PART B: -DESIGN FOR YARD AREA & EQUIPMENT

SUPPORT STRUCTURE
(GANTRY BEAM & TOWERS WITH STRUCTURES & FOUNDATIONS, TRANSFORMER,
REACTOR, FIRE WALL & BURNT OIL PIT, EQUIPMENT SUPPORT STRUCTURES WITH
FOUNDATIONS & SUB STATION UTILITIES, ROAD, DRAIN AND FENCING.)

1. DESIGN PHILOSOPHY:

Substation Gantries, Towers & Equipment’s will be designed as per IS-800:2007 Code of
Practice for Steel Structures & IS 802:2015 . However, Wind Analysis will be done as per IS
875-(Part 3)2016.

All structures shall be designed as per substation layout, section & conductor forces as given /
approved by electrical.

Height & Type of Towers shall be established based on electrical requirements.

A provision of +30 degree angle of deviation of line in horizontal plane and +30 degree angle of
deviation in vertical plane is considered and the resulting worst combination of forces shall be
considered for design. The distance between terminal gantry and dead end tower shall be taken
as 200m for design purpose.

Type and weight of conductor and conductor spans shall be considered as per approved
electrical design input or technical specification. However, for incoming & outgoing lines
conductor span shall be 200 m as mentioned above.

Auxiliary items / accessories such as Tension Insulator, Suspension Insulator weight, length etc.
shall be taken as per standard dimensions of generally used standard types. However, to
account for variation, such weights shall be rounded off to nearest additional 10 % weight.

All foundations shall rest below virgin ground level and the minimum depth of foundation below
the virgin ground level shall be at least 1000 mm. For small equipment & minor foundations like
marshalling kiosks, pylon supports, cable trenches, drains, etc., this may be reduced to 500 mm
with specific approval of the Employer. For safe bearing capacity at various levels latest soil
report to be followed.

2. LOADING:

2.1 Dead Loads:

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Dead Loads shall include the Self weight of structure complete with Gusset plates, connection
bolts, washers etc. Dry weight shall be rounded off to additional 10 % to account for fasteners,
gussets and base plate weight.

Man with Tool – 1.5 KN

2.2 Wind Loads:

Wind load calculations shall be done as per IS: 875(Part 3) latest.

Basic Wind Speed (Vb) = 50 m/sec as per Location

Risk Co-efficient, K1 = 1.08, Based on Table-1 of IS 875-(Part 3) latest

Terrain Height & Structure size factor, K2 = Based on height &Terrain Category-2.

Topography Factor, K3 = 1.0

Importance Factor, K4 = 1.15

Design Wind Speed, Vz = Vb x K1 x K2 x K3 x K4

Wind directionally factor, Kd = 1.0 (Cl. 7.2.1 of IS 875 –Part 3 latest)

Area averaging factor, Ka = 1.0 (Table - 4 of IS 875 –Part 3 latest)

Combination factor, Kc = 1.0(Cl. 7.3.3.13 of IS 875 –Part 3 latest)

Wind Pressure, Pz = 0.6 x Vz2

Design Wind Pressure, Pd = Pz x Kd x Ka x Kc

(Pd Shall not be less than 0.7 x Pz)

3. LOAD COMBINATIONS:

As Beam, Tower as well as Equipment support structures are critical under wind condition
accompanied with electrical design load, analysis and design shall be done for Wind Load only
and Earthquake load case shall be disregarded because Earth quake force is function of mass
& mass of Beam & Tower is minor w.r.to Wind.

Following load combinations are to be considered for beam & tower design….

3.1 Normal Condition:

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Dead Load + Conductor Tension + Wind Perpendicular to Beam

Dead Load + Conductor Tension + Wind Parallel to Beam

3.2 Short Circuit Condition:

Dead Load + Conductor Tension + Wind Perpendicular to Beam

Dead Load + Conductor Tension + Wind Parallel to Beam

For each of the above load combinations, six deviation cases shall be considered as mentioned
below where applicable.

1. 0 deg. Horizontal, 0 deg. Vertical

2. 30 deg. Horizontal, 0 deg. Vertical

3. 30 deg. Horizontal, +30 deg. Vertical

4. 30 deg. Horizontal, -30 deg. Vertical

5. 0 deg. Horizontal, +30 deg. Vertical

6. 0 deg. Horizontal, -30 deg. Vertical

4. DESIGN PRICIPLE FOR TOWER & EQUIPMENT STRUCTURE

4.1 All towers & girder structures shall be Analysed for the combination of dead loads,
live loads, wind loads as per IS: 875 latest, loads due to deviation of conductor, loads
due to unbalanced vertical & horizontal forces, erection loads, short circuit forces,
etc. Switchyard structures shall be designed as per IS-800:2007 but for the condition
of all the three wires on one side being broken. The design of all structures shall be
based on the condition where stringing is done only on one side i.e. All the three
(phase) conductors broken on the other side.

4.2 The minimum thickness of members shall be as follows:

Main members 6 mm Other members 5 mm Redundant members 4 mm

4.3 Vertical load of half the span of conductors / string and the earth wires on either side of
the beam shall be taken into account for the purpose of design. Weight of man with
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tools shall be considered as 150 kgs for the design of structures.

4.4 The girders shall be connected with lattice columns by bolted joints. Section
considered are generally angle & channel . Members are designed as truss members
& supports are designed as pinned supports. Bracings shall be provided in each
orthogonal plane for developing axial stresses.

4.5 Structures shall be modelled in Staad . Modelling shall include column, beams &
bracings using selfweight. Loads shall be calculated in excel & applied in Staad along
with Load combinations. Design parameters shall be provided as per appropriate Code
and Design shall be done in Software. Base Plate & Bolts shall be designed in
standard spreadsheets by extracting reactions from Staad Analysis.

4.6 All equipment supports shall be designed for the worst combination of dead loads,
erection load, wind load/seismic forces, short circuit forces and operating forces
acting on the equipment and associated bus bars.

4.7 All foundation bolts shall conform to IS: 5624 but the steel material shall be MS
conforming to IS: 2062. The minimum bolt diameter shall be 16mm.

4.8 Each tower shall be provided with step bolts of 16mm diameter & 175mm long spaced
at 450mm apart, staggered on faces on one leg extending from about 0.5 metres above
ground level to the top of the tower. The step bolt shall conform to IS: 10238.

4.9 For member design use Ultimate allowable stress, slenderness ratio as per Latest IS
800:2007 & IS 802:2015.

5. MATERIAL FOR STRUCTURAL WORKS:

5.1 Gantry Structure shall be latticed structures - open web type. Structural steel conforming
to Grade IS: 2062.

5.2 Structural Steel shall be galvanized (thickness shall be 85micron) as per provisions given
in IS: 4759.

5.3 All Bolts for connections shall be of 16 mm dia. conforming to IS: 1367 property class
5.6. Nuts shall conform to IS: 1367 of Property class 4.
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5.4 All Switchyard structures shall be galvanized (thickness shall be 85micron) as per
IS:4759 & cl. 22.1 of Technical specification.

5.5 For detailing of reinforcement IS:2502/ IS:5525 and SP:34 shall be followed. Cold twisted
deformed bars (Fe=500 N/mm2) conforming to IS: 1786 or TMT bars as per CPWD
specifications shall be used as reinforcement. However, in specific areas, mild steel
(Grade I) conforming to IS: 432 can also be used. Two layers of reinforcement (on inner
and outer face) shall be provided for wall & slab sections having thickness of 150 mm
and above. Clear cover to reinforcement shall be as per IS: 456 (latest). The
reinforcement steel shall be stored in a elevated platform to prevent rusting and the
fabricated rods shall be properly stacked in a orderly manner.

5.6 RCC water retaining structures like storage tanks, etc. shall be designed as per limiting
cracked section as per latest version of IS: 3370 (Part I to IV) by working stress method.
However, water channels shall be designed as cracked section with limited steel
stresses as per IS: 3370 (Part I to IV) by working stress method.

6. MATERIAL FOR CIVIL FOUNDATIONS:

6.1 Reinforcement : HYSD Bars of Grade Fe415 / Fe500 confirming to IS 1786 and
Technical Specifications

6.2 Minimum 75mm thick lean concrete (1:4:8) shall be provided below all underground
structures

6.3 Structural Concrete :fck = 30 N/mm2

6.4 The material required for site surfacing/stone filling shall be free from all types of organic
/ inorganic materials and shall be of standard quality as per coddle provisions.

7. UNIT WEIGHTS:

a. Concrete (PCC) : 2400 kg/m3

b. Concrete (RCC) : 2500kg/m3

c. Structural Steel : 7850 kg/m3

d. Soil : 1800 kg/m3

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8. MINIMUM CLEAR COVER TO MAIN REINFORCEMENT:

Minimum clear cover to main reinforcement shall be as stated below.

FOUNDATIONS
BOTTOM & TOP FACE 50+10 = 60 mm
COLUMN, 50+10 = 60 mm
PLINTH BEAM & RCC WALL FACE IN 40+10 = 50 mm
CONTACT WITH EARTH.
FOR TOP FACE OF PLINTH BEAM AND 20+10 = 30 mm
TOP FACE OF RCC WALL.
FACE OF RCC WALL NOT IN CONTACT 30mm or dia. of bar whichever is greater
WITH EARTH

9. FOUNDATIONS:

9.1 Foundation Type - RAFT FOUNDATION/ISOLATED for Towers and Lighting Mast.

9.2 Foundation shall be isolated type for equipment support structures in general.

9.3 All foundations shall be checked for one-way shear, two-way shear etc. as per IS456.

9.4 Columns for the towers shall be checked for biaxial bending for two cases i.e.
compression with bending and tension with bending.

9.5 Design of foundation shall be as per IS:456:2000. However, rectangular soil overburden
shall be considered for foundations for equipment support structures as well as tower
foundations.

9.6 For design of Foundation Safe Bearing capacity, Depth of foundation, density of soil,
water table etc. will be considered as per soil & foundation data enclosed along with
Technical Specifications.

9.7 All foundations shall be checked for a factor of safety of 2.2 against sliding & overturning in
normal condition & 1.65 for short circuit condition. The load combinations for load cases shall
be as per IS 875 Part 5 and IS 456:2000.

9.8 All switchyard structures foundation design shall be with factor of safety as 2.2 for normal
condition and 1.65 for short circuit condition..
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9.9 Minimum grade of structural concrete shall be M-30.

9.10 Minimum 75mm thick lean concrete (1:4:8) shall be provided below all underground
structures, foundations, trenches etc.as per clause 10.1(d).

9.11 Reinforcement shall be TMT conforming to grade Fe500 as per IS: 1786.

9.12 Clear cover to reinforcement has been increased by minimum 10mm over and above the
values specified for normal conditions in IS:456 -2000.

10.CABLE TRENCH

10.1 Limit State Method of design shall be followed in general as per provisions of I.S. 456.

10.1.1 Designed to withstand loads of 1000 kg/sq.m from maintenance trucks and a concentrated
load of 200 kg at mid span of cover as per T.S. clause 12.

10.2 Live load on pre-cast covers 200 Kg/m2.

10.3 Minimum 75mm thick lean concrete (1:4:8) shall be provided.

10.4 Grade of Concrete shall be M30

10.5 Vertical wall of cable trench shall be designed as free cantilever subjected to active earth
pressure from earth having density equal to 18.0kN/m3 having an angle of internal friction
Mention as per as per Soil report.

10.6 Top of pre-cast cover slab shall be 300 mm above Formation Level. Grade of concrete for
precast cover slab shall be M35

10.7 Insert plate for cable tray supporting brackets shall be provided as per electrical requirement.

10.8 Road culverts including RCC pipes crossings & road crossing of trenches shall be suitable
for IRC Class A & AA loading.

11. SWITCHYARD ROAD

All road shall be Rigidpavement road. Road construction shall be in conformity with
CPWD/IRC/MOST.
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12. STORM WATER DRAIN

12.1 Network of drain shall be to suit surrounding equipment and cable trench network in outdoor
Switchyard.

12.2 All drains shall be sloped towards out fall point as per site condition. Switchyard drain shall
discharge towards main drain to the extent possible.

12.3 Open drain shall be RCC rectangular drain.

12.4 Rain water harvesting pit shall be provided before the out fall point.

12.5 Longitudinal and perpendicular to the run slope of the drain shall be as per the TS.

13. DESIGN PRINCIPLE FOR TRANSFORMERS, REACTORS, BURNT OIL PIT AND
FIRE WALL

13.1 The foundations of transformer/Reactor shall be of wall type foundation and minimum
reinforcement shall be governed by IS:456

13.2 The transformer/reactor foundations shall be checked for Seismic & Wind design criteria.

13.3 The Transformer/Reactor shall have proper soak pit all around for oil spilling with 33% capacity
all around.

13.4 The Burnt oil pit need to provide for as per codal requirement for oil capacity also burnt oil pit
will be design as per underground structure design.

13.5 The fire wall will be placed between Transformer/Reactor as per electrical requirement. Height
& length of fire wall will be provide with respect to transformer overall size + 500 mm on each
side.

13.6 Foundation design for transformer, reactors, burnt oil pit and fire wall will be design with
factors of safety as 1.5.