1 Refurbishment & Upgrade of the Celilo HVdc Converter Station Mark A Reynolds, PE Sr. Project Manager, POWER Engineers mark.reynolds@powereng.com Karl A Mitsch, P.E. Sr. Project Manager USDOE Bonneville Power Administration kamitsch@bpa.gov
2 Presentation Topics BPA Decision Replace or Refurbish Typical Life of HVdc Equipment Project Approach Consideration and Timeframe Develop Risk exposure
3 Factors Effecting Equipment Life MW load factor of HVdc link Maintained to HVdc OEM recommendations Design specification for equipment Fault and external stresses on equipment Overload stresses on equipment
4 Typical Equipment Life Equipment Life (years) Thyristor Valves + Electronics 35+ Converter Transformer 35+ (varies on MW Loading) Filters 35+ Control & Protection 15+ Cooling Equipment 35+ Smoothing Reactors 35+
Controls Lifecycle (Ideal) 1 5 yrs Under OEM support 6 12 yrs Mid life of controls 13 14 yrs Replacement planning 15 17 yrs Procure and replace controls 5
6 BPA Decision Replace or Refurbish Equipment condition & maintainability Increasing failure rate suggesting end of life Significant increases in maintenance costs Spare parts not available Availability of HVdc OEM support
7 BPA Decision Replace or Refurbish Outage Considerations Replace Build adjacent, cutover (minimize outage time) Refurbish Multiple projects over time (look at collective outage impacts) Provide incentives to minimize outage time Refurbish and operate in monopole configuration to reduce outage impact Replacement power can be very expensive
8 The BPA Decision & Scope Owners Decision Replace HVdc Terminal Facilities at the Northern Terminal (Celilo) Upgrade Link Capacity by Current & Voltage Increases (3410 Amperes, at 560 kv, 3800 MW (Ultimate Rating), 3100 Amperes, at 556 kv, 3450 MW (Phase 1-Rerate)) Transmission Insulation Upgrade by insulator bell additions ( 2~3 bells on 804 structures) Controls Replacement (pre-replacement) control telecommunications changes (analog MW to Digital)
9 BPA Project Approach Define Project & Funding Get HVdc OEM cost estimates Life Cycle Cost of Replace vs. Refurbish Current and future operating expenses Down time or outages needed (replacement power costs)
10 Project Approach Technical Details Establish New Converter Ratings (step plan for rerating) MW transmission line ultimate rating (3800 MW) Develop a separation and cutover plan
Insulator I-String Additions 11
Design & Manufacturing of New HVdc Apparatus 12 Converter Transformers Converter Valves (Thyristor) Control Systems Cooling Plant Instrument Transformers Air Core Smoothing Reactors Other Equipment
Transformer Production 13
New Thyristor Valve Under HV Testing 14
Existing Converter 1 & 2 Switchyard Demolition 15
Movement & Installation of New Converter Transformers (430 Ton Transport Weight) 16
New Converter Transformer Installation 770 MVA, 3-Winding, 1,270,000 pounds 17
New Switchyard Installation 18
New Thyristor Valve Tower Installation 19
20 Controls Systems Testing MACH-3 Factory System Testing in Ludvika Sweden
Celilo Project Schedule 21
Installation Testing & Commissioning Program 22 Subsystem Testing & cable checks Pre-Energization control checks including Interlocks and sequence checks Finalize Energization Sequence& Outage Coordination Planning Partial Load Testing Full Load Testing Staged Line Faults and Performance Testing 30-Day Trial Operation (90 Day Maximum) Commercial Acceptance & Celebration
23 Detailed Commissioning Milestones 9/13/15 Connect new converters to 500 kv AC system and perform Back to Back testing** 10/3/15 Start of PDCI Outage for DC Line Upgrades and reconnection of DC line to new converters 11/3/15 End of PDCI Outage 11/15/15 Exchange of power with Sylmar via one pole is possible **A local Northern Terminal End Back to Back connection will allow the BPA 525 kv HVac Feeders to energize the new converters No. 1 & 2 on the ac side of the new Poles. The HVdc Poles No. 1 & 2 will then be cross connected on the HVdc side providing a local loop at a North Terminal local station to allow a of test the new poles at Celilo, at full voltage and nearly full power levels, with minimal impact to the WECC Network. Only energy losses during the BtB operation will need to be purchased by BPA.
Back to Back Testing Configuration 24
Thank you for your time 25