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    Olympic Tunnel Presentation PGH 3

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    Sivagnana Sundaram
    This document summarizes an Olympic Tunnel 400kV cable project connecting the Hackney and West Ham substations in London. Prysmian was awarded the contract to design, supply, install and commission two 400kV cable circuits in the 6km tunnel. Key aspects of the project included installing 48 drums of cable in 12 weeks, completing 4500 cable sags and 42 cable joints in 17 weeks, and completing the overall installation in 30 weeks. The document provides details on cable specifications, jointing and testing procedures, and health and safety considerations for working in the constrained tunnel environment.

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    Download as PDF, TXT or read online from Scribd

    Olympic Tunnel Presentation PGH 3

    Uploaded by

    Sivagnana Sundaram
    352 views67 pages
    This document summarizes an Olympic Tunnel 400kV cable project connecting the Hackney and West Ham substations in London. Prysmian was awarded the contract to design, supply, install and commission two 400kV cable circuits in the 6km tunnel. Key aspects of the project included installing 48 drums of cable in 12 weeks, completing 4500 cable sags and 42 cable joints in 17 weeks, and completing the overall installation in 30 weeks. The document provides details on cable specifications, jointing and testing procedures, and health and safety considerations for working in the constrained tunnel environment.

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    This document summarizes an Olympic Tunnel 400kV cable project connecting the Hackney and West Ham substations in London. Prysmian was awarded the contract to design, supply, install and commission two 400kV cable circuits in the 6km tunnel. Key aspects of the project included installing 48 drums of cable in 12 weeks, completing 4500 cable sags and 42 cable joints in 17 weeks, and completing the overall installation in 30 weeks. The document provides details on cable specifications, jointing and testing procedures, and health and safety considerations for working in the constrained tunnel environment.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    352 views67 pages

    Olympic Tunnel Presentation PGH 3

    Uploaded by

    Sivagnana Sundaram
    This document summarizes an Olympic Tunnel 400kV cable project connecting the Hackney and West Ham substations in London. Prysmian was awarded the contract to design, supply, install and commission two 400kV cable circuits in the 6km tunnel. Key aspects of the project included installing 48 drums of cable in 12 weeks, completing 4500 cable sags and 42 cable joints in 17 weeks, and completing the overall installation in 30 weeks. The document provides details on cable specifications, jointing and testing procedures, and health and safety considerations for working in the constrained tunnel environment.

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    Olympic Tunnel 400kV Cable Project Hackney Substation To West Ham Substation

    Experience
    Prysmian has been responsible for the design, supply, installation and commissioning of over 450Km of Supertension cables in 44 tunnels worldwide. Of which 9 are in the UK. In January 2006 Prysmian was awarded the contract to design, supply, install and commission the 400kV XLPE cables, accessories, support systems and monitoring systems for the West Ham Hackney tunnel.

    Project scope Full turnkey project to design, supply, install & commission two 400kV cable circuits. Tunnel length 6km Tunnel diameter 4.15 metres Circuit length 6.3km Install and commission both circuits by September 2008. Tunnel to be cleared of temporary services

    Prysmian Supply scope


    Cables: Single core, 2500mm2 copper conductor, XLPe Insulated, Aluminium Sheath, flame retardant oversheath. 48drums, 810m section length. Cable weight 36kg/m. 36 sectionalised 400kV joints, 6 un-sectionalised 400kV joints, 12-400kV outdoor terminations with composite insulators. Continuous Partial Discharge monitoring for all joints and terminations. Continuous monitoring for sheath voltage limiters at each joint bay.

    Accessories:

    Monitoring:

    Prysmian Supply scope


    Steelwork: 210 tonnes of steelwork designed, manufactured and installed to support the cable and accessories in the tunnel and above ground.

    Substations: Design and construction of: - Cast in-situ cable troughs from the tunnel shafts to the Outdoor terminations at Hackney & West Ham. - Associated cable support structures and foundations. - Cable trough forced air ventilation systems. - DAR Cable Protection. - Surge Arrestors.

    Tunnel constraints
    4.15 metre diameter tunnel with no level base for ease of access or use of vehicles solution was to design and manufacture vehicles to run on monorail. Tunnel designed for 4 circuits with the first two circuits to be installed at the top level on either side of the tunnel. All installation and jointing works carried out at some two metres from tunnel invert necessitating special mobile platforms for all works and large scaffold structures (26 tonnes of scaffolding per joint bay) for jointing works.

    Project successes
    Installed 48 drums of cable in 12 weeks. 4500 cable sags completed in 12 weeks. 42 cable joints and 6 outdoor sealing ends installed in 17 weeks. 210 tonnes of steelwork installed throughout the tunnel and shafts. 300 tonnes of scaffolding installed into and removed from the tunnels and shafts within the 6 month cable installation and jointing programme. Overall installation project completed in 30 weeks due to parallel working patterns.

    System Design

    Rating Requirements Summer 1660 MVA (2396 Amps)

    Spring / Autumn 1790 MVA (2584 Amps) Winter 1950 MVA (2815 Amps)

    An additional two circuits would be added at a later date and the above ratings will change

    400 kV XLPE Cable with 2500 mm Copper Conductor


    1 2 3 4 5 6 7 8

    1. 2. 3. 4. 5. 6. 7. 8.

    Central filler Milliken conductor Conductor screen XLPE Insulation Insulation screen Semi-conducting hygroscopic binder Aluminium sheath PE oversheath

    Main Cable Features


    Milliken

    conductor with low AC resistance. XLPE insulation Thick longitudinally welded aluminium sheath. Flame retardent oversheath. Cable is light and robust.

    Reducing AC resistance
    Skin effect

    Proximity effect

    Milliken divides conductor into sectors


    Improves current density in sector Reduces skin effect Widely spaced cables reduces proximity effect Reduced AC resistance means improved rating

    Schematic Arrangement of Circuit


    SVL

    E\E\901\ L

    Detail of cross bonding and SVL connections

    SVL

    West Ham S/S


    SVL

    Note:- all sectionalised joints will have SVL's fitted across the sectionalising insulation

    Hackney S/S

    Cable: 2500mm2 Copper Conductor, 400kV XLPE Cable Single core 300 mm bonding strands

    Single core 500 mm bonding strands


    Ref No. Company

    Symbols

    1LNB-2072 B: LBM 3A Sectionalised Joint Outdoor Termination LBM 7A


    Drawn by

    VJB
    Verified by Title

    GW Unsectionalised Joint
    Customer

    National Grid
    Issue No.

    West Ham - Hackney 400 kV Circuit


    DWG No. Date

    STS9221/D1 issue 3

    11/04/06

    2 x sections with sheaths single point bond


    2 x major sections with sheaths cross-bonded

    Single Point Bonded Sheaths

    No circulating currents in the sheath better rating. Sectionalising insulators protected by SVL. Earthing interconnector to carry the return fault current

    Cross-Bonded Sheaths
    Vr 00 + Vb 120`0 + Vy -120 0 = 0

    Crossed bonded cables are installed in multiples of three. Sheaths voltages balanced out over three-sections. No circulating currents No sheath losses Higher ratings. Joints sectionalising insulators protected by sheath voltage limiters (not shown)

    TA (outlet)

    Cable Rating Assessment Cables will generate losses Majority of heat removed by air ventilation. Rating assessed by Cigre methods Electra 143 Electra 144

    Heat Flow Through Ground

    Heat Generated by Cables

    TA (inlet)

    Heat Flow by Tunnel Air Ventilation

    Monitoring Systems

    Types of Monitoring System Distributed Temperature Sensor (DTS) Sheath Voltage Limiter (SVL) Partial Discharge (Pd)

    DTS Monitoring System


    The temperature sensor is an optical fibre cable. The characteristics of the fibres will change with temperature. The temperature can be measured for the complete route. The hot-spots can be identified. The cable / tunnel temperatures are measured using DTS hardware locate at one substation. The tunnel ventilation can be adjusted to suit.

    DTS Fibre Attached to Cable


    Other fibres installed top and bottom of tunnel.

    SVL Monitoring

    SVL Monitoring Optical fibre and mirror wrapped around SVL. Reflected signal SVL operational. Loss of signal SVL failed

    Optical signal

    Reflection

    SVL Monitoring display

    HMI - All SVLs Operational

    HMI - SVL failed on System 1 J.B. 2/3

    Partial Discharge Monitoring All accessories monitored for PD. Used during commissioning and in service. No power supply in tunnel. PD measurements sent by fibre optic cable to the outside of the tunnel.

    PD Monitoring display

    Cable Installation Jointing and Testing

    Project successes
    Installed 48 drums of cable in 12 weeks. 4500 cable sags completed in 12 weeks. 42 cable joints and 6 outdoor sealing ends installed in 17 weeks. 210 tonnes of steelwork installed throughout the tunnel and shafts. 300 tonnes of scaffolding installed into and removed from the tunnels and shafts within the 6 month cable installation and jointing programme. Overall installation project completed in 30 weeks due to parallel working patterns.

    Planned Cable Arrangement at Shaft 3

    Cable Installation at Shaft 3- Hackney

    Tunnel layout

    Schematic cable & winch arrangement

    Tunnel cross section

    Trial cable delivery

    Trial cable delivery - Hackney

    Cable convoy - Stratford

    Drum storage at shaft 2

    Steelwork installed ready for rollers

    Shaft 2 prior to scaffolding

    Looking down shaft 2 scaffolding

    Base of shaft 2 ready for cable

    Monorail working platform

    Cable installation at height

    Cable installation at shaft 2

    Scaffolding at top of shaft 2

    Pipes at top of shaft 2

    Pipes on scaffolding at top of shaft

    Back tension winch at shaft 2

    Cables installed at high level

    Transposition by joint bays

    Transposition by joint bays

    Cable transposition

    Transposition at joint bay

    Sagging of cables

    Sagging of cables

    Training area for jointing

    Training area for jointing

    Training area for jointing

    Joint bay platform

    Joint bay

    Completed joint

    Completed joints

    Completed joint bay

    HV Test Arrangement

    Termination Arrangement at Hackney

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