SUBSTATION DESIGN MANUAL

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

Revision: 2
Page 2 of 12

Substation Design Manual

Chapter 17 Substation Layouts and Facilities
Outdoor

Document Number
D2010/287838

Document Control
Revision History
Title

Substation Design Manual

Section

Substation Layouts and Facilities Outdoor

Document ID

D2010/287838

Prepared

Hydro Tasmania Consulting

09/10/2009

Reviewed

Hydro Tasmania Consulting

09/10/2009

Revision

Revision
Date

Details

Authorised

Draft

09/10/2009

For client review and input

Final Draft

4/12/2009

Revised following client comments Brendon Gannon

Specialist Engineer

Rev 1

2/11/2010

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

Rev 2

17/01/2012

Name / Position

Revised to suit client comments

Signature

Greg Brand
Manager Contracts
& Projects

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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Substation Design Manual

Chapter 17 Substation Layouts and Facilities
Outdoor

Document Number
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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]

AS 2067

Substations and high voltage installations exceeding 1 kV a.c.

[2]

ESAA

National Guidelines for Prevention of Unauthorised Access to

Electricity Networks

[3]

ENA EG1

Substation Earthing Guide

[4]

ESAA

Substation Earthing Guide

[5]

AS 1940

The storage and handling of flammable and combustible liquids

[6]

ESAA (series)

Guidelines for Oil Containment in the Electrical Supply Industry

[7]

IEEE 980

IEEE Guide for Containment and Control of Oil Spills in Substations

[8]

AS 1379

Specification and supply of concrete

[9]

AS 1478.1

Chemical admixture for concrete, mortar and grout - Admixtures

for concrete

[10]

AS 3600

Concrete structures

[11]

AS 3610

Formwork for concrete

[12]

AS 3799

Liquid membrane - forming curing compounds for concrete

[13]

AS 3972

Portland and blended cements

[14]

AS/NZS 4671

Steel reinforcing materials

[15]

AS 1726

Geotechnical site investigations

[16]

AS/NZS 3725

Design for installation of buried concrete pipes

[17]

AS 1597.2

Precast reinforced concrete box culverts - Large culverts (from

1500 mm span and up to and including 4200 mm span and
4200 mm height)

[18]

AS 4198

Precast concrete access chambers for sewerage applications

[19]

AS 2758

Aggregates and rock for engineering purposes (Series)

[20]

AS 1939

Degrees of protection provided by enclosures for electrical

equipment (IP Code)

[21]

AS 4282

Control of the obtrusive effects of outdoor lighting

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[22]

AS/NZS 3000

Electrical Installations - Wiring Rules

[23]

IEC 61936-1

Power Installations exceeding 1 kV a.c. Part 1: Common rules

[24]

AS/NZS 2312

Guide to the protection of structural steel against atmospheric

corrosion by the use of protective coatings

[25]

AS/NZS 2373

Electric cables - Twisted pair for control and protection circuits

[26]

AS 2650

Common specifications for high-voltage switchgear and

controlgear standards (IEC 60694)

[27]

AS 2870

Residential slabs and footings

[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

[29]

AS/NZS 3947.3

Low voltage switchgear and controlgear - Switches, disconnectors,

switch-disconnectors and fuse-combination units

[30]

AS 4100

Steel Structures

[31]

AS/NZS 61000

Electromagnetic compatibility (Series)

[32]

AS 62271.200

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)

[33]

AS 62271.201

High-voltage switchgear and controlgear - AC insulation-enclosed

switchgear and controlgear for rated voltages above 1 kV and up
to and including 52 kV

[34]

AS 62271.301

High voltage switchgear and controlgear - Dimensional

standardization of terminals

[35]

AS 2791

HV switchgear and controlgear - use and handling of SF6 in HV

switchgear and controlgear

[36]

AS/NZS 1768

Lightning protection

[37]

D2010/287823

Chapter 1 - 11 or 22 kV Metal Clad Switchgear

[38]

D2010/287831

Chapter 6 - HV Cables and Conductors

[39]

D2010/287859

Chapter 15 - Earthing

[40]

D2010/287840

Chapter 19 - AC Supply

[41]

D2010/287847

Chapter 25 - Substation Signage

[42]

D2010/287851

Chapter 28 - Security

[43]

XXX

Chapter 30 - 66 kV Gas Insulated Metal Enclosed Switchgear

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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

Substation Design Manual

Chapter 17 Substation Layouts and Facilities
Outdoor

Document Number
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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

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

Substation Design Manual

Chapter 17 Substation Layouts and Facilities
Outdoor

Document Number
D2010/287838

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

Substation Design Manual

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Document Number
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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

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Chapter 17 Substation Layouts and Facilities
Outdoor

Document Number
D2010/287838

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

Document Number
D2010/287838

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).