DC Railway Electrification System Design

Railway Electrification Infrastructure School

07 June 09

System June 2013

Dr Roger D White Roger.white@atkinsglobal.com

Lecture Contents

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

World System Voltages HV Supply Arrangement Distribution of DC Traction Supply D.C. Feeding Arrangement Trackside DC Substation Design Substation Electrical Performance Specification Traction Return Current Earthing Regeneration DC Magnetic Fields Cable Specification Induced Voltage Lightning Protection Disturbance effects

World System Voltages

DC System Voltage 160, 180, 500, 525, 550, 600,630, 650, 750, 800, 825, 850, 860, 900, 1000,1200, 1350, 1500, 2400, 3000, 3500, 6000DC 11,000 16 2/3 Hz, 15,000 16 2/3 15,000 Variable Frequency up to 50 Hz Zosen to Marienfede [Trial 1901-1904] Three Phase 725 V [Gornergratbahn] , 1125[Jungfraubahn], 3600 16 2/3 Hz three-phase [ 1912-1976] Single Phase AC System Voltage: 6.25/ 50, 6.3/25, 11/ 25, 12.5/60, 20/50 , 20/60 , 25/50, 25/ 60, 50.50 kv/Hz

AC and DC Electrification

400kV GRID
Ea rth W

ire
Grid Site Feeder Station Overhead Contact System Train

R Y B
Busbar + 25kV

25 kV 50 Hz
2 Track Traction Return System

3kV d.c.
DC AC

SGT1 Y-B

66/132kV GRID
E th ar
R Y

ire

Grid Site

Sub Station

Overhead Contact System

AC

Train

1000V 3 phase
DC

0.75/1.5/3 kV d.c.
2 Track Traction Return System

to

AC

DC

NORTH

to

AC

DC

NORTH

to

to

UK DC Networks

NR 750V

DC electrified track 4,285 single track kms; DC sub-stations (430); +420 V DC 210 V DC, giving a supply voltage of 630 V DC 408 km (253 miles)[11 lines electrified in the 1890s

LU Network

550 V DC overhead;

Blackpool Tram (61 Stations route 18km)

Croydon, (39 Stations ; route 28km) Manchester, (50 Stations; route 37km) Midland Metro: ( 23 Stations; 20km) Sheffield: (48 Stations: route 29km) Nottingham Super Tram: (23 Stations; route14km)

750 V DC, Overhead

750V Docklands Light Rail third rail

45 stations route 40km

60 Stations route 77.7km

1,500 V DC, Overhead Tyne & Wear Metro

LRT Passenger Journeys Light Rail and Tram Statistics DoT 2011/2012

HV Supply Arrangement

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

World System Voltages HV Supply Arrangement Distribution of DC Traction Supply D.C. Feeding Arrangement Trackside DC Substation Design Substation Electrical Performance Specification Traction Return Current Earthing Regeneration DC Magnetic Fields Cable Specification Induced Voltage Lightning Protection Disturbance effects
7

High Voltage Supply Feeding Arrangement

Distribution of DC Traction Supply

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

World System Voltages HV Supply Arrangement Distribution of DC Traction Supply D.C. Feeding Arrangement Trackside DC Substation Design Substation Electrical Performance Specification Traction Return Current Earthing Regeneration DC Magnetic Fields Cable Specification Induced Voltage Lightning Protection Disturbance effects
9

DC Railway Contact Systems

600V/650V/750V suburban third rail

630V fourth rail system LUL

Overhead Line

750V LRT/Tram LRT 1500V dc Metro system 3000Vdc OHL suburban and intercity;

10

Factors Influencing DC Substation Spacing

Maximum permissible system voltage drop Traction loading/performance/ Train auxiliaries Third rail conductor cross section Electrification protection settings

11

Most Economic Distance between Substation BS EN 501288

630V d.c. Electrification System is

2-3km [LU] +420V rail

-210 V rail.

660-750 V d.c. Electrification System

3--6km

1500V dc Electrification System

5-13km

3000V dc Electrification System

8-20km

Pictures 1500V Sydney Australia

12

DC. Feeding Arrangement

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

World System Voltages HV Supply Arrangement Distribution of DC Traction Supply D.C. Feeding Arrangement Trackside DC Substation Design Substation Electrical Performance Specification Traction Return Current Earthing Regeneration DC Magnetic Fields Cable Specification Induced Voltage Lightning Protection Disturbance effects

General view of a completed Conductor Beam installation (From Furrer and Frey literature)

13

DC. Feeding Arrangement

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

World System Voltages HV Supply Arrangement Distribution of DC Traction Supply D.C. Feeding Arrangement Trackside DC Substation Design Substation Electrical Performance Specification Traction Return Current Earthing Regeneration DC Magnetic Fields Cable Specification Induced Voltage Lightning Protection Disturbance effects

General view of a completed Conductor Beam installation (From Furrer and Frey literature)

14

DC Traction Feeding Arrangement

33/11kV Supply
Power Transformer Circuit Breaker Normally Closed

33/11kV Supply

Feeder Station

Rectifier Unit Isolator Normally Open Insulated Overlap or Sectioning Gap

I/4

I/4

I/4

I/4

I/4

I/4 Rail current I/8 if both rails available Rail current I/4 if one rail is available per track

15

Feeding Arrangement

Normal Feeding Arrangement

Normal feeding

track sectionalisation areas

Tee feeding arrangement Single end feeding arrangement

Degraded Mode

Loss of supply of transformer rectifier units Bypass feeding arrangement

16

Trackside DC Substation Design

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

World System Voltages HV Supply Arrangement Distribution of DC Traction Supply D.C. Feeding Arrangement Trackside DC Substation Design Substation Electrical Performance Specification Traction Return Current Earthing Regeneration DC Magnetic Fields Cable Specification Induced Voltage Lightning Protection Disturbance effects
17

Supply and converter design arrangements

Transformer winding design factors:

short circuit reactance, commutating reactance

Transformer reactance determine:

d.c. short circuit fault current, operating d.c. voltage regulation, operating load loss [winding resistance] transformer efficiency, Transformer & converter power factor harmonics supply side

18

6 Pulse converter

3 Phase Fully Controlled Bridge

50Hz 3 Phase Line to Line

Vdc 6 Pulse

750V 1500V dc 6 Pulse Rectifier

20 mS

19

12 Pulse Series Bridge Converter

Transformer Secondary Windings Phase Displaced

12 Pulse Converter

Switch Gear and Busbars

Overhead Line or Third Rail

50Hz 3 Phase Line to Line

Vdc 12 Pulse

Return Running Rails 750V 1500 V dc

12 Pulse Rectifier

20 mS

20

12 Pulse Parallel Bridge Converter

Transformer Secondary Windings Phase Displaced

12 Pulse Converter

Switch Gear and Busbars

Overhead Line or Third Rail

50Hz 3 Phase Line to Line

Vdc 12 Pulse

Parallel Interface Transformer

Return Running Rails 750V 1500 V dc

12 Pulse Rectifier

20 mS

21

Rectifier Protection

Short Circuit Protection

short circuit, overloading: thermal relay and over current time relay. failure of one of the rectifier arms. two-phase transformer fault current Diodes fully rated Switching, interruption, lightning. attenuated with a resistor capacitor network commutation hole storage

Internal Short Circuits

Over Voltages

LAR Rectifier Hong Kong

22

Rectifier Mechanical Construction

Diodes

aluminum extruded heat sinks, connected in parallel in a bridge hermetically sealed diode fuses and micro switches,

Heat sinks natural air cooling. AC and DC busbars are arranged at top or bottom of the cubicle.

23

Substation Electrical Performance

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

World System Voltages HV Supply Arrangement Distribution of DC Traction Supply D.C. Feeding Arrangement Trackside DC Substation Design Substation Electrical Performance Traction Return Current Earthing Regeneration DC Magnetic Fields Cable Specification Induced Voltage Lightning Protection Disturbance effects

24

Substation Electrical Performance

1. 2. 3. 4. 5. 6.

Substation rating DC Traction supply voltage Regulation of DC traction voltage DC short circuit fault current Power factor of rectifier unit AC and DC harmonics

25

Typical specification 750V sub station system

Rated capacity 2400kW Rated D.C. traction voltage 600VDC Rated D.C. traction current 4000A Short circuit protection 40 kA 0.25 sec Transformer 22kV/415V Rated Capacity 2 MVA Short circuit protection 40 kA 0.25 Sec

26

Fault Profile

27

DC Traction supply voltage European regulation EN 50163

Table 1 Definition of operating d.c. System Voltages lowest non permanent voltage duration 10min, lowest permanent voltage duration indefinitely, nominal voltage designed system value, highest permanent voltage duration indefinitely highest non permanent voltage duration 5 min. Ref[1] EN50163[Table 1,]

600*

750

1500

3000

400 600 720 770+

500 750 900 950^

1000 1500 1800 1950

2000 3000 3600 3900

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Voltage Regulation with Track Sectioning Hut

33/11kV Supply
Power Transformer Circuit Breaker Normally Closed

33/11kV Supply

Feeder Station

Rectifier Unit Isolator Normally Open Insulated Overlap or Sectioning Gap

I/4

I/4

I/4

I/4

I/4

I/4 Rail current I/8 if both rails available Rail current I/4 if one rail is available per track

29

Short Circuit with track Parallel Hut

33/11kV Supply
Power Transformer Circuit Breaker Normally Closed Rectifier Unit

33/11kV Supply

Feeder Station

Isolator Normally Open Insulated Overlap or Sectioning Gap

Ia

Ia Ia +Ib Ia +Ib Ia +Ib Ib /4 Ib /4 Ib /4 Ib /4

Ib /2

Ib /2

Ib /2

Rail current Ib /4 if both rails available

30

DC Short Circuit Current Waveform

31

LUL Double DC earth fault >100kA

Double Pole Earth Fault Bleed Resistors

Rail leakage

Double Earth Fault +420V

250 Ohm

125 Ohm

Rail Leakage

Rail Leakage

Rail Leakage

-210V

32

Power Factor of Traction Rectifier Unit

Power Factor AC System Characteristic 3 phase Power factor dependencies: Transformer design Converter design/arrangement DC Traction load DC Auxiliary Load Harmonics in the AC Current

33

Production of AC and DC Characteristic Harmonics

Pulse Number DC Harmonics p np

AC Harmonics np 1

0,6,12,18,24

1,5,7,11,13,17,19,23, 25

12

0,

12,

24

1,

11,13,

23,25

34

Harmonics in DC Electrification Systems

Harmonics are responsible for:

Overheating capacitors Overheating generators & induction motors Instability in converter control systems Interference into control systems Noise on telephone lines Interference into signalling systems

System

Planning Levels [IEC 61000-3-6] 5% 4% 3%

Compatibility Levels

400V 6.6, 11, 22 kV >20kV and <145kV 275 and 400kV

8% [IEC 61000-2-2] 8% [IEC 61000-2-12] 5% [UK]

Harmonics can be reduced by:

3%

3.5% [UK]

Increasing converter pulse number Installation of filters

35

Rectifier Performance Characteristics

36

Traction Return Current

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

World System Voltages HV Supply Arrangement Distribution of DC Traction Supply D.C. Feeding Arrangement Trackside DC Substation Design Substation Electrical Performance Specification Traction Return Current Earthing Regeneration DC Magnetic Fields Cable Specification Induced Voltage Lightning Protection Disturbance effects

37

Traction Return Current

Fourth Rail Systems: London Underground UK Diode/Floating Earthed Railway Hong Kong MTRC, DLR Manchester Metro Floating Negative Earth Network Rail Southern, Japan, Australia Singapore MRT, Hong Kong LRT, Lantau and Airport Hong Kong Croydon Tram; Nottingam Tram Sheffield Super Tram, Edinburgh tram; Dubai Metro;

38

Typical Earthing Diode Earthed Railway

Traction Current Catenary

Substation Rectifier DC System Voltage

Traction Return Current

Main Earth bar Diode Earth

Vrail

Vrail

Vrail

Vrail

Distance

Traction Current

Catenary

Substation Rectifier

DC System Voltage

Traction Return Current

Main Earth bar

Vrail

Vrail

Vrail

Vrail

Distance

39

Testing rail insulation

40

Rail and Utility Potentials

Traction Current

Catenary

Vdc Rail Resistance

Rail Return

Leakage Resistance Utility Corrosion Remote Ground Potential of Rails Scale in 10(s) Volts Potential of Utility with Interference Scale in 100(s) mV

41

Traction Earthing

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

World System Voltages HV Supply Arrangement Distribution of DC Traction Supply D.C. Feeding Arrangement Trackside DC Substation Design Substation Electrical Performance Specification Traction Return Current Traction Earthing Regeneration DC Magnetic Fields Cable Specification Induced Voltage Lightning Protection Disturbance effects
42

Traction Earthing and Bonding

Provide a safe return path for traction load; Ensure good return path for fault current; Maintain the potential of all accessible metalwork;

120V Mainline 60V depots

Traction or fault current in metallic services Prevent arcing Protective Earthing: Equipment Functional Earth: Equipment Suppression of Electrical Noise: EMC

Lightning protection,
Corrosion control

43

Earthing Standards European and National

UK and European

European Standard EN 50122 -1 electrical safety and earthing European Standard EN 50122- 2 provision against stray currents BS 7430 Code of Practice for Earthing BS 7671 17th Edition of the IEE Wiring Regulations G59/1 Electricity Association Engineering Recommendation G5/4 Electricity Council Regulations 1-106 Earthing and Bonding of LU Electrical Networks MR-S-PO-0009-Part 1Earthing Code of Practice MR-S-PO-0008 Earthing management E7720 A3 Engineering Standard 25kV 50Hz immunisation SSL-SE-0858-A1 Earthing Practice 1985- Signal Engineering. NR/SP/ELPE/21032 Network Rail Earthing Systems

LUL Standards

Network Rail

44

Typical DC Electrification Earthing Arrangement

Earth Wire

Telecoms PSU

Distribution Network Operator Supply

Telecoms. Cable

DC Voltage NGC Substation

Track circuit

SignallingPSU

Local RECS Station Apparatus Tunnel Structure Rebars Copper Earth Mat

Track Structures

R D White 2007

Station Metallic Structures

45

Depot Bonding Arrangement

M&E Earth M&E earth M&E CPCearth rated for 1500V fault current 300sq mmCu ( to be determined by Siemens) Traction return bonding 6 times 250sqmm ( to be determined by Siemens) Non Electrified lines

AC Sub Station

Fault return path

Traction Bond

Test Track DC Sub Station

Main Earth Bar minimum 400mm2

Infrastructure and Maintenance rails earthed No 1500V

OVPD

Floating

Earthed

Car Wash OCS 1500 V

SS & Car Wash & Approach Roads 400sqmm cables

HMS & LMS 400sqmm cables

Note 1 SS and HMS are the same civil structure Note 2 Failure of the OCS to the structure where rails are floating, the return path is via the MEB and OVPD is required to close to clear dc breakers. Note 3 Failure of the OCS to the structure where rails are earthed the return path is via the MEB and the DC Bonds to clear dc breakers.

Main Earth Bar minimum 400mm2

Stabling Shed (SS) 20 Roads Rails Floating OCS1500V

Propsed new location of the IRJ

HMS Rails Earthed OCS 1500V

Crane

Bogie Drop

Wheel lathe

LMS Rails Earthed OCS 1500V

Main Earth Bar minimum 400mm2

Lift Jacks DPS DPS

Main Earth Bar minimum 400mm2

E&M earth
Fault LMS 1500V earth fault to rails: SS 1500 V earth fault rails LMS 1500V earth fault to structure SS 1500 V earth fault structure Car Wash 1500 V earth fault structure Path Structure bond/rails/return bonds Return bonds Rails Return Bonds Fault Return Path Fault Return Path Protection dc breakers dc breakers dc breakers OVPD& DC Breakers OVPD& DC Breakers

Fault HMS 1500V earth fault to rails HMS 1500 V earth fault structure

Path Return Bonds Structure bonds/Rails/return Bonds

Protection dc Breakers dc Breakers

1
Revision Record

Issue: 1 Drawn by: Checked by: Approved by:

14 Dec 2009 R D White D Ellis

Client: Title:

14/12/09

Proposed DC Rail and Structure Bonding of Traction Maintenance Depot

Project: MMMP

Our Ref: DC Depot Bonding.vsd

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System Earthing

47

Bonding in Tunnel Structures (Dubai)

48

Civil Insulation PSD

Monitoring on PSD Isolation Test

2.000

1.000

0.500

Resistance (M)

0.250

0.125

0.063

0.031

0.016 0 10 20 30 40 50 Humidity (%) 60 70 80 90 100

49

Stray Current Collection

Traction Current

Catenary

Vdc Rail Resistance

Rail Return

Leakage Resistance

Corrosion Remote Ground Potential of Rails Scale in 10s Volts Potential of Utility with Interference Scale in 100s mV

50

Stray DC Current and Corrosion

Protection Required reinforcing bars of railway structures reinforced concrete track bed electrical utilities water and gas pipes Corrosion Discharged of leakage current

Typically 1A corrodes 9.1kg of iron per year

51

North London Lines AC DC Operation

52

Regeneration

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

World System Voltages HV Supply Arrangement Distribution of DC Traction Supply D.C. Feeding Arrangement Trackside DC Substation Design Substation Electrical Performance Specification Traction Return Current Earthing Regeneration DC Magnetic Fields Cable Specification Induced Voltage Lightning Protection Disturbance effects
53

Regenerative Traction Units and Supply Points

Technical Merits of Regenerative Traction Units Reduction of heat Reduction of brake dust Reduction of tunnel maintenance Elimination of brake resistors. Technical Merits of Regenerative System Improved efficiency reduction in energy costs.

Rheostatic brakes on Croydon Trams

Disadvantages of Regenerative Systems More capital investment in traction and supply equipment. More harmonics [medium voltage supply]. Intelligent protection system on the supply and traction. Increase stray current dc network losses charged at 15.57% in the southern region; dc network losses charged at 10.26% for the dc network in Merseyside;

54

DC Magnetic Fields

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

World System Voltages HV Supply Arrangement Distribution of DC Traction Supply D.C. Feeding Arrangement Trackside DC Substation Design Substation Electrical Performance Specification Traction Return Current Earthing Regeneration DC Magnetic Fields Cable Specification Induced Voltage Lightning Protection Disturbance effects
55

Magnetic Electric Fields and Overhead Lines

Magnetic Field Amps/m 1500V DC twin track 3000A per track

Electric Field Volts/m

ELECTRIC FIELD 1500V DC Roger D White WS Atkins Rail

EmagField

56

Cable Specification

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

World System Voltages HV Supply Arrangement Distribution of DC Traction Supply D.C. Feeding Arrangement Trackside DC Substation Design Substation Electrical Performance Specification Traction Return Current Earthing Regeneration DC Magnetic Fields Cable Specification Induced Voltage Lightning Protection Disturbance effects
57

Cables and Conductors Applications

Systems 33kV & 11kV Distribution and substation feed D.C, traction return cables; D.C. feeder cables; Track bonding; Lineside cables; Overhead line conductors; Tunnels [no smoke zero halogen]

58

Cable Insulation Specifications

Track Application

copper and aluminum, XLPE insulation [cross linked polyethylene] concentric solid core, stranded cables . Armour and PVC Coating

Older Cables

oil impregnated insulated paper tapes. Outer core protected by steel tape, or galvanized wire armouring.

HV Supply and Distribution

solid, gas or oil-filled cables. ratings in excess 33kV 33kV fluid filled and XLPE [substation] XLPE [cross linked polyethylene] Armour and PVC Coating 59

Induced Voltage

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

World System Voltages HV Supply Arrangement Distribution of DC Traction Supply D.C. Feeding Arrangement Trackside DC Substation Design Substation Electrical Performance Specification Traction Return Current Earthing Regeneration DC Magnetic Fields Cable Specification Induced Voltage Lightning Protection Disturbance effects
60

Electrical System Characteristics

Victim Cable Position of receptor cables telecoms cables Signalling cables Parallelism of cables/ DC/HV AC mutual impedance as a function frequency screening factors of the earthed conductor Electrical Dependencies Change of traction load or fault current [ time varying] DC Ripple [rectifier supply] Coupling increases with harmonics [j2..f.M] Fast transients [ power supply] Normal load Current Typically < 4000A Fault current typically < 100kA Parallelism with 25kV railways ( 50Hz only) Traction unit psophometrically weighted current
61

Lightning Protection

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

World System Voltages HV Supply Arrangement Distribution of DC Traction Supply D.C. Feeding Arrangement Trackside DC Substation Design Substation Electrical Performance Specification Traction Return Current Earthing Regeneration DC Magnetic Fields Cable Specification Induced Voltage Lightning Protection Disturbance effects

62

Lightning Protection

Lightning Protection on DC switchboard

Prevent OHL surges, Surge protection fitted on each feeder circuit breaker,

Exposed masts on Viaducts

Lightning protection for Radio Antenna and other masts Signal Heads

63

Disturbance effects

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

World System Voltages HV Supply Arrangement Distribution of DC Traction Supply D.C. Feeding Arrangement Trackside DC Substation Design Substation Electrical Performance Specification Traction Return Current Earthing Regeneration DC Magnetic Fields Cable Specification Induced Voltage Lightning Protection Disturbance effects
64

Disturbance Effects of DC Electrification Systems

AC LV and HV Systems AC side harmonics in 3 phase supply AC voltage distortion Power factor Lightning DC and Power System Harmonics DC Side Harmonics Overlap effect, Resonance and system capacitance Traction line filter resonance Magnetic and Electric Fields

Inductive and Radiated Effects

High frequency radiated emissions Traction load traction to regeneration. Power arcs on the ramp end of the rails Disturbance changes supply & traction Switching of the d.c. power [di/dt] Longitudinal Transverse voltages Lightning Harmonics in the return circuits Conductor overheating Corrosion due to DC stray current

Return Circuit and DC Stray Current

65

Key System Interfaces

Physical Interfaces (OLE to Civil structures, Signalling, Comms) OHL clearances Power line clearances Signalling mast clearances Touch and step potentials ( clearance 2.5m) Electrical Supply Interfaces (Depot and mainline ) Supply feeding Segregation of feeding Degraded mode of operation Earthing Interfaces (Traction Return to Civil Earth, DNO Signalling Earth, Comms earth and Third Party Earth) Interconnection of Earths Rating of the earth connection Segregation of earths

Magnetic Coupling (OLE to Comms and Signalling) Induced voltage Noise on telephone systems Disturbances to communication systems Magnetic Coupling (Power Lines to Comms and Signalling) Induced voltage Noise on telephone systems Disturbances to communication systems Stray DC Current (Traction return and civil structures) Civil Clearances Corrosion of railway civil structures Utilities

66

DC Railway Electrification System Design

Railway Electrification Infrastructure School

System June 2013

Dr Roger D White Roger.white@atkinsglobal.com

67