Modernization Manzanillo I The Mexican largest power transmission network of 400 kv with XLPE cable systems: Design and Construction

Transcription

1 21, rue d Artois, F PARIS B1-106 CIGRE 2012 http : // Modernization Manzanillo I The Mexican largest power transmission network of 400 kv with XLPE cable systems: Design and Construction F. G. IBARRA ROMO* Comisión Federal de Electricidad (México) C. F. FUENTES ESTRADA Comisión Federal de Electricidad (México) J. T. ARRIAGA FLORES Comisión Federal de Electricidad (México) M. MAMMERI Silec Cable (France) SUMMARY The increase of Mexico electricity demand, the high fossil fuel costs and stricter environmental regulations applied to government programs, led to Comisión Federal de Electricidad (CFE) to develop strategies for improving competitiveness of electricity generation infrastructure installed, incorporating efficient technologies such as that described in the project to repower to combined cycle power plants Manzanillo I and Manzanillo II. This considers the installation of six new units (222 CC Repowering CT Manzanillo I, U1 and U2 Project) with a net capacity of 1412 MW. They will use natural gas associated with it. Therefore, it was necessary to build a central storage and re-gasification of natural gas (LNG Terminal Manzanillo) to ensure the future supply of fuel. Also, CFE constructed another facilities, like a seaport for entering and unloading of ships with natural gas from abroad, a 200 km gas pipeline from Manzanillo to Guadalajara, and two new substations: Manzanillo I (219 SLT Associated Transmission Network Manzanillo I - U1 and U2 Project) and Manzanillo II, converting from air-insulated substation to gas insulated substation (GIS). This represents a total investment of $ million USD. It is currently emphasizing that the complex thermoelectric (CT Manzanillo I and CT Manzanillo II) have a capacity of MW net installed. However, with the future prospects for modernization units (U3 and U4) of CT Manzanillo I and the modernization units (U1 and U2) of CT Manzanillo II, this complex will have 3,500 MW installed capacity in Modernization of the electrical substation Manzanillo I involved, in the drafting stage, evaluate all the site characteristics, such as space limitations, pollution prevailing in the area, frequency and magnitude of hurricanes and high seismicity of the place, turning out to be determining factors that eventually decide the best option was to build fourteen 400 kv circuits, using XLPE cables systems. The use of high voltage XLPE cable systems in Mexico data since year 2000, with the construction of 230 kv San Bernabé entronque Aguilas - Topilejo transmission lines, which included the installation of four circuits using 75 km of 1x1.600 mm 2 power cable - Cu - XLPE - Pb - HDPE (brand SAGEM, France). In 2006, Mexico begins the 400 kv underground cable projects with Manzanillo II GIS Modernization project, where three *federico.ibarra@cfe.gob.mx

2 circuits are installed and 2 km of 1x1.000 mm 2 - Cu - XLPE - Pb - HDPE cable power were used (brand SAGEM, France). Since then to date, in Mexico are installed 275 km of 230 kv XLPE power cable and 20 km of 400 kv XLPE power cable. To the modernization of Manzanillo I Project, the cable systems supplier was chosen for the evaluation of five international suppliers including the final supplier, Silec from France. The power cable systems installed were two cross sections: 1x2.000 mm 2 - Cu -XLPE - Al welded - HDPE, and 1x1.000 mm 2 - Al - XLPE - Al welded HDPE. Both of them with 28 mm average thickness of XLPE insulation and 0,8 mm thick in the metal of welded aluminum, as well as the inclusion of fire retardant treatment retardant action of fire on the outside deck under the international standard IEC Cable systems met the type tests, and prequalification tests set forth in the scope of international standard IEC same as were witnessed by independent institutions, with the aim to obtain a reliable long installation. At the end of the installation, is performed the tests applied to 260 kv AC for 1 hour at each of the 14 circuits (as set out in IEC 62067) fully installed by using a variable frequency resonant equipment ACRF - Resonant test system of tuned Frequency. The project Modernization Manzanillo I sets new challenges for Mexican engineering and construction systems high-tension cables. The project was not easy. It presented a series of challenges as they had to install a total of 15 km of cable XLPE type, 84 terminals (42 inside type and 42 outdoor type) for all 14 circuits at 400 kv, in just eight months. Also, site conditions forced to undertake new challenges that resulted in the most ambitious network of tunnels ever built in the country: the construction of civil works for 1,4 km of galleries (inner dimensions 2,15 m high and 2,0 m wide). The trajectories of the network tunnels were built in areas occupied by the air-insulated substation Manzanillo I, having the disadvantage that during time construction all conventional substation remained completely energized. As additional consideration, due to that the galleries were built in a nonpublic area, were designed surface vents distributed throughout the galleries to achieve and maintain a comfortable temperature (by convection) in cable systems inside the galleries. KEYWORDS Comision Federal de Electricidad - XLPE Underground Cable Systems - Net of Galleries ACRF - IEC

3 1. Introduction: CFE has taken concrete actions to diversify its sources of supply for power generation. Along the past 10 years, CFE have been building storage and re-gasification terminals for liquefied natural gas (LNG), including the new Liquefied Natural Gas Terminal Manzanillo thereby ensure the future availability of natural gas supply in the Western region of the country, coupled with the upgrading and modernization of its complex Thermoelectric Manzanillo, built for this: - 1 terminal for liquefied natural gas (with capacity 500 million cubic feet per day) - 1 access channel pier and ships natural gas transporters - A pipeline of approximately 200 km long (80 cm inner diameter, from Manzanillo to Guadalajara) - 1 gas insulated substation for 115 kv - 6 turbo-generation units natural gas (resulting in MW of installed capacity) - 2 gas insulated substations, one for 230 kv and another for 400 kv - 14 links using underground 400 kv cable systems - 2 links using underground 230 kv cable systems The total cost associated with these works reached an estimated $ million USD. Figure 1 illustrates an aerial view of the works associated with the CFE Manzanillo required as part of the complex thermo Manzanillo. Figure 1. General overview of Manzanillo complex 1

4 2. Project data: Manzanillo I Modernization Project requires each underground circuit having connected from the new GIS Manzanillo I to each transformer substations or between GIS, the following ampacity capabilities at maximum operating conditions: Ampacity required Circuit Destination [A] 1 Bar 1 of GIS Manzanillo II Bar 1 of GIS Manzanillo II 3 Unit 1 T1 C.T. Manzanillo I 4 Unit 2 T2 C.T. Manzanillo I Unit 3 T3 C.T. Manzanillo I 6 Unit 4 T4 C.T. Manzanillo I 7 Starting Units 3 and 4 T7 C.T. Manzanillo I 60 8 Bank Transformation AT Unit 1 new C.C. to Gas 10 Unit 2 new C.C. to Gas Unit 5 new C.C. to Gas 14 Unit 6 new C.C. to Gas 11 Unit 3 new C.C. to Gas 12 Unit 4 new C.C. to Gas 3. Technical solution: We have to build 14 circuits from the new GIS Manzanillo I (400 kv), whereas the whole area was under operation conventional substation Manzanillo I. That, led us to enter on challenges that resulted in the most ambitious network of galleries ever built in Mexico, resulting in 1.4 km of galleries (inner dimensions 2.15 m high and 2.0 m wide) to install the underground circuits to each of their destinations. Gallery No. Number of underground circuits Approximate linear length[m] 1 2 (1x2.000 mm 2 Cu XLPE) (1x1.000 mm 2 Al XLPE) (1x1.000 mm 2 Al XLPE) (1x1.000 mm 2 Al XLPE) 500 It should be noted that this solution provides the growth and the establishment of new generation plants based on combined cycle which took advantage of the network of tunnels with the available spaces in them for more output and interconnection of GIS underground loops to Manzanillo I u GIS to install a new one in the coming years. Figure 2 illustrates the network of galleries in the complex thermoelectric Manzanillo, which highlights the four main routes. 2

5 GIS Manzanillo I 230 kv Galería No. 4 G.S Manzanillo I 400 kv Galería No. 1 C.C. Repotenciación C.T. Manzanillo I GIS Manzanillo II 400 kv Galería No. 3 Galería No. 2 C.T. Manzanillo I Figure 2. Network of galleries for 400 kv cable systems, General overview of Manzanillo I complex C.T. Manza Figure 3 and 4 illustrate cross section of the gallery type and a photograph of the inside of it Figure 3. Cross Section of the gallery type for systems of 400 kv cables Figure 4. Interior of Gallery 2 to 3 sets of 400 kv cables For energy transportation needs every underground link, engineering analysis were developed using computational tools to determine the temperature distribution within each of the four Galleries and thereby, determining the appropriate cross section of power cable to be used, considering the specific characteristics, which will be subjected during their useful life and the future growth of generation in the project area. Figures 5 and 6 illustrate analysis via finite element method (FEM), in which show temperature distribution inside the gallery type. First 3

6 case without ventilation and second one, which are being built one for every 25 m in length along each path of the four Galleries, in order to ventilate the inside of them and achieve the expulsion of heat generated during operation daily cable systems. Figure 5. Distribution of temperature inside 6 unventilated type cable systems gallery Figure 6. Distribution of temperature inside 6 ventilated type cable systems gallery Figures 7 and 8 illustrate how superficial ventilation was determined to achieve and maintain a comfortable temperature (by convection) in the galleries. Figure 7. Isometric view of the ventilation system in the galleries Figure 8. Ventilation system in the galleries 4

7 4. Cable System Design: For the construction of Manzanillo I Modernization project, we used two types of power cable systems of two cross sections: 1x2.000mm 2 - Cu - XLPE - Al welded- HDPE (1.500 m), and 1x1.000 mm 2 - Al - XLPE - Al welded- HDPE ( m). The supplier of cable systems for 400 kv was chosen for the evaluation of five international suppliers including the final supplier SILEC from France. Cable systems met the pre-qualification type tests set out in the scope of IEC international standard same as were witnessed by independent institutions, with the aim to obtain a reliable long installation. The correspondence of the circuits that were installed power cables from the SE Manzanillo I GIS are: 1x2.000 mm 2 Cu XLPE Al welded HDPE Circuit Destination Approximate linear length [m] 1 Bar 1 of GIS Manzanillo II Bar 1 of GIS Manzanillo II 150 1x1.000 mm 2 Al XLPE Al welded HDPE Circuit Destination Approximate linear length [m] 3 Unit 1 T1 C.T. Manzanillo I Unit 2 T2 C.T. Manzanillo I Unit 3 T3 C.T. Manzanillo I Unit 4 T4 C.T. Manzanillo I Start Units 3 and 4 T7 C.T. Manzanillo I Bank of Transformation AT Unit 1 new C.C. to Gas Unit 2 new C.C. to Gas Unit 3 new C.C. to Gas Unit 4 new C.C. to Gas Unit 5 new C.C. to Gas Unit 6 new C.C. to Gas 230 Cooper Milliken conductor, water blocked (58,3 mm); 2) semiconducting water-swellable tapes; 3) semiconducting screen; 4) XLPE insulation (28 mm); 5) semiconducting screen; 6) semiconducting water-swellable tapes; 7) Welded Aluminum Sheath (0,8 mm); 8) HDPE outer sheath (fix bonded with flame retardant layer). Outer diameter 138 mm and weight 30,3 kg/m. Figure kv cable 1x2.000 mm 2 cable design SIPRELEC HT Cu 230/400 kv 5

8 Aluminum conductor, water blocked (40,1 mm); 2) semiconducting water-swellable tapes; 3) semiconducting screen; 4) XLPE insulation (27 mm); 5) semiconducting screen; 6) semiconducting water-swellable tapes; 7) Welded Aluminum Sheath (0,8 mm); 8) HDPE outer sheath (fix bonded with flame retardant layer). Outer diameter 119 mm and weight 12,4 kg/m. Figure kv cable 1x1.000 mm 2 cable design SIPRELEC HT Al 230/400 kv All power cables included in its outer shell fire retardant treatment retardant action of fire according to the international standard IEC , given the characteristics of the installation. Figure 11. View of the inside to the outside terminals of the 400 kv GIS Manzanillo I Figure 12. View of the 400 kv outdoor terminals of the 400 kv GIS Manzanillo I 5. Commissioning test: In accordance to International Standard IEC 62067, at end of the construction and installation of 400 kv cables systems and proceeded to energize the circuit 14 through the application of 260 kv AC for 1 hour using for this a resonant variable frequency equipment ACRF - Resonant frequency tuned test system of property of the cable systems manufacturer. To 6

9 carry out these tests, we need 15 days to test every phase (42) of the 400 kv circuits, resulting in all satisfactory without failure during the commissioning test phase. 6. Conclusions: - Develop such projects is one of the most appropriate technical solutions, because in places where they are required to achieve a large number of circuits, the underground option through the use of cable systems is optimal. - Implement international regulations such as the standard IEC in the acquisition and testing of systems of cables, a reliable option which transmitted to users and manufacturers a high degree of tranquility in the daily performance during the lifetime of the installation. - The network of four galleries with 1.4 km of length represents major challenges to the CFE, because there was no precedent for this. However it was built in only 8 months of work was achieved, acquired great experience in this kind of underground projects, which will bring you get to keep in mind this kind of solutions for other projects that result in the CFE. BIBLIOGRAPHY [1] IEC Power cables with extruded insulation and their accessories for rated voltages above 150 kv (Um = 170 kv) up to 500 kv (Um = 550 kv) - Test methods and requirements-; Edition 1.1, (incl. am1). [2] IEC/TR Electric cables - Calculations for current ratings - Finite element method ; Edition 1.0, [3] Ramon Granadino, Martin Portillo, Josep Planas, Undergrounding the first 400 kv transmission line in Spain using 2500 mm² XLPE cables in a ventilated tunnel : The Madrid Bajaras Airport project, Jicable [4] Pierre Argaut, Kjell Bjorlow-Larsen, Ernesto Zaccone, Anders Gustafsson, Fabian Schell, Volker Waschk, Large Projects of EHV underground cable systems, Jicable [5] C.H Henningsen and al, New 400 kv XLPE long distance cable systems, their first application for the power supply of Berlin, Cigre paper , [6] Scott Sadler, Simon Sutton, Horst Memmer and Johannes Kaumanns, 1600 MVA electrical power transmission with an EHV XLPE cable system in the underground of London, Cigre paper B1-108,