Session-2

High Voltage Substations Design

Prepared by:
Team7
Heba Abdelaal Elsayed Abdelaal
Mennatullah Hamed Mansour
Mahmoud Abdelnaser Ahmed
Eslam Abdelghani Khattab
Ahmed Reda Abdelmeged
Mohamed Morsy Ahmed

Under the supervision of

Eng. Wael Kamal

Turned in 22 OCT,2024

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Table of Contents:
1. Introduction:.......................................................................................................................................... 4
2. Substation:............................................................................................................................................. 4
2.1 Introduction:.................................................................................................................................. 4
2.2 Classification of Substations: ........................................................................................................ 5
2.3 Bus-Bar Arrangements: ................................................................................................................. 6
2.3.1 Single bus: ............................................................................................................................. 6
2.3.2 Double bus single breaker: .................................................................................................... 7
2.3.3 Double bus double breaker: .................................................................................................. 7
2.3.4 Breaker-and-a-Half ............................................................................................................... 8
2.4 Substation Component: ................................................................................................................. 8
2.4.1 Busbar: .................................................................................................................................. 8
2.4.2 Circuit breaker: ..................................................................................................................... 8
2.4.3 Isolators or Isolating switches: .............................................................................................. 9
2.4.4 Earth switch: ......................................................................................................................... 9
2.4.5 Current transformers (CT): ................................................................................................... 9
2.4.6 Potential transformers (PT): .................................................................................................. 9
2.4.7 Lightning arresters (LA): ...................................................................................................... 9
2.4.8 Power transformers: .............................................................................................................. 9
2.4.9 Wave trap: ............................................................................................................................. 9
2.4.10 OHTL Bay in Details: ......................................................................................................... 10
2.4.11 Auxiliary Power Supply: ..................................................................................................... 10
3. Substation High Voltage Components: ............................................................................................... 12
3.1 Switchyard component:............................................................................................................... 12
3.2 Control Building: ........................................................................................................................ 12
3.3 Battery Room: ............................................................................................................................. 12
3.4 Mechanical, Electrical and Other Auxiliaries: ............................................................................ 12
3.5 General Layout Design: .............................................................................................................. 12
4. Interlocking Logic Diagrams: ............................................................................................................. 14
4.1 Interlocking ................................................................................................................................. 14
5. SAS “System Automation Solutions” ................................................................................................. 15
5.1 Introduction:................................................................................................................................ 15
5.2 Levels of Control ........................................................................................................................ 16

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5.3 Difference between control levels:.............................................................................................. 17
5.4 SAS HARDWARE SPECS: ........................................................................................................ 17

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 1. Introduction:
• The power system generally consists of three main elements: generation, transmission,
and distribution. A substation is part of the power system where voltage is transformed
from one level to another for transmission, distribution, transformation, and switching.
Electric power is produced at power stations, which are usually located in favorable
areas, often far from consumers.

• Electric power is delivered to consumers through an extensive network of transmission

and distribution systems. At various points along this network, it may be necessary to
change the voltage levels for reasons such as distribution efficiency or connecting
different regions within a utility grid. This is achieved using substations, which are
crucial components of the power system. In substations, voltage is transformed from
high to low or vice versa, facilitating transmission, distribution, transformation, and
switching of electricity. Different voltage levels are required for various applications.

• In the electrical grid, different voltage levels are used to perform various tasks. For
example, power is transmitted at high voltages (220 kV, 132 kV, 66 kV) and sometimes
at extra high voltages (400 kV, 500 kV, 765 kV), as well as ultra-high voltages (over
765 kV, according to IEC standards). Using high voltage for power transmission offers
several advantages, such as reducing ohmic losses, minimizing the cross-sectional area
of conductors, increasing power transfer capability, and enabling the transmission of
power over long distances.

2. Substation:
2.1 Introduction:
• Substations serve as the core of a unified utility electrical grid, connecting generation
stations across the country through the transmission network. They enhance grid
reliability by allowing operators to isolate faulty sections and maintain stability. The

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 national electrical grid, facilitated by substations, creates an economically efficient
power system by enabling power generation in one location and its transmission to
distant consumers.
2.2 Classification of Substations:
• Classification based on voltage levels:
1. LV (up to 1000V).
2. MV (1000V to 33kV).
3. HV (33 KV and 220 kV).
4. EHV (above 220KV).
5. HVDC Substation
• Classification based on Insulating Medium:
1. AIS
Air Insulated Substations (AIS) use air as the primary dielectric for phase-to-
phase and phase-to-ground insulation. While they have been in use for many
years, they require significant space and are more vulnerable to environmental
factors such as humidity, rain, and pollutants, which can degrade insulation.
Additionally, AIS infrastructure is susceptible to damage from seismic events,
leading to higher capital and operational costs due to frequent maintenance
needs.

Advantages:
1. The primary choice is for areas with extensive space.
2. Lower construction costs with quality design.
3. Reduced construction time, suitable for expedited installations.
4. Easier maintenance due to visible equipment.
Dis-Advantages:
1. Requiring more space than GIS.
2. Higher maintenance requirements, leading to increased costs.
Location:
1. Outdoor
2. Indoor

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 2. GIS:
Gas Insulated Substations (GIS) utilize gas as the primary dielectric medium,
providing effective insulation within a compact design. This technology has
become increasingly popular due to its numerous advantages.

Advantages:
1. GIS requires significantly less physical space compared to AIS,
making it ideal for urban areas with limited land availability.
2. Reduced Environmental Impact.
3. Lower Maintenance.

Dis-Advantages:
1. Higher Initial Costs
2. Complexity in Design
3. Limited Repair Options

Location:
1. Outdoor
2. Indoor
2.3 Bus-Bar Arrangements:
2.3.1 Single bus:

- This is the simplest bus arrangement, a single bus and all connections directly to one bus.
- Reliability of the single bus configuration is low; if the main bus or connections to circuit
breakers fail, the entire facility experiences an outage, even with proper relay protection.
- Maintenance of switching devices, an outage of the line they are connected to is required.
Furthermore, for a bus outage the entire facility must be de-energized. This requires standby
generation or switching loads to adjacent substations, if available, to minimize outages of loads
supplied from this type of facility.

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- Cost of a single bus arrangement is relatively low, but also is the operational flexibility, for
example, transfer of loads from one circuit to another would require additional switching
devices outside the substation.

2.3.2 Double bus single breaker:

- The double bus-single breaker arrangement connects each circuit to two buses, and there is a
tie breaker between the buses.
- With the tie breaker operated normally closed, it allows each circuit to be supplied from either
bus via its switches. Thus, providing increased operating flexibility and improved reliability.
For example, a fault on one bus will not impact the other bus. Operating the bus tie breaker
normally open eliminates the advantages of the system and changes the configuration to a two
single bus arrangement.
- The double bus–single breaker arrangement with two buses and a tie breaker provides for some
ease in maintenance, especially for bus maintenance, but maintenance of the line circuit
breakers would still require switching and outages as described above for the single bus
arrangement circuits.

2.3.3 Double bus double breaker:

- The double bus–double breaker arrangement involves two breakers and two buses for each
circuit. With two breakers and two buses per circuit, a single bus failure can be isolated without
interrupting any circuits or loads. Furthermore, a circuit failure of one circuit will not interrupt
other circuits or buses. Therefore, reliability of this arrangement is Extremely high.
Maintenance of switching devices in this arrangement is very easy, since switching devices
can be taken out-of-service as needed and circuits can continue to operate with partial line
relay protection and some line switching devices in-service, i.e., one of the two circuit breakers.

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2.3.4 Breaker-and-a-Half
- The breaker-and-a-half scheme is configured with a circuit between two breakers in a three-
breaker line-up with two buses: thus, one-and-a-half breakers per circuit. In many cases, this
is the next development stage of a ring bus arrangement. Like the ring bus, this configuration
provides good reliability; with proper operating relay protection, a single circuit failure will
not interrupt any other circuits. Furthermore, a bus section fault, unlike the ring bus, will not
interrupt any circuit loads. Maintenance as well is facilitated by this arrangement, since an
entire bus and adjacent breakers can be maintained without transferring or dropping loads.

2.4 Substation Component:

2.4.1 Busbar:
- When the number of lines operating at the same voltage levels needs to be connected
electrically, busbars are used. Busbars are conductors made of copper or aluminum, with very
low impedance and high current carrying capacity.

2.4.2 Circuit breaker:

- A circuit breaker is a circuit component that can open or close a circuit under normal and faulty
conditions. It is designed such that it can be operated manually under normal conditions and
automatically under fault conditions. It is a special type of switching device which can be
operated safely under huge current carrying conditions. It is used for timely disconnecting and
reconnecting different parts of the power system for protection and control.

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2.4.3 Isolators or Isolating switches:
- Isolators are employed in substations to isolate a part of the system for general maintenance.
Isolator switches are operated only under no load condition. They are provided on each side of
every circuit breaker.
2.4.4 Earth switch:
- It is a switch normally kept open and connected between the earth and conductor. If the switch
is closed it discharges the electric charge to ground, available on the uncharged line.
2.4.5 Current transformers (CT):
- The lines in substations carry currents in the order of thousands of amperes. The measuring
instruments are designed for low value currents. Current transformers are connected in ines to
supply measuring instruments and protective relays.
2.4.6 Potential transformers (PT):
- The lines in substations operate at high voltages. The measuring instruments are designed for
low value voltages. Potential transformers are connected in lines to supply measuring
instruments and protective relays. These transformers make low voltage instruments suitable
for measurement of high voltages.
2.4.7 Lightning arresters (LA):
- Lightning arresters are the protective devices used for protection of equipment from lightning
strokes. They are located at the starting of the substation and also provided near the transformer
terminals.
2.4.8 Power transformers:
- Power transformers are used generation and transmission network for stepping-up the voltage
at generating station and stepping-down the voltage for distribution. Auxiliary transformers
supply power to auxiliary equipment’s at the substations.
2.4.9 Wave trap:
- This equipment is installed in the substation for trapping the high frequency communication
signals sent on the line from remote substation and diverting them to the telecom panel in the
substation control room. Example for Substation:

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2.4.10 OHTL Bay in Details:

2.4.11 Auxiliary Power Supply:

- By Step-down Transformer

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* The Substation is 220/22kV, 2×75 MVA Outdoor transformers, indoor
GIS type, expandable by a third similar transformer.
* The substation will be connected to the unified 220kV network through opening one circuit
of the existing 220k double circuit single conductor overhead transmission lines.

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 3. Substation High Voltage Components:
3.1 Switchyard component:
• Incoming Lines
• Outgoing Lines
• Busbars
• Transformers
• Insulators
• Capacitor banks
• Circuit-breakers, isolators,
• Earthing switches, surge arresters, CTs,
• VTs, neutral grounding equipment.
• Station cars parking
3.2 Control Building:
• Low voltage AC Switchgear.
• Medium voltage switchgear.
• AC/ DC Room
• SCADA panel’s location
• Control Panels, Protection Panel
3.3 Battery Room:
• D.C. Batteries system
• Washing latrine
3.4 Mechanical, Electrical and Other Auxiliaries:
• Auxiliary Transformers
3.5 General Layout Design:
• Gantry Area

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• Transformer Area:

• Control Building:

• Switchgear Room:

• General Layout:

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 4. Interlocking Logic Diagrams:
4.1 Interlocking

Examples:

[ &]: AND Gate

[>=1]: OR Gate
- We can make this Logic gates depend on states of each element:

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 5. SAS “System Automation Solutions”
5.1 Introduction:
- The System Automation Solutions (SAS) plays a pivotal role in modern industrial
environments by integrating various control and monitoring systems. SAS focuses on the
seamless collection, processing, and analysis of data from multiple sources, ensuring real-
time visibility and control over operations. This system based on IEC 61850 substation
automation protocol. All devices in the network must support IEC 61850.
- The integration of digital signal processing, particularly through units like the Basic
Control Unit (BCU). All analog signals are collected and converted into digital signals.
This conversion allows for more efficient data handling.
- For Example: Circuit Breaker (C.B) signals, each condition—such as open, close, and
trip—is monitored. Each state is represented by a specific electrical signal, for instance,
one state might be at 110 Volt DC.
- All signals are gathered in the control unit, where they are analyzed and classified by a
SAS Engineer. This step is essential to ensure data accuracy and prepare it for further use.
All signals are gathered in the control unit, where they are analyzed and classified by a
SAS Engineer. This step is essential to ensure data accuracy and prepare it for further use.

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5.2 Levels of Control
5.2.1. Switch Yard Components: The switch yard includes essential components such as
Disconnect Switches (D.S), Circuit Breakers (C.B), Earthing Switches (E.S), Gas
Monitoring Boxes, Current Transformers (C.T), and Voltage Transformers (V.T).
These elements play a critical role in managing electrical flow and ensuring safety.
5.2.2. Local Control Cabinet (LCC): After the circuit breaker, cables are routed to the
Local Control Cabinet (LCC). This cabinet serves as the first point of control,
allowing for local monitoring and manual operation of connected devices.
5.2.3. Remote Control Cabinet (RCC): From the LCC, cables are then extended to the
Remote-Control Cabinet (RCC). The RCC facilitates remote monitoring and control,
enabling operators to manage systems from a distance.
5.2.4. Integration with BCU: The next step involves connecting the RCC to the Basic
Control Unit (BCU). The BCU aggregates data from various sources, providing a
centralized point for processing and control.
5.2.5. HMI Integration: Finally, the BCU is integrated with the Human-Machine
Interface (HMI). This integration allows for visual representation of signals and
system statuses on the HMI screen. This integration means that all signals can be
displayed as graphical representations on the screen. Operators can interact with the
HMI to send and receive commands, making it easier to monitor and control the
system effectively. The HMI provides a user-friendly interface, enabling quick
responses to operational needs.

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5.3 Difference between control levels:

5.4 SAS HARDWARE SPECS:

1. B BCU (Bay Control Unit): Each bay is equipped with two BCUs—one designated
as the MAIN unit and the other as a redundant unit for reliability.
2. Industrial Computers: The system includes three industrial computers: two Operator
Workstations (OWS) and one Engineering Workstation (EWS).
3. Industrial Gateways (GTWs): There are four industrial gateways; two are used for
communication with the NECC, while the other two facilitate communication with
the Planet DCS.
4. Data Archiving Unit: This unit archives the substation's status, alarms, events, and
measurements over multiple years, enabling easy retrieval of any historical data at
any time.
5. LCD Screens: The setup features two extended screens for each Operator
Workstation (OWS1 and OWS2) and one additional screen for the Engineering
Workstation.

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6. Laser Color Printer: A laser printer is available for printing data from the
Engineering Workstation (EWS).
7. Industrial Servers: Two industrial servers are included; the first serves as the main
server (Server 1) and the second acts as a redundant server (Server 2).
8. Dot Matrix Printers: Two dot matrix printers are provided—one functions as the
main printer for events from Server 1, and the other serves as a backup for Server
9. GPS Clock: A GPS clock is utilized to synchronize the system time across all
devices, including protection relays, bay control units, and fault recorders.

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