Marmaray Project Contract CR1

Traction Power Supply System (TPS) for Marmaray Project CR1 acc. ERQ 8 by
Marubeni Traction Power Equipment Group (TPE)
Contractor TPE: Project Manager TPE: Balfour Beatty Rail GmbH John Hoogerwerf
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Marmaray Project Contract CR1

Synopsis TPS presentation

General introduction traction power supply Main system data TPS Scope of supply TPE Structuring principles and reference designation Operation principles TPS Design TPS Principles Control & Protection RAMS principles EMC principles Questions
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Marmaray Project Contract CR1

Traction power supply systems in Europe

AC 25 kV 50 Hz AC 15 kV 16 2/3 Hz DC 3.0 kV DC 1.5 kV DC 1.2 kV Electrified rail tracks worldwide (track kilometres 1996): AC 50 (60) Hz ca. 90,000 km AC 16 2/3 Hz ca. 33,000 km DC 3 / 1.5 / 1.2 kV ca. 88,000 km
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Marmaray Project Contract CR1

Principle TPS System 25 kV / 50 Hz - network

G 3~

Power plant

Grid 3 AC 110...400 kV / 50 (60) Hz

L1-L2

L2-L3

L3-L1

TPSS

SP

1 AC 25 kV 50 (60) Hz

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Principle TPS 25 kV / 50 Hz

TPSS
OCS 110...400 kV I/n [A] 25 kV (15 kV)

I [A]

I [A]

Track I [A]

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Typical characteristics traction power supply

One phase of the system permanently earthed during operation High number of short circuits in the overhead catenary system Strong load variations in OCS lines and TPS substations Single phase power demand from energy grids Mobility of its users (locomotives) Stray current corrosion in case of nearby DC-tracks

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Top level requirements for TPS and OCS

Assurance of uninterrupted energy flow to the electric locomotives with high availability
Contact characteristics pantograph - contact wire / construction OCS line / failure strategies

The electric energy shall be supplied according defined quality standards (voltage / frequency / e.g.), stability
Lay out design TPS substations / overhead line wires / switching arrangements overhead line / EMC

(Uninterrupted) receptiveness of the power supply for recuperation energy

Recuperative capacity TPS substations / energy buffer / voltage level overhead line

The transmission losses within the system shall be kept minimal

Switching arrangements OCS - TPS substations - sectioning posts / diameters, geometry, EM coupling

The singular electro technical components are designed to withstand the highest occurring peak loads in a safe and controllable manner
Optimized lay out design TPS substations, sectioning posts and OCS installations

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Specific arrangements AC 25 kV / 50 Hz

High voltage switchgear assemblies (110 400 kV)

assurance of stabile energy supply from the grid (OLTC) two- or three phase switchgear outdoor - or indoor design switchgear

Power transformers (Traction transformers)

1, 2 or some times 3 installed TTs with power range 20 70 MVA (25 or 15 MVA) relatively small short circuit voltage ~8 - 10% - this means high short circuit currents increased demands in respect of short circuit withstand ability increased demands on thermal design due to load cycle (up to 32 MVA)

Medium voltage switchgear assemblies (25 kV)

one-phase or two-phase switchgear outdoor - or indoor design switchgear cable or aerial connection common or segregated direction and OCS section supply with or without OCS test with or without reactive load compensation with or without load balancing equipment
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Environmental arrangements TPS substations

Main environmental establishments are:

Application of alternatives to environment endangering gasses like SF6 according the Kyoto Protocol. Noise reduction by utilizing ONAN type transformers and placement thereof within closed transformer boxes for visual distraction. Oil emerged transformers contain no PCB in their oil. Design of the sumps fit to the transformers dimensions to avoid oil leaking into the ground in the rare case of oil leakage. The sumps of the transformer are equipped with oil separators. Use of silica gel breathers with orange coloured instead of blue coloured indicator for transformers, as latest contains cobalt. Preference for using steel, copper and aluminium for equipment, structures and joints, as these materials can easily be recycled at end of technical lifetime.

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HD 637 S1 EN 50110-1/-2 EN 50121-1/-2/-5 EN 50122-1

Basic applicable standards on TPS system level

Power installations exceeding AC 1 kV Operation of electrical installations Railway applications - Electromagnetic compatibility Railway applications - Fixed installations: Protective provisions relating to electrical safety and earthing Railway applications - Insulation coordination: Basic requirements Railway applications - RAMS Voltage characteristics of electricity supplied by public distribution systems Railway applications - Supply voltages of traction systems Insulation co-ordination Specification for low-voltage switchgear and control gear assemblies Structuring principles and reference designations
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EN 50124-1 EN 50126-1/-2 EN 50160 EN 50163 EN 60071-1/-2 EN 60439-1 EN 61346-1/-2

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Main TPS System Data

System voltages, acc. EN 50163 (MV-side):

Lowest non permanent voltage Umin2 17,500 V Lowest permanent voltage Umin1 19,000 V Nominal voltage Un 25,000 V Highest permanent voltage Umax1 27,500 V Highest non permanent voltage Umax2 29,000 V

System currents, acc. CDS (to be validated in TPS simulation study):

Nominal current TT InTT 1,000 A Max. current 3 hours TT ImaxTT 1,300 A Max. S/C-current of the system Ik 12,000 A

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T0x T01 T02 T03 T04 T05 T06

Scope of Supply Locations

Location Halkali Veliefendi Work Upgrade existing Upgrade existing New substation Upgrade existing New substation Upgrade existing

Stleme Idealtepe Pendik Osmangazi

Plus minimum 5 sectioning posts in between the TPS substations; position pending
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Scope of Supply Utilization of Main Functions

Traction Power Supply System consists of

HV Interconnection for transmission of electrical power from TEIAS grid to TPS substation (by TPI) TPS Substation for transformation and distribution of the electrical power for the OCS (Building incl. services and E&M by TPI) Generation of emergency power at TPSS T03 Stleme for OCS sections in BC OCS Interconnection for transmission of electrical power from the TPS substation to the OCS (by TPI) Sectioning Posts for longitudinal and cross coupling of OCS sections at Neutral Sections in between TPS substations (by OCS) Control equipment to monitor and control all functions and process information within the TPSS and SP locations Protection equipment to clear faults that may occur while operating the TPS System safe, fast and selective

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Scope of Supply Equipment supplies TPE

The design, supply, delivery, installation supervision, testing and commissioning of substation equipment:
single phase traction power transformers primary high voltage two-phase switchgears (GIS and outdoor) medium voltage single-phase switchgears (AIS) standby diesel generator plant incl. step-up transformer (only for TPSS T03 Stleme) power factor compensation equipment incl. step-down transformers control and protection equipment for aforementioned equipment metering at HV level in TPSS control of OCS infeeds direct in front of TPSS protection of OCS system (short circuit & thermally) local human machine interface (HMI) for TPSS control of SP switchgears

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Transformer-side

Scope of Supply HV GIS PASS MO switchgear

TEIAS-side
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Scope of Supply HV GIS PASS MO switchgear

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Marmaray Project Contract CR1 Inside front

Scope of Supply MV AIS TracFeed TAC1 switchgear Side view

Outside front

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Structuring Principles TPS Reference Designation

For structuring of the installations for TPS (and also usable for the entire CR1 system) the standard EN 61346 is applied The structuring is done using three different aspects:
Function (=) aspect (e.g. power switching, transforming, etc) Location (+) aspect (e.g. reference for rooms, floors, walls) Product (-) aspect (e.g. reference for cable, transformer, terminal)

The = aspect is only used on high system level for TPS The + aspect is used for the architectural design of TPS substations The aspect is most commonly used to uniquely reference each singular equipment down to wire and terminal level The structuring principles according EN 61346 are also basis for the structuring of the as-built documentation

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Marmaray Project Contract CR1 +T02A1 +T02A1S1 -T01E1 -T01E1Q1 -T01E1Q1QA1 -T01E1Q1QA1XB5 -T04J1Q5BE1-2

Structuring Principles TPS Reference Designation Examples

building of Veliefendi substation control room in +T02A1 1st switchgear 154 kV in Halkali substation switchgear bay 1 of -T01E1 circuit breaker 1 of -T01E1Q1 terminal strip 5 of -T01E1Q1QA1 1st switchgear 25 kV in Idealtepe substation switchgear bay 5, 1st current transformer 2nd core of that current transformer LV AC distribution in Osmangazi LV DC distribution in Osmangazi
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-T06NE1 -T06NQ1

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Operation Principles for TPS

Each singular TPS substation is operated as two half singular substations. Control of the Traction Power Supply Substation is done from the Operation Control Centres but local operation via local HMI or directly at the switchgear bay is also possible. During normal operation both traction transformers of each substation are operating simultaneously. Each transformer is connected to different phases of the 154 kV grid (if possible) and supplies one section of the OCS. Parallel operation of two transformers within one substation or two adjacent substations is prohibited and is prevented by Neutral Sections in the OCS and interlocking. The traction power supply is designed with 100% traction transformer redundancy the TPS system is designed acc. N-1 failure management scenarios, thus outage of one singular traction transformer (single outage) or that of one singular TPS substation (double outage).
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Typical Single Lines TPS

TEIAS 154 KV HV NETWORK

Typical Substation

Scope TPE

Typical Sectioning Post

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Detail Single Line TPS Substation HV GIS Switchgear & Transformer

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Detail Single Line TPS Substation MV 25 kV AIS Switchgear Assembly

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Detail Single Line TPS Substation MV 25 kV AIS Traction Feeder Bay

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Architectural Design TPS Substation 3D View Building

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Architectural Design TPS Substation 3D Transparent View Building

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Architectural Design TPS Substation Arrangement of Equipment

LV Supply

Compensation Equipment

C&P Cabinets MV AIS TracFeed TAC Control

HV GIS

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Architectural Design TPS Substation Building Design Side View

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Architectural Design TPS Substation Building Design Side View

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Architectural Design TPS Substation 3D View Transformer Box +A1T2

Traction Transformer
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Architectural Design TPS Substation 3D View MV Transformers

Auxiliary Transformer

Step-down Transformer

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Architectural Design TPS Substation 3D View Control Room +A1S1

Communication Cabinets

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Architectural Design TPS Substation 3D Views MV Room +A1J1

C&P Cabinets

TracFeed TAC
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Architectural Design TPS Substation 3D Views HV Room +A1E1

HV GIS

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Architectural Design TPS Substation 3D View Compensation Room +A1R1

Compensation Equipment

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Principles Control & Protection TPS

Within the TPSS control functions are distributed per bay and processed in bay controllers. For overall control and processing a central PLC is projected which also provides the interface with telecommunication, SCADA and local HMI. Protection is as much as possible integrated in combined digital protection & control relays, so called bay controllers. Both primary protection (e.g. transformers buchholz) and algorithms for secondary protection are processed by dedicated protection processors within these bay controllers. To prevent maloperation at each operation level (remote, local, direct or emergency control) interlocking is provided for by software means. If required electromechanical and mechanical interlocking is provided for manual (emergency control) operation level.
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Ethernet Network CU FO

System Configuration (concept) Control TPS substation

Network Cubicle FO CU

(Scope of TAS)

IEC 60870-5-104 HMI Cabinet TM1703 Building Services

.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . . .. . . . . . . . . . . . . . . . . .. . . .. .. .. .. .. .. .. .. . . .. .. .. .. .. .. .. .. .. .. . . . . . . . . . . . . . . . . . . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . . .. . . . . . . . . . . . . . . . . .. . . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . . .. . . . . . . . . . . . . . . . . .. . . .. .. .. .. .. .. .. ..

General Cabinet

CM-0843 CM-0821

.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . . .. . . . . . . . . . . . . . . . . .. . . .. .. .. .. .. .. .. ..

.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . . .. . . . . . . . . . . . . . . . . .. . . .. .. .. .. .. .. .. ..

.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . . .. . . . . . . . . . . . . . . . . .. . . .. .. .. .. .. .. .. ..

.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . . .. . . . . . . . . . . . . . . . . .. . . .. .. .. .. .. .. .. ..

.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . . .. . . . . . . . . . . . . . . . . .. . . .. .. .. .. .. .. .. ..

Aux. Power Supply

.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . . .. . . . . . . . . . . . . . . . . .. . . .. .. .. .. .. .. .. .. . . .. .. .. .. .. .. .. .. .. .. . . . . . . . . . . . . . . . . . . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . . .. . . . . . . . . . . . . . . . . .. . . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . . .. . . . . . . . . . . . . . . . . .. . . .. .. .. .. .. .. .. ..

IEC 60870-5-101/103 HMI GEN

.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..

.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..

.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..

.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..

.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..

154 kV Cabinet

(Scope of TPE)
CM-0821

CM-0821

CM-0821

CM-0821

25 kV Bay 1 Control & Protection

25 kV Bay n Control & Protection

154 kV Bay 1 Control & Protection

154 kV Bay 2 Control & Protection

25 kV Compartment

25 kV Compartment Patchcabel FO FO Fibre Optic CU Cupper

KV parallel interface to utilities floating contacts parallel interface to utilities floating contacts

TracFeed

25 kV Switchgear

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Principles Control TPS substation

Within TPS four (4) control levels are distinguished:

remote control of the entire station by SCADA local control of the entire station by HMI direct control of whole branch by bay controller emergency control on each singular equipment emergency control; electrically by push buttons and/or mechanically by crank
Operation of: Remote SCADA Local HMI Bay Singular TPS substation All TPS substations

Direct

Singular bay within TPS substation

Emergency

Singular equipment

Manually on each equipment within bay

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Principles Control TPS Substation / Switch Bay

Bay Controller Station Switch

Remote control by SCADA / HMI Local control Switch Bay

Remote control by SCADA station unoccupied (default) Local indication on HMI station occupied Local control by HMI station occupied
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Principles OCS Control TPS substation

Green LEDs: MS Panel active LT Lamptest active Red LEDs: RUN Command (output) active FLT MCB trip (Fault) Main Switch Lamp Test

Yellow LEDs: C Position CLOSED O Position OPEN Close Command Open Command

OCS Isolator Control Cards SCADA control remains active!

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Activate Command

MCB per OCS isolator

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Principles Protection TPS substation

Within TPS following protection levels are implemented

Main protection Backup protection Breaker failure protection (within TPS substation)

Following primary equipment is to be protected by dedicated protection

HV interconnection Traction transformers 25 kV Busbar system Track feeders (OCS interconnection and OCS) Compensation equipment Auxiliary transformer Diesel generator set at T03 Stleme

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Protection Coordination TPS substation

The following protection functions are coordinated within TPS

Differential Protection Maximum Current Protection Distance Protection Over / Under Voltage Protection Thermal Overload Protection Circuit Breaker Failure Protection

The coordination between these functions is shown on the Protection Plans The settings are determined in the Protection Study

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Detail Single Line TPS Substation MV 25 kV AIS Protection Plan

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Detail Single Line TPS Substation MV 25 kV AIS Protection Plan Detail

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Detail Single Line TPS Substation MV 25 kV OCS Protection

Characteristic OCS Distance Protection

X

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RAM Principles for TPS

RAMS is assessed according EN 50126

Reliability is assured by utilizing systems and components of well known suppliers with experience in rail applications. For earthquake proof design FEMA 203, Category E is applied. Availability is especially assured by system redundancy in transformer power. Furthermore the stations function independently from each other and are not dependent on local or remote control. Maintainability is assured by transparent design with all singular parts being easily accessible/exchangeable. All components and systems are documented in printed matter. The design enables the preventive maintenance on condition maintenance strategy.

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Maintenance Strategy Maintenance

Preventive Maintenance

Corrective Maintenance

Condition based Maintenance

Predetermined Maintenance

EN 13306, Annex A

For Marmaray CR1 a combination of condition based maintenance and predetermined maintenance has been chosen, also to be described as preventive maintenance on condition.
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Safety Principles for TPS

Safety is assured by design according HD 637 S1, EN 50110 and the EMC Design Guideline. For switching operation the 5 safety rules must strictly be adhered to All installations and systems are well tested in the factory and at site. It is a principle design constraint that protective means are provided for and available in case failures occur in electrical equipment. In case of TPS substations all short circuit current protection equipment has a backup to prevent consequential damage to the affected system. For the relevant fault duration for determination of touch and step voltages the correct operation of protection devices and switches is taken into account as per HD 637 S1, paragraph 9.2.4. If there is a complete outage of the entire TEIAS grid simultaneously on both European and Asian side then for this extremely rare situation trains can leave the tunnel with the help of the standby diesel generator located at T03 Stleme
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Marmaray Project Contract CR1 The main emitter for CR1 are the CR2 commuter trains

EMC Principles of CR1

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EMI of TPS due to environment

Communication, Signalling, EM-Fields Radio, ..
EM-Fields E-Field B-Field

other HV, MV and LV lines, e.g. of TEIAS

EM-Fields

EM-Fields

Traction Current 50 Hz

EM-Fields

B-Field

~ = Rolling Stock
Harmonics

TPS equipment (BBR) Frequency Converter aux. (SYE)

EM-Fields

154 kV Voltage

TEIAS 154 kV
Harmonics

OCS

TPS substation

TPS Equipment (BBR) concerns the scope of TPE within TPS Power compensation switches at high speed without transients, thus no emission

- sources of EM disturbance and harmonics

- passive equipment only emitting the EM disturbances produced by sources

- emissions to the outside world

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EM-Fields

B-Field

B-Field

E-Field

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EMI at HF Experiences other projects

In respect of EN 50121-2 it has been proven that we withhold the emission levels. The proof was done by simulation for low frequencies for both ICNIRP Guidelines and EN 50121-2 and by measurement for radio emission levels by a competent body acc. EN 50121-2. For the measurements 3 separate situations were measured: Before commencement construction: reference measurement After commissioning: installations dead After commissioning: installations live

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EMI at AC 50 Hz Proof ICNIRP Guidelines in 3D Model

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EMI at AC 50 Hz Proof E-Field acc. ICNIRP Guidelines

E [kV/m] RMS

Y-Position [m] 10
8

0.00

0.50

1.0

1.5

2.0

2.5

3.0

3.5

4.0

4.5

> 5.0

E-Field
4

Installations comply with ICNIRP

-4

-8 -15 -10 -5 0 5 10
Z [m] = 2.000

15
f[Hz] = 50

20

-10 -20
OS_STATION_SHIELD_EFELD.GEO 07.10.2004 09:48:08

X-Position [m]

25

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EMI at AC 50 Hz Proof M-Field acc. ICNIRP Guidelines

B [uT] RMS 0.00 50.0 100 150 200 250 300 350 400 450 > 500

Y-Position [m] 12

M-Field
4

Installations comply with ICNIRP

-4

-8

-15

-10

-5

10

15
Z [m] = 1.000

20
f[Hz] = 50

25

30

-12 -20
OS_STATION_SHIELD.GEO 05.10.2004 08:33:10

X-Position [m]

32

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Marmaray Project Contract CR1 Installations comply with EN 50121-2

EMI at radio frequencies Proof EN 50121-2 by measurement

Installation dead Installation live

Prior to construction

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EMC provisions

The primary equipment are all passive components EMC is provided for by
use of metal enclosed cabinets and compartments use of earth mesh in both concrete floors and ground two sided 360o earthing inside the substation of all shielded LV and control cables parallel earthing conductor in cable troughs/trays to minimize AC 50 Hz return currents over the LV and control cable screens bundling of traction power and return current cables single sided earthing of cable screens of power cables at track side to avoid AC 50 Hz return currents over the cable screens single sided earthing of cable screens of LV and control cables within the station to avoid AC 50 Hz return currents over the cable screens well defined connections between earth mesh and return current system application of surge arresters on HV, MV and LV level for all external connections
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EMC provisions (concept)

rack frame

indoor
Top False Floor Frame corner

CONTROL-cubicles supporting frame -X11

702

outdoor
Return current cubicle -X03

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EMC provisions (concept)

CONTROL-cubicles GIS

Under False Floor

Protection Aux. supply

-X12 -X12 -X12 -X12 352

indoor
Top False Floor

-X11
702

-X12

outdoor
Return current cubicle -X03

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EMC provisions (concept)

CONTROL-cubicles GIS Under False Floor

Protection Aux. supply

indoor
Top False Floor

outdoor

Cable screen connected on both sides Cable screen connected only on CONTROLcubicles-side

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End of presentation

Thank you for your attention!

Questions

John Hoogerwerf Project Manager Balfour Beatty Rail GmbH

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