21 30 10 EVizcarra Project Criteria Rev 0

ANTAMINA PROJECT

220 kV VIZCARRA SUBSTATION

BASIC PROJECT CRITERIA

Revised Approved Date

Report 21-30-10-E – Rev 0

REVISION

REV DESCRIPTION DATE

A

B

0

First Issue

Revision with updated project data. Incorporate Bechtel comments. Change in Control System.

General revision with latest design input

April 30, 1999

June 6, 1999

October 28, 1999

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VIZCARRA SUBSTATION. BASIC PROJECT CRITERIA21-30-10-E – Rev 0

220 kV VIZCARRA SUBSTATIONPROJECT CRITERIA

CONTENTS

1.00 PURPOSE

2.00 PROJECT DATA

3.00 SERVICE CONDITIONS

4.00 OPERATION AND MAINTENANCE

5.00 ELECTRICAL DESIGN5.01 Switchgear and Busbar System5.02 Instrument Transformers5.03 Control System5.04 Protection Functions5.05 Telecommunications5.06 Revenue Metering5.07 Auxiliary Services

6.00 INSULATION COORDINATION6.01 Insulation levels6.02 Surge Arresters6.03 Circuit Breakers6.04 Disconnecting Switches6.05 Capacitor Voltage Transformers6.06 Clearances and Spacing

7.00 220 kV SWITCHYARD7.01 Arrangement of 220 kV Switchyard7.02 Shielding against Lightning7.03 Grounding7.04 Metallic Structures7.05 Electric Ducts7.06 Lighting

8.00 CONTROL BUILDING8.01 Layout of Equipment8.02 Lighting and Heating

9.00 CIVIL WORK9.01 Grading, Access and Roads9.02 Drainage9.03 Foundations9.04 Sanitary Services



220 kV VIZCARRA SUBSTATIONBASIC PROJECT CRITERIA

1.00 PURPOSE

The purpose of this document is to provide the project data and design criteria for 220 kV Vizcarra Substation of the electric supply for Antamina Project.

2.00 PROJECT DATA

The objective of the project is to provide electric supply to the Antamina Mine area during the construction and the further operation of the copper-zinc concentrator and mine.

The electric supply will be 120 MW at 0.95 lagging power factor, at 220 kV level, from the existing Tingo María – Paramonga Nueva Transmission Line. Vizcarra Substation will be constructed along this line, near to the town of Huallanca. There will be two incoming 220 kV transmission lines, one from Paramonga Nueva Substation (designation L-253) and the other from Tingo María Substation (designation L-252). One outgoing 220 kV transmission line will be constructed to Antamina (designation L-254). Also, at Vizcarra Substation one Static Var Compensator (SVC) will be installed to meet the requirements of the Antamina electrical power system. The SVC will be installed later and the criteria for this equipment is not a part of this document.

The 220 kV Electrical System has the following characteristics:

Rated Voltage 220 kV rms Rated Frequency 60 Hz Maximum Operating Voltage 242 kV rms Neutral Effectively grounded Maximum fault duty (Ref. 1) X/R Ratios (Ref. 1)

3.00 SERVICE CONDITIONS

The design service conditions for the substation are as follows:

Altitude above sea level : 3600 m Temperature

Maximum : 40°C Average : 30°C



Minimum : -15°C Ice : 6.5 mm Relative Humidity : 70% Precipitation : 1000 mm/year Maximum rain intensity : 10 mm/hour Keraunic Level : 60 storm days/year Maximum Wind : 130 km/h at 5°C Seismic Stress : 4 (UBC) modified as follows

Horizontal acceleration : 0.4 g Vertical acceleration : 0.3 g Frequency : 1 – 33 Hz

4.00 OPERATION AND MAINTENANCE

Operation and maintenance of Vizcarra Substation and Antamina Transmission Line will be on a 24-hour per day, manned basis.

The operation of all Circuit Breakers will be carried out either at the switchyard or from the Control Building of the substation. A local-remote selector switch at the equipment will enable the operation from the control building. Disconnecting Switches will be motor operated from either the switchyard or from the Control Building of the substation. A selector switch at the equipment enables the choice of operation location. Also, Disconnecting Switches will be able to operate manually at the switchyard. Grounding Switches will be manually operated only.

All relevant data for electric power system operation will be transmitted from Vizcarra Substation to Paramonga Nueva Substation, in order to provide the information to the ETECEN Control Center in Lima. No provision is made for remote operation.

5.00 ELECTRICAL DESIGN (Ref. 2)

5.01 Switchgear and Busbar System

A Ring-bus configuration will be employed for 220 kV switching. In the ring bus, two Circuit Breakers are required to isolate each of the transmission lines or the SVC. A Disconnecting Switch will be used to connect each transmission line or SVC circuit to the busbar system. Grounding Switches will be provided with each line (and SVC) switch for maintenance purposes.

The station will be designed for four circuits: three transmission lines and one SVC. Space will be allocated made in the substation yard area and control room to equip one additional circuit.



5.02 Instrument Transformers

Each Circuit Breaker will have three Current Transformers at each of the six bushings. The CT’s will be used for Control, Protection and Metering. The ratio, burden and accuracy class will be

Protection : MR 1200 : 5 A C800Metering and Control : 600/1200 : 5 A 0.3B2

Each circuit will have one set (one for each phase) of Coupling Capacitor Voltage Transformers. The Ring-bus has four segments between breakers and one Capacitive Voltage Transformer with two secondaries will be used for Control, Protection and Metering for each segment. The ratio, burden and accuracy class will be

Protection and Metering : 138 kV:69/115V–69/115 V, Burden Z1200/2000 –1200/2000:1 ratio

5.03 Control System (Ref. 3)

5.03.01 System Description

Control and relay panels in the station control room contain conventional switches for manual control of circuit breakers, bus disconnect switches and line disconnect switches. The SVC position disconnect switch is also controlled from this panel location.Individual panel annunciators will collect alarms from every equipment and relay.Multifunction indicating meters for each line and the SVC position, monitor current, voltage, frequency and active and reactive power.

An RTU will send all the data from Vizcarra Substation to Paramonga Nueva Substation for SCADA system (National Control Center). The external communications to Paramonga Nueva for SCADA system will be IEC-870-5-101 Profile FT 1.2

5.03.02 Functional requirements

a) Alarms

The Control panel annunciators will provide alarms with messages and an audible signal.

b) Event Recorder



The multifunction relays will perform the function of event storage and time/date identification. Data will be downloaded to the control room computer.

c) Fault Location

The Primary and/or Secondary Protection will provide fault location data. This function will have accumulated error no greater than 2% and will be independent of the fault resistance and load current. It will distinguish the faulted line or lines.

d) Disturbance Record

The Primary and/or Secondary Protection will perform this function. All the data can be downloaded to the control room computer in order to enable the evaluation of different events within the power system. Voltage and current signals will be time-synchronized.

5.04 Protection Functions (Ref.1)

Protection will be carried by Multifunction Relays. Each protection zone will include one Transmission Line (or the SVC) and one part of the 220 kV Ring Bus. There will be two relays per protection zone; one is named Primary Protection and the other is named Secondary Protection. Additionally, there will be one Breaker Protection Relay. In the first stage of station operation, before the SVC is in service, this relay will provide overcurrent protection on the corresponding part of the Ring Bus.

Relay ABB – REL 521 will be used for Primary Protection and Relay ABB – REL 316 will be used for Secondary Protection. Backup Protection will be by the impedance function in both Primary and Secondary Relays. Additional backup protection is provided by the overcurrent function in the secondary relays.

In Vizcarra Substation, Primary Protection Relays will work with Trip 1 in the Circuit Breakers and Secondary Protection Relays will work with Trip 2. Relay ABB – REB 551 will be used for Breaker Failure Protection. Each Breaker Protection will operate with one Lockout Relay to trip and block the corresponding breakers. These relays will work with Trip 1 and Trip 2. Direct transfer trip schemes will be provided for each transmission line (Paramonga-Vizcarra, Tingo María-Vizcarra and Vizcarra-Antamina) through the respective power line carriers.

For single-pole auto-reclosing the protection will trip one circuit breaker (all three poles) and the other breaker will trip only one pole for the faulted phase. After a set time the open pole of the breaker will close in order to detect that the fault is extinguished; if not, the three poles will trip and lock open. If the fault has been extinguished, and the single pole has successfully closed, the breaker that originally opened all three poles, will reclose. Single-pole auto-reclosing will be provide for the Paramonga-Vizcarra, and the Vizcarra-Tingo María lines, and not for the



Vizcarra-Antamina line. Automatic three-pole auto-reclosing will be used with line preotection for the Vizcarra-Antamina line

5.05 Telecommunications (Ref. 4)

Power Line Carrier will be used to link Vizcarra Substation with Antamina, Paramonga Nueva and Tingo María. The coupling will be phase to phase, therefore two Line Traps will be used at the incoming of the transmission lines and the coupling devices will be installed under the corresponding Coupling Capacitor Voltage Transformers. Single-Side Band (SSB) equipment will have capability for Teleprotection, Telephone and Data Transmission.

At Paramonga Nueva Substation the corresponding SSB equipment will be connected to the existing Private Automatic Exchange central in order to communicate with ETECEN telephone system. In the same way, at Tingo María Substation similar connections will be done in order to communicate with Aguaytía telephone system.

5.06 Utility Metering

There will be one Utility Metering Panel with provisions for equipment installation (panels and meters provided by others).

5.07 Auxiliary Services (Ref. 5)

5.07.01 Loads and Sources

The main electrical loads at Vizcarra Substation are Primary and Secondary Protection; Utility Metering; Telecommunications and Telephone system; Closing and tripping circuits; control circuits for the SVC and for the SVC transformer auxiliaries, Motors for Disconnecting Switches and Circuit Breakers; Lighting and Equipment Space Heating.

The sources for auxiliary services at Vizcarra Substation will be the following

Normal Source : SVC Power Transformer Temporary Normal Source 400/230 V Wye service from GyM

construction camp diesel generator (temporary, required until the SVC is fully operational)

Alternate source : Vizcarra Diesel Generator Set

Reliability requirements, load segregation and maximum interrupting time are criteria for selecting the manner in which auxiliary loads will be connected to the station service power.



A 1:1 ratio isolation transformer will be used to connect the normal source to the Main Switchboard, which will be at 400/230 V, 60 Hz, Wye, 4-wire SVC transformer. In order to improve the reliability of the second source, the Vizcarra Diesel Generator Set will be connected to an essential distribution board and an automatic transfer panel will transfer feeders from the normal to the alternate source.

Stationary batteries will be used to improve the overall performance of the system. For AC loads there will be one Uninterruptible Power Supply (UPS) with Static Transfer Switch. A 125 Vdc and a 48 Vdc battery will be provided, each with redundant charger circuits.

SVC auxiliary load feeder circuits will be supplied from the main and essential switchboards.

5.07.02 Distribution System

a) The following loads will be supplied from a 400/230 V Wye Distribution Panel, fed from normal and alternate sources - not battery backed

Circuit Breaker Motors Normal Lighting Equipment Heating Control Building Heating Water Pump Panel alarm system

b) The following loads will be supplied from a 230 Vac Uninterruptible Power Supply (UPS), fed from normal and alternate sources - backed by 125 Vdc battery

SVC Computer Control Utility Metering Essential Lighting and Outlets PC computer and printer

c) The following loads will be supplied from a 125 Vdc Distribution Panel fed from normal and alternate sources - backed by 125 Vdc battery

Disconnect Switch Motors Control Panel Primary and Secondary Protection SVC Control Circuits Closing and opening of Disconnecting Switches Closing and tripping of Circuit Breakers Emergency Lighting



d) The following loads will be supplied from a 48 Vdc distribution panel fed from normal and alternate sources - backed by 48 Vdc battery

Telecommunications Telephone system

6.0 INSULATION COORDINATION

6.01 Insulation levels

In order to achieve adequate insulation withstand values, equipment will be purchased with external BIL and 60 Hz ratings at sea level that permit derating to the following minimum values which are corrected for 3600 meters elevation:

Maximum operating voltage 245 kV Rated Frequency 60 Hz Basic Insulation level (BIL) 900 kV Power frequency withstand voltage 460 kV

Then the minimum insulation level for Vizcarra Substation equipment and post insulators will be

Impulse withstand voltage 1239 kV crest Power frequency withstand voltage 633 kV rms Leakage distance 7240 mm

Standard profile ball and socket-type glass suspension insulators will be used. In order to get the insulation level indicated above, the Critical Flashover will be 1522 kV crest and 507 kV rms. Then the suspension string will have eighteen (18) units and the tension string will have nineteen (19) units.

6.02 Surge Arresters

The Metal Oxide Surge Arresters will have the following technical characteristics:

Rated Voltage (Uc as per IEC) 198 kV rms Rated Frequency 60 Hz Classifying Current 10 kA crest Line Discharge Class (as per IEC) 4 Maximum Continuous Operating Voltage (MCOV) 156 kV rms Transient Over-Voltage capability for 10 s 218 kV rms Maximum Residual Voltage, 1 kA crest Switching Surge 405 kV crest External Insulation BIL 1300 kV crest

Surge arresters for the SVC are to be provided with the SVC transformer.

6.03 Circuit Breakers



Three phase, independent-pole operation, dead-tank, sulfur-hexafluoride circuit breakers will have external bushings with 1300 kV BIL (sea level) ratings (internal characteristics do not require altitude correction). Bushing leakage distance is 7240 mm.

6.04 Disconnecting Switches

Vertical-break disconnecting switches will have a sea level rating of 1300 kV BIL (1500 kV across open contacts) and 610 kV, 60 Hz withstand (670 kV across open contacts). Bushing leakage distance is 8077 mm.

6.05 Capacitor Voltage Transformer (Ref. 6)

Line and bus capacitive voltage transformers have a rating of 7400 pF and a BIL of 1050 kV.

6.06 Clearances and Spacing

The phase to phase (center line to center line) spacing will be as follows:

Incoming transmission line : 5500 mm High level conductors : 5000 mm High voltage equipment : 4500 mm

(lower bus level connections)

7.00 220 kV SWITCHYARD

7.01 Arrangement of 220 kV Switchyard (Ref. 6)

For the Ring-bus arrangement, equipment except for dead-tank circuit breakers will be installed on galvanized steel structure of 2500 mm height in order to permit access to the switchyard during operation. The high voltage connections equipment will be at 5 meters minimum height. Circuit Breakers are installed on their standard steel frames, which place the minimum installed height to the bushing pads at 5.1 meters.

For transmission line and SVC connections, lattice steel gantries will be provided to connect circuits to the incoming or outgoing lines. Two connection levels will be used and the upper level will be at 12 meters minimum height.

A bundled configuration with two ACSR “Curlew” conductors per phase will be used for all the 220 kV connections.

The separation between conductors in the bundle will be 200 mm. All the connectors and separators will be suitable for Extra High Voltage (EHV).

7.02 Shielding against Lightning (Ref. 8)



Shielding protection will be suitable for all discharge current greater or equal to the corresponding insulation level of substation. The design will be checked according to the electromagnetic model.

Stranded and galvanized Extra High Strength, 7 x 3.05 mm, 51 mm², overhead shield wire will be installed at the top of each tower connected along the phase conductors. Transmission line shield wires will be connected to the substation gantries and to the substation ground mat.

7.03 Grounding (Ref. 8)

The ground system will provide the safety for touch potential and step potential when the maximum short circuit current flowing to earth. The ground system will be installed in a manner that limits the effect of ground gradients to such voltages that will not endanger the safety of people and equipment under both normal operating and fault conditions.

The main station ground grid will be constructed with copper conductors buried at 0.70 meters and the connections will be welded by exothermic process. The grid will be connected to ground rods at the station corners and on the perimeter. The grid will be extended outside the fenced area at a minimum distance of at least 2 meters, and its extension will protect personnel during opening and closing of gates. All fence posts and gates will be exothermically welded to the grid. Normal operator positions within the switchyard will be provided with special grounding protection.

The main station ground will be designed for a short circuit level of 6 kA. The SVC area ground will be designed for a short circuit level of (later).

The ground resistance of the completed substation network will not exceed 1 Ohm.

7.04 Metallic Structures

There will be two types of structures: the 220 kV equipment supports and the gantries for aerial outgoing conductors and shield wires.

The structures will be lattice type constructed with galvanized steel elements. They will be designed to support Normal and Exceptional Load Condition, whatever the most severe.

Normal Load Condition

Dead loads (weights) Tension of conductors and shield wires Additional loading caused by temperature changes Live loads for maintenance purpose (two persons) Loads during construction



Exceptional Load Condition

Extreme Wind Load which must be considered either along the phase axis and perpendicular to this axis

Dynamic Load caused by short circuit, which must be considered perpendicular to phase axis

Dynamic Load caused by circuit breaker operation during short circuit Dynamic Load caused by earthquake which must be considered either along the

phase axis and perpendicular to this axis

The calculations must be done for the worst combination of normal and exceptional load. The hypothesis will be as follows

I Normal Load Condition at minimum temperatureII Normal Load Condition plus Extreme Wind LoadIII Normal Load Condition plus Dynamic Load caused by shortcircuit plus

Dynamic Load caused by earthquake

The sizing of the equipment support will be for a maximum deflection at the top of 1/300 of the height

7.05 Electrical Ducts

Electrical ducts will be necessary for medium and low voltage power and control cabling. High-voltage equipment will be connected to manholes at the switchyard with galvanized steel tubes.

The manholes will be connected to the Control Building with PVC ducts protected with concrete. Provisions will be made for drainage for each manhole.

7.06 Lighting

There will be normal and emergency lighting. Normal lighting will be supplied from AC distribution system, 230 V, 60 Hz. At the switchyard, there will be an automatic photovoltaic control system for this lighting.

Emergency lighting will be supplied from a 125 Vdc system (with battery). There will be an automatic control system for this lighting, in case of loss of the distribution system. The automatic control will include photovoltaic control for yard lighting only.

8.00 CONTROL BUILDING

8.01 Layout of Equipment



The Control Building will be constructed of steel-reinforced, fired brick with a plaster finish. The roof will be ceramic tile. The building will be single-level with four rooms: Control Room, Medium Voltage Switchgear Room, Distribution and Rectifier Room and Battery Room. All the rooms will have access from the Control Room, except the battery room that will have external access only.

The control room will be provided with ventilation and heating control suitable for manned operation. A toilet room is also provided in the control building.

There will be also one external enclosure for the Diesel Generator Set.

8.01.01 Control Room

The following equipment will be installed in this area

1. Control and Protection Panel Transmission Line to Paramonga Nueva2. Control and Protection Panel Transmission Line to Tingo María3. Control and Protection Panel Transmission Line to Antamina4. Control Panel for Static Var Compensator (SVC)5. Utility Metering Panel6. Telecommunications Panel to Paramonga Nueva7. Telecommunications Panel to Tingo María8. Telecommunications Panel to Antamina9. Computer Desk with Printer10. Telephone Station connected to PLC and Telefónica del Perú

8.01.02 Distribution and Rectifier Room

The following equipment will be installed in this area

1. Main Distribution Panel - 400/230 V, 60 Hz 2. Essential Distribution Panel - 400/230 V, 60 Hz 3. Transfer Load Panel (Diesel/Main Supply)4. Distribution Panel 400/230 V, 60 Hz 5. Battery-Charger No. 1 - 125 Vdc6. Battery -Charger No. 2 - 125 Vdc7. Distribution Panel 125 Vdc8. Battery -Charger No. 1 - 48 Vdc9. Battery -Charger No. 2 - 48 Vdc10. Distribution Panel 48 Vdc11. Uninterruptible Power Supply System, 230 V, 60 Hz

8.01.03 Battery Room



Two sealed Ni-Cd Batteries will be installed in this area. No special ventilation is required for this battery type.

Battery 125 Vdc Battery 48 Vdc

8.02 Lighting and Heating

There will be normal and emergency lighting. Normal lighting will be supplied from AC distribution system, 230 V, 60 Hz. Emergency lighting will be supplied from 125 Vdc system (with battery). There will be an automatic control system for this lighting, in case of loss of AC distribution system. The automatic control will include photovoltaic control for switchyard lighting.

There will be heating system to provide air at 23°C. One central duct will be installed along the building and distribution outputs in the control room.

9.00 CIVIL WORKS

9.01 Grading, Access and Roads

The access will be at NW of the substation and will be integrated with the internal road on the perimeter. The grade will be with 2% of gradient on the NW-SE direction to Vizcarra River.

The road will be 4.88 meter (16 feet) wide plus one external lateral berm of 1.22 meter (4 feet). The minimum internal radius will be 12.2 meter (40 feet).

9.02 Drainage

A system of drains will be provided to collect direct rainfall within the station perimeter and to collect and divert surface water that flows toward the station from the surrounding area. The system will be designed to handle a capacity corresponding to the maximum 3-hour rain intensity as determined from 25-year metereologic data. Drains will empty to Vizcarra River.

9.03 Foundations

Foundations for structures and equipment supports will be designed to Normal and Exceptional Load Conditions as described in Section 7.04, Metallic Structures, of this document.

9.04 Sanitary Services



Sanitary services will consist of one bathroom in the control building. The water will be only for sanitary use; no provision is made for potable water. The sewage system will be with septic tank.



VIZCARRA DESIGN CRITERIA REFERENCE DOCUMENTS

Ref # Number Name

1 21-30-26-E Protection Relay Settings 2 21-31-30-E General Single-Line Diagram3 21-31-32-E Metering and Protection Diagram4 20-30-101-E Requisition for Telecommunications Equipment5 21-30-24-E Auxiliary Services Calculations and Basic Design6 21-30-21-E 220 kV Cable Bus Electrical Phase Spacing Calculation7 21-30-22-E 220 kV Switchyard Shielding Against Lightning8 21-30-20-E Grounding System Calculations and Basic Design



21 30 10 EVizcarra Project Criteria Rev 0

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