CHAPTER 5: Electrical Substations 33KV & Below

2013

1. INTRODUCTION This document details type, site selection, layout and civil engineering requirements for 33kV and below electrical substations. This document must be read in conjunction with relevant Indian Standards. 2. TYPE 3. SITE SELECTION This section deals with physical factors of the proposed site that can significantly affect its viability as a substation location. These factors must be considered before a site is selected for construction of a substation. In addition to the factors listed below consideration should also be given at an early stage as to how the construction phase work will be undertaken, in particular the requirements of the Construction (Design and Management) Regulations. 3.1 Size and Shape The land should preferably be rectangular and open from more than one side and of suitable size and shape to accommodate the present and future needs. Care must be taken to ensure the land is suitable in all respects and that both existing and potential future uses of surrounding land have been considered. In addition suitable access must be available from the public highway. The access must be suitable for both day to day use, and also for delivery of large electrical items. 3.2 Ground Conditions A Geotechnical Ground Investigation Survey should be carried out to determine the following: 3.2.1 Substrata Nature and Bearing Capacity The properties of the existing ground can have a major and costly impact on ground working and foundations. Without knowledge of the ground conditions, foundation design and excavation requirements would have to be based on assumptions. If these assumptions are incorrect, any subsequent changes required will severely impact on cost and economic viability. In some cases where poor ground conditions are encountered, then specialist design and construction will be required, such as piling and de-watering. 3.2.2 Ground water levels A high water table might affect foundation design and construction. It may also impact on ground working methods which again can cause increased costs and

CHAPTER 5: Electrical Substations 33KV & Below

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construction delays. A high water table may also impact on cable laying requirements. 3.2.3 Presence of contaminants Contamination of land can lead to expensive clean up measures or to long term remedial / monitoring requirements. Contaminants may include: Asbestos Costly specialist removal. Heavy metals All excavated material removed from site will be classed as contaminated waste, the disposal of which carries a premium price. Presence of sulphates and other chemicals Use of special types of cements would add to construction cost. Oils Can migrate, via ground water, to adjacent properties and lead to the possibility of future litigation. Gas Either naturally occurring from ground conditions, or from previous uses of the land. In addition to cost and programme implications, the presence of contaminants may present potential health risks during both the construction stage and subsequent operation of the site. 3.3 Site Survey In order to achieve the most practical and cost effective site layout, a detailed topographic site survey should be carried out, ideally prior to the site selection. The site survey information will assist with the design and layout of the site, and will identify issues with ground levels and suitable access. 3.4 Flood Risk Electrical substations should be located and constructed at an elevation with regard to the potential flood risk at the site.

CHAPTER 5: Electrical Substations 33KV & Below

2013

4. SITE LAYOUT This section deals with the factors that need to be taken into consideration when designing the substation layout. The layout must take into account factors such as practical use of space available, operational requirements, safety requirements, and inspection and maintenance requirements. Before considering possible layouts, the following basic system information is required: Plant and equipment to be accommodated & maintained type, quantity and electrical safety clearances. Likely need for future expansion. Cables type, number & site exit/entry locations and directions.

The layout should be prepared using this information, together with the information available from section 3 above, to give a practical, safe, cost effective solution. 4.1 Operational Compound Where possible, substations at all voltages shall be designed with sufficient space to incorporate an additional transformer, and switchgear bay where required, at a later date. These requirements will be specified by Network Strategy at the planning stage. 33kV sites may be designed with 12/24MVA or 20/40MVA transformers. However the transformer foundations and bunds shall be designed to accept both 12/24 and 20/40 units. This will allow subsequent upgrading with minimum additional work. The above requirements may be relaxed where the substation is for a Customers use only and will not supply distribution load. In these cases the sites can be designed for the exact requirements of the Customer. When designing the compound layout, consideration must be given to the following factors: 4.1.1 Fire Safety Clearances The clear distance between transformers or between a transformer and any other oil-containing equipment shall be not less than 6m at 33kV. Where transformers are in noise enclosures this separation may be reduced but should be not less than 4m at 33kV. If this separation cannot be achieved then the provision of a fire barrier wall will be required. This structure shall have a minimum fire resistance of 2 hrs at 33kV. There shall also be adequate fire separation between the transformers and control buildings. This shall be not less than 6m. 4.1.2.3 Access & Maintenance All plant and equipment shall be provided with sufficient free space to permit safe operation and maintenance. Plant over 2.0m high (which will include all transformers) will require full access by powered mobile access equipment. Depending on compound layout and transformer orientation, vehicle access routes within the compound may be required. Spacing of equipment must be such that access for maintenance is possible with adjacent plant / circuits live.

CHAPTER 5: Electrical Substations 33KV & Below

2013

Consideration must be given to means of transformer installation and removal with the other transformer(s) live. The provision of removable compound fence panels (i.e., with bolt down posts) will usually be necessary. 4.1.2.4 Cable Routing Cables need to be as accessible as possible, in case of future faults, jointing, etc. Where cable runs beneath structures cannot be avoided they must be ducted. It is likely that cable/duct excavation and laying will not occur until after the structures have been completed. The potential risk of undermining and/or destabilising the structures must be considered when planning cable routes. If cable trenches are provided, then the trench and covers must be designed to support the appropriate applied loading. This may be pedestrian loading only, or the weight of any plant or vehicles that may need to pass over them for the purpose of equipment installation and/or maintenance.

4.2 Control Room Buidling All sites will usually require a building to house switchgear, control equipment, etc. The building shall be segregated from the main compound area. This can be achieved either by placing the building outside the compound fence area, or by placing the building within the security fence area, but providing a segregating fence between the building and the compound yard. Site specific assessment will be needed to identify exactly what is required. Exact layout will depend on site requirements, including an assessment of security issues. Buildings will consist of: Switchroom(s) for the indoor 11kV or 33kV switchgear. Separate control room for relay panels, batteries, ACDB etc. Store room. Toilet All rooms must have suitable segregation to meet fire protection requirements. Separate external access will normally be provided to each individual room; there must be no direct connecting doors between rooms.

4.3.1 Access Suitable access must be provided form the public highway to the substation site, and also within the substation site. All access roads must be suitable for the delivery of large, heavy substation items. In addition, consideration shall be given for the positioning of a crane to offload plant items, including transformers. For 33kV sites a minimum road width of 4.0 metres must be provided. These dimensions are for straight sections of road; bends will require either a greater road width, or provision for overhang of large equipment delivery vehicles. Exact requirements will depend on site layout and access route. Within the substation site a turning area shall be provided, suitable for a long wheel base panel van. Where feasible an area for the parking of two cars or vans, which does not

CHAPTER 5: Electrical Substations 33KV & Below

2013

block the main access, shall also be provided. This can either be part of the existing road layout or a separate area of hardstanding. The design of the junction of the substation access road with the public highway also needs careful consideration. Designs should take into account sight lines and space required for turning into / out of the access road. 4.3.3 Services In addition to requirements for cabling across the site (power and multicore cables), provision must also be made for other services. A water supply, surface water drainage (including interceptor), foul water drainage, and telecoms connection will usually be required.

CHAPTER 5: Electrical Substations 33KV & Below

2013

5.0 CIVIL ENGINEERING REQUIREMENTS 5.1 General All aspects of the civil works shall be designed to provide a low maintenance durable end product suitable for the purpose intended. Particular emphasis shall be placed on security of the site. Design life for structural elements shall be a minimum of 40 years. In accordance with the requirements of the Construction (Design & Management) Regulations the design of buildings and structures shall be carried out to ensure that construction, maintenance and demolition may be carried out in a safe manner. It is also important that any buildings are built to a high standard and that the finished building shall be designed to be aesthetically acceptable. The design of the civil works and the specification of civil materials shall take into account the environmental impact of all elements. Where possible, environmentally friendly materials and methods of construction shall be incorporated into the works. 5.2 STANDARDS All design and construction including all materials, testing and other procedures shall be undertaken in accordance with latest IEEE and IS. 5.3 BUILDINGS 5.3.1 General Buildings may be either: Brick / block construction with a variety of different roof constructions. Steel portal frame design with profile steel sheet cladding, and brick / block perimeter walls to a minimum height of 2.0 metres. Other proprietary design, such as a panel system, subject to the approval of Network Standards. Access to substation and apparatus shall be adequate for operational and maintenance purposes and provision shall be made for escape in the event of fire. The escape route shall be designed to be clear of any obstructions. Passageways and the minimum clearances between equipment shall be provided as per the requirement. Provision shall be made for entry of power, multicore, telephone and pilot cables, water supply and foul drainage pipes.

5.3.2 Walls All brickwork and blockwork shall be of a 1st class bricks in modular sizes to minimise cutting of bricks and blocks.

CHAPTER 5: Electrical Substations 33KV & Below

2013

All walls shall be constructed to give a durable, low maintenance, dust free finish. Walls shall be painted with smooth paint of light colour. The final coat of paint inside substation shall be applied after installation of electrical equipment. All brickwork and blockwork shall be laid in mortar of appropriate strength for the location and exposure of the wall. A DPC layer shall be provided in all walls at plinth level. Where expansion or contraction joints are incorporated they shall be constructed with approved joint filler and finished with appropriate coloured sealant. Expansion joints shall be so positioned as to coincide with Brick/Block modular sizes to avoid unnecessary cutting. 5.3.3 Floors Floors shall be of stone finish preferably of kota stone for easy cleaning and maintenance laid over RCC grade slabs and designed to withstand the weight of switchgear to be installed. A suitable skirting shall be provided around the room perimeter. The finished floor level will normally be a minimum of 900mm higher than the substation compound. Floors shall be sealed against dust prior to installation of equipment. 5.3.4 Windows and Ventilation Windows are not required for daylight conditions or ventilation in 11KV substations and shall not therefore be provided. Same shall however be provided in 33KV substations for adequate ventilation and natural lighting. 5.4 Earthwork / Foundations Any earthworks shall be carried out in accordance with the site requirement. General site fill material shall be imported graded granular material. All surplus spoil will be removed from site. An assessment of any imported fill material must be made to ensure it is compatible with the earthing requirements of the site. Suitable measures to mitigate unsuitable or contaminated ground conditions shall be adopted by the contractor. Measures may include removal or in situ treatment of the ground or containment. All such works shall be conducted in accordance with procedures approved by the relevant environmental authorities. Foundations and other below ground constructions shall be designed to resist chemical attack from ground contaminants. Excavations for foundations shall be taken down to such depths as to provide a solid foundation suitable for the loading to be applied. Foundations shall be taken down to sufficient depth to avoid being undermined by cable trench excavations. Foundations shall be of a type to suit the ground conditions and shall be designed such that long term differential settlement is kept within acceptable limits for operation of the electrical substation and apparatus.

5.5 CONCRETE

CHAPTER 5: Electrical Substations 33KV & Below

2013

All structural concrete for work below ground level shall meet the requirements for sulphates as identified for each particular site. In addition suitable measures must be taken to avoid the risk of alkali-silica reaction. The minimum grade of structural concrete shall be in accordance with IS456. 5.6 FORMWORK AND REINFORCEMENT All concrete surfaces except top surfaces shall be constructed using suitable formwork of a quality and strength necessary to obtain true surfaces with a fair face. Formwork ties will not be permitted to pass through oil bund walls or exposed structural concrete. 5.7 CABLE DUCTS / TRENCHES All cable ducts and trenches shall be designed to cater for specified future requirements and shall be of suitable construction to sustain all stated applied loadings. The preferred option is to lay all power and multicore cables with suitable tray arrangement inside RCC or brick trenches. Beneath roads these shall be encased in suitable duct arrangement with RCC hume pipes embedded in concrete. When laying cable ducts the opportunity shall be taken to lay additional spare ducts for potential future use. This is particularly advantageous beneath access roads or foundations. The outside trench covers shall be of precast RCC with suitable edge protection and shall be designed to carry the applied loadings and to be capable of being removed easily without a risk of compound chippings falling into the trench/trough. Internal cable trenches shall be provided with removable covers in 6mm thick chequered plates (with suitable lifting hooks). Covers shall be designed for easy removal and reinstatement, and shall be of manageable dimensions and weight. Trench designs shall incorporate suitable access arrangements including ladders, step irons and hand rails where appropriate. Bases of cable trenches shall be laid to falls and shall include suitable drainage provision. Where possible the drainage points shall be connected to the site surface water drainage system. Where water ingress is considered possible, cable trenches within buildings shall be fitted with drainage gullies connected to the storm drainage system, or with a sump and automatic pump. All ducts passing into buildings shall be sealed to prevent ingress of water and vermin. 5.8 SITE SURFACING All newly developed or re-developed areas of substation compound shall be stripped of all topsoil and vegetation and subject to anti-weed treatment. The finished and treated are shall then be resurfaced with a low maintenance finish suitable for easy access for maintenance of equipment. This layer will also act as an electrical insulator to minimise touch and step potentials during electrical fault conditions.

CHAPTER 5: Electrical Substations 33KV & Below

2013

This finish shall be a 150mm thickness of 20mm single size granite, basalt or carboniferous limestone chippings laid on a base of well compacted cement concrete in brick ballast 100mm in thickness. Site surfacing and base shall not be laid until after installation of all cables and electrical equipment on a well compacted and leveled formation. Areas outside the compound but within the boundary fence shall generally be finished in accordance with the compound requirements above. However on some sites there may be a planning requirement for landscaping which will replace some of the stone chipped areas. All landscaping shall be designed to avoid future problems with overhead lines, buried services, etc. and must have minimum maintenance requirements. INTERNAL ROADS AND DRAINAGE Roads shall be designed to suitable horizontal and vertical alignments to meet the requirements in the Site Layout. In particular vertical alignments shall avoid sharp gradient transitions. Gradients shall be kept to a minimum and will usually be determined by drainage requirements. Roads shall generally have drains running along to capture any water flows and avoid any water stagnation. Suitable concrete access paths shall be provided with non-slip finish. Substation roads which will be used for moving of heavy items of substation shall be designed to cater for transformer delivery vehicles. The design of the drainage system must take into account the loadings which may be applied from heavy vehicles such as transformer delivery vehicles. Suitable waste pipes and drainage gullies shall be provided to take away the condensate from dehumidification equipment. It is essential to ensure that all cable ducts and other services which are to be laid under substation roads are in position before construction of the road commences. 5.9 SECURITY All sites shall be risk assessed to determine what security measures are appropriate. The minimum requirement for all sites is to have boundary wall high enough so as to prevent climbing with concertina coil and RBT fencing running over the wall and compound access gates with guard bars. The risk assessment will determine what type of boundary fencing is appropriate and also if further measures are required. Provision of a guard room shall be made to station a guard for round the clock vigil. Substation buildings shall be located, where possible, so they are inside a secured compound. If due to space constraint a substation building forms part of a security perimeter of a site, then additional measures shall be considered to ensure adequate protection. In particular walls shall be smooth faced without climbing aids, and rainwater pipes etc. shall be positioned inside the premises, or protected by anti-climb measures to prevent unauthorized access. RAINWATER HARVESTING