A.E.

Training – Power Plant Philosophy (Part 1)

MV Considerations

September 2011

MV Considerations
Seven basic questions….

1. What’s different about MV & HV Voltages?

2. What are my options for offering either,
– LV Genset plus Transformer
– or, a MV Genset?
3. What do I need to know about CGT MV Alternator
construction?
4. Basic info about Transformers & Station Axillaries.
5. MV Protection, Earthing & AmpsSentry?
6. Surge & Lightning protection?
7. What are operator requirements?

MV Considerations

This discussion document is about CPG gensets

between 3.3kV and 13.8kV at both 50/60Hz.

For most engineers this voltage is different
– It's no longer engineering-as-usual.
– Other variables enter into both design & manufacturing
– Clearance distances, insulation thickness, corona and
geometrical arrangement have to be taken into account.

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MV Considerations

Part 1 – What are…

MV & HV Voltages?

Standard MV & HV Voltage Definitions…

In the US… The US 2005 National Electrical Code (NEC article

490.2), defines any voltage over 600 V as High Voltage.

IEEE defines MV as 1kV to 35kV

IEC defines LV as 50V – 1000V, HV as over 1000V A.C.

In Central Region, EN 50160: 2007 (Clause 3.7 & 3.8), defines

AC voltage for distribution networks as…..
– Less than 1KV - Low Voltage
– 1kV to 35kV - Medium Voltage
– Over 35kV - High Voltage

CONFUSED?

Standard MV & HV Voltages

The following voltages are the most common and the standard
available outputs from CGT machines:

50Hz 60Hz
3,300 V 4,160 V
NB: Different windings are needed
6,000 V 7,200 V to achieve certain voltages. Do not
6,300 V assume that just because 2
6,600 V voltages are close, your required
voltage can be achieved by
11,400 V adjustment.
10,000 V 12,470 V
10,500 V
11,000 V 13,200 V
13,800 V

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 MV Considerations

Part 2 – What are my options for either…

a) LV Gensets plus Transformer

or,
b) MV Gensets?

LV or MV Genset – Paralleling Options

Usual Site Configurations…
Generating at 400V Option Generating at 11kV Option
11kV Switchboard 11kV Switchboard
11,000V 11,000V

11000/400V T/F Station

Service
T/F

LV Synchronising Genset Axillaries

S/B 400V S/B 400V

LV Gensets 11,000 Volt

Gensets
3 N/G Resistors,
or Earthing T/F’s
Solid Earth (chokes). Or as
illustrated, 1 x N/G
Resistor & 3 Contactors.

Ground Ground

LV or MV Genset – The Differences

So what's the cases for and against MV sets?

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LV or MV Genset – The Differences

The case for a LV genset: Against a LV genset:

Lower cost genset.
Additional cost of the

Simple standard site test transformer.

Simple N-G earthing.
Location and space for

transformer.

Easy to maintain gensets.

Efficiency losses of

Easy to repair LV alternator transformer adding to running
locally. cost.

Large and expensive genset
cables.

LV or MV Genset – The Differences

The case for a MV genset: Against a MV genset:

Smaller plant footprint.
Cable installation is

Higher reliability. specialized.

Higher system efficiency
Complex N-G earthing.

(lower running costs).
Commissioning tests are

Smaller cables and no specialised.
transformers.
Plant operators must be

Unlimited number of sets in specialised
parallel.
Rewind or replacement
issues in some countries.

LV or MV Genset – Further Considerations

1. MV & HV Alternators are Larger

– Less tolerant to moisture ingress.

2. Cable Installation
– Smaller csa, but has higher bending radii (less tolerant to vibration),
– Specialist jointing requiring pressure tests after installation.
– Cable termination (jointing) far more costly
– Special operator procedures required for working on MV conductors.

3. Current Capacity of Cables, Breakers & Switchgear

• C2250D5 PRP at 400V 50 Hz = 2887 Amps.
• C2250D5 PRP at 11kV 50Hz = 105 Amps

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LV or MV Genset – Further Considerations

5. Step-Up Transformers
a. Most transformers operate at around 98.5% efficiency
• System efficiency is critical for COP gensets (that’s an added 2.5% loss)
• T/F will derate C2250D5 to 2216kVA ESB &1970kVA PRP
b. Location of transformer (availability of space considerations)
c. Sometimes only ‘dry’ transformers allowed on the site.
• Cast Resin T/F cost the same as a MV alternator

6. Plant Operators are Specialized

– In most countries personnel need to be specially trained and certified in MV
or HV techniques just to start the set.

LV or MV Genset – Key considerations

Summary…

– Current Capacity of Cables & Cable Costs

– Current & Fault rating capacity of Switchgear & Breakers
– Location & Space for Transformers
– Alternator and Transformer Efficiency
– Availability of competent operators.
– How genset interfaces with existing MV/HV equipment.

MV Considerations

Part 3 – What’s different about…

MV Alternator Construction?

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Standard CGT Alternators
Non-Standard MV Considerations…
1. Applications above 1000m require special
considerations
– Electrical Clearances – Reduction in air density causes Ionization of Air
in contact with coils and bare conductors, requiring greater electrical
clearances and or Corona Shields.
– For operating above 1000m there is more insulation & less copper
required in slot than in a standard unit. Full <1000m asl Rating may be
Restricted by the Higher Temp Rise over standard winding.
– Some installations will require special windings.
– Always Refer to Factory for <1000m asl rating.

2. Low Temperature. IEC 60034 standard gives a

minimum operating core temperature of -15degC.
– Storage and transport at or below -15degC also needs to be considered
as the Material Properties Change with temperature.
– Warming causes Condensation & Hoar Frost. Machine must be run 10
min without excitation if core temperature has been warmed from below -
15degC (AGN072).
– Snow must not be allowed into alternator.

Standard CGT Alternators

Non-Standard MV Considerations…
3. Anti-condensation Heaters must be switched on
when stationary.
– Heaters must be used when stationary in all applications to prevent
condensation (even in hot climates).
– In Cold regions, if the core temperature falls below -15 DegC, the
machine must not be run de-excited until it has been warmed and dried.

4. Air filtration is required for dusty environments.

– 5% derate from type rating.
– Add Alternator High Temperature warning/shutdown to indicate when
filters get blocked

5. Voltage Spikes, Solar Flares & Lightning can

destroy your machine.
– Discussed later in Surge & Lightning protection

Standard CGT Alternators

Standard Construction of LV, MV & HV Machines

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Standard CGT LV Alternators
Standard Spec up to 1000 Volts

6 or 12-ends out Stator leads.

2/3rds pitch virtually eliminating Triple-n harmonics
e.g. 3, 6, 9, etc.

Class ‘H’ Insulation (125C/40C).

Wire wound lap winding design construction

Reliability at low cost

Standard CGT MV Alternators

Standard Spec up to 4,400 Volts

6 Ends out Stator leads. Neutrals brought out for

customer CT’s.

2/3rds pitch virtually eliminating triple-n harmonics

Class ‘F’ Insulation (105C/40C). No class H or peak
standby capability (e.g. 150/40, 163/27)

Anti-Condensation Heater Mandatory – prime power
supply considerations?

Standard CGT MV Alternators

Standard Spec 5.5kV to 13.8kV….

6 Ends out Stator leads. Neutrals brought out for
customer CT’s.

2/3rds pitch virtually eliminating triple-n harmonics

Class ‘F’ Insulation (105C/40C). No class H or peak
standby capability (e.g. 150/40, 163/27)

Anti-Condensation Heater Mandatory – prime power
supply considerations?

Windings fitted with corona discharge shields.

Above 6kV – need to consider effect of altitude on
partial discharge (corona)

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 Standard CGT Alternators
Summary of Requirements…

Cannot reconnect windings to parallel star (wye).

Anti-condensation heater essential.

Air filtration for dusty environments.

Above 1000m require special considerations.

Minimum operating core temperature -15degC.

Think about Voltage Spikes, Solar Flares & Lightning.

MV Considerations

Part 4 – Basic information about…

Transformers & Station Auxiliaries.

Two Main Transformer Types

Dry or Cast Resin. Oil Filled.

Normally installed indoors
Must be installed outdoors.
unless specified for outdoor
Must consider containment in
operation.
. case of tank leakage.

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 LV Station Service Switchboard Supply

Generating at 11kV Option

11kV Switchboard
11,000V

Station Transformer
– to supply 400/230V supply into
Station
engine room. Service
T/F

LV Distribution Board
Genset Axillaries
– Engine & Alternator Heaters S/B 400V
– Radiator Fan Motors
– Coolant pumps
– Battery Charger 11,000 Volt
– Switchboard DC systems Gensets

– Fuel transfer pumps

– Lights & power
– Fire alarm
Ground

LV or MV Genset Option
Genset with Step-Up Transformer
These two earth options are usually used with Utilities and not suitable
for island mode unless separate MV Earthing T/F is provided. Always
refer to Protection Engineer for guidance on HV Ground.

11kV S/G Bus 11kV S/G Bus 11kV S/G Bus

YNd T/F Dyn T/F Dyn T/F Avoid LV

Genset
breaker when
ever possible.
Not necessary
and it also
compromises
the protection
LV Genset
star point LV Genset.
to ground Both
gensets
LV Genset and T/F LV
star or delta connected
connected to ground.
(no ground)

If you are supplying step up T/F, always refer to Protection Engineer

for guidance on HV Ground.

LV Station Service Switchboards

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MV & HV Switchboards (to 33kV)

Traditionally three types of MV & HV switchgear:

Bulk Oil or Minimum Oil.
– Oil now out of production (except in certain HV installations)
– Big environmental issues with PCB’s.

SF6 (Sulphur hexafluoride ).

– Being phased out of production.
– SF6 is a potent greenhouse gas with a global warming potential of
22,200 times CO2
– New installations now banned in Europe due to environmental issues.

Vacuum.
– The switchgear of the future.
– Vacuum switchgear may introduce voltage spikes
issues for the generator due to current chopping.

MV Considerations

Part 5 – Networks…

MV & HV Networks Considerations

MV & HV Network Applications

System Components – Comparison of Characteristics

Utility
– Infinite Source, Stiff, Low
Impedance Generator Set
– Constant Frequency – Limited Source, High
Impedance
– Limited Voltage Dips
– Subject to Block Load
Transients (Hz & Volts)
– Voltage & Frequency
Disturbance

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Simplified Distribution Networks

•Faults or outages can occur

anywhere in the system

•When in parallel with the utility

the generators become an
integral part of the utility system

• Generator protection scheme must be

integrated with that of the network to
provide a coordinated solution

MV & HV Network Applications

System Component Characteristics

MV & HV systems Utility Paralleled

When in parallel with the utility, generators
become an integral part of the utility system.

Generator protection must be integrated to
provide coordinated solution.

MV & HV Network Applications

Example

3 x DQKH (QSK60) each rated

2500kVA 6.6kV 50Hz
for Black Start of 300MW gas
turbine plant in Algeria

6MW of Gensets in parallel with

300MW of Turbine = 1:50 ratio.
Location:
AIN BEIDA, 520 km East of Algiers,
OUM EL BOUAGHI
Altitude: 950 m a.s.l.
Temperatures: - 7 °C to 45 °C (17 °C
yearly average)
Humidity: 41 % to 83 % (62% average)

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Primary Genset Protection
(In order of importance)

For Base Load or Non Utility Parallel

1. Differential Protection
2. AmpSentry (or Breaker Overload)
3. NGR or Earthing Transformer

For Utility Parallel Gensets

1. Loss of Utility Protection Relay (ANSI Code 78)
2. Differential Protection
3. AmpSentry (or Breaker Overload)
4. NGR or Earthing Transformer

Differential protection – Simplified example

For three phase loads both balanced and unbalanced, provided there
is no earth fault, the line currents will always summate to zero…

3 Alternator CT’s 3 S/B CT’s

Differential Relays

Main (Remote)
Switchboard

Cummins Confidential

Differential C/T’s
Top view of terminal box

3 C/T’s in star point

– See 3 Neutral C/T’s.

Plus 3 C/Ts in
Switchboard
– C/T’s must be matching
pairs.
– If PE supply Switchboard,
CPG supply both C/T’s.
– If others supply Switchboard
then all C/T’s should be
supplied by others.

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 Grounding Resistors or Transformer

MUST HAVE - Back-up in event of protection failure.

• Resistor sized to pass full rated current
L1 (generally FLC largest set on the system) for
L2 either 10 or 30 seconds.
L3
• The backup protection set to trip if rating of
the resistor is exceeded.
e/f BACKUP EARTH
FAULT
– The NGR does not alter configuration of
protection, but does alter settings and
reduces discrimination that can be
achieved further down the system.
– Backup earth fault is another form of
NER unrestricted earth fault and must be
accounted for in discrimination scheme.

Cummins Confidential

Grounding Resistors or T/F

Only ONE bond on any neutral bus

– Exception: during closed transition transfer consider brief
overlap (50 mS)
– Watch out if a sensitive earth fault is fitted. Even 50mS can
be too long.

MV Considerations

Part 6 – What about…

Surge & Lightning protection?

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Surge & Lightning protection

For Protection of MV Generators & Transformers

– Provide lightning protection for the building
– Keep lightning earths away from equipment earths/neutrals
– Install surge suppressors in switchgear (preferable) or
generator terminal box (least preferable)
– Install Arc Horns on incoming overhead lines

MV Considerations

Part 7 – What are operator requirements…

MV Training?

MV/HV Training

Operators must have MV/HV competence.

– Equipment totally different to LV
– Different operating techniques
– Additional functionality – e.g. earthing facilities
– Lack of interlocks

Operators must have formal training

– Hold valid MV or HV tickets
– Cannot use LV engineers without undergoing additional
training and qualification.

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 MV/HV Training

Importantly – never use your hand to feel if

component is running hot.

Main Difference
– At LV you can approach wiring (400V – 3 inch / 75mm, OK)
– MV comes looking for you (11kV – 3 ft / 1M)

Additionally,
– Operators must be aware MV & HV windings hold a stored
capacitive charge long after Genset has stopped.
– After high voltage tests have been performed, windings must be
grounded.
– Always prove ‘Dead’ before touching

43 9/7/2011 Cummins Confidential

MV Training

Main Difference
– At LV you can
approach wiring to
almost touching
in dry conditions
– MV/HV comes out
looking for you –
there are no
second chances
– Voltages below
around 40kV do
not signal their
presence

MV/HV Considerations –
Finally - a summary of today's session…
As a Minimum…
Priority # 1 – Safety of Operators and Equipment at HV.
Priority # 2 – Consider HV Options available (LV+Tx or HV).
Then always ask your client about…
3. Altitude and temperature
4. Station Transformers & Station Axillaries
5. System Protection

Differential Protection

System Earth, NG Panels & Resistors or Transformers

Backup protection
6. Surge & Lightning protection.
7. Availability of MV & HV Operators.

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Questions

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