SUBSTATION DESIGN MANUAL CHAPTER 17 Substation Layouts and Facilities - Outdoor Power & Water Corporation Power Networks

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Substation Design Manual Chapter 17 Substation Layouts and Facilities Outdoor

Document Number D2010/287838

Document Control Revision History Title Section Document ID Prepared Reviewed Substation Design Manual Substation Layouts and Facilities Outdoor D2010/287838 Hydro Tasmania Consulting Hydro Tasmania Consulting 09/10/2009 09/10/2009

Revision

Revision Date 09/10/2009 4/12/2009

Details

Authorised Name / Position Signature

Draft Final Draft

For client review and input Revised following client comments Brendon Gannon Specialist Engineer Doc No & Doc Id Inserted SLD Initial & Ultimate Drawing Nos inserted Reference Docs [38] to [41] Doc Nos added 17.2 second last paragraph switchyard added, last paragraph of the 11kV Switchboard added 17.7 changed to aggregate shall be installed 17.8 last paragraph added Revised to suit client comments

Rev 1

2/11/2010

Greg Brand Manager Contracts & Projects

Rev 2

17/01/2012

Luke Whitehouse/ Entura

Changes made to this manual since the last revision are highlighted in yellow.

Disclaimer The information contained in this document has been carefully compiled but Power & Water Corporation takes no responsibility for any loss or liability of any kind suffered by any party, not being the intended recipient of this document, in reliance upon its contents whether arising from any error or inaccuracy in the information or any default, negligence or lack of care in relation to the preparation of the information in this document.

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Reference documents Documents listed below are relevant to this chapter of the Power & Water Corporation (PWC) Substation Design Manual. Each reference shall be followed by its list number E.g.: [1]. Any listed reference which has a later edition will take precedence unless indicated otherwise.
[1] [2]

AS 2067 ESAA ENA EG1 ESAA AS 1940 ESAA (series) IEEE 980 AS 1379 AS 1478.1 AS 3600 AS 3610 AS 3799 AS 3972 AS/NZS 4671 AS 1726 AS/NZS 3725 AS 1597.2

Substations and high voltage installations exceeding 1 kV a.c. National Guidelines for Prevention of Unauthorised Access to Electricity Networks Substation Earthing Guide Substation Earthing Guide The storage and handling of flammable and combustible liquids Guidelines for Oil Containment in the Electrical Supply Industry IEEE Guide for Containment and Control of Oil Spills in Substations Specification and supply of concrete Chemical admixture for concrete, mortar and grout - Admixtures for concrete Concrete structures Formwork for concrete Liquid membrane - forming curing compounds for concrete Portland and blended cements Steel reinforcing materials Geotechnical site investigations Design for installation of buried concrete pipes Precast reinforced concrete box culverts - Large culverts (from 1500 mm span and up to and including 4200 mm span and 4200 mm height) Precast concrete access chambers for sewerage applications Aggregates and rock for engineering purposes (Series) Degrees of protection provided by enclosures for electrical equipment (IP Code) Control of the obtrusive effects of outdoor lighting

[3] [4] [5] [6] [7] [8] [9]

[10] [11] [12] [13] [14] [15] [16] [17]

[18] [19] [20]

AS 4198 AS 2758 AS 1939 AS 4282

[21]

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[22] [23] [24]

AS/NZS 3000 IEC 61936-1 AS/NZS 2312 AS/NZS 2373 AS 2650 AS 2870

Electrical Installations - Wiring Rules Power Installations exceeding 1 kV a.c. Part 1: Common rules Guide to the protection of structural steel against atmospheric corrosion by the use of protective coatings Electric cables - Twisted pair for control and protection circuits Common specifications for high-voltage switchgear and controlgear standards (IEC 60694) Residential slabs and footings

[25] [26]

[27] [28]

AS/NZS 3008.1.1 Electrical Installations - Selection of cables - Cables for alternating voltages up to and including 0.6/1 kV - Typical Australian installation conditions AS/NZS 3947.3 AS 4100 AS/NZS 61000 AS 62271.200 Low voltage switchgear and controlgear - Switches, disconnectors, switch-disconnectors and fuse-combination units Steel Structures Electromagnetic compatibility (Series) High-voltage switchgear and controlgear - A.C. metal-enclosed switchgear and controlgear for rated voltages above 1 kV and up to and including 52 kV (IEC 62271-200, Ed. 1 (2003) MOD) High-voltage switchgear and controlgear - AC insulation-enclosed switchgear and controlgear for rated voltages above 1 kV and up to and including 52 kV High voltage switchgear and controlgear - Dimensional standardization of terminals HV switchgear and controlgear - use and handling of SF6 in HV switchgear and controlgear Lightning protection Chapter 1 - 11 or 22 kV Metal Clad Switchgear Chapter 6 - HV Cables and Conductors Chapter 15 - Earthing Chapter 19 - AC Supply Chapter 25 - Substation Signage Chapter 28 - Security Chapter 30 - 66 kV Gas Insulated Metal Enclosed Switchgear

[29]

[30] [31] [32]

[33]

AS 62271.201

[34]

AS 62271.301 AS 2791 AS/NZS 1768 D2010/287823 D2010/287831 D2010/287859 D2010/287840 D2010/287847 D2010/287851 XXX

[35]

[36] [37] [38] [39] [40] [41] [42] [43]

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Table of Contents 17.1 17.2 17.3 17.4 17.5 17.6 17.7 17.8 17.9 17.10 17.11 17.12 Single Line Diagram - Initial Development ................................................................. 6 Single Line Diagram - Ultimate Development ............................................................. 7 Fencing and Gates ................................................................................................... 7 Switchyard Lighting ................................................................................................. 8 Switchyard Civil Works ............................................................................................. 8 Ducts and Trenches ................................................................................................. 9 Transformer Bunding ............................................................................................. 10 Oil Containment .................................................................................................... 10 Fire Walls ............................................................................................................. 11 Transformer Spacing ............................................................................................. 11 Switchyard AC Supply ............................................................................................ 12 Fire Protection ...................................................................................................... 12

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17.1

Single Line Diagram - Initial Development

The typical initial development single line diagram of the substation is shown in the drawing B10-12014. The 66 kV plant shall be an outdoor air insulated switchyard arrangement. The initial development shall comprise: Two (2) 66 kV line circuits A single 66 kV busbar with two (2) 66 kV bus section circuit breakers and disconnectors to form three (3) bus sections, Bus A, Bus B and Bus C Two (2) 66/11 or 66/22 kV power transformers, with provision for a third transformer

For further details on 66 kV indoor Gas Insulated Metal Enclosed Switchgear refer to [43]. The 11 or 22 kV plant shall be an indoor metal clad switchboard arrangement. For further details refer to [37].Initial development shall consist of a single busbar with two (2) sections. Each 11 or 22 kV bus section shall have: o o o o One (1) incoming circuit breaker Five (5) outgoing feeder circuit breakers One (1) capacitor banks circuit breaker One (1) auxiliary transformer/outgoing feeder circuit breaker

One (1) bus section circuit breaker on the right hand side of each bus when viewed from the front

A cable connection chamber shall be installed at the left hand end of Bus 1, when viewed from the front, to facilitate future connection of ring bus cables.

As w ell as the above requirem ents there m ay also be a need to supply facilities to connect a Nom ad substation in the event of a transform er and equipm ent failure. R efer to the scope of w orks for further details.
The designer shall consider all aspects of civil and primary construction and installation of the future equipment in the design as described in section 17.2. The initial substation design shall not impede on the ease of the installation of the future equipment.

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17.2

Single Line Diagram - Ultimate Development

The typical single line diagram of the ultimate substation is shown in drawings B10-12015 and B10-12016. Provision for installation of a third incoming transmission line and a third 66 kV transformer shall be made as indicated on the SLD. This will enable PWC to increase the capacity of its substation with minimal disruptions to the operation of the existing equipment. The designer shall consider the construction of transformer foundations, bund walls and all the other components of the transformer circuit. The space allowed on site for the future equipment shall be sufficient to install equipment of the same type as the equipment being installed.

Foundations for future sw itchyard equipm ent form ing part of the ultim ate developm ent shall not be installed unless called for in the scope of w orks for the specific project.
Ultimate development of the 11 or 22 kV Switchboard will include the installation of a third bus section (No. 3) and connection of cable from this section to No. 1 section to form a ring bus.

17.3

Fencing and Gates

Due to the high voltages within the PWC substations, any access by unauthorised personnel can result in loss of life or serious injury and damage to plant items. To prevent unauthorised access PWC substations shall have adequate fencing and locked gates. Refer to AS2067 [1] Section 5.2. An emergency door/gate shall be provided adjacent to the main gate for the use in emergency evacuation. This door shall have a quick release button that can only be activated from the inside and shall not allow personal to enter into the site. All security fences and gates shall be designed in accordance with [1] and [2]. To reduce the risk associated with step and touch potentials during a fault, fences and gates shall be earthed to the main earth grid in accordance with [1], [3], and [4]. The type of fence shall be TG/CE anti climb, 4 barbed cyclone fence.

Other security m easures shall be selected in accordance w ith the criteria set out in the scope of w orks for the particular site , also refer to [42] for further details on
substation security.

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17.4

Switchyard Lighting

Switchyards and substations shall have sufficient lighting to allow personnel to move around the switchyard and operate equipment safely at night. The designer shall perform lux level calculations to ensure that 20 lux is maintained throughout the switchyard at ground level. Additional lighting shall be provided at places where particular hazard existed such as stairs or step changes in ground level. The outdoor lights shall be of industrial type, and illumination shall cover the entire switchyard area and the property boundary fence. The lighting shall be designed such that the light spill does not disturb neighbouring areas. Substation yard lights shall have High Pressure Sodium bulbs and a minimum of IP56 rating and comply with [20] and [21]. If hinged mast lights are used, the designer shall ensure that the light does not impinge on the clearances around any of the equipment while in motion. The outdoor lighting shall not be on a single circuit. Lighting shall also be on a separate circuit to the outdoor GPOs. Switchyard lighting shall not be mounted on lightning protection masts.

17.5

Switchyard Civil Works

For full description of site civil requirem ents refer to project specific technical docum entation and scope of w ork.
The civil works that shall be undertaken for construction of new substations or switchyards shall cover, but not be limited to: Full geotechnical investigation shall be performed at all new sites in accordance with [15] Permanent datum points shall be installed on the site based on geotechnical investigations The site shall be cleared of any vegetation and other materials Earth works Slopes, crowns and ditches shall be excavated and filled to ensure satisfactory storm water drainage of the site. The installation and design of pipes, culverts and pits shall be in accordance with [16], [17] and [18]. PWC has a preference for a near level site where possible. Where a gradient is required for drainage a fall of 1:50 shall be used.

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The site shall be compacted to achieve appropriate soil strength. Consideration shall be given to operation and maintenance equipment that shall be driven onto the site when designing the switchyard civil works. Substation base layer and finishing - installation of loose crushed granite or other form of rock to a nominal depth of 100 mm, using a maximum of 20 mm aggregate size on the switchyard surface to provide acceptable step and touch voltages. The layer shall be designed in accordance with [19]. Refer to [39] for earthing design details. Road works to ensure that access roads and substation roads are suitable for transport of power transformers and crane as the largest onsite equipment and suit the turning radius of low loader for road used to transport transformers Power transformer foundations and bunds - The power transformer foundations and bund walls shall be connected to the oil containment system. Refer to 17.7 and 17.9 Control building and its foundations Cable ducts/trenches - The main cable duct shall be installed from the substation control building to the outdoor yard equipment. Refer to 17.6. Below ground basement cable ducts shall use, as a minimum, water tight rubber membranes to maintain a seal from external water ingress. Additional concrete admixtures to increase the concrete waterproofing may also be applied if the designer considers the benefits advantageous and economical, however, this does not preclude the use of the rubber membrane.

Modular buildings may be used as long as they are designed to a similar standard.

17.6

Ducts and Trenches

A main cable duct shall be installed from the outside of the control room to the switchyard outdoor equipment. Subsidiary cable ducts shall be installed along each bay of equipment. The ducts shall be constructed from inverted precast concrete box culverts with appropriate checker plate covers and be adequate to support all types of cables including control. LV cables shall be supported on the walls of the duct by means of a cable tray assembly. Buried PVC conduit shall connect the concrete duct to individual items of equipment. Ducting shall be designed to allow stormwater to be drained away from the switchroom via gravity. In situations where gravity draining is not possible, such as a basement, a sump and sump pump may be provided. The duct shall have a sufficient width to allow for a person to stand inside the duct as well as room for mounting two sets of cable trays. Refer to drawings XXX for an example of a typical installation. Also refer to [38] for cabling segregation details. Transformer 11 or 22 kV cabling shall also be installed in concrete ducts or conduits, using separate ducts or conduits for each transformer. The duct covers shall have sufficient strength to withstand the load of heavy vehicles when the trench crosses a substation road or accessway.

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17.7

Transformer Bunding

The transformer bund shall be designed to suit the power transformer requirements. The bund shall capture any transformer oil spill and prevent migration to adjacent transformers and other site equipment, external from the substation, and the environment. Transformer bunds shall be designed to comply with [5], [6], [7] and the minimum requirements shall be as follows: Bunds shall be proven to be free of leaks by testing and commissioning procedures Oil flow shall be directed towards drainage pits Bund size shall be estimated such that minimum distance between transformer perimeter and the top of the bund boundary must be at least half of the height difference between bound boundary and the highest oil containing element of transformer Bund size shall be 110% of the oil volume for a single transformer The bund shall be of the open drain type and allow ease of inspection and maintenance The bund construction material shall be concrete 75-100 mm aggregate shall only be installed within the bund for outdoor unenclosed transformers. The thickness of the aggregate layer shall be determined by the designer in consultation with PWC. Signage shall be placed adjacent to the bund on two sides of the transformer identifying the surface within the bunded area as unstable. Refer to [41] for more details The Bund walls shall be designed to allow for future provision of fire walls and noise walls

17.8

Oil Containment

Oil containment will be carried out in accordance with [5], [6] and [7]. An oil containment facility shall be available at every site to catch and contain any oil spilt within the substation. The oil containment facility shall be located to enable easy access by a truck to pump out the oil. The oil containment facility shall be sized for 110% oil capacity of one transformer. To minimise the environmental impact and the spread of fire throughout the substation the oil containment system shall consist of: Bunding

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Bund drainage system Oil/water separator

An environmental risk/impact assessment shall be undertaken for every new oil/water separator at a zone substation site to assess the risk of off-site impacts arising from discharge of water from the oil/water separator and must be designed to trap oil on site. PWC has a preference for passive oil/water separators. The units shall: be suitable for a 1 in 50 year storm allow a maximum of 30 ppm suspended solids at its outlet allow a maximum of 10 mg/L of oil at its outlet

17.9

Fire Walls

[1] suggests that designers use ENA 18-2008 as a guideline for fire protection of HV substations. This standard establishes that the Building code of Australia (BCA) class 8 requirements can be used as a guide for buildings used for HV installations. Table 6.1 of [1] provides a guide for outdoor transformer segregation. Where a fire hazard exists, HV substation enclosures within or adjacent to buildings must be designed with a minimum FRL 120/120/120 fire rating. Fire barriers providing FRL 120/120/120 are to be used where this minimum cannot be met. Where a transformer fire is part of the risk assessment, then a fire rating greater than 120 minutes needs to be considered. Sufficient space shall be provided around the transformer to the walls of the enclosure or fire wall for the purpose of operation and maintenance access. The structural adequacy, integrity of barrier material and insulative materials must be maintained in the event of a fire for the FRL period. The FRL applies in the same way for the enclosure and any penetrations or opening in the enclosure. Flame traps shall be provided inside the bund of the transformer through the use of a nonflammable pipe within a pit in the bund.

17.10 Transformer Spacing There shall be sufficient spacing between the power transformer bunds to provide safety clearances and service access to equipment in the HV busbar areas, the lines circuits and transformer circuits. Transformers access shall be free from line crossings to allow the transporting and lifting of transformers and buildings without the restrictions presented by overhead lines.

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17.11 Switchyard AC Supply A 3 phase 300 A weatherproof junction box shall be installed adjacent to transformers for supplying power to transformer oil filtering equipment. 15 A outlets shall be strategically positioned throughout the yard to provide power for operation and maintenance. Refer to [40] for further details for AC Supply.

17.12 Fire Protection Fire hydrants shall be strategically located around the switchyard and transformer bays. Thermal detectors shall be installed in the transformer area and connected to the substation fire incident panel (FIP).