Paghahanda ng 110 kV Na Prefabricated Substation para sa Data Center
Pagpapakilala
Sa mabilis na pag-unlad ng teknolohiya tulad ng cloud computing at big data, at sa pagbilis ng pagsipsip ng "Internet +" sa iba't ibang industriya, ang industriya ng digital na ekonomiya ay umuusbong sa mga pangunahing bansa at rehiyon sa buong mundo. Ito ay nangangalakal ng mas mahalagang posisyon sa pang-araw-araw na pamumuhay at sa pambansang ekonomiya. Lalo na sa kasalukuyang epekto ng pandemya ng COVID-19 sa global, ang pagbagsak ng ekonomiya ng mundo ay lumalakas. Ang tanging digital na ekonomiya lamang ang naglaban sa tren at nakatamo ng malakas na momentum ng pag-unlad.
Ang GB 50174 - 2017 Design Code for Data Centers ay nagbibigay ng partikular na definisyon para sa mga data center. Bilang isang pangunahing pasilidad na may kaugnayan sa pagmamanage at pag-imbak ng data, ang isang data center ay maaaring imbak ang iba't ibang uri ng impormasyon ng data. Sa karagdagan, ito ay sumusuporta rin sa mga pangunahing tungkulin tulad ng kalkulasyon at transmisyon ng data upang matugunan ang mga pangangailangan para sa massivong pagmamanage ng data. Ang pagtatayo ng mga data center ay naging isang hindi maiiwasang trend.
Sa industriya ng data center, ito ay kilala bilang digital na real estate, na napaka-kakaiba mula sa mga tradisyonal na proyekto ng pasilidad. Narito ang ilang prominenteng katangian ng mga data center: mataas na konsumo ng enerhiya, mataas na pangangailangan sa reliabilidad, at pangangailangan para sa mabilis na pagtayo. Ang konsumo ng enerhiya ng mga data center ay nakumpol, karaniwang nakakonfigura sa 2N redundancy. Ang malaking kapasidad ng konsumo ng enerhiya ay nangangahulugan na ang mga proyektong data center sa lebel ng parke ay karaniwang nakakonfigura ng espesyal na 110 kV substation para sa mga user.
Gayunpaman, ang pagtatayo ng 110 kV substation ay may maraming puntos ng sakit, na tiyak na ipinakikita sa mga sumusunod na aspeto: Ang siklo ng pagtatayo ng tradisyonal na 110 kV substation sa Tsina karaniwang tumatagal ng 12-24 buwan, na kasama ang lahat ng siklo ng trabaho tulad ng pagsasaayos, pagpili ng lugar, pagsusuri, disenyo, pag-file ng proyekto, pagbili ng materyales, "apat na koneksyon at isang pagpapatas" (access to water, electricity, roads, and telecommunications and land leveling), construction and installation, commissioning, greenery restoration, and production acceptance. Ang mahabang siklo ng pagtatayo ay hindi makakasabay sa pangangailangan para sa mabilis na pagliliver ng mga data center; Dahil sa mga customer at network reasons, ang industriya ng data center sa Tsina ay kadalasang nakalat sa Beijing-Tianjin-Hebei region, Yangtze River Delta, at Guangdong-Hong Kong-Macao Greater Bay Area. Karamihan sa mga rehiyong ito ay relatibong developed cities na may limitadong mga mapupunang lupa, at madalas na nararanasan ang mga problema sa site limitation sa panahon ng pagplano ng proyekto; Ang mga substation ng data center din ay kailangang mag-adjust sa flexible capacity changes ng mga data center.
Para sa mga puntos ng sakit sa pagtatayo ng substation ng data center, ang prefabricated modular substations ay isang mahalagang direksyon ng solusyon. Batay sa konsepto ng modular design, ang mga prefabricated substation ay may mga adhikain ng flexibility at reliability kumpara sa mga tradisyonal na substation sa aplikasyon. Lahat ng sistema sa prefabricated cabin ay ginawa, ininstall, inwired, in-debug, at pre-assembled sa factory. Pagkatapos ng pagkumpleto, ito ay maaari na direktang ma-assembly on-site, na nag-aangkin ng mataas na efisiensiya, nagbabawas ng kahirapan sa pagtatayo, at may mataas na degree ng integration. Ito ay angkop para sa iba't ibang scenario ng pagtatayo ng substation at nagpapakita ng malinaw na mga adhikain.
Ang artikulong ito ay gumagamit ng 110 kV substation construction project ng Data Center No.1 bilang halimbawa, at gumagawa ng detalyadong pagpapakilala sa mga application scenarios, process layout design, at prefabricated cabin process design ng mga prefabricated substation sa mga data center.
1. Buod ng Proyekto
Ang proyektong Data Center No.1 ay matatagpuan sa lungsod ng Suzhou, Jiangsu Province. Ang proyektong ito ay isang renovation ng isang lumang gusali ng pabrika. Mayroon na ang parke ng apat na gusaling pabrika, na sina A, B, C, at D. Ang pangunahing nilalaman ng pagtayo ngayon ay upang maisakatuparan ang kabuuang renovation ng parke nang walang pagbabago sa umiiral na building planning conditions at bumuo ng isang reliable na data center park.
Ang parke na ito ay tumutugon sa Class A data center standard sa GB 50174 - 2017 Design Code for Data Centers at nagplano na bumuo ng isang parke-level na data center na maaaring i-carry ang higit sa 100,000 high-performance servers. Kailangan ng parke na itayo ang 110 kV substation upang matugunan ang mga pangangailangan sa power supply ng parke. Ang substation ay pinapasok ng 2 ganap na independent 110 kV utility power supplies, bawat isa may kapasidad na 80,000 kVA, na bumubuo ng 2N power supply system. Sa normal na operasyon, ang load rate ng bawat line ay hindi lumampas sa 50% ng kanyang full-load capacity, o 40,000 kVA. Kapag may nasira ang isang utility power supply, ang isa pa ay maaaring mag-isa na i-carry ang lahat ng mga load ng data center.
Dahil ito ay isang renovation ng gusaling pabrika, ang karamihan sa lupain ng proyekto ay na-occupy na ng natapos na Buildings A, B, C, at D, na may relatyibong malaking pisikal na space limitations. Ang pangunahing available na outdoor spaces ay ang open space sa kaliwa side ng Building B at ang open space sa pagitan ng Building B at Building D. Para sa tradisyonal na 110 kV substation scheme, kapag ininstall ang 2 main transformers na may kapasidad na 80,000 kVA, kinakailangan ang rectangular site na may haba na humigit-kumulang 70 m at lapad na 40 m. Ang clear distance ng site sa kaliwa side ng Building B ay 30 m, at ang clear distance ng site sa pagitan ng Building B at Building C ay 50 m. Tinitingnan ang fire-prevention distance sa pagitan ng substation at buildings at ang mga pangangailangan ng fire-fighting ring road ng parke, mahirap para sa parehong mga site na matugunan ang mga pangangailangan sa construction space ng tradisyonal na substations.
Ang customer ng proyektong Data Center No.1 ay isang Internet enterprise. Bilang isang base-type na data center project para sa customer na ito, ang parke na ito ay susuporta sa maraming online businesses ng customer at malaking amount ng data transmission, operation, storage, at processing sa likod ng mga businesses. Ang customer ay may mataas na pangangailangan sa reliability ng data center na ito at may limitasyon sa delivery time.
Sa termino ng delivery time, dahil sa mabilis na pag-unlad ng data business ng customer, ang customer ay may napakaurgente na pangangailangan para sa data center, at ang buong data center park ay kailangang ma-deliver sa loob ng 6 buwan. Sa termino ng reliability, ang customer ay nangangailangan na ang dalawang utility power supplies ng 110 kV substation, na backup sa bawat isa, ay ganap na independent mula sa incoming line hanggang sa outgoing line, at ang mga ruta ay higit sa 10 m apart. Ang mga pangunahing equipment tulad ng GIS, transformers, at 10 kV switchgear ay distribyudo sa iba't ibang physical spaces upang iwasan ang isang accident na maaaring makaapekto sa parehong utility power supplies at kaya't makaapekto sa lahat ng businesses ng buong data center.
Dahil sa space limitations, tight time constraints, at mataas na customization requirements ng 110 kV substation project ng Data Center No.1, mahirap para sa tradisyonal na form ng substation na matugunan ang mga pangangailangan ng proyekto. Matapos ang negosasyon at diskusyon kasama ang lokal na grid company, ito ay kinumpirma na ang proyektong ito ay gagamit ng form ng prefabricated modular 110 kV substation.
2. Disenyo ng Process Layout
2.1 Pisikal na Espasyo
Ang 110 kV substation project ng Data Center No.1 ay may kabuuang 2 incoming power lines, at ang mga power supplies ay galing sa utility power supplies ng upstream 220 kV substations A at B. Parehong ang incoming lines ng dalawang utility power supplies A at B ay pumasok sa parke mula sa timog sa pamamagitan ng underground burial. Tinitingnan ang direksyon ng external utility power line routes at ang kasalukuyang sitwasyon ng building sa parke, ang 110 kV substation ay itinatakda sa southwest corner ng parke. Ang plane schematic diagram ng lokasyon ng 110 kV substation ay ipinapakita sa Figure 1.
Ang prefabricated substation ay may haba na 82 m, lapad na 17 m, at may kabuuang floor area na 1,400 m². Para sa tradisyonal na substation sa parehong kondisyon, ang tatlong parameter na ito ay 70 m, 40 m, at 2,800 m², respectively. Kumpara sa tradisyonal na substation, ang floor area ay nabawasan ng higit sa 50%, at ang layout ng substation ay maaaring matukoy batay sa on-site conditions, na mas flexible.
Larawan 1 Schematic diagram ng plano ng lokasyon ng 110 kV substation
2.2 Disenyo ng Process Layout
Ipinalalatag sa Figure 2 ang process layout diagram ng 110 kV substation. Ang interior ng substation ay binubuo ng dalawang prefabricated GIS (SF6 Gas-Insulated Metal-Enclosed Switchgear) cabins, isang prefabricated main equipment cabin, at dalawang outdoor 110 kV transformers. Ang layout ay inayos sa linear pattern.
2.3 Power Routing
Ang substation ng proyektong ito ay halos ganap na symmetrical. Tulad ng ipinapakita sa Figure 2, tinatakan ang firewall sa gitna ng dalawang prefabricated main equipment cabins bilang boundary, sa kaliwa at kanan ay ang prefabricated GIS cabins, prefabricated main equipment cabins, 110 kV transformers, at prefabricated capacitor cabins para sa Route A at Route B power supplies, at ang mga equipment ng Route A at Route B ay ganap na independent.
Ang buong substation ay equipped with an independent enclosure wall at operates independently from the data center park. An independent entrance out of the park is set on the south side. Only professional personnel are allowed to enter the 110 kV substation, and other personnel have no access rights, which can ensure the reliability of the substation's operation.
Ang GIS cabin ay isang single-layer prefabricated cabin. Sa loob nito, ito ay mainly equipped with 110 kV GIS combined electrical appliances with a rated current of 2,000 A. For each part of the design, sulfur hexafluoride (SF6) is an important arc-extinguishing medium and can be applied in GIS. Structurally, GIS is mainly divided into several parts, including voltage transformers, arresters, circuit breakers, and bushings, etc. These parts need to be correctly connected, and the reliability of each component needs to be ensured to effectively achieve the overall function [8].
Ang main transformer mainly uses a three-phase double-winding oil-immersed self-cooled transformer, adopting the YN grounding method, with a voltage level of [10.5 ± (2×2.5%/0.4)] kV, and the specific model is SZ11 - 80000/110.
Ang main equipment cabin has a two-layer structure. The first layer consists of two completely independent 10 kV output cabinet cabins, separated by a firewall, and respectively equipped with 10 kV switchgear and station service transformers corresponding to Route A and Route B power supplies. The 10 kV switchgear uses metal-clad switchgear equipped with vacuum circuit breakers. For feeder cabinets, capacitors, and station service transformers, their rated current and breaking current are 1.25 kA and 25 kA respectively; for incoming lines, they are 3.15 kA and 31.5 kA respectively. The capacity of the station service transformer is selected as 100 kVA, using a SC11 - type dry-type transformer, with a voltage of [110 ± (8×1.25%/10.5)] kV, a wiring group of Dyn11, an impedance voltage Uk = 4%, an IP40 protective enclosure, and an energy efficiency class of 2. To improve the reliability of the system, each 110 kV incoming line corresponds to two sections of 10 kV busbars, which can reduce the scope of an accident in case of a fault .
The second layer needs to be equipped with a grounding transformer, a prefabricated capacitor cabin, etc. A capacitor bank is configured in the prefabricated cabin, with differential pressure protection set, and a capacity of 6,000 kVA needs to be achieved. In addition to the above-mentioned parts, an iron-core reactor is selected in this design, with a reactance rate of 12%. A grounding small-resistance complete set device, with a grounding resistance of 10 Ω and a capacity of 400 kVA. The second layer also has a secondary room. The secondary room is specifically divided into several parts, including video surveillance, kilowatt-hour meter cabinets, electrical energy collection, fault recording, public measurement and control, telecontrol communication, relay protection, computer monitoring, intelligent auxiliary control systems, time synchronization systems, etc.
2.3 Power Routing
In terms of power routing, the 110 kV utility power incoming lines of Route A and Route B both enter from the 17-m-wide short side on the right. The two routes enter in parallel, with a spacing of more than 10 m, and are respectively introduced into the prefabricated GIS cabins corresponding to Route A and Route B. The lines from GIS to transformers for Route A and Route B, the busbars from transformers to 10 kV switchgear, and the outgoing lines of 10 kV switchgear are all independent, and the spacing is more than 10 m.
2.4 Advantages of Process Layout Design
The main equipment of the project, including prefabricated GIS cabins, 110 kV transformers, prefabricated main equipment cabins, etc., are all completely isolated between Route A and Route B. The power routing of Route A and Route B is completely isolated. Compared with traditional substations, it occupies less space, has a high degree of customization, is flexible and effective, and can meet the reliability requirements of data centers.
3. Prefabricated Cabin Technology
This project adopts a whole-station fully modular prefabrication method. On-site, only auxiliary facilities such as strip foundations and firewalls need to be constructed. The production and processing of modular prefabricated cabins can be carried out simultaneously with the civil engineering work, greatly reducing the amount of civil engineering work. It solves the problems of large civil engineering quantities and long construction cycles in the traditional substation construction mode, and avoids the situation where the substation construction time is restricted by civil engineering projects.
3.1 Cabin Technology
The prefabricated cabins are produced and debugged in the factory, ensuring exquisite product quality and a high-standard design implementation level, and avoiding the impact of on-site construction quality on the equipment. Structurally, the bottom frame components of the box body are connected by channel steel, and the door panels and top covers are welded with 2-mm-thick high-quality cold-rolled plates. It has an integral structure and strong impact resistance.
The characteristics of the box body are mainly reflected in three aspects: anti-corrosion, three-layer structure, and sealing, which can meet the basic operation requirements and ensure that each component maintains a stable working state. The outer shell needs to reach a protection level of IP54 or above. The prefabricated cabins adopt a full-working-condition design and also have good wind resistance, seismic resistance, and snow load resistance to ensure the safe operation of the equipment.
The equipment inside the cabin is highly integrated. Through the design of the cabin structure and the coordination of various internal systems, the prefabricated cabin meets the needs of equipment operation. The cabin not only takes into account the primary, secondary, and communication equipment of the 110 kV substation but also considers auxiliary systems such as environmental control, lighting, emergency lighting, fire protection, and grounding.
3.2 Cabin Transportation
The cabin needs to meet high requirements, mainly involving moisture-proof and sealing properties, otherwise, the operation quality cannot be guaranteed. Considering the restrictions on length and width for road transportation in this project, the length of each transportation unit is limited to within 14 m, the width to within 3.4 m, and the height to within 4.5 m. Prefabricated cabins with larger dimensions are transported in sections, and other prefabricated cabins with relatively smaller dimensions are transported as a whole, meeting the requirements of road transportation. If the site has reached the assembly requirements, it can be transported to the site for the next-step assembly .
3.3 On-Site Installation
This project adopts a modular prefabricated method, with less civil engineering work. The main civil engineering contents include two groups of newly built main transformer foundations, four firewalls with a length of 10 m and a height of 6.5 m, two groups of GIS cabin foundations, one group of main equipment cabin foundations, one 20-m³ accident oil pool, a 198-m-long and 2.3-m-high hollow enclosure wall, 14 main transformer supports, and an 80-m-long reinforced concrete cable trench.
The prefabricated cabins adopt a mode of "factory trial assembly must be carried out to simulate the actual operation situation + split transportation to the site and then splicing and installation" on-site. All modules have been trial-assembled in the factory, and problems are discovered in a timely manner without leaving problems on-site, ensuring the on-site construction period and construction quality. On-site hoisting and assembly have a short cycle, and there is almost no raw material accumulation.
For the splicing operation of large-sized cabin parts, the on-site splicing process of "using a crane to initially position the equipment + gradually pushing with a chain block + accurately positioning with a positioning pin" is adopted. To ensure that the splicing of the cabin is "tight-fitting," the on-site hoisting photo is shown in Figure 3.
In order to meet the sealing requirements, the splicing joints are reasonably designed, mainly using the design methods of sealing materials and mechanical structures. In the box body splicing, waterproof buckles and waterproof flanges are used. After the splicing is completed, strong waterproof glue needs to be added to the joint positions, and then treated with a sealing strip. Finally, waterproof buckles and foaming materials are installed in sequence. When all processes are completed and meet high quality requirements, sealing and waterproofing can be achieved.
After each module is in place, primary and secondary connection construction is carried out. The cables inside the modules and the connection cables between them have been completely produced and installed in the factory. Only the connection cables and busbars between each module need to be installed. When each module is assembled in the factory, preliminary joint debugging and testing have been carried out, which can also shorten the on-site debugging and acceptance time.
The 110 kV substation construction project of Data Center No.1 started to communicate the plan with the Suzhou power grid and promote the preliminary procedures in early December. After going through project bidding, equipment procurement, factory production, on-site equipment foundation construction, on-site assembly, equipment debugging, and power-on acceptance, it was officially put into operation in early June. The whole process took less than 6 months, of which the time from project bid determination to project completion and power-on acceptance was about 100 days, which is the project with the shortest substation construction cycle in the data center field. Therefore, compared with traditional substations, the construction time is greatly reduced.
In addition to these advantages, due to the adoption of the modular design concept, it can be efficiently upgraded when necessary in the future, which helps to reduce the costs of maintenance and expansion, so it also shows broad development prospects.
4. Conclusion
Prefabricated substations have addressed the pain points of traditional substations in the field of data centers.
Prefabricated modular substations represent a continuously evolving technology. Their construction aims to better serve the power grid and users. While ensuring safety, reliability, and economic efficiency, they fulfill the needs for rapid construction, space-saving, and reduced investment. It is believed that with the strong promotion of new infrastructure construction such as data centers by the country and the continuous maturity of prefabricated modular substation technology, more and more prefabricated modular substations will be completed and delivered in data centers in the future.
