PJM Generation Interconnection Request Queue #A55 Lakewood 230kV Facilities Study Report 155697 September 2001
Table of Contents DESCRIPTION PAGE 1.0 Introduction 3 2.0 Description of Facilities Included in Study 4 3.0 Facility Study Results 6 4.0 Whitpain 230kV CB Replacements 8 5.0 Project Overview 10 Appendix A (Project Milestone Schedule/Overall Schedule) 13 Appendix B (Alternative Arrangements) 19 Appendix C (Existing and Proposed 1 Line) 22 Appendix D (Lakewood Technical Work Scope) 26 Appendix E (Interconnection Installation) 32 2
1. Introduction 1.1. Project Description This project involves modifying GPU Energy s existing 230 kv Lakewood CoGen substation. This substation is located at 123 Energy Way in Lakewood, New Jersey. The substation is adjacent to the 236 MW dispatchable Lakewood CoGen combined cycle power plant. The substation expansion is required to facilitate the export and transmission of an additional 500 MW of plant generation to be constructed at the site. The existing substation presently ties Con Ed Development s 236 MW generation power capacities to the GPU transmission system. Con Ed Development is planning to install an additional 500MW of generation capacity adjacent to the existing power plant facility. The new generating facility consists of three simple cycle GE 7FA combustion turbine generators. The initial combustion turbine is scheduled for operation in August 2002. A facility impact study identified the need to expand the existing substation to accommodate two additional 230kV lines into the existing GPU substation. The substation modification will provide enhanced power paths and increased reliability for exporting and transmitting the additional power. The existing four-breaker ring bus requires expansion to a seven-breaker ring configuration in order to accommodate a new 500 MW generation connection and (2) transmission line connections. Splitting the existing 230 kv K2011 line will create the two new transmission line terminal connections at the Lakewood CoGen substation. The K2011 line presently interconnects the GPU Larrabee station and the GPU Leisure Village station traversing the same corridor with the Z2026 line from Larrabee to Lakewood CoGen and the U2021 line from Leisure Village to Lakewood CoGen. The new line created from Lakewood CoGen to Larrabee will retain the designation K-2011. The new line created from Lakewood CoGen to Leisure Village will be designated D- 2030. In addition to the work required at Lakewood three 230kV circuit breakers at Larrabee substation need to be replaced because their short circuit interrupting capability will be exceeded by installation of the Lakewood (Ocean Peaking Power) generation. The project will also be allocated cost for the replacement of two over-dutied 230kV circuit breakers at Whitpain substation as explained in section 5.0. 1.2. Project Milestone Schedule See appendix A. 3
1.3. Changes from the Impact Study Since the initiation of the Facilities Study projects A38, A42 and A43 have withdrawn from the Generation Interconnection queue. This has resulted in a reduction in the network upgrades required for the Lakewood (Ocean Peaking Power) project. Specifically the replacement of a wave trap on the I1023 line at Raritan River and the need to replace the W1037E 230kV circuit breaker at Raritan River. Scope of GPU Energy Work 2. Description of Facilities Included in Study 2.1. Rearrangement of Existing 230 kv Transmission Line (K2011) The K2011 line will be cut and the two ends (Larrabee and Leisure Village) will be terminated in the expanded portion of the substation ring bus. 2.2. Substation Expansion The existing 230 kv, four-breaker ring bus will be expanded to accept the two new lines created by cutting and intercepting the K2011 line. The station expansion will also accommodate a new 230 kv short transmission line from the new generating plant. The resulting substation expansion will be configured into a seven-breaker ring. The ring bus will be designed for a maximum current rating of 2,000 amperes and a short circuit rating of 50 kaic. 2.3. Protection Systems GPU is in the process of installing 230 kv breakers on the U2021 and D2030 lines at Leisure Village, and a directional comparison-blocking scheme utilizing Power Line Carrier (PLC) for relay communication between Leisure Village and Larrabee as well as between Lakewood and Leisure Village. The in service date is June 1, 2001 for this work. These modifications will create a Lakewood CoGen to Leisure Village circuit in place of the existing Lakewood CoGen to Manitou circuit. Once circuit K2011 is cut into the Lakewood CoGen substation, the section of line between Lakewood CoGen and Leisure Village will retain the frequencies being presently used on the existing Larrabee-Leisure Village circuit for the directional comparison blocking scheme. The new relays to be installed at the Lakewood CoGen station will match the relays GPU is in the process of installing at Leisure Village A new line will be created between Lakewood CoGen and Larrabee when the existing K2011 line is cut into the expanded Lakewood substation. This line will 4
be protected with a directional comparison-blocking scheme using PLC. A frequency of 92Khz has been chosen for this new line. The primary and back-up relays will consist of SEL-321 and DLP relays for primary and backup protection, respectively. Shortening of the line between Larrabee and the Lakewood CoGen site when K- 2011 is cut into the new ring bus at Lakewood CoGen will necessitate relay replacement of the existing electromechanical line relays used for the K-2011 line protection at the Larrabee substation. The new line protection scheme will consist of SEL-321 and DLP relays for primary and backup protection, respectively. The following CT ratio changes will be required at Larrabee, in conjunction with the replacement of 230kV breakers BG. GK and K4 : a) Breakers "GK" and "BG" CTs associated with G-1021 Line Relays, presently used as bus differential relays: Connect the current transformers on the new circuit breakers 1200/5 to match the ratios used on the capacitor 3 and 4 circuit breakers. b) Breakers "K4" and "GK" CTs associated with K-2011 Line Relays: Since a 2000/5 CT ratio will be required for the "K4" breaker to handle the 796 MVA load capability specified by the GPUE Transmission Planning group, CTs on both the "K4" and "GK" breaker will be connected to a 2000/5 ratio for the K-2011 line relays. c) 230kV breakers "K4" and "4R" and 34.5kV breakers "4A" and "4B" CTs associated with Bank 4 differential HU relays: To meet load requirements, the CTs on the 230 kv "K4" and "4R" circuit breakers will be connected using a 2000/5 CT ratio. Since these CTs are used in the differential scheme for Bank 4, a set of auxiliary CTs with a ratio of 10/5 which are already installed on the 34.5 kv side of the differential circuit but presently not in use will be connected to the HU/T4 differential relays. The CT ratios on the 34.5 kv BK4A and BK4B circuit breakers will be changed to 1500/5 that will effectively change the overall ratio associated with the differential inputs from the 34.5 kv BK4A and BK4B circuit breakers to 3000/5. The relay settings will be revised as required. d) Breakers "RZ", "4R", and Bank 8 CTs associated with R-1032 Line Relays: To meet load requirements, the CT ratios on the CTs on the 230 kv "RZ" and "4R" circuit breakers used for the R-1032 line relays must be changed from 1200/5 to 2000/5. This change will also require that a set of auxiliary CTs with a 1.66/1 ratio be installed on the Bank 8 CTs used for 5
the R-1032 line protection to match the 2000/5 ratio for the line relays. The relay settings will be revised as required. e) Breakers "RZ", "ZD", and Bank 3 CTs associated with Z-2026 Line Relays: To meet load requirements, the CT ratios on the CTs on the 230 kv "RZ" and "ZD" circuit breakers used for the Z-2026 line relays must be changed from 1200/5 to 2000/5. This change will also require that a set of auxiliary CTs with a 1.66/1 ratio be installed on the Bank 3 CTs used for the Z-2026 line protection to match the 2000/5 ratio used for the line relays. The relay settings will be revised as required. 3. Facility Study Results 3.1. 230kV Circuit Rearrangement - The K2011 line, running in the transmission corridor adjacent to the existing substation, will be cut and brought into the station to enhance the capacity and reliability of power export from the station. The line rearrangement is needed as part the transmission infrastructure improvements to accommodate the planned increased capacity of the power plant. - The K2011 line is an existing transmission line that connects the GPU Larrabee station to the GPU Leisure Village station. This line shares the same structures and therefore traverses the same corridor as the Lakewood CoGen to Leisure Village Line (U2021) and the Lakewood CoGen to Larrabee Line (Z2026). - Existing circuit Z-2026 presently terminates at a position protected by breakers ZA and ZB, while circuit U-2021 is terminated between breakers UA and UB. - The existing K2011 line will be cut in the vicinity of the Lakewood CoGen Plant and two line terminals created. In order to avoid crossing any 230kV lines, circuit Z-2026 will be relocated to a new bus position (see proposed alternate B one line in Appendix C). The position vacated by circuit Z-2026 between breakers ZA and ZB will be used for the new Lakewood-Leisure Village line (D-2030). - Two options were proposed for connection to the station (see Appendix B). Option B was selected to prevent the loss of two Larrabee lines in case of a stuck breaker operation during a line fault. - The length of the Leisure Village to Lakewood CoGen Line is approximately 4 miles. The length of the Larrabee to Lakewood CoGen line is approximately 12 miles. - There are no environmental impacts or considerations relative to the line work proposed. Existing Rights-of-Way and transmission corridors will be utilized. 6
- The existing line and the taps to the station expansion are rated 230 kv, AC, and consists of double circuit overhead tower and pole line construction. - The new taps to the station will be accomplished via inter-built tapered tubular poles that match existing construction. Tension spans will be utilized from the tap poles to A-Frame or H-Frame dead end towers inside the station area. - The line and shield conductor size will match existing construction wherever practical and feasible. 3.2. Lakewood 230 kv CoGen Substation Modifications - The purpose of the expansion is to provide the necessary capacity and reliability for the proposed 500 MW power plant expansion. - The existing substation is configured as a four-breaker ring bus. There are two position dedicated to two line terminals, Z 2026 and U2021. There are two positions dedicated to the existing power plant generation power path connections. The ring will be expanded to a seven-breaker ring bus configuration. This configuration will accommodate the two new line terminals created by breaking the K2011 line with the installation of two positions in the ring. The third position created on the ring will be dedicated to the power path connection from the new power plant. - Consultations with the Town of Lakewood Building Department revealed that a construction permit is the only permit required by the Town. - Discussion with the Town of Lakewood Zoning Department indicate the Town may waive the formal zoning review since the substation expansion was indicated in the original zoning board plan submission. - Electrical design will be based on a nominal voltage of 230 kv and a nominal current rating of 2,000 amperes. Rigid bus and strain bus will be used in the design for the station expansion. The short circuit interrupting rating will be designed for 50 kaic. Present worst-case short circuit levels are on the order of 32 kaic for three phase bolted faults and 36 kaic for single line to ground faults. Gas circuit breakers will be used for the three additional circuit breakers. Refer to Appendix D for a full description of the technical work scope. - The civil and structural design will be based on existing design parameters. Existing structure types and material will be used as is appropriate. New foundation design will model existing conditions, as is feasible. Soil boring logs have been reviewed and indicate a soil bearing pressure of 3,000 lbs. would be suitable for design. The size and type of the foundations will match existing conditions as is feasible. - The fence, gates and access roads will be modified to accommodate the larger substation. 7
- A topographic survey, including existing benchmarks has been completed. - A new control building extension/expansion will be constructed adjacent to the existing control building. The building will include the new relay protection, SCADA and communications as well as a new DC power plant. 3.3. Leisure Village Substation Modifications - There is no requirement for any system upgrades at Leisure Village directly attributable to the Lakewood generation addition. The extent of the required work is related to line relay testing during testing and commissioning of circuits U-2021 and D-2030 protection schematics. 3.4. Larrabee Substation Modifications - The protection of the new Lakewood-Larrabee line will consist of a directional comparison-blocking scheme via PLC. The only requirements at Larrabee will be to re-tune the carrier frequency to 92Khz, and the replacement of the carrier set with one having the same 92Khz frequency. Breakers K4, GK and BG will be replaced to address increased short circuit duty resulting from the additional generation at Lakewood. These SF6 gas breakers will be nominally rated 230kV, 3000A. Scope of PECO Work 4.0. Whitpain 230V CB Replacements 4.1 Purpose and Necessity The Impact Study analysis for project A55, as well as all other Queue A projects, used a short circuit analysis methodology that screened for potential overdutied circuit breakers at locations where a project had a contribution equal to or greater than 3% of the circuit breaker s rating. This 3% threshold was used to determine when a project had a cost allocation responsibility for an overdutied circuit breaker. When Queue A Impact Studies were being performed, it was recognized that a particular circuit breaker s rating could be exceeded by the aggregate impact of a number of projects where no single project was found to contribute a short circuit current increase equal to 3% or more of that circuit breaker s rating. The term creepers was used to designate the small group of overdutied circuit breakers which would not be identified in any Queue A impact study but would ultimately be determined when a comprehensive short circuit analysis was performed for the Regional Transmission Expansion Plan. The possible existence of creepers, and allocation of cost assignment to Queue A projects for upgrade of creepers, was communicated publicly at TEAC meetings for Queue A projects. 8
Results from the recently completed comprehensive short circuit analysis for the Queue A Regional Transmission Plan determined that creeper overdutied circuit breakers were found to exist. Those that are of concern to the Lakewood (A55) project are at Whitpain 230kV substation for which analysis determined that Project A55 has cost allocation responsibility. According to the most current information, the cost allocation (based on relative short circuit current contribution of short circuit contribution to the affected circuit breakers after 100% of rating is exceeded) is as follows: Whitpain CB #115 Cost ($250,000 est.) 13.9% - Project A30 $ 34,679 7.0% - Project A36 $ 17,428 8.3% - Project A55 $ 20,843 70.8% - Project A59 $177,050 Whitpain CB #225 Cost ($250,000 est.) 3.0% - Project A29 $ 7,485 15.2% - Project A30 $ 37,914 8.6% - Project A55 $ 21,604 73.2% - Project A59 $182,997 4.2 Material List A detailed material list can be provided upon request upon completion of final design. 4.3 Cost Estimate The total cost estimate for the A55 Lakewood Project share of the breaker replacement is $20, 843 plus $21,604 for a total of $42,447. This is direct material cost. 4.4 Engineering Design Schedule, and Equipment Procurement and Construction Schedule Not established at this point in time. PJM is currently developing a procedure for the timing requirements associated with the replacement of creeper overdutied circuit breakers. The issues which will be addressed by the procedure include; (1) Providing certainty for full Capacity Interconnection Rights (CIRs) to the Interconnection Customer, and (2) Minimizing the possibility that a circuit breaker is replaced too far in advance of actual need or when not required. 9
Based on the information available at this time, the interconnection of project A55 will result in the need for circuit breaker replacements at Whitpain 230kV substation. The cost allocation for project A55 may vary from the percent listed above to potentially 100% if other projects withdraw their Generator Interconnection Request. Other projects in Queues B and C may also be assigned some cost responsibility to reduce the cost allocation to project A55. Therefore, Project A55 must provide security for its allocated cost. Additional security may be required in the future if the cost allocation to the Lakewood Project increases. 5.0 Project Overview 5.1. Total Cost of Facilities & Allocated Cost to Project Developer 10
GPU ENERGY OCEAN PEAKING POWER INTERCONNECTION ESTIMATED COSTS (FERC BREAKOUT, GPU FACILITIES) ATTACHMENT FACILITIES Direct Indirect Carrying Total Cost Cost Cost Cost Labor $ 567,091 $ - See $ 567,091 Materials $ 527,909 $ - Note $ 527,909 Total ABB & GPUE $ 1,095,000 $ - Below $ 1,095,000 $ 1,095,000 LOCAL UPGRADES Direct Indirect Carrying Total Cost Cost Cost Cost Labor $ - $ - See $ - Materials $ - $ - Note $ - Total ABB & GPUE $ - $ - Below $ - $ - NETWORK UPGRADES Direct Indirect Carrying Total Cost Cost Cost Cost Labor $ 1,590,627 $ 30,999 See $ 1,621,626 Materials $ 1,596,359 $ 8,611 Note $ 1,604,970 Total ABB & GPUE $ 3,186,986 $ 39,610 Below $ 3,226,596 $ 3,226,596 ALL FACILITIES Direct Indirect Carrying Total Cost Cost Cost Cost Labor $ 2,157,719 $ 30,999 See $ 2,188,718 Materials $ 2,124,267 $ 8,611 Note $ 2,132,878 Total ABB & GPUE $ 4,281,986 $ 39,610 Below $ 4,321,596 $ 4,321,596 $ 4,321,596 Note: Developer shall reimburse Jersey Central Power & Light Company d/b/a GPU Energy for depreciation, taxes, return, and ongoing operations and maintenance expenses by way of a series of payments over twenty-five years. The basis for these charges is the FERC Fixed Charge Worksheet for Jersey Central Power & Light Company, as filed with the FERC under Docket ER01-2888-000. The actual payments shall be based upon GPU Energy's actual investment in this project, which is likely to differ from the estimates shown in this exhibit. GPU Energy shall impose no Carrying Cost upon the Developer, other than the Return component provided under the FERC Fixed Charge Worksheet described above. 11
The Costs for the breaker replacement at Whitpain 230kV substation is $42,447, all of which are direct equipment costs. 5.2. Summary of Construction Schedules & Overall Construction Schedule for Facilities See Appendix A. 5.3. Comparison of Facilities Construction Schedule with Project Developers Milestone schedule Con Ed Development required ready for service date is April 30, 2002. Although it would have been preferable to complete the 230 kv bus expansion work by November 30, 2001, this will not be possible due the time involved with the permit requirements. 5.4 Interconnection Customers Milestone Schedule Initial energization April 2002 Unit #1 commercial operation August 2002 Unit #2 commercial operation October 2002 Unit #3 commercial operation To be determined 12
APPENDIX A PROJECT MILESTONE SCHEDULES 13
Lakewood 14
Lakewood 15
INTERCONNECTION INSTALLATION SCHEDULE OF WORK (Limited to Lakewood Substation) This Schedule of Work is limited to GPU Energy Attachment Facilities, GPU Energy Local Upgrades and GPU Energy Network Upgrades at Lakewood Substation. It excludes GPU Energy Additional Facilities that may be required to be installed at the Larrabee substation and the Raritan River substation. Task Name Estimated Days Required to Complete Task (See Note 1) Site Mobilization 11 Civil Construction 38 Install Conduit & Cable Trench 49 Grounding Installation 90 Install New Building Addition 92 Structural Steel Erection 104 Control Cable Installation 124 Bus & Switch Installation 178 Receive & Install Breakers 136 Replace DC Battery & Charger 136 Control & Protection Installation 181 Install RTU 195 Testing & Commissioning 249 Project Completion Deadline 250 Note 1: Estimated Days are measured from date when GPU Energy receives all local and state building permits necessary to commence construction. 16
Larrabee Replace Circuit Breakers K4 and GK at Larrabee. (Duration: 16 days. Start: Mon 05/25/02. Finish: 06/15/02) 1. With the newly formed transmission pathways established between Larrabee and Leisure Village feeding through the expanded ring bus at the Lakewood Cogen facility, the existing K2011 line will be taken out of service by opening breakers K4 and GK at Larrabee, and breaker K2011-1 at Leisure Village. 2. ABB will mobilize crews at Larrabee for the breaker replacement phase of the project. Breakers K4, GK and BG will be replaced as part of the overall project scope. 3. Breakers K4 and GK at Larrabee will be isolated by their respective disconnect switches. These breakers will be disconnected and removed from service. The new 3000A circuit breakers will be installed on existing foundations. All breaker leads and connectors will be replaced. Junction boxes will be installed at each breaker location in order to utilize existing breaker control cables. 4. ABB will replace the existing K2011 line relays at Larabee with SEL-321 (Primary) and GE- DLP (Backup) protection according to GPU Energy standards. ABB will also replace the existing carrier set, and retune the line tuners during this step. 5. Breaker BG at Larrabee will remain in service until breakers K4 and GK are replaced, fully tested and returned to service, so as to avoid an outage on the G1021 line to Atlantic Substation. It is anticipated that it will take approximately 3 weeks to replace these two circuit breakers,install the new line relays, test and recommission the system. Replace Circuit Breaker BG at Larrabee. (Duration: 10 days. Start: Mon 06/15/02. Finish: 06/26/02) 1. At Larrabee Substation, ABB will replace breaker BG with another new 3000 A circuit breaker, along with the breaker leads and connectors. This will cause an outage on the capacitor banks, and a brief outage of the B1042 line, by opening breaker HB. All relaying will remain unchanged for the G1021 line. ABB will provide settings for all relays, and commission the new breaker BG as well as perform functional testing. Once functional testing is complete, breaker BG may be placed back in service. It is anticipated that it will take approximately 2 weeks to replace this circuit breaker. 17
Change CT Ratios of RZ and 4R at Larrabee. (Duration: 2 days. Start: 06/29/02. Finish: 07/01/02) 1. ABB will request that 230 kv Breakers RZ and 4R at Larrabee associated with Bank #8 and Bank #12 be opened. During this outage, to meet load requirements, the CT ratios of these breakers will be changed from 1200/5 to 2000/5. This change will also require a set of auxiliary CTs with a 1.66/1 ratio to be installed on the Bank #8 CTs used for R1032 line protection to match the 2000/5 ratio for the line relays. It is anticipated that this outage will take approximately 3 days. Change CT Ratios of Units K4 and 4R at Larrabee. (Duration: 4 days. Start: 07/02/02. Finish: 07/06/02) 1. Finally, ABB will request that 230 kv Breakers K4 and 4R at Larrabee associated with Bank #4 be opened. During this outage, ABB will change the CT ratios on both these breakers to 2000/5. Since these CTs are used in the differential scheme for Bank #4, a set of auxiliary CTs with a ratio of 10/5 which are already installed on the 34.5 kv side of the differential circuit but presently not in use will be connected to the HU/T4 differential relays. The CT ratios on the 34.5 kv breakers BK4A and BK4B will be changed to 1500/5, which will effectively change the overall ratio associated with the differential inputs from the 34.5 kv breakers BK4A and BK4B to 3000/5. 18
APPENDIX B ALTERNATIVE ARRANGEMENTS 19
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APPENDIX C EXISTING AND PROPOSED ONE LINE DIAGRAMS 22
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Larrabee 230kV Substation Breaker Replacement to Bank 9 to Atlantic to Bank 4 to Bank 3 to Bank 8 to Smithburg ZO RZ 4R HD K4 to Smithburg HB BG GK to Lakewood to Lakewood to Bank 7 to Cookstown 230 kv new 25
APPENDIX D LAKEWOOD TECHNICAL WORK SCOPE 26
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APPENDIX E GPU ENERGY INTERCONNECTION INSTALLATION SCOPE AND SCHEDULE OF WORK 32
INTERCONNECTION INSTALLATION SCOPE OF WORK Services to be performed by GPU Energy: GPU Energy will provide all materials, equipment, tools, engineering, drafting, labor, supervision, project management, civil work, electrical construction, and testing needed to design, furnish and install the GPU Energy Interconnection. Additional items for interconnection and reinforcement may be identified, the interconnection configuration may change, and the actual costs may materially differ from the estimated costs shown below. In addition, Con Ed Development will pay for all actual costs incurred by the GPU Energy. Estimated Company Additional Item Project Description Facilities Cost 1 Company Attachment Facilities... $ 1,095,000 a. Provide and install an additional 230kV bus position to the existing four (4) ring bus at Lakewood Substation. 2 Company Local Upgrades... $ 0 a. No Company Local Upgrades have been identified. 3 Company Network Upgrades... $ 3,226,596 To alleviate 34.5kV circuit overloads $ 2,274,696 a. Provide and install two (2) additional bus positions to the existing 230kV 4 position ring bus at Lakewood Substation to accommodate two (2) new 230kV lines at Larrabee substation. b. Cut the existing Larrabee Leisure Village line K-2011 and route into expanded Lakewood 230kV ring bus. Relocate Larrabee Lakewood line Z-2026 from existing ring bus position to a new 230kV bus position to prevent the need to cross any lines. c. Upgrade the CT ratios at Larrabee substation on several breakers around the ring bus and install auxiliary CTs as required. Re-set and calibrate relays as required. d. Replace the existing electromechanical relays at Larrabee substation associated with the Lakewood line K-2011. Replace existing carrier set, re-tune the wave trap to a new frequency of 92kZ. 33
To alleviate circuit breaker short circuit duty problems at Larrabee $ 951,900 e. Replace existing 230kV, 2000A breakers BG, GK and K4 at Larrabee substation with 3000A breakers Total... $ 4,321,596 34