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Project: TIRORA THERMAL POWER PROJECT 1980 MW (2x660 MW Phase – I+1X660 MW Phase – II)
Project:
TIRORA THERMAL POWER PROJECT
1980 MW (2x660 MW Phase – I+1X660 MW Phase – II)
Tirora, Gondia District, Maharashtra
Title:
SIZING CALCULATION FOR UNIT TRANSFORMERS & UATs
Client:
ADANI POWER MAHARASHTRA LIMITED
TIRORA, MAHARASHTRA
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15/12/09
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15/12/08
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Revised as per BTG load list
First Submission
INITIALS
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INITIALS
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INITIALS
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DETAILS OF REVISION
REV
DATE
PREPARED
CHECKED
APPROVED
FICHTNER Consulting Engineers (India) Private Limited
CHENNAI – MUMBAI

Adani Power Maharashtra Limited Tirora Thermal Power Plant (2X660 MW Phase-I + 1X660 MW Phase-II)

Sizing Calculation for Unit Transformers & UATs

TABLE OF CONTENTS

S.No. DESCRIPTION PAGE No.
S.No.
DESCRIPTION
PAGE No.
  • 1.0.0 PREAMBLE

3

  • 2.0.0 REFERENCE DDOCUMENT

3

  • 3.0.0 PROJECT DATA

3

  • 4.0.0 SYSTEM DESCRIPTION

3

  • 5.0.0 DESIGN BASIS

3

  • 6.0.0 PARAMETERS FOR UAT

4

  • 7.0.0 PARAMETERS FOR UT

5

  • 8.0.0 CONCLUSION

6

ANNEXURE-A: UAT Sizing Calculation

ANNEXURE-B: UT Sizing Calculation

Adani Power Maharashtra Limited Tirora Thermal Power Plant (2X660 MW Phase-I + 1X660 MW Phase-II)

Sizing Calculation for Unit Transformers & UATs

  • 1.0.0 PREAMBLE The proposed coal based power plant has 3X660 MW Generating units. Power evacuation is envisaged at 400kV level. Auxiliary power supply for the Plant Unit auxiliaries is derived from the Unit Transformers and Unit Auxiliary Transformers. This document covers sizing calculation for UTs and UATs.

  • 2.0.0 REFERENCE DDOCUMENT Main Single line Diagram (Drawing No.00- 2821710001- E- 001 )

  • 3.0.0 PROJECT DATA

Voltage rating of power evacuation system

: 400 kV +/- 5%

Frequency

: 50 HZ, +3% to –5%.

Generator rating

: 660 MW, 0.85 P.F.

Generator voltage rating

: 22 kV.

Generator voltage variation

: +/- 5%.

Design ambient temperature

: 50 Deg.C.

  • 4.0.0 SYSTEM DESCRIPTION Each Steam Turbine Generator is rated for 660 MW, 0.85 PF. The generation voltage is at 22kV. Each generator shall be connected to the 400kV switchyard through a Step-up Generator Transformer (GT). For each unit, two numbers Unit transformers (UT) and two numbers Unit Auxiliary transformers (UAT) are envisaged to feed Unit Auxiliaries. Unit transformers are energised from 22 kV Generator Busduct tap off. Each UT feeds respective 11 kV Unit Switchboard. Both the UTs will have identical rating. Unit Auxiliary transformers are energised from 11 kV Unit switchboards. Each UAT feeds respective 6.6 kV Unit Switchboard. Both the UATs will have identical rating.

  • 5.0.0 DESIGN BASIS

  • 5.1.0 To provide Auxiliary power supply to Unit Auxiliaries three levels of supplies viz. 11 kV, 6.6 kV and 415V are envisaged.

For Motors rated < 160 kW : 415V supply

For < 160 kW and up to 2000 kW motors: 6.6 kV supply.

For < 2000 kW motors: 11 kV supply.

  • 5.2.0 The following are considered regarding loading of Motors & Transformers.

    • a) For

Unit auxiliaries, Maximum continuous rating (MCR) of the Motors are considered for

transformer sizing.

  • b) For the Motors, where Maximum continuous rating (MCR) is not available, MCR rating is assumed as 85% of the name plate rating for pump motors and 80% for fans & mill motors.(As followed by BTG supplier)

  • c) For LT Transformer feeders, 80 to 85% of name plate rating is considered as continuous load.

Adani Power Maharashtra Limited Tirora Thermal Power Plant (2X660 MW Phase-I + 1X660 MW Phase-II)

Sizing Calculation for Unit Transformers & UATs

  • 5.3.0 Reactive kVA consumption of the transformer shall be considered to arrive at input kVA rating of the Transformer.

  • 5.4.0 Unit LV service transformers will be fed from 11 kV Switchboard.

  • 5.5.0 CW pumps and cooling tower loads are consider ed in UT sizing, as these loads are considered as Unit load.

  • 5.6.0 While sizing the UT/UAT, additional load on one bus due to outage of one of the largest transformers to be considered.

  • 5.7.0 Unit Auxiliary transformer shall normally feed 50% of the 6.6 kV Unit auxiliaries. Under outage of one UAT, the other UAT shall feed 100% of the 6.6 kV Unit auxiliaries. Accordingly, UAT will be sized.

  • 5.8.0 Each Unit Transformer shall be based on the following:

    • a) Under normal operation 50% of 11 kV Unit Auxiliaries 50% of Unit LV service Transformers 50 % of 6.6 kV Unit Auxiliaries

    • b) Under outage of a UAT 50% of 11 kV Unit Auxiliaries 50% of Unit LV service Transformers 100 % of 6.6 kV Unit Auxiliaries

  • 6.0.0 PARAMETERS FOR UAT

  • 6.1.0 MVA Rating Sizing Calculation for Unit Auxiliary Transformer is enclosed as Annexure-A. As per sizing calculation, 16 MVA rating is adequate. As most of the time, transformer will be loaded up to 50% only, ONAN/ONAF rating is preferred. ONAN rating will be 60% of ONAF rating.

  • 6.2.0 Voltage Ratio Secondary voltage is selected 5% higher than the system voltage to account for reactance voltage drop in the transformer itself. Accordingly no load voltage ratio will be 11/ 6.9 kV.

  • 6.3.0 Impedance 10 % impedance is proposed with which, fault contribution from source will be about 20 kA and fault contribution from motors will be about 5 kA. As 6.6 kV Switchgear is rated for 31.5 kA, proposed impedance will be adequate.

  • 6.4.0 Vector Group As Generator Transformer vector group is YNd11 and Unit Transformer vector group is Dyn1, UAT transformer Vector group is proposed as Dyn11.

  • 6.5.0 LV Neutral

  • Adani Power Maharashtra Limited Tirora Thermal Power Plant (2X660 MW Phase-I + 1X660 MW Phase-II)

    Sizing Calculation for Unit Transformers & UATs

    Earth fault current of 6.6 kV system need to be limited to a safe value, so that core stampings are not damaged/getting welded during an earth fault. An earth fault limiting current of 300 to 500 A is generally followed in Power industry. Accordingly, to limit the earth fault current 400A NGR is proposed in the LV neutral of UAT.

    • 6.6.0 Tap Changer As Unit transformer is provided with OLTC for voltage control, each UAT is proposed to have a off circuit tap changer with + 5 % to – 5% tap in steps of 2.5 %.

    • 6.7.0 Losses UAT will be always be partially loaded (about 50%) during normal operating conditions. During failure of other UAT only, UAT will be loaded to about 90%. Hence it is preferred to keep the core losses lower. For the transformers of this capacity, Efficiency will be in the order of 99.6% at full load.

    • 7.0.0 PARAMETERS FOR UT

    • 7.1.0 MVA Rating Sizing Calculation for Unit Transformer is enclosed as Annexure-B. As per sizing calculation, 35 MVA rating is adequate. As most of the time, transformer will be loaded up to 80% only, ONAN/ONAF rating is preferred. ONAN rating will be 80% of ONAF rating.

    • 7.2.0 Voltage Ratio Secondary voltage is selected 5% higher than the system voltage to account for reactance voltage drop in the transformer itself. Accordingly no load voltage ratio will be 22/ 11.5 kV.

    • 7.3.0 Impedance 10 % impedance is proposed with which, fault contribution from source will be about 20 kA and fault contribution from motors will be about 10 kA. As 11 kV Switchgear is rated for 40 kA, proposed impedance will be adequate.

    • 7.4.0 Vector Group As Generator Transformer vector group is YNd11, UT transformer Vector group is proposed as Dyn1, so that it matches with 11 kV side of Station Transformer.

    • 7.5.0 LV Neutral Earth fault current of 11 kV system need to be limited to a safe value, so that core stampings are not damaged/getting welded during an earth fault. An earth fault limiting current of 300 to 500 A is generally followed in Power industry. Accordingly, to limit the earth fault current 400A NGR is proposed in the LV neutral of UT.

    • 7.6.0 Tap Changer Each UT is proposed to have a full-rated on-load tap changer (OLTC) to control the 11 kV Unit bus voltage with in the permissible limits of 11 kV system, when the grid/generator voltage

    Adani Power Maharashtra Limited Tirora Thermal Power Plant (2X660 MW Phase-I + 1X660 MW Phase-II)

    Sizing Calculation for Unit Transformers & UATs

    fluctuates. As Generator voltage is maintained with in +/- 5% by AVR, OLTC range is proposed with + 10 % to – 10% tap in steps of 1.25 %.

    • 7.7.0 Losses UT will be always loaded to about 80%. Hence it is preferred to keep the copper losses lower. For the transformers of this capacity, Efficiency will be in the order of 99.6% at full load.

    • 8.0.0 CONCLUSION Proposed rating of Unit Auxiliary Transformer is :

    Three phase, 10/16 MVA ,ONAN/ONAF, Z=10%,

    Off circuit tap changer with taps ranging from + 5% to –5% in steps of 2.5%.

    No.of UAT: 2 Nos for each Generator.

    Proposed rating of Unit Transformer is :

    Three phase, 28/35 MVA ,ONAN/ONAF, 22/11.5 kV, Z=10 %,

    On load tap changer with taps ranging fr om + 10% to –10% in steps of 1.25%.

    No.of UT: 2 Nos for each Generator.

    1980 MW, TPP Tirora , APML

    UAT Sizing Calculation

    ANNEXURE - A to

    Doc.No. 2821-EL-DSN-703, Rev.B

                   

    No.of

     

    No.of

     

    S.No

    Description of loads connected

    No.of

    drives

    Working

    Rated kW

    Load

    Factor

    Efficiency

    PF

    working

    Feeders

    Estimated

    kVA

    working

    Feeders

    Estimated

    kVA

     

    11/6.9 kV Unit Auxiliary Transformer

             

    UAT-1A/2A/3A

    UAT-1B/2B/3B

    1

    Coal Mills

    8

    6

     

    0.8

    • 800 0.8

    • 0.93 3

     

    2581

    3

    2581

    2

    Sealing air fan

    2

    1

     

    0.8

    • 185 0.8

    • 0.93 0

     

    0

    1

    199

    3

    BFP Booster pump

    2

    2

     
    • 630 0.85

     
    • 0.93 1

    0.85

     

    677

    1

    677

    4

    Boiler start recirculation pump

    1

       
    • 400 0.85

     
    • 0.93 0.85

           

    5

    CEP

    3

    2

    1120

    0.85

     
    • 0.93 1

    0.85

     

    1204

    1

    1204

    6

    CCCW

    2

    1

    560

    0.85

     
    • 0.93 1

    0.85

     

    602

    0

    0

    7

    Inst. Air compressor

    1

    1

    400

    0.8

     
    • 0.93 0.85

       

    1

    405

     

    Sub total

                 

    5065

     

    5066

     

    Required rating of UAT, kVA

                   
    • 10131 10131

     
     

    Required rating of UAT with voltage regulation, kVA

               
    • 10591 10591

     
     

    Required rating of UAT with 10% margin, kVA

               
    • 11650 11650

     
     

    Proposed rating of UAT, kVA

                   
    • 16000 16000

     

    1980 MW TPP, Tirora, APML

    UT Sizing Calculation

    ANNEXURE - B to

    Doc.No.2821-EL-DSN-703, Rev.B

     

    Description of loads

    No.of

    Workin

    Rated

     

    Load

    Efficienc

     

    No.of

    Estimated

    No.of

    Estimated

    S.No

    connected

    drives

    g

    kW

    Rated kVA

    Factor

    y

    PF

    Feeders

    kVA

    Feeders

    kVA

     

    11 kV Motors

                 

    UT-1A/2A/3A

    UT-1B/2B/3B

    1

    ID Fan

    2

    2

    6000

     

    0.8

     
    • 0.95 0.85

    1

     
    • 5944 5944

    1

     

    1

    FD Fan

    2

    2

    2800

     

    0.8

     
    • 0.95 0.85

    1

     
    • 2774 2774

    1

     

    2

    PA Fan

    2

    2

    3650

     

    0.8

     
    • 0.95 0.85

    1

     
    • 3616 3616

    1

     

    3

    CW Pump

    2

    2

    3600

     

    0.85

     
    • 0.96 0.85

    1

     
    • 3750 3750

    1

     

    4

    11/6.9 kV Unit Auxiliary Transformer

    22

               

    1

     
    • 5065 5066

     

    5

    Turbine Service Transformer

    2

    2

     

    2500

    0.4

       

    1

     
    • 1000 1000

    1

     

    6

    Boiler Service Transformer

    2

    2

     

    2000

    0.4

       

    1

     
    • 800 800

    1

     

    7

    CT Service Transformer

    2

    2

     

    2000

    0.4

       

    1

     
    • 800 800

    1

     

    8

    ESP Service Transformer

    6

    4

     

    2500

    0.85

       

    2

    4250

    2

    4250

     

    Sub total

                     
    • 27999 28000

     
     

    In case of outage of one largest transformer, additional load on UT

             
    • 33065 33065

     
     

    Required rating of UT with voltage regulation, kVA

                 
    • 34568 34568

     
     

    Proposed rating of UT, kVA

                     
    • 35000 35000

     
     

    Margin available during normal operation

               

    20.9

     

    20.9