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Challenging Substation Design

Challenging Substation Design

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Published by: nagraj204 on Aug 07, 2012
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colm.twomey@esbi.ie 1
C. TwomeyESB InternationalIrelandSUMMARY
 ESB (Electricity Supply Board) Networks has an extensive (15+) programme of 110kV/MVsubstations to be built within a regulated budget by 2010.A comprehensive cost-reduction study was undertaken which included a review of currentpractice in a number of other utilities and an enquiry to a wide range of manufacturers basedon an open functional specification.The tenders received were evaluated against a full range of cost factors including materialcost, installation costs and lifetime costs.The outcome of the study was a decision to standardise on the use of 110kV gas-insulatedequipment (either hybrid modules or conventional GIS) for new 110kV substations and alsoto use this equipment as far as possible in extensions or refurbishment of existing AISsubstations.A further outcome was a decision to replace conventional buildings with prefabricatedenclosures for various functions e.g. 38kV GIS, MV switchboards, control/relay rooms,battery rooms, store rooms where it makes economic sense to do so.
Hybrid, substations, cost reduction, prefabricated equipment
CIGRESC B3 Berlin 2007
 http : //www.cigre-berlin-2007.org 
colm.twomey@esbi.ie 2
The Irish electricity system had a maximum demand of 5042 MW at the end of 2006. Thenetwork which is owned by ESB contains four 400kV stations, twenty seven 220kV stationsand approximately one hundred and thirty 110kV stations. The 400kV network comprises twolines connecting a 900MW generating station on the west coast to the main load centre of thecapital city of Dublin on the east coast. The 220kV network is the main transmission network to which about 66% of generation is connected. In addition, due to the dispersed pattern of development in Ireland much of the 110kV network outside Dublin is operated as part of thetransmission system (with about 16% of generation capacity including most of the windgeneration connected to it) rather than as a sub-transmission system.The historical transformation ratios to distribution voltages are 110/38kV and 38/10kV. In themid 1990’s it was decided to introduce a new voltage level of 20kV with the long term aim of moving to a single MV voltage replacing both the 38kV and 10kV levels.At this stage most of the 10kV network with the exception of urban cabled networks has beenupgraded to 20kV. The original intention was to freeze the 38kV system with all futuretransformation to be directly from 110kV to 20kV. However due to the dispersed nature of theload it has proved uneconomic to do this in all cases so a certain amount of 110/38kVdevelopment has continued.Since 1996 Ireland has undergone an unprecedented rate of economic development withdemand for electricity growing continuously. The average rate of load growth since 1996 hasbeen of the order of 5% and this rate of load growth is still continuing at present.Meeting this load growth has required a corresponding network development effort fromESB.During this period one 400kV station, six 220kV stations and over thirty 110kV stations havebeen built. The ongoing construction programme includes the construction of at least four110kV stations per year.Traditionally ESB carried out all detailed design in house and used ESB staff for allconstruction work. Meeting the concentrated workload of this programme in addition to anextensive refurbishment of the MV network could only be done through the extensive use of installation contractors and also a limited introduction of turnkey projects for a series of urban110kV/MV GIS stations.This process was also complicated by the need to respond to the change in environment froma single national vertically integrated utility to a liberalised regulated system mandated by EUlegislation which has taken place over this period.ESB is at present operating in its second 5 year (2005-2010) price review period which hasimposed significant cuts in allowed capital and operating costs.This has resulted in a challenge to:-
Deliver the required programme-
Review critically every aspect of the historical project delivery method-
Maintain an absolute commitment to quality-
Reduce the project delivery cycleTo meet these requirements a comprehensive cost reduction study was undertaken. This studycovered the whole field of various issues associated with the substation construction project
colm.twomey@esbi.ie 3life cycle. The initial stage of the study identified the following areas as being the mostpromising for cost reduction.1)
Use of prefabricated equipment and buildings2)
Reduction in site dimensions3)
Reduction in construction time4)
Reduction in engineering costs5)
Optimisation of individual design issues6)
Reduction in life cycle costs7)
Use of mobile plant8)
Review of site purchase commercial issues9)
Review of construction contract arrangement10)
Review of material purchase tender strategyThis paper will describe the outcome from the work carried out in areas 1-6.
Existing standard designs
110/38kV (Station dimensions are 90m x 84m)-
110kV: Single stranded busbar with AIS equipment. The station is laid out andequipment rated where appropriate for an ultimate development of six feeders, two63MVA transformers and a sectionaliser bay. All disconnectors are manually operated.-
38kV: single tubular or solid busbar with phases in a vertical formation. The layoutallows for an ultimate development of six feeders, two transformer bays, a housetransformer bay and a sectionaliser bay.The initial station development is frequently in the form of a tail-fed 31.5MVA transformerwith a small number of 38kV bays. The station may be then extended by a 110kV loop-inwith the installation of a busbar. A second transformer could follow in due course and thetransformers could eventually be replaced by 63MVA units.110kV/MV (Station dimensions are 63m x 37m)-
110kV: A tubular copper busbar with AIS equipment. The station is laid out as a H-typelayout of two feeder bays and two 20MVA transformer bays with a sectionaliser bay. Alldisconnectors are manually-operated. The transformer secondary voltage is selectable as10kV or 20kV. The design of the station allows for a possible uprating to 31.5MVAtransformers. It does not allow for additional bays.-
MV (where MV is 10kV or 20kV): Single busbar metal-enclosed switchgear rated foroperation at 10kV or 20kV in a building sized for an ultimate capacity of 20 feeders. Theinitial installation is fitted with the number of feeders immediately required.110kV/MV (Station dimensions are 34m x 34m)-
110kV: Single busbar GIS. The normal initial layout is two feeders and two 20MVAtransformer bays and a sectionaliser bay with space left to add an additional feeder ateach end of the busbar. The transformer secondary voltage is selectable as 10kV or 20kV.The design of the station allows for a possible uprating to 31.5MVA transformers.-
MV (where MV is 10kV or 20kV): Single busbar metal-enclosed switchgear rated foroperation at 10kV or 20kV with space for an ultimate capacity of 20 feeders. The initialinstallation is fitted with the number of feeders immediately required.

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