CHAPTER 21:

Uprating And
Expanding Existing
Substations
 Applicability
Modern practice requires that certain environmental and safety issues be
addressed in any substation uprating or expansion project, even though the
existing substation may not have been designed with such issues in mind.
Seismic criteria for the area of installation have to be considered. A suitable
oil spill prevention plan, possibly including oil containment facilities, has to
be implemented. Fire protection methods (including physical separation,
barrier walls, and sprinkler systems) should be weighed against the safety
concerns and the costs of fire insurance to arrive at an appropriate design.
Several other environmental issues should be considered, as applicable:
noise abatement, aesthetics, disposal and containment of hazardous
materials, and containment of electromagnetic fields.
 Feasibility
Cost is usually a primary factor when determining a course of action:
construction of a new facility versus uprating and/or expanding an existing
facility. Prepare construction cost estimates for the schemes under
consideration. Generally choose the plan with the most favorable cost/benefit
ratio, provided that such action is consistent with the near- and long-range
system plan.
With facility expansion or new construction, include in cost estimates
potential impacts due to underground obstructions and environmental concerns.
 Major Equipment Uprating

Power Transformer Bus System

Oil Circuit Breaker
Current Transformer (CT)
Wave Trap
Coupling Capacitor Voltage
Transformer (CCVT)
Voltage Transformer (VT)
Disconnecting Switches
Surge Arresters
Raceway System
Auxiliary Systems
Relaying and Metering
 Substation Expansion
Substation expansion is the addition of transmission,
subtransmission, or distribution circuits to existing substations. These
additional circuits may be required on the primary or secondary side. In
some cases modifications to the switching scheme may be necessary or
desirable. At the same time, capacity may be increased with the
installation of an additional transformer(s). Figure 21-1 shows a substation
expansion adding 69 kV line, a 69/12 kV transformer, and a 12 kV
distribution structure to an existing substation consisting of 69 kV line, a
69/34.5 kV transformer, and a 34.5 kV distribution structure.
 Substation Expansion
Other Consideration in Substation Expansion
Site Work
Grounding
Raceway System
Control House
Equipment
 Equipment
Bus System: Make a conservative estimate of expected fault currents at the
higher voltage level and establish the bus BIL along with ground clearances to
personnel, roads, and fencing. Following the methods outlined in other chapters,
design the bus and insulators at this level taking into account contemplated full
load bus current.
Transformers and Circuit Breakers: The selection of transformers and circuit
breakers together with their associated isolating switches is detailed in other
chapters of this guide. Specify this equipment for the operating voltage. Design
foundations and switch structures for the higher, future voltage. When the higher
voltage becomes a reality, cutover will be more orderly and less time-consuming.
Specify disconnecting switches with the phase spacing of the higher level.
 Equipment
Carrier Equipment, Surge Arresters, and Voltage Devices: Specify this equipment
at the operating voltage. However, foundations and supporting structures can and
should be designed for the higher voltage for the reasons set forth previously.
Auxiliary Systems: Check and possibly revise or increase in capacity several
equipment items in the auxiliary systems to successfully expand an existing substation:
1. Auxiliary transformer capacity
2. Throwover switch ratings, full load and momentary
3. Low-voltage ac and dc panel circuit capacity and adequacy of mains
4. Low-voltage switchgear circuit capacity
5. Battery and charger capacity
 Planning For Uprating
Or Expansion
All programs involving substation construction require planning.
The trend is toward assessment of existing substations and individual equipment to
develop a predictive maintenance and substation life extension program. This approach
implements a planned program for evaluating substation components and making
modifications or individual equipment replacements to improve reliability and extend the
overall substation life.
Reliability analysis is being implemented in many maintenance programs to assess the
probability of failures and prioritize modifications based on safety, economics, obsolescence,
and power quality.
Maintenance planning should be a part of the early stages of uprating or expansion
projects. Such planning includes visual inspections, periodic testing, maintaining of spare
parts inventories, logging of equipment test results, and logging of misoperations and
maintenance records.
 Planning For Uprating
Or Expansion
Consider safety issues during the planning stages of any project. Provide and
maintain proper tools, personnel protective equipment, safety procedures, and safety
training.
A Critical Path Method (CPM) or similar method is recommended for scheduling
the actual uprating or expansion activities. Include the detailed activities of
engineering, material specification, procurement, manufacturing, and delivery times
together with itemized construction activities. The construction work may need to be
performed in phases to minimize outage time on particular circuits. Plan required
service outages to cause the least revenue loss and customer inconvenience. Factor
into the program adequate time to account for contingent delays that can and will
occur. Inform customers of forthcoming service outages so they can plan their
activities around the outages.
 Substation Upgrading
Bus System: Make a conservative estimate of expected fault currents at the
higher voltage level and establish the bus BIL along with ground clearances to
personnel, roads, and fencing. Following the methods outlined in other chapters,
design the bus and insulators at this level taking into account contemplated full
load bus current.
Transformers and Circuit Breakers: The selection of transformers and circuit
breakers together with their associated isolating switches is detailed in other
chapters of this guide. Specify this equipment for the operating voltage. Design
foundations and switch structures for the higher, future voltage. When the higher
voltage becomes a reality, cutover will be more orderly and less time-consuming.
Specify disconnecting switches with the phase spacing of the higher level.