Design Status Report

Scheme Number 20004

Scheme Title Rayleigh 4th SGT

Table of Revisions

Revision Date of
Reason for Revision Revised by
Number Revision
0 15/08/05 Draft Issue for Client Comments P.Kendrew
1 06/09/05 Modified in line with clients comments P.Kendrew
2 14/02/06 Modified in line with clients comments P.Kendrew

Notes for Completion

1. Please complete the above table each time a revision is made.

2. The document must be updated immediately prior to scheme handover to Construction and prior to design
reviews in addition to other times as appropriate.

3. The tabular format of this document is provided for consistency of presentation, but may be modified if one
particular report would be improved by an alternative format.

4. The contents in this report may not be exhaustive and can be added to.

Form TP146.12
Contents

1. Summary of design changes

2. Chosen design

3. Alternative design

4. Emergency return to service considerations

5. Additional requirements for scheme sanction costs

6. Outstanding design requirements

7. Energis communications status

8. SCS / Database status

9. Compliance checks
1. SUMMARY OF DESIGN CHANGES

Date Design Change Reason Engineer

2. CHOSEN DESIGN

2.1 Background

A modification application has been placed by EDF with NG to provide a fourth 240MVA
400/132kV SGT (SGT3) at Rayleigh Main and take the opportunity to replace the existing
132kV AIS substation at Rayleigh local with a new 20 Bay GIS substation located at the
Rayleigh Main Site.

The new 240MVA SGT (SGT3) will be installed within the spare bay at Rayleigh main
adjacent to SGT1 bay and connected into one of the bay’s of the new 132kV GIS Substation.

The works will also include the replacement of the existing SGT2 transformer with a new
240MVA SGT2. These works will be carried out on completion of SGT3 installation.

SGT3 and SGT2 together with the existing SGT circuits SGT1 and SGT4 will be connected to
the new GIS substation via new 132kV XLPE cables. All works associated with 132kV cables
and GIS substation will be within EDF self build contract.

The new 132kV GIS substation will be located on the Rayleigh Main 400kV site. Following
completion of the works the existing Rayleigh local site together with redundant OHL’s and
Towers would be decommissioning and scrapped by EDF.

As background to the present state of the 400kV substations, a condition assessment report
has been produced. For information and reference please refer to the following document :

NGT document Ref: TBC

Rayleigh 400kV Substation Spare Bays Condition Assessment

2.2 Scheme Work Scope Overview

The required works are summarised as follows:-

400kV Equipment

 Transportation of SGT3 400/132kV 240MVA transformer from ex-works storage point

to the site (Including Offloading), Installation, testing and commissioning.
 Transportation of SGT2 400/132kV 240MVA transformer from ex-works storage point
to the site (Including Offloading), Installation, testing and commissioning.
 Installation of Dispersed Relay room containing HV Control and Protection
Equipment.
 Installation new 400kV SF6 Live Tank Circuit Breaker (SGT3)
 Installation of new 400kV AIS centre rotating post disconnector (SGT3)
 Installation of one three phase set 400kV Post Current Transformers (SGT3)
 Installation of one three phase set 400kV Surge Arrestors (SGT3)
 Installation of one three phase set 400kV Surge Arrestors (SGT2)
 SGT 400kV Protection ( Detailed within section 7 )
 400kV Bay Protection Modifications
 132kV Equipment

 Installation of one three phase set 132kV Surge Arrestors (SGT3)

 Installation of one three phase set 132kV Surge Arrestors (SGT2)
 Installation of one three phase 132kV earth switch (SGT3)
 132kV XLPE power cables and associated cable sealing ends ( to be supplied /
Installed by EDF – not part of these works)
 OHL - removal of existing towers and conductors

132kV LV Protection ( to be supplied / Installed by EDF )

2.3 DESIGN OUTLINE

Associated Drawings:

Overall Site Plan Drawing No. 5038600/09.01/0001

Typical Section SGT3 Bay Drawing No. 5038600/09.01/0002
Key Line Diagram for SGT3 Drawing No. 5038600/09.02/2000
Site Plan SGT3 Roads and Drainage Drawing No. 5038600/09.01/0003

Plant & Configuration

There is currently 1 spare 400kV bay adjacent to SGT1 bay on the Rayleigh Main 400kV
substation site. Logically this remaining spare bay would lend itself to the installation of the new
SGT3 transformer bay required.

The existing Main and Reserve busbars have been extended to include for the spare bay
requirements including reserve and main busbar disconnectors. The new SGT3 and associated
bay equipment will therefore be connected to the existing Main and reserve busbar
disconnectors as shown on SGT3 Plan and section drg. 5038600/09.01/0002.

The arrangement of the transformers is such as to obtain the optimum separation whilst
maintaining safety clearances from adjacent circuits and access roads. In the case of SGT3,
the separation is inadequate between the adjacent SGT1 bay equipment in accordance with
NGTS2.20. Consequently a fire/blast wall will be required to be constructed to segregate the
transformers.

This scheme presently does not call for a new auxiliary transformer supply although all
transformers will be supplied with tertiary connections as standard under the bulk purchase
agreement.

SGT3 will have 400kV HV busbar connections and 132kV LV busbar connections onto cable
sealing ends. The 132kV sealing ends are arranged outside of the skidway outline and extent
off the transformer tank to allow ease of installation (and future removal). The 132kV post
insulator supports are to be demountable on bases flush with the main skidway.

SGT3 will be fitted with both HV and LV surge arrestors.

SGT2 replacement transformer will be the same specification as SGT3 which is physically
bigger than the existing SGT2. Therefore on removal of the existing SGT2 the existing
transformer foundation and associated 132kV equipment foundations would require
modifications to accommodate the new SGT.

The adjacent Tilbury/Grain circuit to SGT2 Bay is in close proximity and would require detailed
design to prove safety and electrical clearances in accordance with relevant NGTS
requirements are maintained for the new SGT2.
The proposed location for the new 132kV GIS substation shall be adjacent to the 400kV
Rayleigh Main site within NG land ownership boundary. The GIS solution was considered to be
the preferred option as opposed to an AIS switchgear solution due to the limitation of land
available to accommodate the new substation.

The land area is sufficient to accommodate a new 20 bay 132kV GIS substation, comprising of
line disconnector, main and reserve busbar selector disconnectors, circuit breaker and
associated earth switches.

The proposed route for the new 132kV XLPE cables associated with SGT3 shall be through the
land area which currently accommodates the CSE compounds associated with SGT1, SGT2
and SGT4. The cables would then cross the access road at a suitable point for routing to the
new 132kV GIS Substation as shown on the overall Site Plan drawing. The cables will be laid
in surface troughs, with heavy duty covers, to provide a clear long term identification of circuit
route.

New 132kV XLPE Cables associated with existing SGT1, SGT2 and SGT4 circuits will be
installed from each of the existing cable sealing end compounds. The cables would then be run
in parallel with SGT3 cables and routed to the new 132kV GIS substation.

EDF shall be responsible for the construction of the new GIS substation and all works
associated with the installation of 132kV cables.

The new 132kV GIS substation located at Rayleigh main will replace the remote Rayleigh local
132kV site. This will allow existing OHL circuits feeding the remote Rayleigh local site to be
removed together with the associated towers.

Civils

It is envisaged that the vast majority of the civils for the new SGT3 can be carried out as a
single work package well in advance of system outages. The requirement is for the transformer
to be mounted within a ‘moat type’ bund in accordance with NGTS requirements.

The proximity between SGT3 and SGT1 is such that a full height fire wall is required between
the two to satisfy NGTS requirements.

Ground investigation and contamination survey to be completed in advance for SGT3 bay
before a contract is placed.

The existing blockhouse shall be refurbished for the SGT3 bay in line with current NGTS
requirements.

The new drainage together with modifications to access road will be required as shown on
drawing No. 5038600/09.02/0003.

Protection & Control

The proposed 400kV bay blockhouse will be equipped with the following :
 LV supply
 110V dc battery, charger and distribution
 48V dc battery, charger and distribution
 SCS RTU (Instem system)
 SCS LAN connection and fibre optic patch boxes
 Lighting and small power
 Heating

The protection requirements are to be standard for a new SGT’s in accordance with NGTS
3.24.8 as applicable. All SGT protection and control equipment will be housed within the new
blockhouse.

The SCS RTU appears fully operational and equipped with all necessary hardware. The
installation will require wiring to new I/O cards within the blockhouse RTU and database
modifications as required.

The SGT’s will need to be incorporated within the respective existing 400kV busbar protection
& CBF schemes and the 132kV busbar protection scheme.

In line with NGTS requirements, the SGT’s will have LV Connection protection (i.e. unit current
balance protection) on the 132kV cables due to the circuit length being in excess of 50m. Unit
protection CT’s will be provided within the LV turrets of the new transformer and be matched
with the new CT within the 132kV GIS circuit breaker. This provides the ‘end to end’ protection
discrimination zone.
3. ALTERNATIVE DESIGNS CONSIDERED

3.1 Substation Configuration

400kV substation
The arrangement for SGT3 is dictated by the availability of the spare bay. Consequently, no
other designs were considered suitable for the SGT3 location.

3.3 Civil

Standard designs envisaged

3.4 132kV Power cable routes

The proposed cable routes are to take into account the land available to accommodate the
easement requirements for cables, avoiding existing site services and future development for
the site.

3.5 132kV Substation Options

GIS locations

The preferred location for the new 132kV GIS has been agreed between NG and EDF. The
GIS substation will be located within a Greenfield site adjacent to the main 400kV site and is
shown on the overall site Plan.

AIS solution

An AIS option was considered for the 132kV Substation but was discounted as it could not be
accommodated within the available land area.

3.6 Protection & Control

400kV Substation
Standard NGTS requirements envisaged for new SGT installation. No variation from policy or
the implementation of type registered standard bay solutions envisaged.

4. EMERGENCY RETURN TO SERVICE CONSIDERATIONS

The following table were established during the design development to record the sequence of working
within each stage and serve to identify the key outage requirements and associated ERTS proposal. ERTS
figures are subject to confirmation following detailed design consideration.

SGT 3 Connection

Ref Description ERTS Notes

On completion of all other works :
400kV Outage Works
1.1 Outage on Main 2 8/12 hrs
1.2 Proximity Outage on SGT1 2/4 hrs
1.3 Extend/commission busbar protection scheme
1.4 Connect Main bar
1.5 Pressure test 132kV cable tails
1.6 On completion of above, complete final
commissioning checks
1.7 On completion of 1.1 to 1.06.
Energise SGT3
5. ADDITIONAL REQUIREMENTS FOR SCHEME SANCTION COSTS

COST
ITEM REQUIREMENT
ESTIMATE

6. OUTSTANDING DESIGN REQUIREMENTS

(eg. Type Registration)

6.1 Protection & Control

DATE
ITEM REQUIREMENT
RESOLVED

Confirmation required regarding location of existing ATCC.

Thought to be within the 400kV SCS.
1. ATCC
Since the 132kV is quite remote, there could be a dedicated
ATCC at Rayleigh Local 132kV

Can NG/EDF confirm that this scheme is still required? Are

2. Rayleigh 132kV Autoclose
the fault levels still an issue.

6.2 Civil
DATE
ITEM REQUIREMENT
RESOLVED
Full ground investigation required at 400kV substation at the
1. Ground investigation points of construction to provide a basis of design for plant
and equipment foundations.
As part of the ground investigation (item 1) lab analysis
required to establish presence or otherwise of ground
2. Contamination Survey
contamination requiring special precautions in relation to
handling / disposal or remediation.

Carry out a structural assessment of the existing foundations

3. Structure survey
and concrete structures scheduled to be re-utilised.

Carry out structural design assessment of the location and

construction of the new fire wall between SGT3 and SGT1 to
4. Fire Barrier Wall
ensure design meets all NGTS requirements for clearances
and fire retention.

Carry out structural design assessment of the location and

construction of the new fire walls between SGT2 and
5. Fire Barrier Wall adjacent Tilbury grain and Area Board Tx compound to
ensure design meets all NGTS requirements for clearances
and fire retention.
6.3 Plant
DATE
ITEM REQUIREMENT
RESOLVED
Nomenclature for new switchgear and equipment to be
1. Plant nomenclature
agreed on stage by stage ops diagrams.

Condition assessment to be carried out on Existing main and

2. Existing 400kV main and
reserve bar disconnectors to prove they are suitable for re
reserve bar disconnectors
use as part of this scheme design.

6.4 OHL
DATE
ITEM REQUIREMENT
RESOLVED

Location for new towers associated with the Chelsmford East

New 132kV towers / Braintree line to be confirmed as current proposed location
is on a hill side.

6.5 Cable
DATE
ITEM REQUIREMENT
RESOLVED

Easement requirements to accommodate all circuits to be

2. 132kV cable routing
confirmed

6.6 Site Infrastructure

DATE
ITEM REQUIREMENT
RESOLVED

1. Consider modifications to PAC system installation currently impedes clear access for
main 400kV access envisaged transformer delivery

Request all other utility records for circuits/services within the

2. Stats. Records.
vicinity of / crossing the Rayleigh substation site

6.7 Other Issues

DATE
ITEM REQUIREMENT
RESOLVED

1. Nuclear licence Establish whether the site re-configuration impacts on any

consideration NGC nuclear licences

Overall outage planning to be verified in relation to other

2. Liaison with other schemes
schemes which may be running concurrently.
7. ENERGIS COMMUNICATIONS LINK

EQUIPMENT IDENTITY STATUS / REQUIREMENT

Rayleigh 400/275kV No new requirements

8. SCS / DATABASE STATUS

EQUIPMENT IDENTITY STATUS / REQUIREMENT

Instem RTU Outstation installed and operational. Fully equipped.
SGT3 400kV bay
Database changes required to provide full SGT bay control and monitoring

9. DESIGN DELIVERY COMPLIANCE CHECKS

ITEM STATUS / REQUIREMENT

TBA

 Summarise extent of compliance checks required, targeting items of risk