, OPTION-III
Option-III scheme is alike to Option-I of basic engineering scheme. It covers major benefits of full redundancy, lowest cost out of
all other options, conveyor isolation by simple interlocking.
Lesser number of locations for major electrical installations gives better reliability.
9.0
RECOMMENDATION
The study shows that Option-III scheme for Power reticulation is most suitable in terms of technical reliability, operation and
maintenance convenience as well as overall economics for T0 expansion at AAPCT. Hence, we recommend Option-III for its
benefits as summarized in report.
10.0 ANNEXURE-I
Annexure-I is attached.