raaf williams (point cook) redevelopment electrical …

PREPARED BY: WEBB AUSTRALIA GROUP (VIC) PTY LTD ABN 61 073 585 305 [email protected] www.webbaustralia.com.au

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CONSULTING ENGINEERS ELECTRICAL LIGHTING MECHANICAL SECURITY COMMUNICATIONS AUDIO VISUAL

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EST02008-01-0932-AZ000-RPT-EL-0001 REV D.DOCX

RAAF WILLIAMS (POINT COOK)

REDEVELOPMENT

ELECTRICAL MASTER PLAN

& DEVELOPMENT PLAN

RAAF WILLIAMS (POINT COOK) REDEVELOPMENT ELECTRICAL MASTER PLAN AND DEVELOPMENT PLAN

EST02008-01-0932-AZ000-RPT-EL-0001 REV D.DOCX 2 OF 38 WEBB AUSTRALIA GROUP (VIC) PTY LTD ISSUE D SDR ABN 61 073 585 305

RAAF WILLIAMS (POINT COOK)

REDEVELOPMENT ELECTRICAL MASTER PLAN

& DEVELOPMENT PLAN

Copyright © 2021 Webb Australia Group (VIC) Pty Ltd. All rights reserved. This specification may not be reproduced or transmitted in any

form or by any means in part or in whole without written permission of Webb Australia Group (VIC) Pty Ltd ABN 61 073 585 305

Document Status

Rev No.

Date Amendment Author Reviewer Approved By

Name Name Signature Name Signature

A 03.03.2021 CDR (Draft) B Harding G Lowe

B 25.08.2021 SDR B Harding G Lowe

C 06.09.2021 SDR B Harding G Lowe

D 13.10.2021 SDR (Final) B Harding G Lowe

TABLE OF CONTENTS

1. BACKGROUND ....................................................................................................................... 4

2. EXISTING INSTALLATION ........................................................................................................ 5

2.1 INCOMING SUPPLY ................................................................................................................... 5

2.1.1 Supply Configuration............................................................................................................... 5

2.1.2 HV Intake and Primary Switching Station .................................................................................. 5

2.1.3 HV Rings and Interconnector Cables ........................................................................................ 5

2.1.4 Capacity ................................................................................................................................ 5

2.1.5 Condition ............................................................................................................................... 6

2.1.6 Reliability ............................................................................................................................... 6

2.1.7 Redundancy........................................................................................................................... 6

2.2 EXISTING LOADS ....................................................................................................................... 6

2.2.1 Magnitude .............................................................................................................................. 6

2.3 LOAD DISTRIBUTION ................................................................................................................. 6

2.3.1 Load Profile ........................................................................................................................... 6

2.3.2 Power Factor ......................................................................................................................... 7

2.4 PRIMARY DISTRIBUTION ........................................................................................................... 7

2.4.1 Configuration ......................................................................................................................... 7

2.4.2 Condition ............................................................................................................................... 7

2.4.3 Reliability and Redundancy ..................................................................................................... 7

2.5 SECONDARY DISTRIBUTION ..................................................................................................... 7

2.5.1 Configuration ......................................................................................................................... 7

2.5.2 Capacity ................................................................................................................................ 7

2.5.3 Reliability and Redundancy ..................................................................................................... 8

2.6 POWER CONTROL AND MONITORING SYSTEM (PCMS) ............................................................ 8

2.7 DEFICIENCIES ........................................................................................................................... 8

2.7.1 Incoming Supply (Primary Distribution) Capacity ....................................................................... 8



2.7.2 Incoming Supply Reliability and Redundancy ........................................................................... 8

2.7.3 Capacity ............................................................................................................................... 8

2.7.4 Secondary Distribution Capacity .............................................................................................. 8

2.7.5 Secondary Distribution Reliability ............................................................................................ 8

2.7.6 Distribution Substations .......................................................................................................... 8

3. PROPOSED BASE LOADS ........................................................................................................ 9

3.1 FACILITIES TO BE ADDED TO THE RAAF WILLIAMS (POINT COOK) .......................................... 9

3.2 FACILITIES TO BE DEMOLISHED ............................................................................................... 9

3.3 FACILITIES TO BE REFURBISHED/ADAPTIVE REUSE ................................................................ 9

3.4 ULTIMATE BASE LOAD .............................................................................................................. 9

4. ELECTRICAL MASTER PLAN .................................................................................................. 10

4.1 INCOMING SUPPLY ................................................................................................................. 10

4.2 HV DISTRIBUTION ................................................................................................................... 10

4.2.1 General Arrangement ........................................................................................................... 10

4.2.2 Primary Distribution .............................................................................................................. 10

4.2.3 Secondary Distribution ......................................................................................................... 11

4.3 EMERGENCY POWER GENERATION ...................................................................................... 11

4.3.1 Generation .......................................................................................................................... 11

4.4 POWER MONITORING SYSTEM .............................................................................................. 11

4.4.1 System Requirement ............................................................................................................ 11

4.4.2 Recommendation ................................................................................................................. 11

5. DEVELOPMENT PLAN ............................................................................................................ 12

5.1 INCOMING SUPPLY ................................................................................................................. 12

5.1.1 Powercor works ................................................................................................................... 12

5.2 SECONDARY DISTRIBUTION ................................................................................................... 12

5.2.1 Substation Replacements ..................................................................................................... 12

5.3 STAGING OF THE WORK ......................................................................................................... 12

5.4 EMERGENCY POWER GENERATION ...................................................................................... 12

5.4.1 CEPS ................................................................................................................................. 12

5.5 POWER CONTROL & MONITORING SYSTEM (CPMS) ............................................................... 12

5.5.1 Implementation..................................................................................................................... 12

6. REFERENCES ....................................................................................................................... 14

6.1 REFERENCED DOCUMENTS.................................................................................................... 14

6.2 ABBREVIATIONS ...................................................................................................................... 14

APPENDIX A DRAWINGS .......................................................................................................... 15

APPENDIX B COST ESTIMATE ................................................................................................... 16

APPENDIX C LOADS TBA ......................................................................................................... 17

APPENDIX D POWER FACTOR CORRECTION CALCULATION ....................................................... 18



1. BACKGROUND

RAAF Williams (Point Cook) is the home of Defence aviation in Australia dating back to 1911

RAAF Williams (Point Cook) has had limited investment in infrastructure and facilities and is consequently in need of a major upgrade.

This master plan has been prepared using the guidelines of the MIEE and electrical principles developed by Webb in consultation with Defence in a number of similar master plans for Defence establishments.

RAAF Williams (Point Cook) is the oldest continuously operating military airfield in Australia and is listed on both the National

Heritage List, and Commonwealth Heritage List. The Base provides a secure military airhead for the greater Melbourne area and

aerodrome operations for Defence and authorised civilian aircraft. The Base’s historical legacy and heritage values, coastline

location and airfield capability make it a unique Defence asset.

RAAF Williams (Point Cook) currently supports limited functions following the cessation of flying training activities in the early 1990s.

Consequently, there has been limited infrastructure investment, resulting in degradation of infrastructure and assets.

The Base requires a significant redevelopment of its existing assets and infrastructure in order to sustain the existing capability and

realise its 2040 Future Plan.

The layout of the Base and a large majority of the buildings have significant heritage values. ‘Point Cook Air Base’ is entered on both

the National Heritage List, and Commonwealth Heritage List for its historic, rare, representativeness, social and associational values.

The Base is also recognised on the Victorian Heritage Register, the Victorian War Heritage Inventory, and the National Trust of

Australia (Victoria). Development will consider the maintenance, preservations and adaptive reuse of significant heritage assets in

line with the EPBC.



2. EXISTING INSTALLATION

2.1 INCOMING SUPPLY

2.1.1 Supply Configuration Incoming supply The electricity supply to RAAF Williams (Point Cook) is received and metered at High Voltage (HV) from the DNSP

(Powercor) incomer. LV 4 The HV Incoming Supply is at 22kV.

The electricity supply from Powercor’s 22kV distribution network is via a short radial overhead spur,taken from their overhead

network which runs along Aviation Road, north of the Base. The conductor immediately outside the Base is a ‘Neptune’ (19/3.25

AAC), which has a current carrying capacity of 243A or 9.3MVA.

The Powercor network upstream of this point comprises sections of both underground and overhead conductors, details and capacity

of which could not be confirmed with the DNSP.

There is no overhead lightning shielding conductor on the overhead line sections in the network just outside of the Base. The 2013

Strategic Analysis and Zone Options report stated that the Base and surrounding areas experience a high electricity failure rate and

there is uncertainty about the electricity supply network to meet the needs of future development at the Base.

At the time of the 2008 GHD HV System report, the HV Incoming supply from Powercor originated from the Laverton Zone

Substation (ZSS), via Feeder LV005 which supplies a total of 4500 other customers in the area, in addition to Defence. The Base is

at the extremity of that feeder. There is a Powercor circuit breaker upstream of the site at the Zone substation.

The ZSS feeder LV4 has a capacity is 380A and is currently utilised to 327A at 22kV.

The 22kV feeder to the Base is not dedicated to Defence, and there is no redundancy of supply as the final section of the HV

incoming supply to the Base, being a short radial overhead line spur to the entrance to the Base, presents a single and common

point of failure.

In the 2014 BEAP report, Powercor advised that the feeder to the Base can be interconnected at several points, to allow supply to

the Base to be restored in the event of an upstream fault on Powercor’s network. The switching can be done using remote controlled

network switches by Powercor, with the first opportunity of interconnection to an alternate feeder being approximately 310m from the

Base.

At the Base entrance, the overhead supply terminates to a pole mounted switch (SW 21908, on Pole 91) owned and operated by

Powercor and transitions to an underground cable via a cable termination, which is fitted with lightning surge arresters. The

underground cable connects to the Powercor ground-mounted 22kV metering cubicle, just outside of the 22/11kV transformer

outdoor fenced-compound. The assets downstream of the 22kV metering cubicle are owned and operated by Defence.

Further liaison with Powercor will be required to receive up to date information on the load status of the feeder in Point Cook Road,

as the area is developing rapidly with more housing coming on line.

2.1.2 HV Intake and Primary Switching Station

There is one HV Intake Substation (ISS) at RAAF Williams (Point Cook) located at the entrance to the Base. The ISS is a brick/masonry building (Building S81). Electricity is received from Powercor at 22kV and stepped down to 11kV using a single 22/11kV Dyn11 oil-filled transformer, rated for 2.5MVA with +/- 5% off-load tap changer.

The transformer is manufactured by ASET and was built in 1989 (i.e.greater than 25 years old). The transformer is housed outside the ISS in a fenced compound. The transformer 11kV star point is directly and solidly connected to earth, and does not restrict the earth fault currents. The 22kV cable from the Powercor metering cubicle enters the 22kV section of the Defence-owned ISS and supplies a small two-panel, one-bus 22kV switchboard. A Yorkshire (YSF6 22kV 1250A) 16kA removable circuit breaker supplies the 22/11kV step down transformer. The protection for the transformer circuit includes:

• Overcurrent / Earth Fault protection using GEC MCGG relays

• Transformer differential protection using GEC MBCH relays

• Transformer auxiliaries protection using Buchholz gas and pressure relay.

The ISS also houses a three-panel, one-bus 11kV switchboard, which is supplied from the 11kV side of the step down transformer. The three switchgear are Yorkshire (YSF6 11kV) removable circuit breakers. The three 11kV circuits are:

• 11kV Main Isolator

• Substation No.1 Ring Main Unit (RMU)

• CEPS Ring Main Unit (RMU).

2.1.3 HV Rings and Interconnector Cables

Defence owns, maintains and operates a small 11kV HV network at RAAF Williams ( Point Cook) which comprises the following:

• An 11kV HV ‘Ring Feeder’ between the ISS and the ‘CEPS’ RMU, which supplies HV Substations 1, 3 and 2 (towards the northern are of the base). The open point is at HV Substation 3.

• An 11kV ‘Interconnector’ (which does not supply any HV Substations) links the ISS and the ‘CEPS’ RMU. The interconnector feeder travels south from the ISS to the ‘CEPS’ RMU

• An 11kV ‘Radial Feeder’ from the ‘CEPS’ RMU which supplies HV Substations 4 and 5 (towards the Southern side of the Base). It travels south along Williams Road. The label ‘CEPS’ is a misnomer, as there is no CEPS at RAAF Williams (Point Cook). The ‘CEPS’ RMU is a Kiosk RMU unit with 3 x circuit breakers and no generating units. A CEPS connection was planned as a future addition but never materialised. The 2008 GHD HV System report stated that the HV Interconnector cable is a 95mm² XLPE/HDPE cable, rated for 230A (or 4.4MVA). The report stated that the HV Ring feeder and the Radial Feeder are 70mm² XLPE cables, rated for 195A (or 3.7MVA). The details (size and rating) of all HV Ring and Radial feeders are unknown and not shown on the HV SLD. The CMS was unable to provide confirmation of the ring size and rating. The ring cable conductors (Al or Cu) could not all be confirmed due to lack of labelling.

2.1.4 Capacity

The Distribution Network Service Provider, Powercor, have not provided up to date information on the status incoming supply feeder. HV Feeder.



2.1.5 Condition

The condition of the overhead incoming feeders is generally satisfactory although there have been several reported faults. Powercor have advised that this section of their reticulation is very vulnerable to faults due to the overhead installations transiting large areas of vegetation.

2.1.6 Reliability

We have no information at this time regarding the reliability of the Powercor feeder in Point Cook Road. Further liaison with Powercor will provide the information for the next iteration of this report.

2.1.7 Redundancy

We have no information at this time regarding the redundancy of the Powercor feeder in Point Cook Road. Further liaison with Powercor will provide the information for the next iteration of this report.

2.2 EXISTING LOADS

2.2.1 Magnitude

After inquiries to the Supply Authority Powercor, consumption information was gathered for the 12-month period starting September 2019 and ending October 2021. The peak demand of the RAAF Williams (Point Cook) was recorded at 434 kVA.(approximately 11 A at 22 kV) during November 2019 as obtained from the Powercor data.

The data reveals the impact of Covid 19 pandemic upon the reduced load throughout most of 2020 due to the population reduction at the Base.

There is no Base wide generating capability at RAAF Williams (Point Cook) other than two local emergency generators (LEG) that provide emergency power for the Communications Centre Building (Comcen) P145 and the Building P9.

A generator located in building P25 as part of substation No 2 is not utilised, and as part of the Redevelopment project will be removed from site

2.3 LOAD DISTRIBUTION

Load Types

In general terms, the Base may be divided into two general load-type groups, offices and air side flight control and offices

• Offices loads typically comprise fluorescent lighting, air conditioning and appliance loads whose magnitude corresponds to the general level of human activity during the day and some night activity.

• Air side accommodation consists of flight control buildings, aircraft hangers for the museum displays, the main museum buildings and aircraft parks.

• Load Estimates

Of the 5 distribution substations, some have Maximum Demand Indicators from which metered demands can be obtained, however a portion of those are faulty and not reliable. At this time actual load determination for each substation could not be accurately determined. When the buildings occupancy returns to normal pre Covid 19 levels a more accurate determination of load will be carried out.

Substations for the Base are connected in single ring main configuration. i.e. two radial feeds are connected with two parallel interconnection points each with a normally open point.

Each limb of the ring main is identified by the first substation it connects to outside the intake substation and the HV switches are labelled accordingly The limbs of the ring main have had their open points arranged so that each limb shares approximately half the load.

The maximum demands for the incoming feeder (i.e. for each limb of the ring main) have been obtained from the DNSP over the year of September 2019 to October 2020:

The Laverton zone substation feeder is not dedicated to the Base as it transits several civilian areas of Point Cook and environs before it arrives at RAAF Williams (Point Cook) .

The load on the feeder as communicated by UE is 327Amps (12.5 MVA) of which RAAF Williams (Point Cook) uses 11 Amps (413 kVA).

The above load information has been supplemented with conductor and cable capacities from section 2.5, to calculate utilisation, shown below in Table 2. These are current-carrying capacities, and do not account for limitations related to voltage drops.

2.3.1 Load Profile

Utilising information from Powercor (the current energy retailer) obtained in October 2020, annual and daily load profiles have been produced. These can be found in Figure 1 below.

The sample period for this data is the 12 month period from the 1st of September 2019 to the October 2020.

Figure 1 Monthly Maximum Demand (Sept 19 to Oct 20)

As can be seen from the annual load profile, greater demand has occurred in the time frame previous to the Covid 19 pandemic and a general reduction in load has emerged from the first lock down period of March 2020 until October 2020.

The significant data for typical analysis can therefore only be determined from the period before Covid 19 which as shown is the period September 2019 to February 2020.

Examining the daily load profiles for typical summer day (in Figure 2 below), demand rises quickly in the early morning until 06:30 AM and then rising steadily until 02:30, PM then declines until 07:00 PM, then steadily declining to a minimum at 11:00 PM. This dip in demand signifies that there is little night activity at the Base. The total variance in demand over a day is approximately 300 kVA. The outstanding peak demand for the 31 January is repeated over several weeks during January and February only, and only on



individual days. Generally, the peak demand for all other periods is below 400 kVA. The winter profile shown in Figure 3 indicates a similar characteristic to the summer profile but at a lower average..

Figure 2 Summer Daily Load Profile

Figure 3 Winter Daily Load Profile

2.3.2 Power Factor

Information provided by Powercor indicates that the average power factor at the Base is 0.87. The data provided spanned from September 2019 to October 2020. Over those 12 months, the power factor ranged from 0.711 to 0.93. This shows that the Base is not in compliance with the National Electricity Rules (AEMC) minimum power factor requirement of 0.90.

2.4 PRIMARY DISTRIBUTION

2.4.1 Configuration

Under normal operation, electrical supply is taken from the LV 4 feeder to the Intake Switching Station The incoming feeder is terminated directly onto the HV 22 kV switchboard in the ISS

2.4.2 Condition

The condition of the incoming network equipment is unknown, with no known shortcomings. The ABS had no visually detectable faults.

2.4.3 Reliability and Redundancy

RAAF Williams (Point Cook) is afforded no redundancy, as the LV4 feeder is the only connection to the Base

2.5 SECONDARY DISTRIBUTION

2.5.1 Configuration

The HV network consists underground distribution throughout all areas.

The existing configuration is best described as a single ring, consisting of two limbs interconnected at two points and a number of radial feeds off the main ring. Open points are maintained in the two interconnectors.

Distribution substations are connected to each system via spurs or ring main units (RMU).

2.5.2 Capacity

Not all of the cable and conductor capacities that make up the various reticulation could be ascertained.

All underground HV cables are labelled at the respective ring main unit where they are terminated and all cables are 95 mm sq. Cu XLPE

Voltage Drop Consideration

The RAAF Williams (Point Cook) is not a large Base and HV circuits are of the order of 5 kilometres in length. At the supply voltage of 11 kV it is not anticipated that voltage drop will be an issue for the Redevelopment Project forward for the next 20-25 years.

Overhead Reticulation

There is no HV overhead reticulation at RAAF Point Cook.

Distribution Substations

Some substations installed do not have LV service protective device. A fault on the LV board would rely on the MV fuses to blow, which may have such a delay that no practical protection is provided at all. This arrangement does not comply with mandatory statutory requirements and is a safety hazard.



The status of the existing substations presented in the BEAP report for compliance condition and capacity are tabulated below. These have also been validated as part of the Redevelopment Project.

Table No 1 Substations Status

Substation Compliance Date of original Installation Condition Capacity

HV Sub/RMU 1 Non-compliant 1988 Poor Within limits


HV Sub/RMU 3 Non-compliant 1996 Fair Within limits


HV Sub 5 Compliant 2016 Good Within limits

“CEPS” RMU Compliant 2016 Good Within limits

Overall service status Non-compliant Poor Within limits

Overall precinct status Non-compliant Within limits

2.5.3 Reliability and Redundancy

Reliability

At this time there is no anecdotal evidence of reliability issues at RAAF Williams (Point Cook)

Redundancy

There is no redundancy available for the incoming power supply HV network.

2.6 POWER CONTROL AND MONITORING SYSTEM (PCMS)

There is no PCMS at RAAF Williams (Point Cook). Only some of the distribution substations are equipped with Maximum Demand Indicators (MDIs), however some of these are not functional.

Some substations are fitted with smart meters the readings from which have been used to measure peak load demand.

Also most buildings at RAAF Williams (Point Cook) are fitted with smart meters from which the load estimations for this report have been determined.

2.7 DEFICIENCIES

2.7.1 Incoming Supply (Primary Distribution) Capacity

The supply authority Powercor have not advised to date the status of the power supply capacity, ongoing liaison with Powercor will address these issues.

2.7.2 Incoming Supply Reliability and Redundancy

As the supply from the Laverton Zone Substation is susceptible to lightning strikes, wind-blown debris, fauna and other external factors. These impacts negatively on both the reliability on the supply feeder LV4

2.7.3 Capacity

TBA

2.7.4 Secondary Distribution Capacity

The existing secondary capacity is sufficient, and the use of 95 mm sq underground cables is now allowable under the latest version of Section 26 of the MIEE. However taking into account the potential estimated maximum demand of the ring main circuits and the requirement to maintain a 50 % reserve capacity it has been decided to install 120 mm sq cables.

2.7.5 Secondary Distribution Reliability

As the secondary distribution is all underground cable construction it is considered as reliable.

2.7.6 Distribution Substations

Some of the newer distribution substations have LV boards that lack a main circuit breaker. This is a non-conformance with AS/NZS 3000, as the transformer, LV and HV cabling have no overload protection. The reliance on MV fuses provides little protection under overload as it will only operate for a fault. These arrangements are unsafe, as an earth fault in the board would appear as a low-level phase-to-phase fault on the MV side. The MV fuses may take minutes to operate (if they operate at all).

Six of the distribution substations are equipped with Schneider RMUs. These are well known in the industry for being reliable. These are protected with fuses in the RMU.

The distribution substations are adequately labelled.



3. PROPOSED BASE LOADS

3.1 FACILITIES TO BE ADDED TO THE RAAF WILLIAMS (POINT COOK)

The Redevelopment Project has no new buildings.

3.2 FACILITIES TO BE DEMOLISHED

At this time no buildings are intended to be demolished as part of the redevelopment.

3.3 FACILITIES TO BE REFURBISHED/ADAPTIVE REUSE

The Redevelopment Project anticipates approximately three existing buildings to be refurbished to various levels either minor refurbish or full adaptive reuse as tabled below

Table 2 Buildings refurbished and adaptive reuse

Precinct Additional Load (kVA)

Comments

Building 33 Kitchen Mess and LIA

365

New fully equipped kitchen added to refurbished LIA wing

Removed from scope however may re emerge in DDR.

Load considered for SDR

Building 87 50 Removed from scope

Museum Alternations 20 Removed from scope

Total 365

The resultant effect of the Redevelopment Project works loads diversified minus the facilities to be demolished and adding in the buildings for adaptive reuse is 415 + 365= 780 kVA site total load.

The analysis of load growth across the RAAF Williams (Point Cook) HV network for the next several years considers two elements:

The addition of new (or expansion of existing) facilities.

A load growth factor of 3% per annum has been allowed for future load growth, for the years 2022 through to 2042.

3.4 ULTIMATE BASE LOAD

Considering the Redevelopment Project scope, the electrical demand of the Base is given in Table 4. The additional load has been added February 2023 until completion in June 2025.

Beyond the completed construction program, a 3 % load growth factor has been applied for the remainder of the 20 year period up to the year 2042.

The Total projected Base load after all planned expansion and disposal works are completed – is 1.34 MVA in 2042.

Figure 4 shows this data graphically, including the total capacity of the existing incoming supply arrangement as advised by Powercor.

Figure 4 Projected Base Load to 2042

The total capacity of the incoming LV4 is 9.8 MVA and the expected total load growth for the next 20 years is expected to reach 1.45 MVA this does not allow for other customers on this feeder.



4. ELECTRICAL MASTER PLAN

4.1 INCOMING SUPPLY

The RAAF Williams (Point Cook) Redevelopment Project Brief requires the following;

“a. Investigate, assess and provide recommendation for redundancy in the existing feeder, including by duplicating the feeder between the Powercor meter and intake switching station;

b. Investigate, assess and provide recommendation for the need to renew, replace or provide new signage and fire safety equipment in accordance with Statutory Regulations, Australian Standards, BCA-NCC and Defence requirements at the HV intake switching station;

c. Investigate, assess and provide recommendation for renewal or replacement of earthing to the HV intake switching station in accordance with Statutory Regulations, Australian Standards, BCA-NCC and Defence requirements;”

Duplication of the existing feeders has been assessed and, it is recommended that provision for two (2) off 22 kV supplies be connected to a new Intake Switching Station (ISS), consisting of a second circuit breaker metering assembly for termination of a second future supply.

Both supplies would be connected from the existing 22 kV overhead lines that presently enter the Base from the Powercor.

At this time a second feed to the Base is not possible.

New signage and fire safety equipment will be provided in all substations that are to be retained and new kiosk substations as required.

Earthing testing will be performed at several areas across the Base before SDR stage to determine the earthing requirements and ensure compliance with codes.

It is intended to relocate the incoming power supply to a new ISS and decommission the existing ISS. A new Intake Switching Station will be built to house the 22 kV switchgear and the relevant accessories for operation.

The projected load growth is shown against the proposed upgrade in supply in Figure 4, and Table 6

4.2 HV DISTRIBUTION

4.2.1 General Arrangement

The general arrangement adopted for HV networks at Defence establishments is for distribution substations to be connected as a ring main. These ring mains are connected between major switching nodes, called Primary Switching Stations (PSS) so that the ring mains is connected to a different PSS at each end. At RAAF Williams (Point Cook) there is no PSS (s) the incoming supply is routed directly via the ISS. It is proposed to have one ring main circuit on the Base.

There is a moveable open point on the ring mains that can be used to change how much of the ring main is fed from one circuit breaker at the ISS and how much is fed from the other in order to facilitate power transfer in the event of an outage.

This arrangement allows a high degree of flexibility as it allows any failures in the HV network to be quickly bypassed using switching operations and power restored until equipment or cables are repaired.

The existing ISS does not have sufficient space to accommodate the required numbers of 22 kV circuit breakers to connect the circuits proposed in the Master Plan. For this reason it is recommended to install a new ISS as detailed below.

4.2.2 Primary Distribution

Existing ISS Location Building P81

The existing ISS is located in Building P81 and consists of 2 No 22 kV “Yorkshire” SF6 circuit breakers. One circuit breaker controls the single incoming supply from Powercor. The other breaker controls the 22/11 kV transformer.

The room in which the existing circuit breakers are installed is considered unsatisfactory as reported in the BEAP Report as follows

• Poor earthing at this location.

• Emergency and exit lighting and signage not installed.

• No protection grading, fault level, arc flash studies or earthing reports have been provided.

Although these issues can easily be remedied, the following more serious issues were discovered during recent investigations.

• The space restraints for accommodating further circuit breakers is a limiting issue, there is provision for an additional circuit breaker to be installed at either end of the existing switchboard, for a total complement of 5 No circuit breakers. This would not be adequate for the ultimate design for the site which would require at least ten circuit breakers to be installed.

• There would be considerable down time in inserting a second Powercor feed. This would require a complete shutdown of the site service for several days.

• There is no room to accommodate the Power Control and Monitoring System (PMCS) as required by the MIEE.

• Vintage of the existing superseded Yorkshire switchgear. This would require new switchgear and protection devices.

• Conversion of the site to 22 kV by removal of the isolation transformer and the existing 22 kV and 11 kV switchboard and replace with a single 22 kV switchboard.

• The power factor for the Base is outside the limits required by the MIEE (0.9 or above) and power factor correction will have to be employed There is insufficient space to locate an external Power Factor Correction (pfc) module local to the ISS. This unit would also require a further 22 kV circuit breaker.

Proposed ISS Location

Under the proposed supply option a new Intake Switching Station would be constructed.

There are four principal considerations in locating the new ISS:

• Easy access for the incoming overhead feeders from Powercor and allowing adequate free space for construction,

• There are no heritage issues with this location.

• Cable routing for the ring main will be more efficient using this site.

• Ease of installing the new cabling for the ringmains whilst the existing ISS is still in service, and then cutting over to the new ISS when all substations are complete.

The auxiliary systems and the 22 kV switchboard would be located in the ISS building. Adequate space would be allowed within the switchroom buildings to accommodate the PCMS equipment, and UPS and other auxiliaries as required by the MIEE.

It is recommended that a new ISS on a new site be provided as part of the Redevelopment Project to offer flexibility in the future for connection of a ring main circuit.



Power Factor Correction (PFC)

Bulk power factor correction consisting of IP66 enclosures would be installed external to the ISS on a concrete slab.

Refer to Appendix D for calculation details.

4.2.3 Secondary Distribution

The existing secondary reticulation is required to be reviewed as described in the Redevelopment project Brief as follows

The new ring mains cabling will be designed for a system fault level of 250 MVA for one second. For this reason a minimum cable size of at least 185 mm2 Al/XLPE will be provided. This cable has a capacity of 275A (10.5 MVA) when installed in conduit, will be employed, as a construction expedient, to enable trenches to be backfilled once conduits are installed. The cable is also used by supply authorities is in most cases widely available and cost effective compared to the equivalent copper cable.

• The present substations loads have been summated;

• Known planned loads have been added to certain rings;

• 3% annual growth has been added to each ring, in proportion to each ring’s current load.

The ring is shown on drawings in Appendix A.

Table 7 Master Planned Load (refer to tables 3,4 and 5 for details of loads)

Ring / Radial Diversity Diversified

Planned Load (MVA)

Ring Load (including 3% load growth)

(MVA)

Ring Capacity (MVA)

Loaded Capacity

Ring main 0.8 415 kVA x .8 =0.332

1.35 10.8 12.5%

The above ring capacities are based on 185 mm sq Al cables in order to meet the requirement that any one cable shall be able to support the entire base load (should the neighbouring feeder be out of commission) and maintain a 50 % reserve capacity.

Operations During Equipment or Cable Failure

Following the failure of HV equipment or cables on the ringmains, the fault is quickly isolated using switching operations so that power can be restored. This involves moving the ring open point.

The proposed new arrangement allows for the ring feeders to be fed from either end, to effectively isolate and bypass any faults that occur on the network. The new network configuration will effectively eliminate the existing spur connected transformers and provide alternate supply routes for these substations.

4.3 EMERGENCY POWER GENERATION

4.3.1 Generation

There is no centralised emergency power generation at RAAF Williams (Point Cook) however, there are two local emergency generators at Sub station 1 Pillar No1 that supports Building P9 and building P 145 Comcen.

Defence have advised that a CEPS is not required for this Base however it is intended to fit out one of the substations No 2 as a future CEPS that will be fitted with the necessary switchgear and interconnector cable for future generator insertion at substation 2 when required.

4.4 POWER MONITORING SYSTEM

4.4.1 System Requirement

The existing control and monitoring infrastructure is limited to stand-alone MDI meters installed at a selection of substations, smart meters in most buildings and these is manifestly inadequate.

4.4.2 Recommendation

A comprehensive PCMS is required to monitor substation and supply loading. This system would be extended to all of the substations within RAAF Williams (Point Cook) area of the Base.

The PCMS system will consist of a PLC network run over a dedicated fibre-optic communications backbone designated the Defence Engineering Services Network (DESN). A new DESN will be utilised.

The user interface will consist of a commercially available SCADA package such as CITECT running on a PC. Such a system will allow remote monitoring of electrical engineering services from a central location, such as the ISS.

Monitoring Functions

The PCMS would have the following monitoring functions:

ISS switchboard

• Remote control of ISS 22 kV switchgear from within a dedicated control room within the ISS.

• Power flows on each incoming and outgoing circuit

• Open/closed/tripped status of each circuit

• Switchboard fault indications, e.g. trip circuit supervision

• DC system parameters and status

• RMU and communications faults

Distribution Substations

• Remote control at each substation location via a free standing physically isolated remote control panel.

• Open/closed/tripped status of RMU

• Power flows at substation LV switchboard, both incoming and outgoing

• RMU and communications faults

Process Alarms

Various alarms and status, including sewerage pumping stations, and local emergency generators.

The PCMS would be utilised as a monitoring system only and would not be used for control.

The RMUs and the low voltage outgoing switches will be fitted with auxiliary contacts which are used to indicate trip and open positions. Such information can also be collected by the PCMS, and indicated on the PCMS computer.



5. DEVELOPMENT PLAN

This section details the works that will be undertaken as part of the RAAF Williams (Point Cook) Redevelopment Project

5.1 INCOMING SUPPLY

5.1.1 Powercor works

The following works will be negotiated with Powercor:

• Upon construction and fit out of a new ISS a new feed will be connected to the circuit breaker in the new ISS. This will involve removal of the existing metering enclosure and the 22/11 kV transformer

• Disconnection of the existing ISS, removal of the overhead “tee off” feeding the existing ISS. This work to proceed once the new ring mains secondary distribution for the Base is ready to be cut over.

5.2 SECONDARY DISTRIBUTION

5.2.1 Substation Replacements

The existing secondary reticulation is required to be reviewed as described in the Redevelopment Project Brief as follows, the investigative responses are shown below each brief item.

“a. Investigate, assess and provide recommendation for renewal or replacement of HV substations to Statutory Regulations, Australian Standards, BCA-NCC and Defence requirements;

Development Plan investigations; all substations have been reviewed and recommended for replacement due to the age of the transformers some dating from 1986, and non compliance with the MIEE regarding undersized cables and condition of the kiosk substations.

b. Inspect and test all substations (incl. 6 RMU‘s) and ensure each substation is repaired of any defect and is fully compliant with Statutory Regulations, Australian Standards, BCA-NCC and Defence requirements. Investigate, assess and provide recommendation for renewal or replacement. Works identified may include:

i. Repair transformer gas and oil leaks;

ii. Repair or replacement of rusted substation panelling;

iii. Repair or replacement of insulated conductors or install insulated enclosure/barriers with danger labels.

iv. Repair or replacement of cable glands and shrouds at RMUs in HV substations.

vi. Upgrade fire / emergency exit items at all substations; and

Development Plan investigations; It is recommended that the above issues be resolved universally with the replacement of the substations 22kV ring main units.

c. Investigate, assess and provide recommendation for renewal or replacement of electrical meters at substations with a SMART Meter in accordance with Statutory Regulations, Australian Standards, BCA-NCC and Defence requirements including the installation of a new DESN and reporting through a centralised BMS.

Development Plan investigations; the above issues will be resolved with the replacement of all substations with kiosk substations complete with new HV ring main units and transformers, low voltage distribution switchboards and DESN cubicles connected to the DESN network for data connectivity to the PMS.

Where no meters are installed, install new metering in accordance with Statutory Regulations, Australian Standards, BCA-NCC and Defence requirements.”

Development Plan investigations; new smart metering will be provided at all substations as required

The following works will replace the existing non-compliant substations with new kiosk substations or new substations embedded in new buildings as part of the Redevelopment Project.

Table 8 Substation Upgrades

Substation Existing capacity kVA

Proposed capacity kVA Comments

Kiosk substation No 1 800 750 Replace with kiosk inc HV RMU, Transformer, LV DESN etc

HV Sub/RMU 2 800 750 Replace with HV RMU, Transformer, LV DESN etc


Kiosk substation No 4 800 750 1750 750

Replace with kiosk inc HV RMU, Transformer, LV DESN etc


Kiosk substation No 6 N/A 500 New kiosk inc HV RMU, Transformer, LV DESN etc

Kiosk substation No 7 N/A 500 New kiosk inc HV RMU, Transformer, LV DESN etc

Local Emergency generator Adjacent substation No 4

Nil 100 Connected to sub No 4 to support flight line loads ie. airfield lighting

Local Emergency generator Adjacent pillar 1 substation No 1

100 100 Connected to pillar No 1 sub 1 to support local building in the area

The replacement of the substations will also include the removal and decommissioning of the existing underground 11 kV cabling, as each substation will now be connected with22 kV underground cable to its neighbouring substation in both directions to form a ring main.

5.3 STAGING OF THE WORK

The works will be staged to optimise and minimise down time for the Base.

5.4 EMERGENCY POWER GENERATION

5.4.1 CEPS

Defence have advised that a CEPS is not to be provided as RAAF Williams (Point Cook) the design is considering provision for a future CEPS.

5.5 POWER CONTROL & MONITORING SYSTEM (CPMS)

5.5.1 Implementation

The implementation of a PCMS across the Base will be permitted by the upgrade of all Base communications ICT networks including the DESN as part of the Redevelopment project.

Optical fibre links will be established to all substations on the Base.

All new facilities should have electronic metering with communications in accordance with the MIEE.



Communications conduits will be provided between the facility and the supplying substation to allow the future installation of communications cabling from the meter to the substation.



6. REFERENCES

6.1 REFERENCED DOCUMENTS

(a) Base Engineering Assessment program (BEAP) Report 2014 Part 3 Electrical RAAF Williams (Point Cook)

(b) Olex, 2009, 'High Voltage Catalogue'.

6.2 ABBREVIATIONS

AAC All Aluminium Conductor

AI Aluminium

CB Circuit Breaker

CEPS Central Emergency Power Station

Cu Copper

DC Direct Current

DESN Defence Engineering Services Network

DHA Defence Housing Australia

DNSP Distribution Network Service Provider

HQ Headquarters

HV High Voltage

ISS Intake Switching Station

LEG Local Emergency Generator

LHD Landing Helicopter Dock (Canberra Class) LIA Live in Accommodation

LV Low Voltage

MDI Maximum Demand Indicator

MIEE Manual of Infrastructure Engineering Electrical

PMS Power and Monitoring System

PFC Power Factor Correction

PILC Paper Insulated, Lead Covered

PLC Programmable Logic Controller

PWC Power and Water Corporation

RMU Ring Main Unit

RTU Remote Terminal Unit

SCADA Supervisory Control and Data Acquisition

SF6 Sulphur Hexafluoride

SS Switching Station

XPLE Cross-linked Polyethylene

ZSS Zone Substation



APPENDIX A DRAWINGS

EST02008-01-0932-AZ001-DRW-HV-0102 [C] Existing conditions HV network schematic.

EST02008-01-0932-AZ001-DRW-HV-0104 [C] Proposed HV network schematic.

POWERCOR DISCONNECTSWITCH ON POLE No.91

POWERCOR POLE MOUNTEDDISCONNECT SWITCH

(OPERATION OF THIS SWITCH ISBY POWERCOR PERSONNEL ONLY)

K

22kV POWERCOROVERHEAD INCOMER

VTCT POWERCOR METERING CUBICLE

POINT OF SUPPLY

K

BUSBAREARTHINGDEVICE

1 2 1

MAIN INCOMING 22kVCIRCUIT BREAKERMAIN SWITCH

2.5 MVA22/11kV TRANSFORMER

VT PRIMARYFUSES

VT SECONDARYFUSES INSTRUMENTATION AND

FUTURE SYNCHRONISATION

22 1

11kV BUS CIRCUIT BREAKER11kV MAIN ISOLATOR

1111 12

CENTRAL EMERGENCY POWERSTATION RING MAIN UNIT11kV CIRCUIT BREAKER

11kV BUSBAR

33 4

SUB No.1 RING MAIN UNIT11kV CIRCUIT BREAKER

INDOOR 22kVSWITCHGEAR

OUTDOORTRANSFORMER

INDOOR 11kVSWITCHGEAR

INDOOR INTAKESUBSTATIONBUILDING P81

50AMCCB

25KVA 1000/415VTRANSFORMER

NON DIRECTIONAL BEACON

CADF BUILDING

ON

OFF

EARTH

25KVA 415/1000VTRANSFORMER 32A

MCCB

32A/63AFUSES

TRANSFORMER ENCLOSURE LV MAIN SWITCHBOARD

415VMAIN SWITCH

TRANSFORMER 800kVA

11kV/415V

1kV U/G CABLE 3CORE 7/0.036

KIOSK SUBSTATION No.1

63A

3 4

6

RING SWITCH SUB 1 - INTAKE SUB

RING SWITCH SUB 1 - SUB 3

TRANSFORMER SWITCH SUB 1-T

POINT COOK SITESUBSTATION

11kV RMU

5

11kV/415V


63A

5 6

8




11kV RMU

7

11kV/415V


63A

5 6

8


RING SWITCH SUB 2 - CENTRALEMERGENCY POWER STATION


11kV RMU

7

9 10RING SWITCH CENTRAL

EMERGENCY POWER STATIONSUB 2


EMERGENCY POWER STATIONINTERCONNECTION


EMERGENCY POWER STATIONSUB 4


3x63A PFF

1817

15

SPARE

RING SWITCHSUB 5 - SUB 4

TRANSFORMERSWITCH SUB

5-T

11kV RMU

16


1615

13

RING SWITCHSUB 4 - SUB 5

RING SWITCHSUB 4 -

CENTRALEMERGENCY

POWERSTATION

TRANSFORMERSWITCH SUB

4-T

11kV RMU

14

TRANSFORMER 100kVA

TRANSFORMER 800kVA

500kVA 11kV/425V

500kVA 11kV/425V3x63A PFF 100A

MCCB

25kVA 1000/415VTRANSFORMER

SEWAGE TREATMENT PLANT

BUILDING 467

25kVA 415/1000VTRANSFORMER32A

MCCB

TRANSFORMERENCLOSURE

LV MAIN SWITCHBOARDBLDG 120

415VMAIN SWITCH


ENVIROTRANSFORMER

22kV CABLE

CEPS BUS

NOT TO SCALE

SINGLE LINE DIAGRAM

C

EXISTING CONDITIONS HV

NETWORK SCHEMATIC-

JD WPH GL13.10.21SDR WPH

EST02008-01-0932-AZ001-DRW-HV-0102

NORTH

SCALE BAR

0932RAAF BASE POINT COOK

EST02008RAAF WILLIAMS (POINT COOK) REDEVELOPMENT

NORTH POINT

0 20.0m10.05.010.0 15.0

SCALE 1:500 SHEETA1NATURAL

The information on this drawings is obtained from

the current MSP, which will need to be validated

through site surveys as part of the planning phase

CLIENT

CONTRACT ADMINISTRATOR

MANAGING CONTRACTOR

PROJECT

BASE

WORK ELEMENT

PHASE: SCALE@A1: REV DATE:

RevisionDRAWING NUMBER:

CONSULTANT

DRAWN: CHECK: APPROVED:

TITLE

ASSET NUMBER & NAME

DESIGN:

AMENDMENTS:

LEGEND

EMAIL [email protected] 03 9652 0333 LEVEL 9, 128 EXHIBITION STREET MELBOURNE VIC 3000 AUSTRALIAWEBB AUSTRALIA GROUP (VIC) PTY LIMITED ACN 61 073 585 305

CONSULTING ELECTRICAL ENGINEERSTECHNOLOGY CONSULTANTS

LIGHTING CONSULTANTS

AUSTRALIA

DRAWING TO BE PRINTED IN COLOUR

NTS

A 28.07.21COST PLAN ISSUE SDRB 25.08.21DRAFT SDR

WORK ELEMENT 01

SERVICES INFRASTRUCTURE

ELECTRICAL INFRASTRUCTURE

AZ001

C 13.10.21FINAL SDR

POWERCOR DISCONNECTSWITCH ON POLE No.91

POWERCOR POLE MOUNTEDDISCONNECT SWITCH

(OPERATION OF THIS SWITCH ISBY POWERCOR PERSONNEL ONLY)

K

22kV POWERCOROVERHEAD INCOMER

VTCT POWERCOR METERING

POINT OF SUPPLY

VT PRIMARYFUSES

VT SECONDARYFUSES INSTRUMENTATION AND

FUTURE SYNCHRONISATION

22 1

22kV BUS CIRCUIT BREAKER22kV MAIN ISOLATOR

1111 12

INTERCONNECTOR22kV CIRCUIT BREAKER

22kV BUSBAR

33 4


NEW INTAKESWITCHING

STATION (ISS)

50AMCCB

25KVA 1000/415VTRANSFORMER

NON DIRECTIONAL BEACON

CADF BUILDING

ON

OFF

EARTH

25KVA 415/1000VTRANSFORMER 32A

MCCB

32A/63AFUSES

TRANSFORMER ENCLOSURE LV DISTRIBUTION PILLAR (PART)

415VMAIN SWITCH

TRANSFORMER 750kVA

22kV/415V



24 23

6

RING SWITCHSUB 7

RING SWITCHSUB 2

22kV RMU

5

22kV/415V

SUBSTATION No.2

5 6

21

RING SWITCHSUB 1

RING SWITCHSUB 3

22


1718

20

RING SWITCHSUB 3

22kV RMU

19


1920

22

RING SWITCHSUB 5

RING SWITCHSUB 2

22kV RMU

21

TRANSFORMER 750kVA

500kVA 22kV/425V

500kVA 22kV/425V

3313 34

100AMCCB

25kVA 1000/415VTRANSFORMER

SEWAGETREATMENT PLANT

TO BE REMOVED

BUILDING 467

25kVA 415/1000VTRANSFORMER32A

MCCB

TRANSFORMERENCLOSURE

LV MAIN SWITCHBOARD(PART)BLDG 120

415VMAIN SWITCH


22kV/415V


1516

18

RING SWITCHSUB 6

RING SWITCHSUB 5

22kV RMU

17

TRANSFORMER 750kVA

22kV/415V


1314

16

RING SWITCH ISS

RING SWITCHSUB 4

22kV RMU

15

TRANSFORMER 500kVA

NOTES:

11

12

22/11 kVTRANSFORMER TO BEREMOVED ENVIRO TRANSFORMER TO

BE REMOVED

REMOVE EXISTING 22KVCABLE, DISCONNECT FROM22/11 KV TX

RING SWITCHSUB 4


1313 14

PFC 22kV CIRCUIT BREAKER

TRANSFORMER 500kVA

22kV/415V


3 4

23

RING SWITCHISS

RING SWITCHSUB 1

22kV RMU

24EXISTING TO BE

RECONNECTED TO NEWSUB 1 LV SWITCHBOARD

PILLAR

EXISTING TO BERECONNECTED TO NEWSUB 5 LV SWITCHBOARD

PILLAR

INTE

RCON

NECT

OR

ALLOWANCEFOR FUTUREFEEDER

07.ISS

07.T

07.01

01.07

01.T

01.02

06.ISS

06.T

06.04

04.06

04.T

04.05

05.04

05.T

05.03

03.05

03.T

03.02

02.01

02.T

02.03

02.ISS

RIFLE RANGEPOWER SUPPLY

FOR FUTURECEPS

NORTH

SCALE BAR

0932RAAF BASE POINT COOK

EST02008RAAF WILLIAMS (POINT COOK) REDEVELOPMENT

NORTH POINT

0 20.0m10.05.010.0 15.0

SCALE 1:500 SHEETA1NATURAL

The information on this drawings is obtained from

the current MSP, which will need to be validated

through site surveys as part of the planning phase

CLIENT

CONTRACT ADMINISTRATOR

MANAGING CONTRACTOR

PROJECT

BASE

WORK ELEMENT

PHASE: SCALE@A1: REV DATE:

RevisionDRAWING NUMBER:

CONSULTANT

DRAWN: CHECK: APPROVED:

TITLE

ASSET NUMBER & NAME

DESIGN:

AMENDMENTS:

LEGEND

EMAIL [email protected] 03 9652 0333 LEVEL 9, 128 EXHIBITION STREET MELBOURNE VIC 3000 AUSTRALIAWEBB AUSTRALIA GROUP (VIC) PTY LIMITED ACN 61 073 585 305

CONSULTING ELECTRICAL ENGINEERSTECHNOLOGY CONSULTANTS

LIGHTING CONSULTANTS

AUSTRALIA

DRAWING TO BE PRINTED IN COLOUR

C

PROPOSED HV NETWORK

SCHEMATIC-

JD WPH GL13.10.21SDR WPH

EST02008-01-0932-AZ001-DRW-HV-0104

NTS

A 28.07.21COST PLAN ISSUE SDRB 25.08.21DRAFT SDR

WORK ELEMENT 01

SERVICES INFRASTRUCTURE

ELECTRICAL INFRASTRUCTURE

AZ001

C 13.10.21FINAL SDR

AutoCAD SHX Text

1. ALL HV CABLES SHALL BE 3C 22KV AL 185mm XLPE ALL HV CABLES SHALL BE 3C 22KV AL 185mm XLPE 2 XLPE INSTALLED IN 150mm DIA UPVC HD CONDUITS 2. EXISTING 11KV CABLES TO BE REMOVED IF INSTALLED EXISTING 11KV CABLES TO BE REMOVED IF INSTALLED IN CONDUIT OR ABANDONED IF DISCOVERED TO BE BURIED DIRECT



APPENDIX B COST ESTIMATE New ISS and Associated works; TBA



APPENDIX C LOADS TBA



APPENDIX D POWER FACTOR CORRECTION CALCULATION

raaf williams (point cook) redevelopment electrical …

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