“Design of 400/220kV Sub-station”

S.M. MUJUMDAR
General Manager (sub-station Engineering) Jyoti Structures Ltd.,
27th April 2005 Mumbai
Agenda

Overview of 400kV sub-station Design Process Design considerations Question / An

swer
Imp. considerations in substation design

Safety of personnel and equipment Reliability and Security Adherence to Statutor

y obligations – I.E. rules, Environmental aspects Electrical design considerations
Structural design considerations Ease of maintenance Possibility to Expand
System parameters
Sr. 1. 2. 3. 4. 5. 6. 7. 8. Description Nominal system voltage Max. operating vo
ltage Rated frequency Number of phases System neutral earthing Corona Extinction
voltage Min. creepage distance Rated short ckt. Current for 1 sec. 400kV 400kV
420kV 50Hz 3 320kV 25mm/kV 40kA 1000 mV (320kV) 220kV 220kV 245kV 50Hz 3 156kV 2
5mm/kV 40kA 1000 mV (156kV)
Effectively earthed
10. Radio interference voltage at 1MHZ (for phase to earth voltage)
System parameters Contd..
Sr. 11. Description Rated insulation levels i) Full wave impulse withstand volta
ge -- for lines -- for reactor/ X’mer -- for other equipments ii) Switching impuls
e withstand voltage (dry/wet) iii) One min. power freq. withstand voltage (dry/w
et) -- for lines -- for CB / Isolator -- for other equipments 400kV 220kV Remark
s
1550kVp 1300kVp 1425kVp 1050kVp
1050kVp 950kVp 1050kVp
680kV 520kV 610kV 630kV
460kV 460kV 530kV 460kV
(Line-ground) (open terminals)
Substation Bird’s view
400kV Circuit Breaker
400kV Isolator
400kV Current Transformer
400kV CVT
400kV Surge Arrester
Shunt Reactor & NGR
400/220 kV Auto Transformer
400kV Bus Post Insulator
Wave Trap
Functions of substation equipments
Equipment 1. Bus-Bar 2. Circuit Breaker 3. Isolators 4. Earthing switch 5. Curre
nt Transformer 6. Voltage Transformer 7. Lightning Arrester Function Incoming &
outgoing ckts. Connected to bus-bar Automatic switching during normal or abnorma
l conditions Disconnection under no-load condition for safety, isolation and mai
ntenance. To discharge the voltage on dead lines to earth To step-down currents
for measurement, control & protection To step-down voltages for measurement, con
trol & protection To discharge lightning over voltages and switching over voltag
es to earth
Functions of substation equipments Contd…
8. Shunt reactor 9. Neutral-Grounding resistor 10. Coupling capacitor 11. Line –Tr
ap 12. Shunt capacitors 13. Power Transformer To control over voltages by provid
ing reactive power compensation To limit earth fault current To provide connecti
on between high voltage line & PLCC equipment To prevent high frequency signals
from entering other zones. To provide compensations to reactive loads of lagging
power factors To step-up or step-down the voltage and transfer power from one a
.c. voltage another a.c. voltage at the same frequency. Compensation of long lin
es.
14. Series Capacitor
Functions of Associated system in substation
System 1. Substation Earthing system -- Earthmat -- Earthing spikes -- Earthing
risers Function To provide an earthmat for connecting neural points, equipment b
ody, support structures to earth. For safety of personnel and for enabling earth
fault protection. To provide the path for discharging the earth currents from n
eutrals, faults, Surge Arresters, overheads shielding wires etc. with safe step-
potential and touch potential. To protect the outdoor substation equipment from
lightning strokes.
2. Overhead earth wire shielding or Lightning masts. 3. Illumination system (lig
hting) -- for switchyard -- buildings -- roads etc.
Contd..
4. Protection system -- protection relay panels -- control cables -- circuit bre
akers -- CTs, VTs etc. 5. Control cable 6. Power cable 7. PLCC system power line
carries communication system -- line trap -- coupling capacitor -- PLCC panels
To provide alarm or automatic tripping of faulty part from healthy part and also
to minimize damage to faulty equipment and associated system.
For Protective circuits, control circuits, metering circuits, communication circ
uits To provide supply path to various auxiliary equipment and machines. For com
munication, telemetry, telecontrol, power line carrier protection etc.
Contd…
8. Fire Fighting system -- Sensors, detection system -- water spray system -- fi
re prot. panels, alarm system -- watertank and spray system 9. Auxiliary standby
power system -- diesel generator sets -- switchgear -- distribution system 10.
Telephone, telex, microwave, OPF To sense the occurrence of fire by sensors and
to initiate water spray, to disconnect power supply to affected region to pin-po
int location of fire by indication in control room. For supplying starting power
, standby power for auxiliaries
For internal and external communication
Basic drawings for design/construction

Single Line Diagram General Arrangement Drawing Electrical Plan and Section Cont
rol Room Architectural layout
Supporting drawings

Structural layout Earthmat layout Civil layout Erection Key Diagram Lighting Lay
out
Single Line Diagram – 220kV
General arrangement layout
Electrical layout
Electrical Section
Control room layout
Control room layout
Structural layout
Earthmat Layout
@ @ @ @
@ @ @
@
@
Civil layout
Erection Key Diagram
4P3 4LA
4SSTM-D4SSTM-D4SSTM-D
4C1
4C2
4V
4P
4I1
4I1 4I1 4I1 4I1 4I1 4I1
4I
4I
4I
4I
4P3
4DTTM-1
4LA 4LA 4LA
4LA
4IC2
N1
4DTTM2
4DTTM1
4W1
4I
R1 R1 R1
4W1
4P1
4W
4C1
4C2
4V
4P
4I1
4I
4I
4IC1
4DTTM-1
4P3
4LA
4W1
4W1
4DTTM2
4I
4I
R2
4DTTM1
4P1
4C1
4C2
4V
4P
4I1
4DTTM-1
4DTTM2
4DTTM1
4P3
4LA
4SSTM-D4SSTM-D 4SSTM-D
4W1
4W
4C1
4C2
4V
4P
4I
4I
4I
4I
4P3
4LA
4IC2
4W1
4W1
4DTTM2
4DTTM1
4W
4P1
4I1
4DTTM-1
4LA 4LA 4LA
N1
4I
R1 R1 R1
4C1
4C2
4V
4P
4I
4P3
4LA
4IC1
4W1
4W1
4DTTM1
4P1
4I1
4I2
4DTTM-1
4DTTM2
4I
4I
4I
R2
4C1
4C2
4V
4P
4I
4I
4DTTM1 4DTQB-2 4DTQB2
4DTQB2
EW1 EW2 4SSTM-D 4DTTM1 4T1 4S1 4S1 4T1 4S1 4T1 4S1 4S1 4S1 4P 4S1 4V 4W 4W 4I 4I
R1 4S1 4LA 4S1 4P 3 4S1 4I 4S1 4S2 4S2 4S2 4DTTM2 4TM 4S2 EW2 EW2
EW1 EW2 EW2
4I1
4I2
4DTTM-1
4DTTM2
4I
4I
4I2
4B
4B
4I2
4B
4B
4I2
4B
4B
4I2
4I2
4B
4B
4I
4I
4I
4I
4I2
4I2
4B
4B
4I2
4B
4B
4DTQB-1
4DTQB1
4DTQB1
4W1
4W
EW1 EW2
4DTTM1 4S2
4S2
4S2
4S2
4DTTM2 4S1 4SSTMD
4SSTM-T 4S1 4S1 4S1 4TBSM 4S1 4I 4S1 4S1 4P 1 4P 1 4IC1 4IC2 4TBSM 4S1 4I2 4I 4I
1 4B 4B 4TBSM
4S1
4S1 4S1 4LA
4S1
4S1 4C1 4C2 4I1 4I2 4IC2
Lighting Design

Adequate lighting is necessary for safety of working personnel and O&M activitie
s Recommended value of Illumination level Control & Relay panel area - 350 Lux (
at floor level) Test laboratory - 300 Lux Battery room - 100 Lux Other indoor ar
ea - 150 Lux Switchyard - 50 Lux (main equipment) - 20 Lux (balance Area / road
@ ground level)
Single Bus arrangement
Single Bus System
Merits 1. Low cost Demerits 1. Fault of bus or any circuit breaker results in sh
ut-down of entire substation 2. Difficult to do any maintenance 3. Bus cannot be
extended without completely deenergizing substations 4. Can be used only where
loads can be interrupted or have other supply arrangements. Remarks 1. Used for
distribution substations upto 33kV 2. Not used for large substations. 3. Section
alizing increases flexibility
2. Simple to Operate 3. Simple Protection
Main & Transfer Bus
Main & transfer busbar system
Merits 1. Low initial & ultimate cost Demerits 1. Requires one extra breaker cou
pler Remarks 1. Used for 110kV substations where cost of duplicate bus bar syste
m is not justified .
2. Any breaker can be taken out of service for maintenance.
2. Switching is somewhat complex when maintaining a breaker
3. Potential devices may 3. Fault of bus or any be used on the main bus circuit
breaker results in shutdown of entire substation.
Double Busbar arrangement
Double Bus Bar Single Breaker system
Merits 1. High flexibility Demerits 1. Extra bus-coupler circuit breaker necessa
ry. Remarks 1. Most widely used for 66kV, 132kv, 220kV and important 11kv, 6.6kV
, 3.3kV substations.
2. Half of the feeders 2. Bus protection scheme connected to each bus may cause
loss of substation when it operates. 3. High exposure to bus fault. 4. Line brea
ker failure takes all circuits connected to the bus out of service. 5. Bus coupl
ers failure takes entire substation out of service.
Double Busbar with Double breaker
Double Bus Bar Double Breaker system
Merits 1. Each has two associated breakers 2. Has flexibility in permitting feed
er circuits to be connected to any bus 3. Any breaker can be taken out of servic
e for maintenance. 4. High reliability Demerits 1. Most expensive Remarks 1. Not
used for usual EHV substations due to high cost. 2. Used only for very importan
t, high power, EHV substations.
2. Would lose half of the circuits for breaker fault if circuits are not connect
ed to both the buses.
Double main & transfer
Double main bus & transfer bus system
Merits 1. Most flexible in operation 2. Highly reliable 3. Breaker failure on bu
s side breaker removes only one ckt. From service 4. All switching done with bre
akers 5. Simple operation, no isolator switching required 6. Either main bus can
be taken out of service at any time for maintenance. 7. Bus fault does not remo
ve any feeder from the service Demerits 1. High cost due to three buses Remarks
1. Preferred by some utilities for 400kV and 220kV important substations.
One & half breaker scheme
One & half breaker scheme
Merits Demerits Remarks 1. Used for 400kV & 220kV substations. 1. Flexible opera
tion for breaker 1. One and half maintenance breakers per circuit, hence higher
cost 2. Any breaker can be removed from maintenance without interruption of load
. 3. Requires 1 1/2 breaker per feeder. 4. Each circuit fed by two breakers. 5.
All switching by breaker. 6. Selective tripping
2. Protection and 2. Preferred. auto-reclosing more complex since middle breaker
must be responsive to both associated circuits.
Ring Bus
Mesh (Ring) busbar system
Merits 1. Busbars gave some operational flexibility Demerits 1. If fault occurs
during bus maintenance, ring gets separated into two sections. 2.Auto-reclosing
and protection complex. 3. Requires VT’s on all circuits because there is no defin
ite voltage reference point. These VT’s may be required in all cases for synchroni
zing live line or voltage indication 4. Breaker failure during fault on one circ
uit causes loss of additional circuit because of breaker failure. Remarks 1. Mos
t widely used for very large power stations having large no. of incoming and out
going lines and high power transfer.
Minimum Clearances
400kV 1. Phase to Earth 3500 mm 220kV 2100 mm
2. Phase to phase
4200 mm (Rod-conductor configuration) 4000 mm (Conductor-conductor configuration
) 6400 mm
2100 mm
3. Sectional clearance
4300 mm
Clearance Diagram
Bus Bar Design

Continuous current rating. Ampacity caculation as per IEEE:738 Short time curren
t rating (40kA for 1 Sec.) IEC-865 Stresses in Tubular Busbar Natural frequency
of Tubular Busbar Deflection of Tube Cantilever strength of Post Insulator Aeoli
an Vibrations
Gantry Structure Design

Sag / Tension calculation : as per IS: 802 1995 Sr. 1. 2. 3. 4. 5. Temp Min. Min
. Every Day Every Day Max. (ACSR 750C/ AAAC 850C) Wind Pressure No wind 36% No w
ind 100% No wind T <= 22% of UTS T <= 70% of UTS Clearances Limits
Contd..

Short Circuit Forces calculation As per IEC : 865 Short circuit forces during sh
ort circuit Short circuit forces after short circuit Short circuit forces due to
“Pinch” effect for Bundled conductor Spacer span calculation

Factor of safety of 2.0 under normal condition and 1.5 under short circuit condi
tion
spacers
Spacer span Vs Short Ckt. forces
GRAPH OF SPACER SPAN Vs CONDUCTOR TENSION FOR 400 KV TWIN MOOSE ACSR CONDUCTOR
12000.00 CONDUCTOR TENSION PER PHASE IN KG.
10000.00
8000.00
6000.00
4000.00
2000.00
0.00 0 2 4 6 8 10 12 14 SPACER SPAN IN MTRS.
Earthing Design
Guiding standards – IEEE 80, IS:3043, CBIP-223. 400kV & 220kV system are designed
for 40kA. Basic Objectives: Step potential within tolerable Touch Potential limi
t Ground Resistance Adequacy of Ground conductor for fault current (considering
corrosion)
Touch and step potential
Lightning Protection – Ground Wire
FIG-4a
FIG-4b
Lightning Protection – Lightning Mast