Substation Engineering and Design
Substation Engineering and Design
4.0 GROUNDING
4.1 Substation Grounding 7-9
9.0 COMMUNICATION 13
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12.2 Protection Scheme 16
12.3 The Control Department 16
12.4 Overhead Lines 16
12.5 Handing Over 16
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TRINIDAD AND TOBAGO ELECTRICITY COMMISSION Page 1 of 16
SOP # ES&P 4121 Revision:0 Prepared by: _____________
Effective Date: Approved by: ____________
Policy: The design phase is the most important phase in the life cycle of a product. The
inherent quality, effectiveness, safety and customer satisfaction of a product are
established during this phase. No matter how carefully a product may be
manufactured or how perfect the quality control program, these inherent qualities
cannot be improved except through design enhancement. Therefore, it is crucial
that adequate planning and controls be established, implemented and maintained
during the design phase to assure that the quality, effectiveness, safety and
customer satisfaction of a product are optimally enhanced prior to manufacturing.
- Performance of normal and worst-case testing to evaluate and assure that the
product design and manufacturing processes will perform as intended under
all reasonable circumstances.
Purpose: To outline the steps for the planning, development and review of new products.
Scope: This statements applies to all new product developments and significant changes
to existing products.
SUBSTATION ENGINEERING AND DESIGN Page 2 of 16
Definitions: Failure Mode and Effects Analysis - Failure Mode and Effects Analysis (FMEA)
is an evaluation technique for testing the design of products in which failures are
assumed to occur. FMEA is useful for evaluating reliability, safety and general
quality where, for example, the evaluator assumes that:
The probability of each failure actually occurring and, if it does, the resulting
effect are analyzed. Then, where needed and feasible, hazards and faulty
performance are designed out of the device; or compensated or prevented/reduced
by interlocks, warning signs, explicit instructions, alarms, etc. Risks cannot
always be removed from products, but they should be known and controlled to the
extent feasible with existing technology.
Procedure:
The need for a substation arises from system studies in System Planning or from the
establishment of new customers. In the case of system development, the general area for
the substation site is given. A single line diagram is developed following which a
preliminary layout of the substation is done to determine the approximate land size
required. At this time, the supply voltage, the number of feeds and load capacity are
finalized. This layout is done for the substation’s ultimate requirements. Investigations
are then carried out in the region for a suitable substation site.
In the case of a customer driven substation, the customer provides a site for the substation
to interface at the Point of Supply, usually at an Isolator. Substations are located at the
boundary of the Customer property preferably with independent access to the site.
Coordinating meetings with all stakeholders are held regularly.
The nominal supply voltages from the National grid are 132kV, 66kV, and 33kV. The
traditional substation design approach is to follow the tried and proven designs. However
new substations often require different busbar configurations, which in turn require
busbar design calculations as shown in section 3.
Traditional substation design caters for circuit breakers controlling the entry of power
into the substation. Each circuit breaker has an isolator on either side of it. Power from
the lines flow into a Bus, from which Load is supplied. The level of reliability required
determines the configuration of the switchgear, the higher the required reliability, the
greater the amount of circuit breakers, isolators and also the cost of the substation.
Figures 1, 2 and 3 show the commonly used switching arrangements, while figure 4
shows a layout for a typical substation with required clearances. This layout can be
modified to achieve bus configurations required.
The standard layout utilizes copper tubing for busbars, although there are stranded
bus substations as well. In stranded type substations, the supports for the
conductors, the space requirement, the type of structures and the type of
equipment are different from copper tubing busbars.
Indoor substations occupy less space than outdoor type and are mostly used where
available land for substation construction is minimal or expensive. It can also be
used where the environment is very unfriendly
The power supply to such a substation is via cable and the cable route and
trenches must be designed to cater for cable bending radius. Special
arrangements have to made by the switchgear manufacturer for the termination of
these cable onto the circuit breakers. Special lightning arresters must also be
ordered for the protection against surges.
Table 1
The adopted busbar design methodology based on IEEE Std. 605-1998 is explained
below. This design procedure is not intended for busbar design below 33kV.
3.1 Ampacity
The capacity requirements for the bus conductor are usually determined by either
the electrical system requirement or the ampacity of the connected equipment.
Normal T&TEC design utilizes, either 38mm or 76mm diameter copper busbars.
The standard current rating for the 38mm busbars available from stock is 800Amp
and 1200Amp, while the standard available rating for the 76mm busbars is 1500
Amp. The Design Engineer establishes the required current ratings and either
matches it to the standard available stock, or acquires new busbars of suitable
rating.
Damage to busbars may be caused by fatigue due to excessive fibre stress due to
vibration. Calculations are done to determine the Natural frequency of the busbar.
Either alternating current or wind may induce vibrations in a busbar with
frequencies near the natural frequency of the bus conductor. If twice the natural
frequency of the bus span is greater than the Aeolian force frequency, the either
the bus span length may be changed or dampers can be added to the busbars.
Gravitational forces determine the vertical deflection of the bus conductors and
are a component of the total force, which act on the busbars. These forces
normally comprise of the weight of the conductor and dampers (if present).
The bus structure is designed to withstand the forces due to winds. In T&TEC the
design wind speed is now taken to be 43 m/s. Consideration should be given to
the height above the ground of the busbars. Other factors which affect the wind
forces are wind gust, busbar shape, diameter and exposure of the conductors.
Busbars are designed to withstand forces produced by magnetic fields due to fault
currents. Calculations show that this force overshadows the other forces
previously discussed. This force is dependent upon conductor spacing, fault
current, degree of asymmetry, structure flexibility, corner and end effects.
Busbars must have enough strength to withstand the forces of gravity, wind and
short circuit to maintain its mechanical and electrical integrity. The span should
also not sag excessively under normal conditions.
FG=Fc+FD
4.0 GROUNDING
A substation system consists of a copper grid buried in the soil. In T&TEC, the
practice is to construct the grid from 4/0 copper. All joints buried in the ground
should be made exothermically. Copper clad, 2.44 metre foot ground rods are
placed on the perimeter of the grid at all joints, while 4.88 metre ground rods are
installed at power transformers, lightning rods and all line terminal structures.
Designing the grid generally consist of determining the required length of copper,
the number of ground rods and the spacing of the copper conductor.
Grounding design in T&TEC follows the IEEE guide for Safety in AC Substation
Grounding, IEEE std. 80, the latest revision being in 2000. The design engineer
performs the calculation manually, or can use a T&TEC “In-house” program to
perform the calculations. Generally the latter is followed as the design is much
faster and alternatives can be easily evaluated.
Using the four pole Wenner method, determine the soil resistively, s. A detailed
description of the method of use can be found in the inside cover of the
“Vibroground Test set” or in manuals found in the ES&P department.
Determine the suitable conductor size. In T&TEC, generally 4/0 copper is used
as the minimum size for substation grounding. Calculations must be performed to
verify its adequacy using the following equation:
197.4
Akcmil = I
TCAP K +T
ln o m
tcα r ρ r K o + Ta
Where:
Where: Estep70 and Etouch70 are the maximum tolerable step and touch voltages
Design a preliminary grid consisting of a conductor loop around the entire area,
plus adequate cross conductors to provide convenient access for equipment
grounds. The spacing between conductors should be as even as possible and
should not be less than 2.5 metres. Ground rods should be located at joints on the
perimeter conductor, at transformer neutrals, lightning masts and at the base of
surge arresters on the terminal structures.
1 1 1
Rg = ρ + 1+
LT 20 A 1 + h 20 / A
Whereρ is the soil resistivity
L is the total length of conductor
h is the depth of burial
Calculate the Grid Potential Rise, GPR. If the GPR is below the tolerable Touch
Voltage, no further analysis is required. Only the conductors required to connect
the equipment to the grid, the pigtails are to be added.
If the computed mesh voltage is below the tolerable touch voltage, the design is
complete. If the computed mesh voltage Em
Ρ ⋅ IG ⋅ Km ⋅ Ki
Em = is greater than the tolerable touch voltage, the design must
LC + LR
be revised by adding more copper. This is usually done by reducing the design
spacing or by adding ground rods. The Area covered by the grid can also be
incurred.
A satisfactory design is obtained when both the mesh voltage and the Es step
voltage are below the tolerable values.
ρ ⋅ IG ⋅ Ks ⋅ Ki
Es =
0.75 ⋅ LC + 0.85 ⋅ LR
A drawing is then prepared showing the conductor location, ground rods, pigtails
and fence earthing.
Based on the design, the exothermic joints, molds, tools and jumpers are ordered.
Inclusion of the fence within the ground grid area. Under this philosophy, the perimeter
conductor of the grid will parallel the fence at a short distance of 1.0m outside. The
crushed rock covering will also be required outside the fence.
Placement of the fence outside the ground grid area with close electric coupling between
fence and adjacent earth along its length, but with no electrical tie between the fence and
the main station grid. This method is to be applied when the distance between the ground
grid and the fence is greater than 2.5m and is preferred.
In either case, the perimeter ground conductor and fence should be bonded at frequent
intervals approximately every other 7 meters. Exothermic joints are used for constructing
the system.
There are two preferred methods for designing substations against lightning strikes
adopted by T&TEC. The design utilizing the empirical curves are employed for 33kV
and 66kV Substations, while the Electromagnetic model is preferred for 132kV
substations. The methods adopted for protecting substations against lightning strikes
utilizes lightning masts.
The substation equipment is laid out and drawings for the General arrangement
and elevations are prepared. The design assumes that masts are used at some
Central location within the substation. Generally, it will be located at a point of
symmetry within the substation, commonly in the vicinity of the bus section. The
data required for the calculations include the heights of tallest equipment to be
protected within the substation and the horizontal separation from the mast.
Using this data, the required height of the mast is determined from the graphs.
All substation equipment is then examined to ensure that no section sticks out
form the area of protection.
The Rolling Sphere method is adopted for this design. The procedure consists of
rolling an imaginary sphere of radius S over the surface of the substation. The
sphere rolls up and over (and is supported by) lightning masts, shield wires,
substation fences, and other grounded objects that can provide lightning shielding.
Equipment which remains below the curved surface created by the path of the
surface of the rolling sphere will be protected. Equipment which rises above this
path is not protected. The parameters of the sphere are as follows:-
Step 1:
Rc In [2h]=Vc
Rc 1500kV/m
Step 2:
Step 3:
Step 4:
Sm = 8 k I 0.65
Lightning masts are located at strategic points to ensure that all parts of the
equipment to be protected are within the zone of protection.
I=Is/2
At these points, the voltage will double. Surge arresters should be incorporated at
the bushings of transformers to minimize this effect.
In the preliminary stages of the design, a list of the major equipment is complied. Steps
are then taken to acquire all major equipment. A project schedule is prepared and
procurement done to in a manner to ensure the timely arrival of equipment for
construction. The Protection & Meter Department, the Control Department, the
Distribution Subdivision and the Supplies Department must be notified of deadlines and
material procurement must be coordinated to achieve set deadlines.
The non-stock materials are procured by the Engineering Services and Planning
department, with technical advice provided other departments as required. The
major non-stock items required comprise:-
Transformers, Circuit Breakers, Exothermic joints, molds and accessories,
Ground rods, Steel structures, nuts and bolts
The single line diagram must be finalized and provided to the Protection and Meter
Department early for design work and equipment procurement and preparation of the
specification for the current transformers. Project scheduling also has to be done to
facilitate simultaneous work required to be done by staff.
9.0 COMMUNICATION
Adequate security lighting must also be determined for the substation. The minimum
lighting level recommended is two LUX as is common internationally. However,
additional lighting is usually requested for security reasons at strategic locations.
Based on the area of the substation and the lighting level recommended, the Wattage of
the lights is determined. The manufacturer’s manual is consulted to obtain the
specification for the luminaries and the appropriate number of lamps is then decided.
The design engineer positions the lamps to provide uniform lighting level throughout the
substation. The switchyard and gates are special locations where operating personnel
request extra lighting due to security concerns. The mounting for the luminaries must be
determined and provisions made in the drawings, and must be included in the civil scope
of works. The switchhouse and the lighting mast are choice candidates for the mounting
of luminaries.
Some substations require lighting around the fence. This is expected to act as a deterrent
to Vandals.
T&TEC substations usually are designed with a switchhouse to house equipment, which
are not designed to be exposed to the weather. The switchhouse must be suitably located
to avoid the threat of flooding. The switchhouse normally has a concrete roof and is
constructed form concrete/blocks. The doors are made from steel and those, which are
installed in rooms, which are not air-conditioned, have louvers to provide ventilation.
The rooms, which house high-voltage switchgear, must have at least two exits and the
rear door must have “Panic Bars for emergency exiting”. All doors must be adequately
sized to allow equipment movement.
1. 12kV room in which to install the 12kV switchgear. Not all substations need 12kV
switchgear and therefore this room is optional. A drawing from the manufacturer
will provide details of the size of the equipment. Sufficient room, normally one
metre must be left at the back and sides of the switchgear. Some types of 12kV
switchgear are withdrawn able and space equivalent to the depth of the switchgear
plus space for switching personnel to operate (normally one metre) must be left at
the front. The Manufacturer’s drawing must be consulted to ensure that the front
doors can be opened freely. The trench must be accurately sized to support the base
of the switchgear.
2. Control room in which to install the protection equipment. This room will contain
the protection panels, which house the protection relays, switches, meter etc. The
trenches must be accurately sized to support the protection panels. Trenches musts
be designed to provide cable access to the equipment to which the cables must be
connected, the switchyard, the battery room, the communication room, the main a.c.
115/230 Volt power panel. There must be room at the back of the panels to allow
technicians to work freely; normally 1 metre is adequate. The Protection design
engineer must be consulted to determine the number and size of protection panels,
which will be required in the room, including future panels.
3. Battery room. This room is standard and is used to house the battery and charger,
which provides a D.C. supply for the circuit breakers and protection equipment. On
the walls of the room, the distribution panel for the D.C. supply is installed. The
size of this room is usually at least 2 metres X 3 metres, but the final design should
be done in conjunction with the battery Manufacturer’s drawing ensuring adequate
space. The battery room should be air conditioned to maximize the life of the
battery. Ducts must be installed to the main cable trench to access the Control
room.
4. Toilet and Storage Room. It is customary to provide a toilet in switchhouses for use
by operating and maintenance personnel.
5. House supply. It is required that an A.C. 115/230 Volt supply be provided in the
switchhouse. The Transmission & Distribution Department should be consulted to
determine the direction from which this supply can be taken to determine the Point-
of-Entrance (POE) on the building. In some cases, the house supply will be
provided directly from the switchgear panel, in which case no POE will be required.
The A.C. panel should be sized to provide sufficient A.C. cables to cater for
Protection requirements. The A.C. panel is normally located close to the POE, and
as close to the Control room as possible. The Protection Design Engineer and
Electrical supply shops should be consulted to finalize the Panel size. Spare
breakers must be provided.
8. Lighting. All rooms should have adequate lighting to allow personnel to operate
effectively. The lights should where practical, be located to light up both the front
and back of equipment, such as protection panels and 12kV switchgear.
9. Trench covers. All trenches must be neatly covered with trench covers flush
to the final finished flooring. These covers should be made up in sections
which are easily removable, but which fit snugly over the trenches in lips.
All Isolators and circuit Breakers are operated to ensure smooth operation.
All Commissioning tests are done on the Circuit Breakers. The resistance
of all joints are measured and recorded.