SUBSTATION

DESIGN MANUAL

December 2012
Asset Management Department, TNB Distribution Division
 Chapter 1: Introduction
1 Introduction
Background
1
1
Objectives
Scope of this Manual
3
3
i
Chapter 2: Substation Design & Configuration
Overview 6 Electrical Clearance 12

2 Design Philosophy
Substation Categories
7
8
Site Considerations
Operation and Maintenance
13
SUBSTATION
Considerations 17
Major Components 10
Safety Considerations 17
DESIGN MANUAL
Chapter 3: PMU, PPU and 33kV SSU Design The TNB power distribution
3
Introduction 18 Mini PPU 34 network includes medium and low
Pencawang Masuk Utama 33kV Primary Switching Station
(PMU) 18 (33kV SSU) 50 voltage power lines, substations,
Pencawang Pembahagian Utama Testing and switching stations and metering
(PPU) 26 commissioning 54 system.
Chapter 4: P/E, 11kV SSU and S/S Design
4 Introduction 55 Switching Station (S/S) 93
Proper design and construction of
the substations is aimed to ensure a
Indoor Distribution Substation Compact Substation Unit
(Indoor P/E) 60 (CSU) 95 reliable and robust electricity
11kV Primary Switching Pole Mounted Substation distribution network. This is
Station (11kV SSU) 82 (PAT) 105 important in order to achieve
5 Outdoor Distribution
Substation (Outdoor P/E) 85
Pole Mounted Substation
(PAT) with RMU 125
optimum system performance,
reduce system losses and improve
Chapter 5: Design for Substations with Special Requirements customer satisfaction.
Mobile SSU 130 Flood Prone Areas 144

6
This manual covers the distribution
Chapter 6: Primary Equipment
substations and related equipment.
Transformers 153 Feeder Pillar 257
Switchgear 211 Current Transformer (CT) 264
The manual is a compilation of
Neutral Earthing System 239 Potential Transformer (PT) 270 various documents, circulars and
Medium Voltage Fuse 252 requirements pertaining to the

7 Chapter 7: Secondary Equipment

design and construction of the
distribution network.
Overview 273 Secondary Wiring 296
Protection/Protective Metering 297
Relaying 273 Communications 302
Control 284 Other Secondary
8 DC & AC Auxiliary Systems
Heater
289
294
Equipment 308

Chapter 8: SCADA System

Overview 320 Remote Terminal Unit
Master System 322 (RTU) 325

9 Communication System 324 SCADA-ready Substations 329

Chapter 9: Earthing
Overview 330 Earth Connections
Earth Connections Below-Ground 353
Above-Ground 334
10 Chapter 10: Fire Fighting System
Overview 363 System Components 372
Fire System Requirements
for TNB Substations 364

11 Mobile Equipment
Chapter 11: New Technology
375 Cast Resin and Synthetic December 2012
Energy Efficient Distribution Ester 390
Transformers 384 RMU CB 395 Asset Management Department
Containerised PPU 402 TNB Distribution Division
Substation Design Manual

December 2012

Asset Management Department

Distribution Division
Tenaga Nasional Berhad
Wisma TNB
Jalan Timur, Petaling Jaya
Selangor

Disclaimer: This Substation Design Manual is a document providing technicians, engineers, and
managers of the Distribution Division of Tenaga Nasional Berhad with an understanding of proper
substation system design. The information in this document has been prepared in good faith and
represents the Asset Management Department’s intentions and opinions at the date of issue.
The Asset Management Department may change any information in this document at any time.
ii Substation Design Manual

Acknowledgement
We would like to express our deepest gratitude to the management of the Distribution Division,
for giving us the opportunity to develop the TNB Distribution Division’s Substation Design Guide.

Special thanks to Hj. Ismail Mohd Din (SGM), Hj. Esmet Sidqie bin A.Muttalib, Young Zaidey bin
Yang Ghazali, Sharizal bin Shamuri, Hannah binti Ahmad Rosli and Mohd Khairul Ikram bin Ghazali
from Substation Section, Engineering Service Unit, Asset Management Department for their
valuable contribution and assistance in developing this manual.

Our appreciation goes to Ideris Shamsudin from Pejabat Pengurus Kawasan Petaling Jaya;
Tan Siew Hwa from Unit Perancangan dan Pembangunan Sistem; Hj. Muhamad Subian Sukaimy,
Dr. Abd Rahman bin Khalid and Zaini Zainal from Protection; Mohd Jaffery Raffles and Sek Yean
Ling from SCADA; Noor Adnan Abdul Aziz, Mohd Fatani bin A Rahman, Ahmad Ridhaudin Abdul
Razak, Mohd Fauzi bin Mohd Ismail and Ahmad Suhaimi bin Mohamed from Jabatan Perancangan
& Pembangunan Aset; Mohd Faris Ariffin from Overhead Section, Engineering Service Unit;
Zahari Dollah and Mohammad Khuzairee bin Ibrahim from Unit Perkhidmatan Pengurusan Aset;
Mohd Fahami Jaapar and Kamarul Azam Abu Kassim from Unit Perkhidmatan Perjangkaan; and
finally Mohd Nazri bin Rahmat and Syamsul Fahrizal bin Samsu from Pengurus Kawasan Kulim.

The project team would also like to express our gratitude to Pairolani bin Safari @ Hj Hashim and
Govindan Gopal from ILSAS, Bangi. Not forgetting Nurul Azlina Abdul Rahman, Ir. Noradlina
Abdullah and Mohd Aizam bin Talib from TNB Research Sdn. Bhd. and Muhamad Faiq Mohd Rozi
from MTM Sdn. Bhd.

Our appreciation also goes to the Uniten Team, comprising Mohd Zafri Baharuddin, Fareha binti
Mohd Zainal, Dr. Noor Miza binti Muhamad Razali, Adzly Anuar, Nadhira binti Mat Nashim,
Shahrul Iznan, Nurul Aishah binti Mohd Rosdi, Redia binti Mohd Redzuwan, Kamalambigai A/P
Munusamy, Nurulaqilla binti Khamis and Norizzati Shafinaz binti Sabri for their untiring efforts
and patience towards the successful completion of this manual.

We welcome any feedback and improvement advice that will be useful for future revisions of this
manual.

Thank you.

Ir. Wan Nazmy bin Wan Mahmood

General Manager,
Engineering Services,
Asset Management Department,
Distribution Division, TNB.
 Substation Design Manual iii

Foreword
VP Distribution Division, Datuk Ir. Baharin Din

As Malaysia progresses to achieve Vision 2020, TNB

plays a vital role in ensuring sufficient and strategic
injection of electricity power is available by the
building Transmission Main Intake Substations,
Primary Distribution Substations and Distribution
stations. With continuous expansion of the
distribution network and its ever challenging
environment, it is essential that the spirit of “do it right the first time” be
instilled among TNB personnel and appointed contractors. Properly designed
substations and correct installation of related equipment will ensure reliable
and quality power supply, longer equipment lifespan and improved system
security as well as safety.

From time to time, various technical and engineering circulars and guidelines
have been issued to ensure standard practices on substation design,
construction and installation are practiced among the states and areas.
However, there is a need to compile these guidelines in a form of a practical
handbook to be made more available and accessible for easy reference
throughout the Distribution Division.

TNB Distribution Division through the Distribution Asset Management

Department, in collaboration with ILSAS and Universiti Tenaga Nasional, have
taken a step forward to develop this manual which incorporates the latest
technological changes in substation equipment and design, existing relevant
instructions and circulars, as well as approved technical specifications.

Therefore, I would like to take this opportunity to congratulate the project

team from the Asset Management Department, as well as ILSAS, TNB
Research and Universiti Tenaga Nasional, for their impressive effort in
developing this useful manual for substation design for the distribution
system.

Thank you.
iv Substation Design Manual

Table of Contents
Chapter 1: Introduction ..............................................................................1
1.1. Background ...................................................................................1
1.2. Objectives .....................................................................................3
1.3. Scope of this Manual .....................................................................3
Chapter 2: Substation Design & Configuration ...........................................6
2.1. Overview .......................................................................................6
2.2. Design Philosophy .........................................................................7
2.3. Substation Categories ....................................................................8
2.4. Major Components ...................................................................... 10
2.5. Electrical Clearance ..................................................................... 12
2.6. Site Considerations ...................................................................... 13
2.7. Operation and Maintenance Considerations ................................ 17
2.8. Safety Considerations .................................................................. 17
Chapter 3: PMU, PPU and 33 kV SSU Design ............................................18
3.1. Introduction ................................................................................ 18
3.2. Pencawang Masuk Utama (PMU) ................................................. 18
3.3. Pencawang Pembahagian Utama (PPU) ....................................... 26
3.4. Mini PPU ..................................................................................... 34
3.5. 33kV Primary Switching Station (33 kV SSU) ................................. 50
3.6. Testing and commissioning .......................................................... 54
Chapter 4: P/E, 11 kV SSU and S/S Design ................................................55
4.1. Introduction ................................................................................ 55
4.2. Indoor Distribution Substation (Indoor P/E) ................................. 60
4.3. 11 kV Primary Switching Station (11 kV SSU) ................................ 82
4.4. Outdoor Distribution Substation (Outdoor P/E) ............................ 85
 Substation Design Manual v

4.5. Switching Station / Stesen Suis (S/S) ............................................ 93

4.6. Compact Substation Unit (CSU) ................................................... 95
4.7. Pole Mounted Substation (PAT) ................................................. 105
4.8. Pole Mounted Substation (PAT) with RMU ................................ 125
Chapter 5: Design for Substations with Special Requirements ............... 130
5.1. Mobile SSU ............................................................................... 130
5.2. Flood Prone Areas ..................................................................... 144
Chapter 6: Primary Equipment .............................................................. 153
6.1. Transformer .............................................................................. 153
6.2. Switchgear ................................................................................ 211
6.3. Neutral Earthing System ............................................................ 239
6.4. Medium Voltage Fuse ............................................................... 252
6.5. Feeder Pillar .............................................................................. 257
6.6. Current Transformer (CT) .......................................................... 264
6.7. Potential Transformer (PT) ........................................................ 270
Chapter 7: Secondary Equipment .......................................................... 273
7.1. Overview .................................................................................. 273
7.2. Protection/Protective Relaying .................................................. 273
7.3. Control...................................................................................... 284
7.4. DC & AC Auxiliary Systems......................................................... 289
7.5. Heater ...................................................................................... 294
7.6. Secondary Wiring ...................................................................... 296
7.7. Metering ................................................................................... 297
7.8. Communications ....................................................................... 302
7.9. Other Secondary Equipment ..................................................... 308
vi Substation Design Manual

Chapter 8: SCADA System ...................................................................... 320

8.1. Overview ................................................................................... 320
8.2. Master System .......................................................................... 322
8.3. Communication System ............................................................. 324
8.4. Remote Terminal Unit (RTU) ...................................................... 325
8.5. SCADA-ready Substations .......................................................... 329
Chapter 9: Earthing ................................................................................ 330
9.1. Overview ................................................................................... 330
9.2. Earth Connections Above-Ground .............................................. 334
9.3. Earth Connections Below-Ground .............................................. 353
Chapter 10: Fire Fighting System .............................................................. 363
10.1. Overview ................................................................................... 363
10.2. Fire System Requirements for TNB Substations .......................... 364
10.3. System Components .................................................................. 372
Chapter 11: New Technology ................................................................... 375
11.1. Mobile Equipment ..................................................................... 375
11.2. Energy Efficient Distribution Transformers ................................. 384
11.3. Cast Resin & Bio-Degradable Oil Immersed Transformers ........... 390
11.4. RMU CB ..................................................................................... 395
11.5. Containerised PPU ..................................................................... 402
Appendix ................................................................................................... 406
Appendix A: Metering Calculations ......................................................... 406
Appendix B: CPPU Bukit Gambir Earthing Calculations ............................ 407
Appendix C: IP – Ingress Protection Ratings............................................. 428
List of Abbreviations ................................................................................... 431
Glossary ..................................................................................................... 435
 Introduction 1
1

Chapter 1: Introduction

1.1. Background
Electricity distribution is the delivery of electricity from the transmission
network to end users or customers through the distribution network as shown
in Figure 1-1. The TNB power distribution network includes medium and low
voltage power lines and cables, substations, switching stations and metering
system. Typical medium voltage in the network is 11 kV and 33 kV. Some
parts of Perak and Johor distribution network consist of 6.6 kV and 22 kV
systems; however these are being phased out in stages.

Distribution substations consist of equipment such as transformers and circuit

breakers, and are interconnected by a network of underground cables and
overhead power lines. There are several types of distribution substations
which can either be of outdoor or indoor design, and either stand-alone or
attached to a building.

The functions of a distribution substation may include a combination of the

following:

(a) To manage the distribution network by switching elements in and out of

the system to transmit power from main intake stations or other
networks to load centres and in some cases direct to consumers.
(b) To change or transform voltage levels within the distribution network,
such as 33kV/11kV and/or 11kV/0.4kV
(c) To provide data concerning system parameters (voltage, current flow,
power flow) for use in operating the utility system.
(d) To isolate faulted section from the healthy sections of the distribution
network.
(e) To allow an element to be isolated from the rest of the distribution
network for maintenance or repair.
 2 Substation Design Manual
1

GENERATION

132kV 132kV 275kV

132kV/275kV
TRANSMISSION

275kV/132kV 275kV/132kV

PMU PMU
132kV/11kV 132kV/33kV

PPU PPU
33kV/11kV
DISTRIBUTION

33kV SSU

S/S 11kV SSU

P/E
11kV/0.4kV
CUSTOMER

Residential Commercial Industrial

Figure 1-1: Electricity supply network

 Introduction 3
1
1.2. Objectives
Proper design and construction of the substations is aimed to ensure a
reliable and robust electricity distribution network. This is important in order
to achieve optimum system performance, reduce system losses and improve
customer satisfaction.

1.3. Scope of this Manual

This manual covers the distribution substations and related equipment. The
manual is a compilation of various documents, circulars and requirements
pertaining to the design and construction of the distribution network.

Topics in this manual are arranged according to the following chapters:

Chapter 2: Substation Design & Configuration

This chapter provides an overview of the different types of substations, along
with their design philosophy and type selection criteria.

Chapter 3: PMU, PPU and 33 kV SSU Design

This chapter covers main design criteria for Main Intake
Substation/Pencawang Masuk Utama (PMU), Primary Distribution
Substation/Pencawang Pembahagian Utama (PPU), and 33 kV Primary
Switching Station/Stesen Suis Utama (33 kV SSU).

Chapter 4: P/E, 11 kV SSU and S/S Design

This chapter details out the main design criteria for all distribution substations
and switching stations of 11 kV and below. These are the indoor and outdoor
substations/pencawang elektrik (P/E), compact substation units (CSU), pole
mounted substations (H-pole), 11 kV primary switching station/stesen suis
utama (11 kV SSU) and switching stations/stesen suis (S/S).

Chapter 5: Design for Substations with Special Requirements

This chapter covers substations under special requirements such as Mobile
SSU for rapid deployment situations and mitigation construction methods for
substations located in flood prone areas.
 4 Substation Design Manual
1
Chapter 6: Primary Equipment
This chapter describes the substation primary equipment such as
transformers, switchgears, Neutral Earthing Resistors (NER) and feeder pillars.

Chapter 7: Secondary Equipment

This chapter explains secondary equipment that covers the functions of
protection, metering and communication. These include instruments, relays,
control panels, DC and LV supply and optical fibres.

Chapter 8: SCADA System

This chapter briefly explains the structure of the SCADA system for remote
monitoring and control of geographically dispersed assets to Regional Control
Centres. This chapter also explains the main functions and equipment related
to this system.

Chapter 9: Earthing
The chapter primarily covers the objectives of good earthing design, the earth
connections above and below ground levels and the earthing components
used.

Chapter 10: Fire Fighting System

Fire fighting system requirements for TNB substations are discussed in this
chapter. The fire fighting system components are also introduced.

Chapter 11: New Technology

The chapter covers several new technologies which are introduced to the
distribution system in order to increase system reliability, security and
efficiency. The chapter covers mobile equipment, RMU circuit breaker and
containerised PPU.
 Introduction 5
1
This manual is a mandatory guide for distribution substation design
requirements in any Region and Area (kawasan).

Additional supporting documents to accompany this manual include:

1. Electricity Supply Application Handbook (ESAH), where dimensions of the

various types of built up P/E design is detailed out.

2. Buku Panduan Piawai Baru Rekabentuk Pencawang Elektrik (Jenis

Bangunan) Bahagian Pembahagian, for schematic drawings of standard
PPU design.

3. Distribution Planning Guidelines, where basic principles and general

policies of distribution system planning are outlined.

4. Underground Cable System Design Manual, for interconnecting cable

specifications.

5. Penyambungan Pengalir Kabel Bawah Tanah, as a guideline for conductor

connection techniques.

6. Capacitor Bank Guideline, for information on capacitor banks inside

substations.

7. For testing and maintenance methods, please refer to the latest editions
of the following documents:

o Transformer Maintenance Manual

o Switchgear Maintenance Manual
o Cable Maintenance Manual
 6 Substation Design Manual

Chapter 2: Substation Design &

2 Configuration

2.1. Overview
Substation design depends on many factors, either from geographical,
technical, regulatory, or demographic requirements which determine the type
of substation to be constructed.

The main issues in determining the design of a particular substation are

reliability and cost. A good design attempts to strike a balance between these
two, to achieve sufficient reliability at the optimum cost.

Sufficient land area is required for installation of equipment with necessary

clearances for electrical safety and sufficient access to perform operation and
maintenance of components such as transformers and circuit breakers. In
dense urban areas where land is costly, gas insulated switchgear may save
money overall.

The design should also allow easy expansion of the station, if required.
Environmental effects of the substation must be considered, such as drainage,
noise, water supply and road traffic. Earthing must be calculated to protect
equipment in case of a short circuit in the distribution system. Ideally, the
substation site must be reasonably central to the distribution area to be
served.
 Introduction 7

2.2. Design Philosophy

TNB Distribution Division substations are designed with objectives to ensure:
2
(a) Correct engineering practice

(b) Compliance with acts and regulations

(c) Availability, reliability and security of supply

(d) Optimisation of cost – Using TNB Engineering economics model (Financial

Evaluation Template from MV Planning Guideline)

(e) Ease of construction, operation and maintenance of substations

(f) Safety of public, personnel and equipment

(g) Customer requirements are fulfilled

(h) Flexibility to meet changing demand

(i) Adoption of green initiatives

(j) Consideration of climate and environmental change

(k) Positive corporate image

(l) Prolonged equipment life through life cycle and risk assessment
 8 Substation Design Manual

2.3. Substation Categories

Substations are categorised according to the voltages they handle and
2 whether the substation performs voltage transformations or only switching
functions.

2.3.1. Transmission Main Intake /

Pencawang Masuk Utama (PMU)
Transmission Main Intake Substation / Pencawang Masuk Utama (PMU) is the
interconnection point of 132 kV or 275 kV to the distribution network. The
typical transmission capacity and voltage transformation provided at the PMU
are as follows:
 132/33kV, 2 x 90 MVA
 132/11kV, 2 x 30 MVA
Other voltage transformations are also catered for based on special site
requirements.

2.3.2. Primary Distribution Substation /

Pencawang Pembahagian Utama (PPU)
Primary Distribution Substation is normally applicable to 33 kV and 22 kV
interconnecting networks with 11 kV networks. It provides capacity injection
into 11 kV network through a standardized transformation of 33/11 kV or
22/11 kV.

Typical transformer capacities used in PPU are 7.5 MVA, 15 MVA and 30 MVA.

2.3.3. Primary Switching Stations / Stesen Suis Utama (SSU)

Primary Switching Stations / Stesen Suis Utama (SSU) are stations with circuit
breakers, established to serve the following function:-.
 To supply a dedicated bulk consumer at 33 kV, 22 kV or 11 kV.
 To provide bulk capacity injection or transfer from a PMU/PPU to a
load centre for further localized distribution.
This manual will detail out the 33 kV SSU and 11 kV SSU.
 Introduction 9

2.3.4. Distribution Substation / Pencawang Elektrik (P/E)

A distribution substation / Pencawang Elektrik (P/E) is a combination of
switching, controlling, and voltage step-down equipment arranged to reduce 2
medium voltage (MV) of 33 kV, 22 kV and 11 kV to low voltage (LV) for
residential, commercial, and industrial loads.

Typical capacity ratings are 1000 kVA, 750 kVA, 500 kVA, 300 kVA and 100
kVA. The design of these substations varies widely according to network
requirement.

Some distribution substations would include a dedicated customer substation

with a metering room. This substation would be similar to the typical
distribution substation except that all of its capacity would be reserved for the
service of one customer. Coordination with the customer is of primary
importance in determining the technical requirements.

Standardized M & E designs of 11/0.4 kV substations are available in the latest

version of the Buku Panduan Piawai Baru Rekabentuk Pencawang Elektrik
(Jenis Bangunan) Bahagian Pembahagian, TNB.

2.3.5. Switching Stations / Stesen Suis (S/S)

Switching Stations / Stesen Suis (S/S) are stations with RMU or VCB which
normally do not contain transformers and operates only at a single voltage
level to distribute to feeders.
 10 Substation Design Manual

2.4. Major Components

The specifications for major components are determined by the parameters
2 of the power system and their expected functionality when in operation. The
following are some functional descriptions of major components in a
substation. Selection of equipment requires the utmost consideration. Cost,
schedule, and performance penalties may be incurred as a result of improper
selection.

Other associated subsystems in the electrical installation of substations

include protection, metering, control and communication systems, earthing
system, fire fighting system, lighting system and security system.

2.4.1. Transformer
 Transformers step up or step down voltages and transfer power to
different voltage levels.
 Power transformers work at the MV level and above.
 Distribution transformers function to step down to low voltage
distribution voltages.
 Local transformers are distribution transformers that provide supply
locally to the substation only.

2.4.2. Switchgear
 Switchgear is a switching device used to control, protect and isolate
electrical network.
 It may comprise of disconnectors, switches, fuses or circuit breakers.
 Typically, for MV switchgears, they are compartmentalised and metal-
enclosed.
 Configuration may be of single or double busbar system.
o A busbar is a strip or bar of copper, brass or aluminium that conducts
electricity within a substation.
o Busbars connect incoming and outgoing circuits.
 Introduction 11

2.4.3. Circuit Breaker

 The circuit breaker is a component inside the switchgear.
 A circuit breaker is an automatically operated electrical switch designed 2
to protect an electrical circuit from damage caused by overload or short
circuit. Its basic function is to detect a fault condition and, by interrupting
continuity, to immediately discontinue electrical flow.
 They are located at designated switching points or both ends of protected
zones.

2.4.4. Disconnector/Isolator
 Disconnector/isolators function to provide isolation from live parts for the
purpose of maintenance.
 They can only be operated in off-load condition.
 They are located inside the switchgear.
 Separate isolators are used for pole-mounted installations.

2.4.5. Lightning Arrestors

 In overhead installations, lightning arrestors function to discharge over-
voltage surges to earth and protect the equipment insulation from
lightning surges.
 They are connected between phase conductor and earth.
 Located at the end of an incoming line and also near transformer
terminals, they form the first line of defence against surges into the
substation.

2.4.6. Potential Transformers

 Potential Transformers (PT) function to step down voltage for
measurements, protection and control.
 They are located on the feeder side of the circuit breaker.
 There are also known as Voltage Transformers (VT).

2.4.7. Current Transformers

 Current Transformers (CT) steps down current for load measurement,
protection and control.
 12 Substation Design Manual

2.5. Electrical Clearance

2 2.5.1. Safety Clearance

Safety clearance is the minimum distance to place partitions of safety barriers
from normally exposed live parts while working in a substation. The minimum
safety clearance is shown in Table 2-1.

2.5.2. Working Clearance

Working clearance is the minimum safe distance to be observed between
normally exposed live parts and any person or tools while working in a
substation. The minimum working clearance is shown in Table 2-1.

2.5.3. Phase Clearance

Phase-to-earth and phase-to-phase clearances should be coordinated to
ensure that possible flashovers occur from phase to earth rather than from
phase to phase. The minimum phase clearance is shown in Table 2-1.

Table 2-1: Minimum phase clearance in millimetres

Description 275 kV 132 kV 33 kV 22 kV 11 kV
Safety clearance between earth
and the nearest point not at 2440 2440 2440 2440 2440
earth potential of an insulator
Safety clearance between earth
and the nearest live unscreened 4570 3500 2740 2740 2590
conductor
Working clearance between any
person or person with tools to 3050 2440 1220 1220 914
earth

Phase/Live metal to earth 2082 1270 381 279 203

Phase/Live metal to different

2388 1473 432 330 254
phase
 Introduction 13

2.6. Site Considerations

2.6.1. General 2
It is becoming increasingly important to perform initial site investigations prior
to the procurement of substation site. The following factors should be
evaluated when selecting a substation site:

(a) Location of present and future load centre

(b) Location of existing and future sources of power
(c) Availability of suitable right-of-way and access to site by overhead or
underground transmission and distribution circuits
(d) Location of existing distribution lines
(e) Access roads into the site for heavy equipment under all weather
conditions
(f) Possible objections regarding appearance or noise
(g) Soil resistivity
(h) Drainage and soil conditions
(i) Cost of earth removal, earth addition, and earthmoving
(j) Atmospheric conditions: salt and industrial contamination
(k) Cost of cleanup for contaminated soils or buried materials
(l) Space for future as well as present use
(m) General topographical features of site and immediate neighbouring areas;
avoidance of floodplains or wetlands
(n) Public safety and public concern; avoidance of schools and playgrounds
(o) Security from theft, vandalism, damage and sabotage
(p) Total cost including transmission and distribution lines with due
consideration of environmental factors
(q) Possible adverse effects on neighbouring communications facilities

2.6.2. Appearance
Appearance is becoming increasingly important to the public. In some areas,
zoning regulations and suggestions by local authorities often mean screening,
painting, or other measures to improve appearance. The general trend is to
locate substations in a way that they are not strikingly visible to the public.
 14 Substation Design Manual

A substation set back from a heavily travelled road may be acceptable with
little or no architectural treatment.
2 Substations strategically located facing main roads can be used to place
1
company contact information .

Generally, it is better to use complementary rather than contrasting colours.

2
Colouring can be used to blend substation equipment into the background .

Lighting in the compound is typically a means to deter vandalism and theft. It

also provides safety for crews who may be performing maintenance at night.

2.6.3. Public Safety

Substations should be safe for people who may have occasion to be near
them. The primary means of ensuring public safety at substations is by the
erection of a suitable barrier such as a fence.

Appropriate warning signs should be posted on the substation’s barrier fence

or walls. For each substation site, assess whether standard signs are sufficient.
Special bilingual signs or additional signs, such as “No Trespassing” / “Dilarang
Masuk”, may be advisable for some areas.

2.6.4. Effluent
Effluent is water pollution, such as liquid waste or sewage from industrial
facilities discharged into surface waters. Upon the failure of a container filled
with a pollutant, such as oil in a transformer or oil circuit breaker, no harmful
quantity of such pollutant (oil) may be allowed to enter a navigable waterway.
For PPU, it is necessary to have a Spill Prevention Control and
Countermeasures (SPCC) plan of action for disposing of effluent, should spills
or leaks occur.

1
Arahan Naib Presiden (Pembahagian) TNB (Dasar Perkhidmatan dan Amalan
Kejuruteraan), Bil. A08/2012, Penceriaan Pencawang Pembahagian Utama dan
Pencawang Elektrik Jenis Bangunan TNB.
2
Arahan Naib Presiden (Dasar Perkhidmatan dan Amalan Kejuruteraan), Bil. A02/2010,
Penggunaan Warna Cat yang Dibenarkan untuk Dinding Luar Semua Bangunan
Pencawang Baru TNB.
 Introduction 15

2.6.5. Weather
As dependence on the use of electricity grows, it is increasingly important that
substations operate more reliably in extremes of weather than in the past. 2

2.6.5.1. Rain
Malaysia’s climate experiences an average of 250 centimetres of rain per year.
As such, a substation should be designed to be operable under predictable
conditions of rainfall.

Flood prone areas are to be avoided. Mitigation methods for substations in

flood prone areas are explained in Chapter 5.2.

Rain can also lead to soil erosion. Areas prone to soil erosion such as steep
slopes are to be avoided.

2.6.5.2. Lightning
Malaysia has among the highest number of lightning strikes per year in the
world. Typically, for a tropical country, the keraunic level ranges between 100
to 180 Thunderstorm days per year (based upon the Malaysian
Meteorological Office).

Lightning can cause transient conditions which can trip circuit breakers and/or
damage equipment. Lightning surge arresters are the measure normally
employed for pole-mounted substation lightning protection. For substation
buildings, shielding is provided by lightning rods.

2.6.5.3. Humidity
Being in a tropical climate, the equipment must also operate under high
humidity conditions. Consideration should be given to install differential
thermostat-controlled heating in cabinets such as circuit breaker enclosures
where condensation could be a problem.

2.6.5.4. Altitude
Equipment that depends on air for its insulating and cooling medium will have
a higher temperature rise and a lower dielectric strength when operated at
higher altitudes. Dielectric strength of air, current ratings of conductors
 16 Substation Design Manual

operated in air, and ambient temperatures should be corrected for altitude

variation. Applications above normal specified elevation limits are considered
2 special, and the manufacturer should be consulted for a recommendation.

2.6.6. Other Considerations

2.6.6.1. Wildlife and Livestock
A substation should be protected from wildlife and livestock. The primary
means of protection is the perimeter barrier. This is generally a chain link
fence that keeps out larger animals. It may also be necessary to have rodent
and/or reptile barriers. Insect screening should be applied where local
experience indicates it is beneficial. Avoiding attractive nesting and perching
sites usually minimizes damage by birds. Adequate clearances and insulation
should be provided to prevent electrocution of wildlife.

2.6.6.2. Airborne Foreign Material

Airborne seeds, leaves, debris, dust, and salts that are local phenomena could
be a problem. Build-up could occur that would compromise electrical
insulation or interfere with cooling. Appropriate prevention measures should
be included in the design of a substation expected to be exposed to such
contamination.

2.6.6.3. Reactive Gasses

If a substation is to be situated next to a sewage treatment plant, landfill or
waste disposal facility, the developer must take preventive measures to avoid
reactive gasses from entering the substation area. These measures must be
proven before approval can be considered. If reactive gasses from nearby
sources cannot be contained, it is a priority to relocate the substation to
another location. If relocation is infeasible due to prior planning approval or
etc., the developer must provide all undertaking related to the substation.
 Introduction 17

2.7. Operation and Maintenance Considerations

The substation site must have infrastructure facilities such as roads, drains,
water pipes, and sewage system, whichever is required. Substation sites
2
should also consider land setback requirements, road widening reserves,
rivers, routes in and out of street corners and reserve buildings or space for
future expansion.

For simplicity and ease of maintenance, substation equipment arrangements,

electrical connections, signs, and nameplates should be as clear and concise
as possible.

A substation may occasionally experience emergency operating conditions.

The provision of additional load of some equipment or connections should
always be considered and appropriately accounted for in the design.

Substation design needs to allow maintenance to be accomplished with a

minimum impact on a substation’s operation. Allocation of adequate working
space is necessary. In selecting equipment, consider the service intervals
recommended by the manufacturers and past experience in using a particular
manufacturer’s equipment.

2.8. Safety Considerations

It is paramount that substations are safe for the general public and for
operation and maintenance personnel. Practical approaches include the
employment and training of qualified personnel, appropriate working rules
and procedures, proper design such as on earthing systems, and correct
construction. The safeguarding of equipment also needs to be considered in
substation design.
 18 Substation Design Manual

Chapter 3: PMU, PPU and 33 kV SSU

Design

3 3.1. Introduction
This chapter presents general information concerning the design of the
physical arrangement of PMU, PPU and 33 kV SSU. It describes various types
of substations, illustrates typical layouts, and presents technical criteria of
these substations.

3.2. Pencawang Masuk Utama (PMU)

3.2.1. Overview
Main Intake Substation / Pencawang Masuk Utama (PMU) is the
interconnection point between Transmission’s HV network to the
Distribution’s 33 kV, 22 kV and 11 kV MV network. Distribution Division is
responsible for the MV primary and related secondary equipment within the
PMU.

Main Intake Substations / Pencawang Masuk Utama (PMU) are managed by

Transmission Division. However, Distribution Division is responsible for the
operation and maintenance of MV circuit breakers, panels and MV cable
panel inside the PMU.

Figure 3-1 is a PMU line diagram showing the responsibility boundary over the
assets, operations and maintenance work between Transmission and
Distribution.
 PMU, PPU and 33kV SSU Design 19

M
HV Busbar
R

M Main
Bus R Reserve
HV Incomer (CB)
Coupler OG Outgoing
NER Neutral earth
Y Y NER
resistor
Δ Δ Asset Boundary

Operation & 3
TNBT Maintenance
Y Y
Boundary

TNBD MV Incomer (CB)

M
MV Busbar
R

Bus
Coupler O/G Feeder
O/G Feeder

Figure 3-1: Line diagram and boundary of responsibility of a TNB PMU

Figure 3-2: PMU with outdoor Air Insulated Switchgear (AIS) switchyard
 20 Substation Design Manual

Figure 3-3: PMU with indoor Gas Insulated Switchgear (GIS)

Figure 3-4: 132 kV Gas Insulated Switchgear (GIS)

 PMU, PPU and 33kV SSU Design 21

3.2.2. PMU Layout

Total land area required for a PMU depends mainly on the type of the primary
equipment selected to be used. The equipment is usually classified by the
switchgear; being either Air Insulated Switchgears (AIS) or Gas Insulated
Switchgears (GIS). AIS equipment has to be installed in a switchyard and thus
require much more space than GIS equipment. Additionally if a capacitor
3
bank is required in the PMU, the land requirement will further increase.
Minimum land requirements for PMU are summarised in Table 3-1 below.

Table 3-1: PMU minimum land requirements

Minimum Land Size
Equipment Insulation
(NOT inclusive of Land Setback)
(a) 130 m x 130 m
Air Insulated Switchgear (AIS)
(b) 160 m x 150 m (with capacitor bank)
(a) 60 m x 80 m
Gas Insulated Switchgear (GIS)
(b) 140 m x 75 m (with capacitor bank)

AIS PMU consists of a large switchyard with equipments that are controlled
from a nearby substation building. Typical arrangement of the AIS PMU
substation building is shown in Figure 3-5 and switchyard arrangement in
Figure 3-6. An example GIS PMU layout is shown in Figure 3-7.

AC
Control Room Relay Room
Room

Telecontrol Battery LV Switchgear

Toilet
Room

Figure 3-5: Major equipment in the AIS substation building

 22 Substation Design Manual

(1) (2) (3) (4)

(5) (6) (7) (8) (9)

1. Fly bus
2. Lightning shield conductor
3. Busbar
 Aluminium Tubular
 Supported on post insulators
4. Circuit breaker
 Open and close operations
5. Power transformer
6. Isolators/disconnects
 Isolation duty
 Located on both sides of circuit breaker
 No current make or break rating
7. Current transformer
 Step down current measurement
 Protection and control
8. Potential transformer
 Step down voltage measurement
 Protection and control
9. Surge arrestor
 Discharge over-voltage surges to earth

Figure 3-6: Major equipment in the AIS PMU switchyard

 PMU, PPU and 33kV SSU Design 23

Figure 3-7: Layout of a GIS PMU and typical locations of major components
 24 Substation Design Manual

3.2.3. Electrical Criteria

The electrical design guideline is prepared based on the following system
configuration:

Table 3-2: Typical ratings in a PMU

Components System Configuration
3  275/132/33 kV at 240, 180 MVA
 132/33 kV at 90, 45, 30, 15 MVA
Transformers  132/22 kV at 60, 30 MVA
 132/11 kV at 30, 15, 7.5 MVA
 Local/earthing transformers
 2 incomer feeders
 1 bus-section
132 kV AIS
 1 bus-coupler
Switchgear
 2 transformer feeders
 1 spare bay
 2 incomer feeders
 4 cable feeders
132 kV GIS
 1 bus-section
Switchgear
 1 bus-coupler
 2 x 90 MVA transformer feeders
 2 incomer feeders
 4 cable feeders
33 kV Switchgear  1 bus-section and 1 bus-coupler for double bus in existing
systems; or
 2 bus-tie panels for GIS (single bus) for new installations
 2 incomer feeders
 14 outgoing cable feeders
11 kV Switchgear
 1 bus-section; or
 1 bus-coupler for double busbar

TX Rated Secondary Voltage

Capacity 33 kV 22 kV 11 kV
90 MVA 12
Neutral earth resistor 60 MVA 8
(NER) in ohms 45 MVA 24
30 MVA 36 16 4
15 MVA 73 8
7.5 MVA Solid Grounding
 PMU, PPU and 33kV SSU Design 25

3.2.4. Civil Criteria

Transmission Division is responsible for the design, construction and
installation of the PMU. Distribution Division would witness the
commissioning of the MV side and is responsible for constructing and
installing outgoing feeders in the PMU compound.

For civil requirement details, please refer to the “Design Guideline for Built-In 3
GIS Substation” and “Transmission Design Philosophy & Guidelines for
Substations” by the TNB Transmission Division.
 26 Substation Design Manual

3.3. Pencawang Pembahagian Utama (PPU)

3.3.1. Overview
Primary Distribution Substation / Pencawang Pembahagian Utama (PPU) in
the TNB Distribution network manages primary voltages of 33/11 kV. The PPU
3 is normally to step-down the voltage from 33 kV to 11 kV for distribution to
pencawang elektrik (P/E) and customers. Figure 3-8 is a sample single-line
diagram for a basic PPU.

To other PPUs

NOP
3L5 1L5 4L5
2L5

R
1W0 Double bus 33kV
M
1S0
1H0 2H0

T1 T2
30MVA 30MVA
33/11kV 33/11kV

31 32
30 Single bus 11kV

13K5 11K5 9K5 7K5 5K5 3K5 1K5 2K5 4K5 6K5 8K5 10K5 12K5 14K5

Local

Figure 3-8: Typical single line diagram of a PPU

 PMU, PPU and 33kV SSU Design 27

In Figure 3-8, the breakers are numbered systematically with codes as listed in
Table 3-3.

Table 3-3: Typical numbering/coding for circuit breaker in a PPU

Installation 33 kV code 11 kV code
5L5, 3L5, 1L5 or 5, 3, 1
Outgoing Feeder
5P5, 3P5, 1P5 or or
(left side)
5S5, 3S5, 1S5 5K5, 3K5, 1K5
3
1HO (from 33 kV)
Incomer 1 or 31
1TO (from 132 kV)

Bus Coupler 1WO 34*

Bus Section 1SO 30

2HO (from 33 kV)

Incomer 2 or 32
2TO (from 132 kV)
6L5, 4L5, 2L5 or 6, 4, 2
Outgoing Feeder
6P5, 4P5, 2P5 or or
(right side)
6S5, 4S5, 2S5 6K5, 4K5, 2K5
*Notes: only applies for 11 kV double busbars

The PPU would typically contain 33/11 kV transformers, AIS or GIS switchgears
and their control panels, a local transformer for the building supply, auxiliary
battery supply, capacitor banks for power factor correction, and Neutral Earth
Resistance (NER). The NER is connected to the star point of the transformer
to limit the earth fault current.

At present there are two types of PPUs which are the conventional PPU (7.5
MVA, 15 MVA and 30 MVA) and Mini PPU (5 MVA). Mini PPU are installed for
low load areas such as outskirt/rural areas.

The following highlight some typical PPUs found in the distribution network.
 28 Substation Design Manual

3.3.1.1. One and a Half Storey PPU

The PPU should be ideally constructed as One and a Half Storey buildings.
The bottom half of the building houses the cable cellar where the
underground cable entry point is. These cables are channelled up to the first
floor to connect to the switching and control rooms. Transformer and
NER/NEI bays are located outside the building.
3

Figure 3-9: One and a Half Storey Primary Distribution Substation (PPU)
– Front view

Figure 3-10: One and a Half Storey Primary Distribution Substation (PPU)
– Rear view
 PMU, PPU and 33kV SSU Design 29

3.3.1.2. Single Storey PPU

Underground cables in single storey PPUs are placed in trenches instead of in
cable cellars. This results in less flexibility for cable installation or
reconfiguration.

Figure 3-11: Single Storey PPU

3.3.1.3. Special Type (Three/Four Storey) PPU

In certain locations where space is limited, the PPU may be constructed
vertically. This option is not recommended as the design needs to be
specifically customised to the requirements of each location. This in turn will
result in slower project implementation and commissioning.

Figure 3-12: Three-storey PPU

 30 Substation Design Manual

Figure 3-13: Four-storey PPU

3.3.1.4. Outdoor PPU

Outdoor PPUs were the early form of the PPU. Plans are in place to
refurbish/upgrade existing outdoor PPU to become indoor PPU.

Figure 3-14: Outdoor PPU

 PMU, PPU and 33kV SSU Design 31

3.3.2. PPU Layout

The site for PPU should be at least 46 m x 46 m in size, not including land
setback requirements.

Major components of a typical PPU are listed in Table 3-4. Figure 3-15 and
Figure 3-16 shows the location of these components in a PPU.
3
Generally the lowest floor is the cable cellar and the top floor holds all other
primary and secondary equipment located in the switch room, control room
and battery room. Transformer and NER bays are located outside the building
structure.

Table 3-4: Major components in a PPU

Primary  Transformer (Power & Local Transformer)
Equipment  Switchgear
 NER/NEI (Neutral Earthing System)
 Power Cables
Secondary  Battery / Battery Charger
Equipment  Control and Relay Panel (Protection Relays, Unit
Protection, OCEF)
 Marshalling cubicle
 Remote Terminal Unit (RTU)
 Control Cables (Pilot or Fibre)
 32 Substation Design Manual

Cable cellar

3
Underground Spare bay
cable trench

Distribution
transformer
bays

NER bay
Local transformer bay
Capacitor bank bay
Figure 3-15: Typical ground floor layout of a PPU

Control room

11 kV switch room with

cable entry slots Battery room

33 kV switch
room with cable
entry slots

Roller
shutter door

Loading bay

Figure 3-16: Typical first floor layout of a PPU

 PMU, PPU and 33kV SSU Design 33

3.3.3. Electrical Criteria

Table 3-5 summarises the standard electrical ratings for equipment in a PPU.

Table 3-5: Electrical ratings for the PPU

Parameters System Configuration
Voltage rating  33/11 kV
 22/11 kV
3
 11/33 kV(step-up)
 33/(22 or 11 kV) – dual ratio transformer
Transformer  2 x 30 MVA
installed capacity  2 x 15 MVA
 2 x 7.5 MVA
Local transformer 300 kVA
Switchgear  33 kV GIS-Single Bus bar
 11 kV AIS-Single Bus bar
Battery charger  Charger – 110 VDC 35 A
 Battery – 150Ah
Neutral Earthing 33/11 kV NER
Resistor (NER)  Transformer 30 MVA – 4 ohm
 Transformer 15 MVA – 8 ohm
22/11 kV NER
 Transformer 30 MVA – 4 ohm
 Transformer 12.5 MVA – 8 ohm
Solid earthing  Transformers 7.5 MVA and below
Earthing Less than or equal to 1 ohm

3.3.4. Civil Criteria

For detailed civil criteria, refer to the PPU Handbook (Panduan Asas
Rekabentuk dan Pembinaan Bangunan Pencawang Pembahagian Utama
(PPU) 33/11 kV Bahagian Pembahagian, TNB).
 34 Substation Design Manual

3.4. Mini PPU

3.4.1. Overview
Mini Primary Distribution Substation or Mini PPU is a 33/11 kV 5 MVA PPU
introduced as an initiative to improve the system performance at suburban
3 and rural areas normally located far from any existing PMU/PPU with load
3
density less than 5 MVA fed through long distance 11 kV distribution lines .

The Mini PPU can also contribute in losses reduction in the suburban and rural
area by means of:

 Shortening the 11 kV feeder length

 Reducing the 11 kV load per feeder

Figure 3-17: 33/11 kV, 5 MVA Mini PPU

3
Surat Pekeliling Pengurus Besar Kanan (Pengurusan Aset) (Perkhidmatan dan Amalan
Kejuruteraan) Bil. A25/2012 Panduan Perancangan Dan Pemasangan Mini PPU
33/11kV 5MVA untuk Pertingkatkan Prestasi Sistem Pembahagian
 PMU, PPU and 33kV SSU Design 35

Limitations on the use of the Mini PPU should also be considered:

(a) Mini PPU are not suitable for cities or densely populated areas which are
typically connected by underground cables. These underground cables
are typically rated at 30 MVA; however the jumper (288A/16.4 MVA) and
33 kV isolator (400A/22.8 MVA) are rated below 30 MVA, which will
introduce bottleneck to the network.
3
(b) The pole-top circuit breaker short circuit rating is 12.5 kA; therefore it can
only be used with systems having short circuit levels not exceeding 90%
of the rating, which is 11.25 kA.

3.4.2. Basic Design Configuration

3.4.2.1. Major Components
The basic configuration of a Mini PPU consists of the main components listed
in Table 3-6.

Table 3-6: Primary components and secondary equipment in a Mini PPU

Primary Components  5 MVA Transformer, with maximum dimensions of
3.3 m(L) x 3.5 m(W) x 3.4 m(H)
 33 kV Switchgear – Pole Top Circuit Breaker
 11 kV Switchgear – VCB Type A1 / RMU Outdoor
 Lightning Arrester
o 36 kV, 10 kA
o 12 kV, 10 kA
Secondary Equipment  30 VDC Remote Control Box
o Battery/Charger 30 VDC

The single line diagram of the Mini PPU is shown in Figure 3-18. Figure 3-19
and Figure 3-20 provides further illustration of the basic Mini PPU
4
configuration .

4
A16/2010 - Panduan Perancangan dan Pemasangan Mini PPU 5MVA 33/11kV
 36 Substation Design Manual

33 kV bare overhead line/ABC

2
150 mm Silmalec

3 3 x 36 kV, 10 kA MOV
Lighting Arrestor (LA)
3-pole switch 36 kV, 400 A

Pole top circuit breaker 3 x 12 kV, 10 kA

36 kV, 630 A MOV LA
3 x 12 kV, 10 kA
MOV LA

3 x 12 kV, 10 kA
MOV LA
5 MVA 33/11 kV
Transformer

3 x 12 kV, 10 kA
MOV LA
2
240 mm 3C XLPE Al

B2 11 kV VCB Indoor

Figure 3-18: Basic configuration of a Mini PPU 5 MVA

 PMU, PPU and 33kV SSU Design 37

21 1
2

3 20

4 3

3 3

19
2

5
7 3
8

16
6
5 MVA 33/11 kV 17
18 6000 Transformer
9
11 10
3420
18

1740 7 12 1615
1600

R 1000 R 13
15 14 15
13
2000 1850

No Description
1 Tubular steel pole 15 m or Spun pole 10 m, 5 kN
2 Lightning arrester 36 kV, 10 kA
3 Bare aluminium conductor 150 mm sq. (Silmalec) with insulating cover
4 3-pole switch 36 kV, 400 Amps
5 Pole top circuit breaker 36 kV, 630 Amps (Auto-recloser)
6 3-pole switch operating rod
7 ABC, 33 kV, 3 x 150 mm sq. + 50 mm sq. aluminium
8 Wooden peg 6” x 6”
9 PVC pipe 150 mm class B with UV protection
10 Pole top circuit breaker control box
11 Pole top circuit breaker control wire
3-core XLPE insulated aluminium cable with MDPE outer sheath 11 kV,
12
240 mm sq.
13 Single wall HDPE corrugated pipe 150 mm
14 Transformer plinth 2700 x 1850 mm (length x width)
15 Angle iron bracket 50 x 50 x 5 mm
16 HV cable box, air type, 33 kV
17 LV cable box, air type 11 kV
18 Angle iron bracket 50 x 50 x 5 mm
19 Bimetal lugs 150 mm sq. (See Detail A)
20 Copper strip 25 x 3 mm with black coating
21 Parallel grooved clamp 150 mm sq.
Figure 3-19: Mini PPU 5 MVA 33/11kV design configuration
 38 Substation Design Manual

28

22

3 25

22
26 8

23

22 24

18 22

27
29
22

No Description
8 Wooden peg 6” x 6”
18 Angle iron bracket 50 x 50 x 5 mm
22 C-channel iron cross arm min. dimensions 50 x 50 x 100 mm
with 5 mm thickness
23 Flexible steel strap
24 Half stay clip
25 Stay insulator (big)
26 Stay wire 7/8 swg
27 Stay bow and thimble
28 Universal band
29 Aluminium cleats

Figure 3-20: Mini PPU 5 MVA 33/11 kV design configuration

(isometric view)
 PMU, PPU and 33kV SSU Design 39

3.4.2.2. Electrical Criteria

The Mini PPU is suitable for 33 kV overhead lines with spur or T-off feeder
configuration. Table 3-7 summarises the standard electrical ratings and
configuration for equipment in a Mini PPU.

Table 3-7: Typical electrical ratings and configuration of Mini PPU

Item Typical Electrical Ratings and Configuration 3
Incoming  The incoming 33 kV system must be from an overhead system,
33 kV either bare conductors or Aerial Bundle Cable (ABC).
system
Pole-top  A 3-pole switch and auto-recloser is installed to function as a 33
circuit kV pole-top circuit breaker (with auto-recloser function turned
breaker OFF).
 Pole-top circuit breaker must be installed correctly to prevent it
from falling off the H-pole structure.
2
Cable  33 kV ABC (3x150 mm ) is used to connect from the pole-top
circuit breaker to the primary side of the 5 MVA 33/11 kV
transformer.
2
 11 kV XLPE Al 3-core (240 mm ) cable is used to connect from
the secondary site of the 5 MVA 33/11 kV transformers to the
VCB (B2 type) in the switchgear room.
 Both sides of the messenger wire for the 33 kV incoming cables
must be tied to the H-Pole structures and to the transformer
body.
 The 33 kV incoming cable must be bonded to the H-Pole
structure, by single point earth bonding using copper braids.
 The cable bending radius (R in Figure 3-19), shall be minimally:
o Single core – 20 x cable diameter
o Three core – 15 x cable diameter
o ABC – 7 x cable diameter (overall diameter of the ABC)
 Suitable bimetal lugs sizes must be used for the transformer tail
connections.
 All cable terminations must use types/brands approved by TNB.
VCB  Three VCB (A1 type) panels are used for 11 kV system
reticulation.
 One VCB (A1 type) panel is used for the local transformer
supply.
Lightning  Surge arresters are installed on both MV and LV terminals of
Arrester the transformer.
 40 Substation Design Manual

3.4.2.3. Civil Criteria

In general the construction of building structures should follow the civil
requirements of indoor substations as stated in Subchapter 4.2.4 and
requirements of pole-mounted structures as stated in Subchapter 4.7.4.

Additionally, requirements specific to this substation are listed here.

3
Table 3-8: Mini PPU civil design requirements
Item Minimum Requirements

The dimension for the 5 MVA 33/11 kV Mini PPU depends on

the poles, transformer and 11 kV switchgear building layout.
Dimension of  11100 x 21000 mm (Layout A – Figure 3-21), or
Mini PPU
 19000 x 13000 mm (Layout B – Figure 3-22), or
 14620 x 14620 mm (Modified P/E – Figure 3-23)

 Room size: 5000 x 5100 mm

 The room design (which includes the civil and structure
Switchgear
design, earthing system and drain outlet) is according to
Room
Pekeliling Pengurus Besar Kanan (Kejuruteraan) Bil
A49/2009 (Design standard of SSU 11 kV substation).

The plinth for Mini PPU components must be able to withstand

Plinth the weight of 1.4 times the dead load. The weight for the
5 MVA transformer is 15 tonnes (15,000 kg).

The fence for the Mini PPU must be installed for the safety
Fence purpose and also to indicate the area of the substation. The
fence must be 3.05 metres tall.

3.4.3. Mini PPU Layout

3.4.3.1. New Installations
Land size for a Mini PPU depends on the arrangement of electrical poles,
transformer and 11 kV switching room. Figure 3-21 and Figure 3-22 show two
possible layouts for the Mini PPU.
 PMU, PPU and 33kV SSU Design 41

Ultimately, arrangement of these components must comply with the

minimum clearance between each component and substation building:

1. Distance between the H-pole and the 5 MVA transformer is 2 metres.

2. Distance between the 5 MVA transformer and the 11 kV switchgear
building is 2 metres.
3. Distance between the 11 kV switchgear building and the 300 kVA local
3
transformer is 2 metres.
4. Distance between the substation fence and any Mini PPU component or
building is 2 metres.
5. Distance between the gate and the switching room building is 3 metres.
6. The 33 kV incoming cables must be installed at least 600 mm away from
the H-Pole structure.

17000

760 Cable chute

2000

for outgoing
5000
cables

4000 760 Local

1000 Tx
B2 A1 A1 A1 A1 300 kVA
5100

900 VCB 900

5 MVA 33/11 kV

11000
4000

2000

Transformer 1000
760 800
Battery Charger
1200
Feeder
2 000

2 000 2000 Pillar

1500 800 A
Cable chute
for outgoing
2 000

cables
Pole Top CB

1000 1000

4000
Note
900 mm trench depth sand filled 1. A1 configuration VCB shall be used with approved type relays.
with cement rendered 2. Battery charger shall be 30 Vdc 10A/40Ah

Figure 3-21: Layout of the Mini PPU – Layout A

 42 Substation Design Manual

10100

Local Tx

800
2000
300 kVA

1200
Cable chute 2000
for outgoing
cables
3
1000
Feeder Pillar

1000
800 A

A1 900 Cable chute

760
for outgoing
A1 cables

4000
5000

A1

4000
1500
VCB
A1
17000
B2 Battery
3 000
19000

Charger
760 Cable chute
900

760 760
2000

for outgoing
5000
cables
2000

20004000 5100 760 Local

1000 Tx
B2 A1 A1 A1 A1 300 kVA
5100

900 VCB 900

5 MVA 33/11 kV

11000
5 MVA 33/11 kV
4000

2000

Transformer 1000
4000

Transformer
760 800
Battery Charger
1200 Note
Feeder1000
2 000

2 000 2000 Pillar

4000 1500 800 A 1. A1 configuration VCB
2 000

Cable chute
for outgoing approved type relays
2 000

Pole Top CB
cables 2. Battery charger shall
2 000

Pole Top
1000 1000 CB 900 mm trench d
with cement ren
1000

4000
Note
900 mm trench depth sand filled 1. A1 configuration VCB shall be used with approved type relays.
with cement rendered 2. Battery charger shall be 30 Vdc 10A/40Ah

Figure 3-22: Layout of the Mini PPU – Layout B

 PMU, PPU and 33kV SSU Design 43

3.4.3.2. Modification of Existing P/E

Depending on site requirements, existing indoor standalone single chamber
P/E buildings (14.6 m x 14.6 m) can be modified and transformed into Mini
PPU.

Transformation from existing P/E into Mini PPU is encouraged so that new
Mini PPU can be established in a shorter timeframe and procurement for new 3
land can be avoided.

The following criteria should be considered for new Mini PPU located at the
sites of existing P/E distribution substation:

1. The 33/11 kV 5MVA transformer to be placed in front of the P/E building.

2. The existing 11/0.4 kV transformer to be relocated outdoor.

3. The existing P/E building is modified to become an 11 kV VCB switching

room.

4. Replace chain link with brick wall of 2.13 meters in height, with extra
height of 3.05 meter high for walls adjacent to the transformer to provide
for safety measures and pleasant view to the neighbouring households.

5. The minimum safety and working clearances must be complied.

The suggested modified P/E layout for a Mini PPU is shown in Figure 3-23.
 44 Substation Design Manual

14620 – (48’-0’)

3480 4620 3050 3480

7670 Local
3165

Tx

600 New 2130 high brick wall

to replace existing
3 900
chain link fence
4600

Existing P/E
14620 – (48’-0’)

2500

3.3m New 3050 high brick wall

to replace existing
1.5m
chain link fence
3.5m
6865

Plinth
5 MVA H-pole with pole-top CB
Tx

4Nos, 160mm
1865

CHDPE Pipe

4 meter wide gate

3995

Figure 3-23: Mini PPU layout for modification of existing standalone

single chamber substation

3.4.4. Connection Guidelines

Connection schemes for the Mini PPU are as follows:

(a) Spur with 33 kV ABC or bare overhead line directly from 132/33 kV PMU
source or 33/ 11kV PPU;
(b) Ring with 33kV ABC between two or more Mini PPU fed by feeders from
the same or different 132/33 kV PMU or 33/11 kV PPU.

Table 3-9 shows a summary of Mini PPU connection scenarios and guides on
planning schemes with accompanying diagrams.
 PMU, PPU and 33kV SSU Design 45

Table 3-9: 33kV Network Connection Scheme to Mini PPU

33kV Network Connection 33kV Connection
Scenario
Scheme Criteria / Requirement
Erection of new (a) Connection of Auto-recloser must be installed
2
Mini PPU 33/11 kV 33 kV ABC, 3 x 150 mm , at the T-off point between the
5 MVA Al., from 33 kV bare ABC and bare overhead lines to
overhead lines control operation and isolation.
(Figure 3-24) 3
(b) Spur connection of Total load of the 33 kV main
2
33 kV, ABC 3 x 150 mm , feeder to the PPU must comply
Al., from an existing with the n–1 contingency.
PPU.
(Figure 3-25)
(c) Connection of 33 kV i. Spur connection if feedback
2
ABC, 3x150 mm , Al., is 100% through 11 kV
from 132/33 kV PMU. ii. Ring connection if 11 kV
(Figure 3-26) network could not support
100% feedback
Erection of Connection of 33 kV ABC, Add H-pole and Auto-recloser at
2
2nd/3rd Mini PPU 3x150 mm , Al., from Mini PPU for operational control
to existing Mini existing Mini PPU and feedback 33 kV network.
PPU network (Figure 3-27) (Number of Mini PPU depends
on protection coordination
ability)

In principle, a spur connection is suitable to be set up at the early stage of

Mini PPU establishment at rural areas with the condition that the connected
11 kV network is free from any non-transferable load (NTL) problem if the 33
kV network experiences supply disruptions.

If NTL is possible or when the same 33 kV network needs to be connected to

additional Mini PPU, a ring connection should be established as the next stage
of the 33 kV network expansion.

It should be noted that any loop in – loop out (LILO) connection from Mini
PPU to the existing main feeders between PMU to PPU, between PPUs or
between SSUs with fully switched equipment is prohibited. This is to ensure
the stability of the unit protection scheme and the operation of the main
feeders.
 46 Substation Design Manual

33 kV bare overhead lines

33 kV ABC
3 x 150 mm2

Mini PPU

Figure 3-24: T-off connection from 33 kV bare overhead lines to Mini PPU
 PMU, PPU and 33kV SSU Design 47

33 kV Incoming Feeder 1

33 kV Incoming Feeder 2

PPU

33 kV
Interconnector
to another
PMU/PPU

33 kV ABC
2
3 x 150 mm

Mini PPU

Figure 3-25: Spur connection from an existing PPU to a Mini PPU

 48 Substation Design Manual

PMU
3 132/33 kV

2
ABC 3 x 150 mm
33 kV
Mini PPU

Figure 3-26: Spur connection from an existing PMU to a Mini PPU

 PMU, PPU and 33kV SSU Design 49

A typical connection from a PMU to two Mini PPUs is shown in the single line
diagram of Figure 3-27 below.

Legend:
PMU 132/33 kV Lightning arrestor
Pole-top circuit
breaker 3
3-Pole Switch

Connection from
another PMU
or same PMU
(different bus)

2 2
ABC 3 x 150 mm ABC 3 x 150 mm
33 kV 33 kV

2
ABC 3 x 150 mm
33 kV

Mini PPU No.1 Mini PPU No.2

Figure 3-27: Connection between PMU and multiple Mini PPUs

 50 Substation Design Manual

3.5. 33kV Primary Switching Station (33 kV SSU)

3.5.1. Overview
33kV Primary Switching Station / Stesen Suis Utama (33 kV SSU) refers to a
station that supplies power via circuit breakers to ‘bulk supply customers’ and
3 other distribution circuits at the 33 kV voltage level.

The 33 kV SSU bus-tie is designed using single-bus switchgears with bus-tie

system to avoid total shutdown to customers for maintenance works. This
configuration is illustrated in Figure 3-28.

33 kV incomer 33 kV incomer

7S5 3S5 4S5 8S5

5S5 1S5 2S5 6S5

Bus-tie

33 kV Consumer Service Feeder 2nd 33 kV Consumer Service Feeder

Figure 3-28: The design of bus-tie for 33kV SSU

 PMU, PPU and 33kV SSU Design 51

The main advantages of SSU 33 kV using Bus-Tie are:

 Electrical supply for 33 kV bulk consumers will not be interrupted

whenever the switching station is under maintenance. Therefore, the
system reliability is not affected.
 In the event of component failure such as switchgear flashover, only half
the bus will be affected and supply to customer can be restored 3
immediately through the other bus.
 This configuration provides a safe and convenient way to perform
maintenance work.

33 kV incomer 33 kV incomer

7S5 3S5 4S5 8S5

Section A Section B

5S5 1S5 2S5 6S5

Bus-tie

100% Load
nd
33 kV Consumer Service Feeder 2 33 kV Consumer Service Feeder

Section under Shutdown

Figure 3-29: Supply feedback to SSU A

From the above diagram, the maintenance unit can perform half bus
shutdown for Section A without causing supply disruption to consumers
because the consumers’ load can be transferred to the second service cable.
 52 Substation Design Manual

3.5.2. 33 kV SSU Layout

The site for 33 kV SSU should be at least 30 m x 30 m in size, not including
land setback requirements.

Figure 3-30 shows the typical layout of 33 kV SSU and locations of major
components. Generally the SSU contains a switchgear room, control room,
3 battery room and metering room. Incoming and outgoing cable connections
would be installed in underground cable trenches or a half-storey cable cellar.

However, the actual design may vary according to the availability of land and
suitability to the site.

Table 3-10: Major components in an SSU

Primary Equipment  Switchgear
 Power cables
Secondary Equipment  Battery / Battery Charger
 Control Relay Panel (Protection Relays,
Unit Protection, OCEF)
 Marshalling cubicle
 Remote Terminal Unit (RTU)

Cable entry via

cable cellar

Switchgear room

Control room

Store
Battery
room
Metering room

Figure 3-30: Typical layout of 33kV SSU and locations of major components
 PMU, PPU and 33kV SSU Design 53

3.5.3. Electrical Criteria

Table 3-11 below summarises the typical electrical ratings in a 33 kV SSU.

Table 3-11: Typical ratings in a 33 kV SSU

Item Typical ratings
Voltage rating  33 kV
Switchgear  33 kV GIS – Single busbar with bus-tie (for new areas) 3
 33 kV GIS or AIS – Double busbar (existing areas)
 Incomers as required
 2 Outgoing feeders to consumer
 2 Breakers for Bus-tie (where applicable)
2
Interconnecting  3 x 33 kV XLPE 630 mm Al Single Core (single bonding
Cables between practice shall be strictly followed for single core cable as
Bus-Ties (where stipulated in Arahan Naib Presiden Bil A06/2010 Amalan
applicable) Single Point Bonding pada Transformer Tail di dalam
PMU/PPU)
Protection for  OCEF and Current Differential protection scheme on both
bus-tie (where bus-ties
applicable)  At least one of the switchgears on the bus-tie must be
normally off (on soak)
 OCEF setting for both switchgears must follow the settings
supplied by the manufacturer
 Switch configuration and position during normal
operation, shut-down, contingency, as well as during
operation and equipment ownership must follow the
Interconnection Operation Manual (IOM) that exists
between the RCC and consumer.
Battery charger Charger – 110 VDC 35 A
and battery Battery – 150 Ah
Earthing Less than or equal to 1 ohm

3.5.4. Civil Criteria

In general the construction of building structures should follow the civil
requirements of indoor substations as stated in Subchapter 4.2.4.
 54 Substation Design Manual

3.6. Testing and Commissioning

Before commissioning the PMU, PPU or 33 kV SSU, specific tests are to be
carried out on substation equipment to ensure safe and reliable operation.
The following are some tests that are to be performed, wherever applicable:

Pre-commissioning tests:
3
(a) Current transformer test
(b) Instrumentation transformer test
(c) Power transformer test
(d) Secondary equipment test
(e) Instrumentation verification tools test
(f) Validation test major component
(g) Testing the stability of the protection scheme
(h) Switchgears operation test
(i) Power transformers operation test
(j) Substation battery system test
(k) Test indication to the SCADA system
(l) Transducer test
(m) Grounding system test
(n) Heating test

Commissioning tests:
(a) Live phasing test
(b) Phasing voltage test instrumentation
 P/E, 11 kV SSU and S/S Design 55

Chapter 4: P/E, 11 kV SSU and S/S

Design

4.1. Introduction
This chapter covers general design, illustrates typical layouts, and presents
technical criteria of various types of stations for the MV/LV distribution
network. The types of substations that will be covered in this chapter are:
4
4.2 Indoor Distribution Substation / Pencawang Elektrik (P/E)
4.3 11 kV Primary Switching Station / Stesen Suis Utama 11 kV (11 kV SSU)
4.4 Outdoor Distribution Substation / Pencawang Elektrik (P/E)
4.5 Switching Station / Stesen Suis (S/S)
4.6 Compact Substation Unit (CSU) / Pencawang Elektrik Padat
4.7 Pole Mounted (H-Pole) Substation / Pencawang Atas Tiang (PAT)
4.8 Pole Mounted (H-Pole) Substation (PAT) with RMU

Subchapter 4.2 introduces construction guides applicable for all substation

building structures. Standardised distribution substation buildings and their
schematic drawings are made available in the latest versions of the following
documents:

 Electricity Supply Application Handbook (ESAH)

 Buku Panduan Piawai Baru Rekabentuk Pencawang Elektrik
(Jenis Bangunan) Bahagian Pembahagian

Subchapter 4.4 provides guides on outdoor substation structures.

Construction guides and schematic details of pole-mounted substations are

introduced in Subchapter 4.7.
 56 Substation Design Manual

4.1.1. Characteristics of Distribution Substations

Typical distribution substations will have several MV feeder circuit
connections: one or more incoming feeders; and one or more outgoing
feeders. Spur substations will only have one MV incoming feeder connection.

MV circuits connect to the substation through switchgears which are used

principally to isolate the substation from the MV network for maintenance,
fault sectionalizing, or when replacement of substation equipment is required.
The switchgear used can be either vacuum circuit breakers (VCB) or ring main
4 units (RMU).

The MV circuit can then be stepped down to LV via a transformer to supply LV

customers. MV customers can also receive directly from the substation.

Figure 4-1 and Figure 4-2 show sample single-line diagrams for distribution
substations.

MV Incoming MV Outgoing
feeder feeder

VCB

Transformer

LV customer MV customer

Figure 4-1: Basic VCB Distribution Substation (P/E) with 1 incoming feeder,
1 outgoing feeder, 1 LV transformer feeder, 1 MV customer
 P/E, 11 kV SSU and S/S Design 57

MV Incoming MV Outgoing
feeder feeder

4
Transformer 1 Transformer 2

LV customer 1 LV customer 2

Figure 4-2: Basic RMU Distribution Substation (P/E) with

1 incoming feeder, 1 outgoing feeder, and 2 LV transformer feeders

4.1.2. Characteristics of Switching Stations

A switching station is a combination of switching and controlling equipment
arranged to provide circuit protection and system switching flexibility.
Incoming connections are typically from PPU and outgoing connections are
usually to P/E or MV customers.

Incoming Incoming

VCB VCB
Busbar

Outgoing

Figure 4-3: Typical switching station single line diagram

 58 Substation Design Manual

4.1.3. Comparison of Substations

It is useful to note the differences between substations and switching stations
for operational purposes.

 P/E will have switchgears that are either VCB or RMU. For Indoor P/E
these switchgears will be installed in a switching room.

 P/E will also have a distribution transformer installed inside a transformer

room/chamber. Additional transformers require separate chambers.

4  11 kV SSU are characterised by a bus section. SSU connect to multiple

feeders at 11 kV that can go to other substations, distribution
transformers or direct to bulk consumers.

 S/S are stations without transformers and function only as switching or

T-off points using an RMU with three switches (3S) or VCBs.

 PAT are distribution substations with components and equipment that

are mounted on poles.

Figure 4-4: Indoor – standalone, single chamber without metering room

 P/E, 11 kV SSU and S/S Design 59

Table 4-1 highlights the characteristics and main differences between indoor
distribution substations and 11 kV switching stations.

Table 4-1: Comparison of distribution substations and

11 kV switching stations
Pencawang Elektrik (P/E)
RMU VCB
Single chamber Double chamber Single chamber Double chamber

11 kV SSU (VCB)
no transformer 1 Transformer 2 Transformers

Substation (No transformer)

PAT (Pole-mounted)
VCB RMU
 60 Substation Design Manual

4.2. Indoor Distribution Substation (Indoor P/E)

4.2.1. Overview
The indoor distribution substation or pencawang elektrik (indoor P/E) is a
substation with all primary equipment installed within a building structure.
Indoor P/E can be built either standalone or attached to a building. Both can
be of single or double chamber type, with or without a metering room.

4.2.1.1. Indoor – Standalone

4
Possible configurations are single chamber or double chamber, with or
without metering room. This is the ideal choice with the principal advantages
as follows: -
(a) It facilitates installation of fully switched facilities, or power factor
improvement capacitors, if and when required.
(b) It facilitates the installation of automation equipment, such as SCADA,
remote switching facilities, etc.
(c) It provides easy access, and space separating it from adjacent buildings,
thus minimize the risk to the adjacent building (due to safety reasons).
(d) For substation with extra land area, it can accommodate additional
extension of switchgear or compact substation to meet the increasing
customer demand.
(e) Removes the need for any special fire fighting facilities. The use of
portable dry type powder fire extinguishers is sufficient.

4.2.1.2. Indoor – Attached to a Building

Possible configurations are single chamber or double chamber, with or
without metering room and with or without SCADA facilities. This alternative
has similar advantages to that of a separate building, except: -
(a) Little or no land space, as developers usually provide the minimum space.
(b) The need to install fully automatic fire fighting equipment to meet fire
safety requirements.
(c) Design of the building must be in line with developers’ layout plan with
emphasis on aesthetics and landscaping.
(d) Building owners may need to incorporate fire fighting facilities for their
premises.
 P/E, 11 kV SSU and S/S Design 61

In practice, the real estate developer will construct and provide the substation
building based on the requirements specified by TNB during project planning.

Substation architectural designs and colour schemes need to be in harmony

with the surrounding, as required by Arahan Naib Presiden Bil. A2/2010.

The following figures show sample indoor substations.

Attached P/E

Figure 4-5: Indoor – attached, double chamber P/E designed to blend with
surrounding structures

Figure 4-6: Indoor – standalone, double chamber P/E designed to blend with
surrounding structures
 62 Substation Design Manual

4.2.2. Indoor P/E Layout

Typical indoor substation building sizes are shown in Table 4-2 and Table 4-3
taken from ESAH version 3.

 The sizes below can also cater for SCADA equipment installation.
 Total land area required will need to take into account of land setback
requirements.
 Please refer to the latest version of ESAH for updates or changes in layout
design.

4 Table 4-2: Standard sizes of 11/0.4 kV indoor substations

(without Metering Room)
S/Gear
Building Overall Tx Room Length
S/Gear Room
Type (mm) (mm) (mm)
(mm)
1 Single chamber Standalone VCB 7600 x 5100 4600 3000 5100
2 Double chamber Standalone VCB 10600 x 5100 4600 3000 5100
3 Single chamber Attached VCB 8600 x 5700 5600 3000 5700
4 Double chamber Attached VCB 13000 x 5700 7000 3000 5700
5 Single chamber Standalone RMU 7000 x 4000 4000 3000 4000
6 Double chamber Standalone RMU 10000 x 4000 4000 3000 4000
7 Single chamber Attached RMU 8000 x 5700 5000 3000 5700
8 Double chamber Attached RMU 13000 x 5700 7000 3000 5700

Table 4-3: Standard sizes of 11/0.4 kV indoor substations

(with Metering Room)
S/Gear
Building Overall Tx Room Length
S/Gear Room
Type (mm) (mm) (mm)
(mm)
1 Single chamber Standalone VCB 7600 x 5700 4600 3000 5700
2 Double chamber Standalone VCB 10600 x 5700 4600 3000 5700
3 Single chamber Attached VCB 7600 x 5700 4600 3000 5700
4 Double chamber Attached VCB 12000 x 5700 6000 3000 5700
5 Single chamber Standalone RMU 7000 x 5700 4000 3000 5700
6 Double chamber Standalone RMU 10000 x 5700 4000 3000 5700
7 Single chamber Attached RMU 7000 x 5700 4000 3000 5700
8 Double chamber Attached RMU 11000 x 5700 5000 3000 5700
 P/E, 11 kV SSU and S/S Design 63

Major components of a typical indoor P/E are listed in Table 4-4. Figure 4-8
and Figure 4-9 shows the location of these components in indoor P/Es.

 Switchgears are installed in switching rooms.

 Distribution transformers are placed inside transformer rooms/chambers.
Each transformer requires a separate chamber.
 Feeders for P/E are all connected by underground cables which enter and
exit the substation via PVC ducts.
 Feeder pillars are located outside the building structure.
 Attached substation rooms are larger in size to accommodate the feeder
pillars, and the additional ventilation fans and fire fighting equipment.
4

Table 4-4: Major components in an indoor distribution substation

Primary Equipment  Switchgear (VCB / RMU)
 Transformer
 Feeder pillar
Secondary Equipment  Battery Charger with Battery
(For VCB only)  Control Relay Panel (Protection Relays,
Unit Protection, OCEF)
 Remote Control Box (RCB)
 Remote Terminal Unit (RTU)

Customer LV Fire-fighting Transformer

room control panel rooms

RCB panels Switching room

Figure 4-7: Indoor – attached, double chamber with

RCB and RTU panels (SCADA ready)
 64 Substation Design Manual

Transformer with VCB in the Underground Ventilation

guards in a chamber switching room cable trench blocks

Feeder pillar

RCB LV feeder
underground ducts
Manhole 11 kV feeder
underground ducts
Figure 4-8: Layout of Standalone Indoor Substation – Double Chamber

Metering Transformer VCB in the Ventilation blocks

room in a chamber switching room (where possible)

Insulating mat

Ventilation
fans

11 kV
feeder cables
RCB

Feeder pillar
LV feeder
underground cables
Figure 4-9: Layout of Attached Indoor Substation – Double Chamber with
Metering Room
 P/E, 11 kV SSU and S/S Design 65

4.2.2.1. Switching Rooms

Indoor substations will always have switchgears which are either vacuum
circuit breakers (VCB) or ring main units (RMU) which are installed in a
switching room. Rooms installed with VCB will be slightly larger due to the
VCB’s larger size compared to the RMU.

4.2.2.2. Transformer Room/Chamber

Indoor P/E will also have a distribution transformer installed inside a
transformer room/chamber. Additional transformers require separate
chambers to ensure containment during any emergency. 4
4.2.2.3. Metering Room
Certain indoor substations that are supplying to LV and 11 kV bulk customers
will have a metering room, connected either to the transformer tail or feeder
pillar for LV bulk customer or to the switchgear for MV/HV customer.

Suggested locations for the metering room with respect to the customer are
shown in the following Subchapters (4.2.2.4 and 4.2.2.5).

For 33 kV bulk customers, the metering room shall be located at the

customers’ premise.

General design requirements of the metering room are as follows:

 The metering room is an enclosed looked room for the purpose of

installing metering cubicles, and must have its own dedicated entrance,
separated from the transformer/switchgear rooms by walls.
 The metering room is separated so that the meter may be accessed
without having to enter the high voltage zone.
 The minimum size for the room is 2.0 m(W) x 2.0 m(L) x 2.5 m(H) and
located inside the substation/switching station for LV and 11 kV bulk
customers.
 Location of the metering cubicle inside the metering room shall be as
represented in Figure 4-10.
 66 Substation Design Manual

2000

Metering
550 Cubicle

1100
2000

Entrance

Figure 4-10: Layout for installing metering cubicle in the metering room

4.2.2.4. P/E Location for LV Bulk Customer

For LV bulk customer, the preferred type of building is the standalone indoor
substation. Suggested location of the substation with respect to the
customers’ facility and main switch board (MSB) is shown in Figure 4-11 and
Figure 4-12.

Substations for LV bulk customers must be located at the front area of the
gated factory with a separate access from the main factory access. This is
required because of the following objectives:

 TNB personnel can enter the substation easily without getting permission
from the customer.
 TNB personnel can perform cable and substation upgrading work without
disturbing roads/facilities inside the customers’ compound.
 P/E, 11 kV SSU and S/S Design 67

Criteria of new substation location for LV bulk customer:

(a) Size of the substation must comply with setback and frontage
requirement of the local authority
(b) Customers’ MSB room are recommended to be place next to the
substation (Figure 4-11)
(c) If customers’ MSB room cannot be located next to the substation due to
unavoidable technical issues, customers’ MSB room can be located at the
factory’s building (Figure 4-12) with these conditions:
i. The LV service cable cannot have any straight through joints and the
length of the cable must be less than 250 meters; 4
ii. Voltage drop from the substation to the customers’ MSB is less than
5% as suggested in the LV Planning Guideline;
iii. If LV service cable is of single core type, it must be laid in a concrete
trench with earthing copper tape (extended from transformer star-
point connection) at the bottom for the physical protection of the
cable and for ease of maintenance. The concrete trench needs to be
filled with sand and cement rendered.

Factory
Fence

TNB metering
Customers’ room
MSB
P/E

Road

Figure 4-11: Location of P/E with attached MSB room for LV bulk customers
 68 Substation Design Manual

Customers’ MSB
Factory

Fence

LV service cable inside

concrete trench
4 TNB metering
room
P/E

Road

Figure 4-12: Location of P/E with detached MSB room for LV bulk customers

4.2.2.5. P/E Location for MV Bulk Customer

The substation location for MV bulk customers is dependent on the land area
of the factory:

 If the land area is big, an indoor standalone P/E located at the front area
of the gated factory is preferred.
 If the land area is small, an attached substation is allowable provided 24
hour accessibility to the substation is possible.
 P/E, 11 kV SSU and S/S Design 69

4.2.3. Electrical Criteria

Table 4-5 summarises the standard electrical ratings for equipment in the
indoor substation. All electrical clearances presented in Subchapter 2.5 must
be adhered to.

Table 4-5: Typical ratings in a conventional P/E

Equipment/component Rating and size

Voltage rating 11/0.433 kV

Transformer installed capacity 500 kVA, 750 kVA, 1000 kVA

4
 12 kV Ring Main Unit (RMU); or
Switchgear
 12 kV Vacuum Circuit Breaker (VCB)

Feeder pillar 800 A, 1600 A

4.2.4. Civil Criteria

The following are guidelines for typical substation civil requirements to
provide proper working environment for the equipment and personnel
working within the indoor substation.

Guidelines provided here are also applicable to all other distribution

substations with building structures.

4.2.4.1. Compound area

A flat surface ideally desired for the layout and operational function of a
substation. It permits uniformity in foundation elevations and structure
heights. Unless there are property restrictions, severe topographical features,
subterranean rock, or other considerations dictate otherwise, the substation
surface should be graded nominally flat.
 70 Substation Design Manual

4.2.4.1.1. Land Requirement

The required land size must consider the size of the substation as shown in
Table 4-2 and Table 4-3 previously. Additional setback and frontage
requirement of local authorities must also be considered.

Under normal circumstances the following land size is sufficient for

Standalone Indoor P/E:

(a) Single chamber – 13.6 m x 14.8 m

(b) Double chamber – 16.6 m x 14.8 m
4
4.2.4.1.2. Foundation

Piling requirements need to be decided based on evaluation of the soil

condition which should have been evaluated during initial site investigations.

4.2.4.1.3. Surfacing Material

For standalone substations, the compound area outside the building structure
should be paved with tarmac or cement of 50 mm (2 inches) thickness with
150 mm (6 inches) of crusher run underneath.

4.2.4.1.4. Gate and Fence

 Substation gate and fence should ideally be 2.1 metres or 7 feet tall.
 Decorative gate and fence designs are encouraged to harmonize with the
surrounding.
 Fence for standalone substations can be substituted with concrete kerbs
(minimum 150 mm in height) or bollards to mark the substation area.
 For attached substations, whenever possible, removable barriers have to
be installed 3 metres in front of the switchgear room and transformer
room doors such that the entrance to the substation is not blocked.

4.2.4.1.5. Drainage

 Drainage should be built surrounding the substation around 750 mm from

the outside wall to the centre of the drain.
 The drainage must be connected to the nearest existing draining system
in the vicinity.
 P/E, 11 kV SSU and S/S Design 71

4.2.4.2. Structures

4.2.4.2.1. Floor

 The substation floor should be made of Reinforced Concrete (RC).

 Surface finishing of the outdoor area should be at one level.
 Floors are to be painted with epoxy green paint.
 Minimum safety clearance should be marked with yellow paint.
 The substation RC floors need to cater for the weights of equipment to be
installed on it. The minimum floor loadings are shown below:

Table 4-6: Minimum floor loadings for indoor P/E

4
Equipment Floor load

Nominally 7000 kg
Transformer
1.4 x transformer weight

Nominally 8000 kg
Indoor Switchgear
1000 kg x VCB panel number
(VCB/RMU)
(8 panels in switching room)

Feeder Pillar 1000 kg

4.2.4.2.2. Walls

 All walls for building structures should be constructed using red clay
bricks laid with 1:3 cement sand mortar.
 All walls should be 230 mm thick.
 All walls should be reinforced with expanded metal (exmet) at every
fourth course in order to strengthen the wall structure.
 Partition walls between switching room and transformer room should be
230 mm thick and 2100 mm tall.
 72 Substation Design Manual

Expanded
metal layer

4 Figure 4-13: Expanded metal (exmet) layer at every fourth course

4.2.4.2.3. Damp-Proof Course (DPC)

 Damp-proof course (DPC) is necessary to prevent moisture ingress into

the ground beam as well as termite infestation prevention.
 The DPC consists of 25.4 mm or 1 inch thick 1:1 cement sand-screed
bedding laid on the ground beam. Upon drying, a bituminous felt is laid
with liquefied bitumen.

Wall drying out

above DPC
New plaster

Skirting
New chemical DPC
DPC membrane
Ground level
in solid floor
Rising damp

Figure 4-14: Damp-proof course (DPC)

 P/E, 11 kV SSU and S/S Design 73

4.2.4.2.4. Ventilation

 Ventilation blocks (batu angin) can be used to provide sufficient aeration

for the substation equipment.
 To prevent entry of pests into the substation building, anti-vermin plastic
or stainless steel mesh netting mounted on aluminium frames must be
installed on the outside of the ventilation blocks.
 The ventilation blocks for the switch room shall be covered with awnings
to prevent rain water from entering the switch room which would affect
the switchgears.
4

Figure 4-15: Ventilation blocks with anti-vermin plastic mesh

 Attached indoor substations require additional ventilation in the form of

an exhaust fan. The exhaust fan must be at least 12 inches in size and
installed with thermostat control. The fan should be pulling air out of the
substation.
 74 Substation Design Manual

4.2.4.2.5. Doors

 All louvered doors shall be made of Composite-Fibre Reinforce Plastic.

 All louvered doors shall be installed with plastic anti vermin netting or
stainless steel mesh netting mounted on Aluminium frame fixed on the
inside of the door.
 Doors should be sized to fit the equipment to be installed inside the
room. Transformer rooms require large double leaf doors to
accommodate the size of the transformer.
 Suggested door dimensions are as follows:
4 (a) Transformer room: 2400 mm(W) x 3000 mm(H) double leaves
(b) Switchgear room: 1500 mm(W) x 3000 mm(H) double leaves

4.2.4.2.6. Roofing

For all standalone substation buildings, the roofing style should match the
styles of the surrounding building and area.

If no specific roofing style is required, the roof should be of reinforced

concrete (RC) flat type constructed with proper water proofing treatment.

 RC flat roof designs shall cater for a waterproof slab, cast with waterproof
concrete, cement screed with waterproofing agent, and provide for
minimal shrinkage with anti cracking reinforcement.
 A layer of bituminous material must be applied to waterproof the
concrete slab roof.
 For the attached P/E substation-type, if there are pipes across the top of
the substation, two layers of water proof concrete roof slabs should be
built. The first layer (closer to the substation) must contain a bituminous
layer.
 P/E, 11 kV SSU and S/S Design 75

4.2.4.2.7. Cable Trenches

 All trenches in the substation are to be filled with washed river sand.
 Washed river sand has the following advantages:
(a) Avoid moisture from entering into the switchgear via the cable entry.
(b) Better heat dissipation and minimisation of impact due to fire
hazards.
(c) Has arc quenching property which can protect neighbouring cables
from a cable that is at fault.
(d) From a safety aspect – closed trenches can eliminate the risk of staff
falling into the trench. 4
 A 50 mm (2 inch) thick cement render (1:2, cement:sand) is required to
cover the trench. This is to minimize condensation of water from inside
the trench and to prevent entry of vermin through the trench.
 The spacing from the trench floor to any beam or structure that may
protrude into the trench should be 600 mm minimum. This is to ensure
sufficient space to install the cable in the trench.

4.2.4.3. Installations

4.2.4.3.1. Pipes/Ducts for Feeder Cables

 All incoming and outgoing MV and LV feeder cables to the substation

need to be installed via pipes/ducts for added mechanical protection.
 The type of pipe to be used is PVC Class B with different diameters
depending on its use as follows:
a) 150 mm diameter – for 11 kV MV multi-core cables
b) 200 mm diameter – for 11 kV MV single core cables laid in trefoil
formation.
 A suitable number of pipes/ducts need to be prepared for current and
future use.
 A draw wire shall be provided for each duct to facilitate cable laying.
 All cable pipes/ducts should be sealed to prevent water from entering the
substation.
 76 Substation Design Manual

 For 11/0.433 kV substations, two layers of three PVC Class B 150 mm

diameter pipes need to be laid from the trenches until they reach beyond
the drain and/or road kerb.
 For 11 kV SSU, 1 layer of three PVC 200 mm diameter pipes and 1 layer of
four PVC 150 mm diameter pipes are needed.
 For drainage crossings, G.I. pipes need to be used as a protective sleeve.
However, only multi-core cables and single-core cables laid in trefoil are
allowed in G.I. pipes. It cannot be used with single core cables laid
singularly (alone) due to induced and circulating eddy currents in the G.I.
pipes.
4
4.2.4.3.2. Transformer Guard and Bushing Cover

 All transformer bushings should be shrouded with transformer bushing

covers.
 Additionally, transformer guard needs to be installed at all transformers in
substations because:
- No live parts should be exposed without a barricade
- There is still voltage potential on the bushing covers
- To protect the metering CT which is connected at the LV cable
support bracket

Transformer
guard

Figure 4-16: Transformer guard

 P/E, 11 kV SSU and S/S Design 77

4.2.4.3.3. Feeder Pillar

The feeder pillar must be installed outside the substation building to facilitate
access by fault finders and the LV maintenance team during breakdown or
shutdown.

4.2.4.3.4. Metering CT for LV Bulk Customer

 For LV bulk customer, the metering current transformer (CT) is installed

on the LV service cable connected to the secondary side of the
transformer.
 Metering CT provides current readings to an energy meter through 4
2
2.5 mm 12-core copper multi-core cables.
 LV cable support brackets are used to support the LV Cable and the
metering CT as shown in Figure 4-17.

2
Connections between meter and CT will use 2.5 mm , PVC/SWA/PVC,
12-core, copper multi-core armoured cables.

Table 4-7: The maximum allowable distance between metering CTs and
metering cubicle for LV consumer
Cross Connection Maximum
Secondary Rated
CT Burden (VA) of Conductor Distance
Current (A) 2
(mm ) Allowable (m)
7.5 5 2.5 12.0
7.5 5 4.0 20.0

Figure 4-17: CT on the cable support bracket

 78 Substation Design Manual

4.2.4.3.5. Metering CT for MV Consumer

 For metering installations up to 33 kV, current (CT) and potential

transformers (PT) shall be provided and installed by TNB at TNB's
outgoing switchgear feeder.

2 2
Connections between meter and CT will use 2.5 mm or 4.0 mm ,
PVC/SWA/PVC, 12-core, copper multi-core armoured cables, depending
on maximum allowable distance as in Table 4-8.
 The armoured cable shall not be buried or enclosed, and preferably laid
on cable trays.
4
4.2.4.3.6. Metering CT for HV Consumer

 A ‘marshalling box’ with independent sealing facility shall be provided by

the consumer for the purpose of terminating the secondary circuit cabling
of the CT and PT.

2
Connections between meter and CT will use 2.5 or 4.0 mm ,
PVC/SWA/PVC, 12-core, copper multi-core armoured cables, depending
on maximum allowable distance between CT and meter as in Table 4-8.
 For metering installations of 132 kV and above, CTs and PTs shall be
provided and installed by the consumer at consumer’s incoming
switchgear in accordance with TNB’s specifications. TNB shall witness the
commissioning tests of both CTs and PTs.

Table 4-8: The maximum allowable distance between metering CTs and
metering cubicle for MV and HV consumer
CT burden Secondary rated Cross-sectional area Maximum allowable
2
(VA) current (Amps) of conductor (mm ) distance (m)
15 5 2.5 30
15 5 4.0 47
30 5 2.5 65
30 5 4.0 100
30 1 2.5 1,647
30 1 4.0 2,545
Where meter burden for current circuit = 0.5 VA/ph

Calculations of the maximum allowable distance between metering CT and

metering cubicle can be found in Appendix A.
 P/E, 11 kV SSU and S/S Design 79

4.2.4.3.7. Earthing System

 Copper tape/strip of 25 mm wide x 3 mm thick (1” x 1/8”) is used as the

earthing conductor.
 The copper strip should be installed on the side wall of the concrete
trench wall, 60 mm from the top of the trench to prevent theft.
 Earthing layouts for different substations are shown in Subchapter 9.2.3.

60mm
4

Copper strip

Figure 4-18: Copper strip for earthing in a concrete trench

4.2.4.3.8. Operating Equipment

The substation should be provided with its own respective operating

equipment such as the operating gear and earthing gear. The equipment
should either be stored on racks or placed in a cabinet.

4.2.4.3.9. Fire Fighting System

 Fire extinguishing equipment should be located near the entrance of the

building.
 If automatic equipment is used, there should be means of switching off
the equipment when work is being carried out in the substation. This is
typically done through a fire-fighting control panel.
 For attached substations, fire-fighting equipment is installed inside the
substation building structure.
 Detailed guidelines are presented in Chapter 10: Fire Fighting System and
Pekeliling A08/2011.
 80 Substation Design Manual

4.2.4.3.10. Lighting, Fittings and Wiring

 Single phase wiring is required to be done with G.I. conduit complete with
main-switch, ELCB, MCB Distribution Board and separate earthing. The
source of supply is from the feeder pillar.
 Wiring in conduits for the Earth Fault Indicator (EFI) should be provided
inside the switchgear room.
 Adequate lighting points should be provided and power socket outlets
should be installed at convenient locations for the use of hand lamps,
hand tools, etc.
4  Emergency lighting is also required inside the substation with its own
battery capable of supplying three hour of backup power to the
emergency light.
 External lighting should utilise weather proof light fittings and operated
via a photoelectric control unit (PECU).

4.2.4.4. Finishes

4.2.4.4.1. Colour

 Selection of colours should be harmonized with the surrounding

environment such that they blend/match the neighbouring structures.

4.2.4.4.2. Signboard/Signage

 A signboard containing the name of the substation must be installed at

the front of the substation, facing the nearest road.
 The signboard should be installed at eye level for easy identification
(around 1800 mm from floor level).
 Appropriate warning signs should be posted on the substation’s barrier
fence. Substations, no matter how small, should have one sign per side, as
a minimum. For each substation site, assess whether standard signs are
sufficient.
 Special bilingual signs may be advisable for some areas.
 P/E, 11 kV SSU and S/S Design 81

Head
protection No smoking

Body protection Hand protection

Foot protection Eye protection
Figure 4-19: Standardised signboard containing substation details 4

1245
20 20 20 20
505 330 330
20
155
20
155
20
210 1005
20

210

20
155
20

155 155 155 155

20 155 20 155 20 155 20 20 20 20 20

Figure 4-20: Standardised signboard dimensions

200 200

150 150

240 240

Figure 4-21: Standardised warning and electrical hazard signs

 82 Substation Design Manual

4.3. 11 kV Primary Switching Station (11 kV SSU)

4.3.1. Overview
Essentially, the 11 kV Primary Switching Station or Stesen Suis Utama (11 kV
SSU) is a switching station which is installed with 12 kV, 630 A, 30 VDC VCB
panels, with or without distribution transformers. Additionally, it must also be
installed with a bus-section panel.

11 kV SSU is built for the following functions:

4  As a switching station
 To give bulk supply to 11 kV customers
 To give LV supply via 11/0.433 kV distribution transformer

Incoming Incoming

VCB VCB

Outgoing

Figure 4-22: Example single line diagram for primary switching station
(11 kV SSU) without transformer

Incoming Incoming

VCB VCB

Outgoing

Figure 4-23: Example single line diagram for primary switching station
(11 kV SSU) with transformer
 P/E, 11 kV SSU and S/S Design 83

Figure 4-24: Primary switching station (11 kV SSU)

4.3.2. 11 kV SSU Layout

The building features and civil criteria are similar as those for the indoor
distribution substation in Subchapter 4.2.4. The difference is in the dimension
of the building and rooms. Please refer to ESAH for details on the dimension
and layout arrangement.

The 11 kV SSU consists of:

 Switchgear room with bus-section
 Transformer room (as required)
 Battery room
 Metering room (as required)

The number of VCB panels that can be erected in an SSU is subjected to the
maximum load duty of the DC charger and battery. Typically one unit of a
30 VDC, 10 A charger with 40 Ah battery can cater for a maximum number of
5 VCB panels. However, the actual allowable number of panels can be
determined by calculating the DC load profile duty cycle using IEEE 1118.
 84 Substation Design Manual

Underground
Switchgears with cable trench
bus-section

Ventilation blocks

Insulating
mat

RCB

LV feeder
underground cables

Figure 4-25: Layout of 11 kV SSU

4.3.3. Electrical Criteria

Table 4-9 summarises the standard electrical ratings for equipment in the
indoor substation.

All electrical clearances presented in Subchapter 2.5 must be adhered to.

Table 4-9: Major components in an 11 kV SSU

Primary Equipment - Switchgear (VCB only)
- Transformer (if required)
- Feeder pillar (for SSU with transformer only)
- Power cables

Secondary Equipment - Battery / Battery Charger

- Remote Terminal Unit (RTU)
 P/E, 11 kV SSU and S/S Design 85

4.4. Outdoor Distribution Substation (Outdoor P/E)

4.4.1. Overview
Outdoor substations (Outdoor P/E) are similar in function to their indoor
counterparts. Outdoor P/E are favoured for their cost advantages, and used
mainly for rural electrification and system improvement. They are also used
for industries that have very large land areas such as farms.

The advantages of outdoor and semi-outdoor type substation are:

 Low cost 4
 Require smaller land area
 Easy and fast to install

incoming outgoing

RMU 11 kV, 630 A

Transformer
11/0.433 kV

Feeder Pillar
1600A/800A

Figure 4-26: Single line diagram for outdoor distribution substation

 86 Substation Design Manual

4.4.2. Outdoor P/E Layout

Outdoor substation layout is similar to the indoor substation layout except
that the equipment is in the open air.

Ventilation
Roof
Barbed wire blocks for walls
Switchgear

Transformer
4 guard
Transformer

Feeder pillar

Stone chips Doors

Figure 4-27: Layout of outdoor substation and locations of major

components

The typical existing fencing is the chain link fence. However, for new and
future installations, ventilation blocks are preferred for fencing because they
partially conceal the outdoor substation from public view as well as contain
splashes of oil and/or arcing resulting from any possible flashover.
Additionally the solid structure helps to deter unauthorized entry more
effectively

A roof is erected for the switchgear to cover the RMU as a protection from
direct sunlight and heavy rain as well as providing a comfortable area for
working personnel.
 P/E, 11 kV SSU and S/S Design 87

Figure 4-28: Typical outdoor substation with ventilation block fencing

Transformer

Switchgear Feeder Pillar

Figure 4-29: Typical outdoor substation with chain link fencing

 88 Substation Design Manual

4.4.3. Electrical Criteria

Table 4-10 summarises the standard electrical ratings for equipment in the
outdoor substation. All electrical clearances presented in Subchapter 2.5 must
be adhered to.

Table 4-10: Typical ratings in an Outdoor P/E

Equipment/component Rating and size

Voltage rating 11/0.433 kV

Transformer installed capacity 300 kVA, 500 kVA, 750 kVA, 1000 kVA
4
Switchgear 12 kV Ring Main Unit (RMU)

4.4.4. Civil Criteria

In general the construction of outdoor substations should follow the civil
requirements stated here.

4.4.4.1. Compound Area

4.4.4.1.1. Land Requirement

 Under normal circumstances the minimum land size required for an

Outdoor P/E is 7620 mm x 7620 mm (25 ft x 25 ft).
 Total land size including drainage is 8400 mm x 8400 mm (27.5ft x 27.5ft).
 The land area of the substation shall be raised by 100mm above the road
level to prevent water flow into the substation and for ease of
transportation.

4.4.4.1.2. Plinth

 Plinths shall be designed to cater for the loads as described below:

Equipment Plinth load

1.4 x transformer weight
Transformer
Nominally 7000 kg
Outdoor Switchgear
5000 kg
(RMU)
Feeder Pillar 1000 kg
 P/E, 11 kV SSU and S/S Design 89

 All plinths should have at least 150 mm above ground level. Plinth may
need to be taller depending on special site requirements such as flooding.

Figure 4-30: Suggested switchgear plinth dimensions

Figure 4-31: Suggested feeder pillar plinth dimensions

 90 Substation Design Manual

4.4.4.1.3. Floor

 The substation floor surrounding the plinths must be covered with 150
mm of stone chips in order to limit the step and touch voltage levels to a
safe value as the crushed stone layer provides an insulation in series with
the body.
 Optionally, a layer of tarmac is allowable as long as it matches the
required insulation level of the stone chips.
 Both stone chips and tarmac have similar function to the insulating mat in
the indoor P/E.
4  The additional benefit of using stone chips or tarmac is to reduce
grass/vegetation growth.

4.4.4.2. Structures

4.4.4.2.1. Roof

 RMU used in outdoor substations are designed with IP54 ingress

protection which means they are suitable for outdoor applications.
 However a roof should still be provided to cover the RMU for additional
protection from direct sunlight and heavy rain as well as providing a
comfortable working area for personnel.
 Ardex corrugated sheets can be used as the roof material because they
are cheap, easy to install and durable.

4.4.4.2.2. Fence/Wall

 Ventilation blocks are to be used as walls for new installations and

upgrading of the Outdoor P/E.
 The height of the walls needs to be at least 1800 mm to keep the
substation equipment hidden from outside view.
 Installation of barbed wire on top of the wall can help to prevent
unauthorised entry.
 Chain link fences can be used if the outdoor substation is located in an
extremely low traffic area.
 P/E, 11 kV SSU and S/S Design 91

4.4.4.2.3. Drainage

 Water drainage shall be provided at the corners of the walls at floor level
to enable water to flow from within substation to the outside drainage.

4.4.4.2.4. Doors


o
The door shall be erected preferably at 90 angle from the RMU location
to enable quick exit in emergency situation during switching.
 Double leaf composite doors are to be used with the dimensions 1300
mm(W) x 1800 mm(H) each door.
4
4.4.4.2.5. Signboard/Signage

 Suitable and sufficient signage as mentioned in Subchapter 4.2.4.4.2 must

be installed.

4.4.4.3. Installations

4.4.4.3.1. Transformer Guard and Bushing Cover

 Outdoor substations are more prone to entry by animals compared to

indoor substations. As such, all transformer bushings are to be shrouded
with transformer bushing covers to prevent interruption/tripping due to
shorting by animals.
 Additionally, transformer guards also need to be installed as justified in
Subchapter 4.2.4.3.2.

4.4.4.3.2. Feeder Pillar

The feeder pillar is installed in a recessed part of the outdoor substation wall
as in Figure 4-27.

4.4.4.3.3. Earthing System

 Copper tape/strip of 25 mm(W) x 3 mm thick (1”x1/8”) is used as the

earthing conductor.
 The copper strip shall be direct buried in the ground. The earthing layout
is shown in 9.2.3.3.
 92 Substation Design Manual

4.4.5. Safety Clearances

Outdoor P/E design should comply with the minimum working clearances
presented in Subchapter 2.5. The proposed designs here have the following
working clearances:

 Clearance between transformer and wall/fence is 1500 mm.

 Clearance between switchgear and wall/fence is 495 mm.

4
 P/E, 11 kV SSU and S/S Design 93

4.5. Switching Station / Stesen Suis (S/S)

Switching stations or stesen suis (S/S) are built as part of system improvement
to introduce switching or T-off points. They consist of RMU with three-switch
(3S) configuration. The typical features of switching station are as follow:

 Dimension : 3000 (L) x 3000 (W) mm

 Plinth able to support up to 5000 kg.
 Roof type: Ardex corrugated sheets.
 Civil criteria for outdoor substation for floor, plinth and roof can be
applied to the switching station construction. 4
 Chain link fencing shall be built around the RMU to provide sufficient
safety clearance.

Figure 4-32: Switching station / stesen suis (S/S)

 94 Substation Design Manual

Figure 4-33 shows the location of a switching station in a single line diagram.
When required, switches A and C can be turned on to provide feedback supply
in the event of network failure.

S/S

NOP NOP

A B C

Figure 4-33: Single line diagram of switching station

 P/E, 11 kV SSU and S/S Design 95

4.6. Compact Substation Unit (CSU)

4.6.1. Overview
The Compact Substation Unit (CSU or Compact Sub) is a substation with type
tested equipment comprising of a distribution transformer, medium voltage
switchgear, low voltage feeder pillar, connections and associated equipment,
all in a compact enclosed unit.

A CSU is shown in Figure 4-34 and a basic line diagram is shown in Figure 4-35.
4
Advantages of the CSU include:
 Require only a small site (7000 mm x 4000 mm);
 Physically small and therefore unobtrusive, and can be erected quickly;
 Available in 500 kVA and 1000 kVA capacities;
 Can be installed in a shorter time compared to a conventional substation.

However, a disadvantage of the CSU is that if faults affect any individual

component inside the unit, the whole unit may need to be replaced
completely. Its capacity is also fixed and cannot be expanded. The CSU is also
considerably more expensive than conventional substations.

As such, the compact substation can only be considered as a last resort after
all options have been exhausted on a case by case basis. It is considered as a
special feature design in which special features cost is charged to the
customer as per Clause 8.0 of Statement of Connection Charges 1994/1995.

Circulars related to the compact substation unit are:

1. A7-2004 Pekeliling Kejuruteraan & Logistik – Use Of Package or Compact

Type 11 or 415 kV Substation In TNB Distribution Network
2. A30-2009 Arahan Naib Presiden (Pembahagian) – Garis Panduan
Penggunaan PE Padat Bersaiz 500 kVA Untuk Bekalan Elektrik Skim
Pembangunan Perumahan
3. A02-2011 Arahan Naib Presiden (Pembahagian) – Garis Panduan
Penggunaan Pencawang Elektrik Padat Untuk Bekalan Elektrik Ke
Kawasan Komersial
 96 Substation Design Manual

Figure 4-34: A typical CSU

MV incoming MV outgoing

RMU 11 kV, 630 A

Transformer
11/0.433 kV

Feeder Pillar
800 A or 1600 A

Figure 4-35: Single line diagram of a CSU

 P/E, 11 kV SSU and S/S Design 97

The technical and economic considerations in selecting CSU against stand-

alone indoor type substations (P/E) can be summarised as follows:

i. Demand estimates and demand growth to determine transformer size

to be used
ii. Space requirements, if any, notably by the developer
iii. Aesthetic requirements, if any, notably by the developer and or local
authority
iv. Maintainability of components
v. Life cycle costs comprising of capital cost, O&M cost, replacement and
upgrading costs 4
Other considerations may be satisfied during the design and planning stage.

4.6.1.1. Application of CSU

Upon request from developer, CSU are allowed to be utilised for new housing
and commercial developments, taking into consideration of appropriate
distribution network design to ensure security and restoration time to
consumers will not be affected. Additionally for all other situations, prior
approval must be obtained from the respective Regional Chief Engineer
(Ketua Jurutera Operasi Wilayah) to deploy the CSU.

Detailed explanations on the use of the CSU are as below.

4.6.1.2. Development with Limited Land

In development areas that have limited land/space and cannot meet the
minimum requirements of conventional standalone indoor substations, a
compact substation can be considered.

Examples would include instances of a temporary supply scheme, supply to

street lighting along major roads, supply to major billboards or even supply to
existing factories/outlets with limited available space.

In these cases, the compact substation can normally be considered. Prior

approval must be obtained from the respective Regional Chief Engineer
(Ketua Jurutera Operasi Wilayah)
 98 Substation Design Manual

4.6.1.3. Low Voltage Reinforcement of Existing Developed Area

Low voltage reinforcement of existing developed areas typically involves
substation sites to be acquired by TNB. In case of this situation, the use of
CSU is preferred subject to satisfying the following:

 Insufficient space to construct a conventional indoor substation

 Cost of constructing a conventional indoor substation is more expensive
compared to a CSU.
 A shorter duration of time is required to complete the low voltage
reinforcement works.
4
Prior approval must be obtained from the respective Regional Chief Engineer
(Ketua Jurutera Operasi Wilayah)

4.6.1.4. Temporary Use of the CSU

There are cases whereby CSU are used on a temporary basis for supply
projects. These would include cases due to unavailability of certain materials
or even due to demand/request from the customer/authorities to meet
certain deadlines which may be ceremonial in nature etc.

Prior approval must be obtained from the respective Regional Chief Engineer
(Ketua Jurutera Operasi Wilayah).

4.6.1.5. CSU for New Domestic Developments

CSU 500 kVA is encouraged to be installed for new domestic development
with the following guideline:

 CSU 500 kVA to be placed close to the load centre.

 CSU 500 kVA not to be placed at the corners of one development.
 CSU 500 kVA cannot be placed close to each other to ensure efficient load
distribution to the consumers.
 CSU 500 kVA is considered as ‘special feature design schemes’ in which
special features cost is charged to the consumer.

CSU with sizes bigger than 500 kVA for domestic development requires prior
approval from the respective Regional Chief Engineer (Ketua Jurutera Operasi
Wilayah).
 P/E, 11 kV SSU and S/S Design 99

4.6.1.6. CSU for New Commercial Developments

Both 500 kVA and 1000 kVA CSU are allowed (upon request by developer) to
be used in commercial areas depending on the load requirements.

However, application of CSU in commercial development is considered as

special feature design schemes in which a special features cost is charged to
the consumer.

4.6.2. CSU Layout

The dimension and weight of CSU are dependent on the transformer size and 4
manufacturer. Table 4-11 shows typical dimensions and weight of a compact
substation. Figure 4-36 is a layout view of the CSU.

Table 4-11: CSU dimensions and weight

Height 2000 mm
Overall length 2500 mm
Overall width 2000 mm
Without transformer: 1300 kg
With 500 kVA transformer: 3310 kg
Weight
With 1000 kVA transformer: 4500 kg
Nominally: 5000 kg

LV Feeder Transformer RMU

Pillar

2000
Doors

2500
Figure 4-36: Top view of a CSU
 100 Substation Design Manual

RMU MV
transformer
tail

Figure 4-37: RMU compartment in a CSU

Incoming
disconnector unit

Outgoing fuse-switch
disconnectors

Figure 4-38: LV feeder pillar compartment in a CSU

 P/E, 11 kV SSU and S/S Design 101

RMU Compartment
630A 11 kV 3-phase 50 Hz

HRC fuse

11 kV in 11 kV out
4

Transformer Compartment

11 kV/433 V
Transformer
1000 kVA

LV Feeder Pillar Compartment

1 x 1600 A
Incoming
Disconnector

A x3

3 x CT PF kWh (0-1600 A)
1600/5 A
F

10 x 400 A
Outgoing Fuse-switch
Disconnector

Figure 4-39: Detailed single line diagram of 1000 kVA CSU

 102 Substation Design Manual

4.6.3. Electrical Criteria

The voltage rating for the CSU is 11kV/433V and is currently only available in
500 kVA and 1000 kVA capacities. A summary of compact substation
specifications and dimensions are given in the table below.

Table 4-12: CSU technical specifications, measurement and dimension

Power Rating 500 kVA 1000 kVA
Input Unit 1 x 800 A 1 x 1600 A
Output Unit 6 x 400 A 10 x 400 A
CT, class 1.0, 7.5 VA
4 LV Feeder Pillar
Ammeter
Metering
Power factor meter
kWh meter
Type Hermetically Sealed/Oil
Transformer
Voltage 11kV/433V
Type Ring Main Unit (RMU)
Insulation SF6 gas
Switchgear Rated Voltage 12 kV
Ring feeder – 630 A
Rated Current
Transformer feeder – 200 A
Cover Mild steel
Kiosk/Enclosure
Base Channel Steel
The overall maximum dimension for the enclosure should not
Dimensions 2
exceed 2.0 m height and 2.5 m x 2.0 m or 5.0 m sitting area

4.6.4. Civil Criteria

The following are guidelines to provide proper working environment for the
equipment and personnel working around the CSU.

The criteria mentioned here is applicable to both the 500 kVA and 1000 kVA
CSU.

4.6.4.1. Land Requirement

The required land area for a compact substation is 7000 x 4000 mm. This
consists of the plinth and working clearance around the CSU.
 P/E, 11 kV SSU and S/S Design 103

4.6.4.2. Plinth
Minimum size of the CSU plinth is 4600 x 2200 mm. The CSU sits in the middle
of the plinth and it must be able to support the weight of the CSU which is
approximately calculated as 1.4 x 5000 kg = 7000 kg.

The specification of the plinth shall be as in Figure 4-40 and Figure 4-41
below. Proper plinth design is important to ease cable laying and termination
to the CSU.
earth strip embedded in concrete plinth
with earthing rod in earthing chamber 200x200mm Opening
Earth strip embedded in concrete plinth with
earthing rod
earth strip embedded4600
with in earthing
earthing
in concrete plinth
chamber
rod in earthing 200 x 200 mm
chamber 200x200mm Opening
4
100 1000 400 1230 770 1000 100
900 100 4600 100 900
100 1000 150 400 1230 770 150 1000 100
300
900 100 100 900
150
150 150
300 460 700
A
150
400 460 700
A
Trench
A 400 Opening A
Removable LVTrench
cable Removable
Concrete Opening
Trench
400 Termination Concrete 400
Slab
Removable LV cable Opening Removable
Concrete Trench Slab
400 Termination 11kV cable Concrete 400
Slab 1600 Opening 980
Termination Slab 2200
11kV cable
1600 980
Termination 2200
400
400
400
400

400
400 460 700
460 700
150150
300 300
150150

Foundation/RC structure to
structural engineer’s details

Figure 4-40: Compact substation plinth (top view)

Compact Sub
900 Compact Sub 900
900 900
100 100mm
thick
100 concrete 100mm
Angle
800 Iron
Cement 800 slab thick
300 Angle
50mm x 50mm Ready-Mix concrete
800 800 slab
Iron Grade 25
300 50mm x 50mm 1000
2 layers Trench diisi
Trench diisi
4 nos dengan pasir 2 layer
dengan pasir Foundation/RC 150mm 1000
150mmp 2 nos 150mmp
600 2 layerscable chute Trench diisi thick trench
Trench diisi structure to cable chute
4 nos dengan pasir base on
dengan pasir 2 layer
150mmp structural 50mm thick 150mm
600 2 nos 150mmp screed
cable chute thick trench
150 engineer’s details cable chute base on
50mm thick
screed
150
100 50 800 50 100 400 1230 770 100 50 800 50 100

100 50 800 50 100 400 1230 770 100 50 800 50 100

Figure 4-41: Compact substation plinth (side view – Section A-A)

 104 Substation Design Manual

The area around substation plinth can be filled with crusher run and a thin
layer of premix to ease maintenance work in a future and prevent unwanted
vegetation growth.

4.6.4.3. Compound Area

CSU do not require fencing because it complies with the Internal Arc
Classification Class B requirement which is safe for the public in the event of
fault occurring in the RMU.
4
Developers/consumers are allowed to plant trees outside of the CSU site to
help it blend into the surrounding area. However it should be provided that
the 2 meters wide access road to the substation site is not blocked.

Suitable and sufficient signage as mentioned in Subchapter 4.2.4.4.2 must be

installed.

Figure 4-42: CSU with decorative plants

 P/E, 11 kV SSU and S/S Design 105

4.7. Pole Mounted Substation (PAT)

4.7.1. Overview
Pole-mounted substations or Pencawang Atas Tiang (PAT), also known as
H-pole substations, contain substation components and equipment that are
safely and securely mounted on pre-stressed spun concrete poles. Pole-
mounted substation designs can be used for both 33 kV and 11 kV systems to
be stepped down to LV.

It is the most economical substation because it does not require any high 4
voltage switchgear and utilises only a small piece of land. These substations
can also be erected in a very short amount of time due to its simple design
and construction requirements.

PATs are suitable for rural areas where the load density is low. At the same
time, a larger number of these small capacity substations may be required to
satisfy customer demand. Pole-mounted substations can be considered for
the following conditions:

 Flood prone areas

 Rural area with low load consumption (below 300 kVA)
 Limited land area

The disadvantages of PAT are that they are not encouraged as a permanent
solution and not more than 3 such substations may be erected in series.
 106 Substation Design Manual

As can be seen in the single line diagram in Figure 4-43, the PAT is connected
to 11 kV or 33 kV MV feeders, preferably isolated by 3-pole switches,
protected by external drop-out fuses, feeding to a transformer which steps
down voltage to be distributed via an LV feeder pillar. Optionally, LV may be
distributed through a fuse-switch disconnector (black-box) as shown in
Figure 4-44.

MV incoming MV outgoing
4

Isolator link Isolator link

Lightning
EDO Fuse arrester

Distribution
transformer

Feeder Pillar
Link switch

Fuse-switch
disconnector

Figure 4-43: Single line diagram for pole-mounted substation connected to

feeder pillar with MV isolator link
 P/E, 11 kV SSU and S/S Design 107

MV incoming MV outgoing

Isolator link Isolator link

Lightning
EDO fuse arrester

Distribution
transformer

Fuse-switch
disconnector

Figure 4-44: Single line diagram for pole-mounted substation connected to

fuse-switch disconnector (Black box) with MV isolator link
 108 Substation Design Manual

4.7.2. PAT Layout

4.7.2.1. Major Components
Major components on the pole-mounted substation and their functions are
listed in Table 4-13 and each component is shown on the poles in Figure 4-45
through Figure 4-49.

Table 4-13: Pole-mounted substation major components and their functions

No Component/Equipment Function
1 MV underground and  As the incoming and outgoing of the
4 MV ABC cables substations
2 Covered jumper conductors  As a T-off
 Interconnector between equipment
/component
3a Isolator link  To provide isolation
 Must only be operated during off-load
condition
3b SF6 Load Break Switch (LBS)  Alternative to isolator link to provide isolation
 Can be operated in on-load conditions
 Some have the facility to earth the circuit
4 Lightning arrester  To discharge lightning strikes and protect
transformer
5 Expulsion Drop-Out (EDO)  Provides fused protection of the transformer
fuse  The fuse will operate and provide isolation
when there is a fault on the HV and LV side of
the transformer
6 Insulating covers  Covers exposed parts of live components to
prevent interruption of supply due to shorting
caused by animals.
7 Distribution transformer  Transforms the MV voltage 33/0.433 kV or
11/0.433 kV
8 Fuse-switch disconnector  To provide isolation
400 A (black box)  Provides fused protection of the downstream
circuit by disconnecting immediately upon
fault
9 Feeder pillar (FP)  To provide isolation
 Provides fused protection of outgoing circuits
 Electricity distribution point for LV system
 P/E, 11 kV SSU and S/S Design 109

(3a) (2)
Isolator link Covered jumper
conductors

(4) 4
Lightning arrester

(1)
Underground
(5)
MV cable
EDO fuse

(6)
Insulating
covers

(7)
Distribution
transformer

Figure 4-45: Major components on the pole-mounted substation

 110 Substation Design Manual

Figure 4-46: Fuse-switch disconnector on the pole-mounted substation

Feeder pillar

LV feeders

Figure 4-47: Feeder pillar used with the pole-mounted substation

 P/E, 11 kV SSU and S/S Design 111

Pin Isolator

Lightning
arrestor
Jumper
Conductor

EDO Fuse
4
Isolator Link
with animal
guard
Anti climbing
device
EFI

Figure 4-48: Typical 11 kV pole-mounted substation layout

 112 Substation Design Manual

Figure 4-49: Typical 33 kV pole-mounted substation layout

 P/E, 11 kV SSU and S/S Design 113

4.7.2.2. Types of PAT

Generally, PAT can be classified into two types, 2-pole and 4-pole structures.
The number of poles used in an H-pole structure is determined by the weight
of the distribution transformer to be installed on it.

 The type of pole used is 10 meter spun concrete pole (5 kN cantilever

strength).
 Typically, 2-pole structures are sufficient to support 100 kVA transformers
for both 33/0.433 kV and 11/0.433 kV.
 For 300 kVA and larger transformers for both 33/0.433 kV and 11/0.433
kV, the 4-pole structure is needed to cater for the additional weight. An 4
example is shown in Figure 4-50.
 33 kV link unit / isolator links are heavy and thus require a 4-pole
structure.

Figure 4-50: 4-pole structure 11 kV PAT

 114 Substation Design Manual

U-shaped channel irons are used to support the transformer, lightning

arrester, EDO fuse and pin insulators on the pole.

Channel iron dimensions and distance between the poles depend on the
system voltage level as per Table 4-14. Equipment for 33 kV are larger and
thus longer channel irons are required.

Table 4-14: Sizes of channel Iron

Pole-mounted Dimension of channel iron Distance between the
System voltage level Length x Width x Height (mm) poles (centre-to-centre)
4 11 kV system 2500 x 100 x 50 1800mm

33 kV system 2800 x 100 x 50 2200mm

The number of channel irons required to support the transformer on the pole
differs for each type of pole-mounted substation as follows:

 2-pole structure requires minimum 2 pieces of channel irons.

 4-pole structure requires minimum 7 pieces of channel irons.

Wooden cross arms, as shown in Figure 4-51, are forbidden to be used to

substitute channel irons as an effort to reduce tripping of the system due to
animals. This is because wooden cross arm is susceptible to decay especially
when inferior wood is used.
 P/E, 11 kV SSU and S/S Design 115

Wooden
cross arms

Figure 4-51: Wooden cross arms shall not be used to replace channel irons

4.7.2.3. Insulating Covers

All pole-mounted substations must be installed with insulating covers. These
covers are used to cover the exposed parts of live components to prevent
interruption of supply due to shorting between live parts or between live
parts to earth by animals. The insulating covers are designed to be UV
resistant and anti tracking since they will be used outdoors.

There are 5 types of insulating covers to be used on PATs listed here and
shown in Figure 4-52:

1. Animal guard
2. Conductor cover
3. Lightning arrester cover
4. Drop out fuse cover
5. Transformer bushing cover
 116 Substation Design Manual

(1) Animal guard

(2) Conductor
cover
(3) Lightning 6
arrester cover

(4) Drop out fuse cover

(5) Transformer bushing cover

Figure 4-52: Insulating covers for equipment on the PAT

 P/E, 11 kV SSU and S/S Design 117

4.7.3. Electrical Criteria

Table 4-15 summarises the standard electrical ratings for equipment on the
33 kV and 11 kV PAT. All electrical clearances presented in Subchapter 2.5
must be adhered to.

Table 4-15: Pole-mounted substation ratings

Equipment/component Rating
Transformer rating 33/0.433 kV 11/0.433 kV
Tx installed capacity 100 or 300 kVA
Isolator link Rated voltage: 36 kV Rated voltage: 12 kV
Rated continuous current: 400 A
4
SF6 Load Break Switch Rated voltage: 36 kV Rated voltage: 12 kV
(LBS) Fault making capability: Fault making capability:
25 kA, 3s 20 kA, 3s
Rated continuous current: 400 A
Lightning arrester Rated voltage: 36 kV Rated voltage: 12 kV
Maximum Continuous Maximum Continuous
Operating Voltage, Operating Voltage,
MCOV = 29 kV MCOV = 9.6 kV
Standard Nominal Discharge Current = 10 kA
Line Discharge Class = Class 1
Expulsion Drop-Out (EDO) Rated voltage: 36 kV Rated voltage: 12 kV
fuse Rated continuous current = 100 A
Fuse-switch disconnector Rated continuous current = 400 A
Feeder pillar (FP) Rated continuous current = 400 A, 800 A, 1600 A
MV underground cable Incoming and outgoing: Incoming and outgoing:
2
150 mm Silmalec bare 11kV XLPE 3C Al cable
conductor or 33 kV ABC encased in 150 mm G.I. pipe
or PVC Class B pipe
2 2
Jumper conductor ABC, 33 kV 3 x 150 mm Al ABC, 11 kV 3 x 150 mm Al
LV underground cable Connection to feeder pillar:
 LV XLPE, 4-core, 185 mm2, Al (for 100 kVA transformer)
 PVC/PVC, 1-core, 300 mm2, Al encased in 150 mm G.I.
Pipe or PVC Class B pipe (for 300 kVA transformer)
Connection to fuse switch disconnector:
 ABC LV 3x95 mm2 + 1x70 mm2 (for 100 kVA transformer)
 ABC LV 3x185mm2 + 1x120mm2 (for 300 kVA transformer)
 The outgoing cable from the fuse switch disconnector that
connects to the first pole is typically LV XLPE, 4-core,
2
185 mm , Al underground cable
 118 Substation Design Manual

4.7.4. Civil Criteria

The following are guidelines of typical civil requirements to provide proper
working environment for the equipment and personnel working around the
pole-mounted substation.

Guidelines provided here are also applicable to all other substations with pole
structures.

4.7.4.1. Structures

4 4.7.4.1.1. Concrete Footing

The pole should be planted 1800 mm deep in the ground. Underground

concrete footing is required as a support base for each pole. The dimension of
the concrete footing is 760 (L) x 760 (W) x 760 (H) mm.

4.7.4.1.2. Stay Wires

Usually, 4 numbers of stay wires are used to support the 2-pole structure. For
2
33 kV PAT where the primary incoming cable uses bare conductor 150 mm ,
Silmalec, the pole structure is to be supported by 4 numbers of stay wires (45
tonne, SWG 7/8).

Legend:
Pole
Transformer
Stay wire

Main Road
Figure 4-53: Stay wire (top view)
 P/E, 11 kV SSU and S/S Design 119

4.7.4.1.3. Concrete Base

For area that has limited space for stay wires, a concrete base (concrete grade
25) is used to support the structure. The dimension of the base depends on
the system voltage level as shown in the following table.

Table 4-16: PAT concrete base dimensions

PAT system voltage Dimension of concrete base

11 kV system 300 (H) x 760 (W) x 2600 (L) mm

33 kV system 300 (H) x 760 (W) x 3400 (L) mm 4

Concrete base

Concrete footing

Figure 4-54: Concrete base and footing for 11 kV PAT

 120 Substation Design Manual

4.7.4.2. Installations

4.7.4.2.1. Isolator for Incoming and Outgoing

Typically, direct connection from incoming cable to the jumper is widely
practiced. However the use of isolator link or SF6 Load Break Switch (LBS) is
preferred at both incoming and outgoing cables for ease of isolation as it can
be operated in on-load condition.

SF6 load
break switch

Figure 4-55: H-pole using SF6 Load Break Switch (LBS)

 P/E, 11 kV SSU and S/S Design 121

4.7.4.2.2. Lightning Arrester

Lightning arresters must be installed at HV jumper and at the first pole of LV

overhead system.

4.7.4.2.3. MV Feeder Cables

Buried underground cables are preferably used for feeder cables instead of
overhead cables to connect to the first pole. This practice is to prevent
animals like squirrels and monkeys from reaching the pole-mounted
substation via any overhead line.
4
All underground cables entering and leaving the PAT should be encased in
150 mm G.I. pipe or PVC class B pipe (3 m long, with 2.7 m above ground and
0.3 m underground) and attached to the pole for cable protection. All cable
terminations must be of a type/brand pre-approved by TNB for use in the
distribution system.

For 11 kV connections the incoming and outgoing feeders use XLPE, 3-core,
2
150 mm , aluminium underground cables. Sometimes, the incoming cables
consist of 11 kV ABC.

For 33 kV connections, the incoming and outgoing feeders typically use

2
150 mm Silmalec or 33 kV ABC overhead cables, as the 33 kV PAT’s usually
tap off from existing 33 kV overhead system to give LV supply to nearby areas.

4.7.4.2.4. LV Feeder Cables

For LV system, typical connection from the secondary side of the transformer
to the fuse switch disconnector or feeder pillar is shown below:

Table 4-17: LV feeder cables specifications

LV distribution Typical cable connection from secondary side of transformer
equipment used 100 kVA transformer 300 kVA transformer

Fuse switch LV ABC, LV ABC,

2 2 2 2
disconnector 400 A 3x95 mm + 1x70 mm 3x185 mm + 1x120 mm
LV XLPE, LV PVC/PVC,
2 2
Feeder pillar 4-core, 185 mm , Al 1-core, 300 mm , Al
underground cable underground cable
 122 Substation Design Manual

To achieve buried connection to the first pole of the low voltage overhead
system for prevention of animal encroachment, the outgoing cable from the
fuse switch disconnector that connects to the first pole is typically LV XLPE, 4-
2
core, 185 mm , Aluminium underground cable.

Underground cables should be mechanically protected from external factors

by encasing them in:

 Type of pipe: 150 mm G.I. pipe or 150 mm PVC class B pipe

4  Recommended length: 3 m with 2.7 m above ground and 0.3 m
underground

The single core cables must be laid in trefoil and must not be laid singularly
(alone) in a G.I. pipe. This is to avoid induced and circulation currents in the
G.I. pipe.

Due to the height of the transformer on the PAT, the stressing effect of the
weight of the connected cables to the LV transformer bushings, especially
when LV underground cables are used, can be damaging to the bushings.
Hence, proper and sufficient cable clamping must be provided to support the
weight of the LV transformer tail.

All cable terminations must be of a type/brand pre-approved by TNB for use

in the distribution system.
 P/E, 11 kV SSU and S/S Design 123

4.7.4.2.5. Jumper Conductors

Jumper conductors connect the incoming cable to the lightning arrester, down
to the EDO fuse and then to the HV bushing of the transformer. The
conductors used are typically:


2
For 33 kV PAT – ABC, 33 kV 3x150 mm , Aluminium

2
For 11 kV PAT – ABC, 11 kV 3x150 mm , Aluminium

Jumper conductors are essentially covered conductors as they are unscreened

and therefore have potential on them. As such, sufficient clearance must be
4
ensured from the jumper conductors to any earthed metallic/conductive
bodies on the pole.

4.7.4.2.6. Feeder Pillars and Fuse-Switch Disconnectors

Fuse-switch disconnectors (black box) are widely used for connection to LV

feeders.

However, the use of a feeder pillar is also allowable to provide more outgoing
LV feeders for better load distribution. Using several fuse-switch
disconnectors to achieve this has the disadvantage of being prone to lose
contact issue as several LV cables will be connected to a transformer bushing.

4.7.4.3. Safety and Signage

 Anti-climbing devices should be fitted at the pole section below the
transformer channel iron base. This is to prevent excess to the high
voltage zone.
 Substation signage with danger notices must be prominently displayed
below the transformer channel iron base.
 124 Substation Design Manual

Anti-climbing device
4

Substation signage

Figure 4-56: Substation signage

4.7.5. Safety Clearances

(a) Ensure that under all possible conditions, the clearance from the ground
level or any adjacent object which a member of the public can stand upon
to the lowest live terminal is at least 3 meters.
(b) Any un-insulated wires running down the pole for earthing purposes must
be insulated or guarded in some way for at least 3 meters above the
ground level.
(c) Stay wires fitted to the pole should have insulators installed at least
3 meters above the ground level.
 P/E, 11 kV SSU and S/S Design 125

4.8. Pole Mounted Substation (PAT) with RMU

4.8.1. Overview
Pole mounted substations (PAT) with insulating cover and ring main units
(RMU) is a combination of insulated pole-mounted with outdoor substation
for the 11 kV system.

The advantages of the PAT and RMU are ease of operation, suitable to limited
land area and cheaper construction costs compared to outdoor P/E.
4
However, it is important to ensure that permission to use the appropriate
land area is obtained from the local authorities.

RMU 11 kV, 630 A

11 kV incoming 11 kV outgoing

Distribution
transformer

Fuse-switch
disconnector

Figure 4-57: Single line diagram for PAT with RMU connected to fuse-switch
disconnector
 126 Substation Design Manual

RMU 11 kV, 630 A

11 kV incoming 11 kV outgoing

Transformer
11/0.433 kV

Feeder Pillar
1600A/800A

Figure 4-58: Single line diagram for PAT with RMU connected to feeder pillar
 P/E, 11 kV SSU and S/S Design 127

4.8.2. Layout of PAT with RMU

Main components on the PAT with RMU are similar to the standard pole-
mounted substation. However a Ring Main Unit (RMU) functions as the
isolating component.

4
Transformer
bushing covers

Transformer

RMU

Feeder pillar

Figure 4-59: Layout of PAT with RMU and fuse-switch disconnector

 128 Substation Design Manual

4.8.3. Electrical Criteria

Table 4-18 summarises the standard electrical ratings for equipment on the
PAT with RMU. All electrical clearances presented in Subchapter 2.5 must be
adhered to.

Table 4-18: Major components in a PAT with RMU

Equipment/component Typical rating and size
Transformer  11kV/433V,
 100, 300, kVA
4 RMU  12 kV, 630 A
 Configuration 2L + 1T
MV underground cable  Incoming and outgoing: 11 kV 3C cable encased in
2
150 mm G.I. Pipe (1.8m long)
 Transformer T-off: 11 kV, XLPE, 3C, 70 mm2, Al,
2
encased in 150 mm G.I. Pipe (1.8 m long) as riser
going up the pole
LV underground cable Connection to feeder pillar
 LV XLPE, 4-core, 185 mm2, Al (for 100 kVA
transformer)
 PVC/PVC, 1-core, 300 mm2, Al encased in 150
2
mm GI pipe or PVC Class B pipe (for 300 kVA
transformer)
Connection to fuse switch disconnector
 LV ABC 3 x 95 mm2 + 1 x 70 mm2 (for 100 kVA
transformer)
 LV ABC 3 x 185 mm2 + 1 x 120 mm2 (for 300 kVA
transformer)
 The outgoing cable from the fuse switch
disconnector that connects to the first pole is
2
typically LV XLPE, 4-core, 185 mm , Al
underground cable
Fuse-switch disconnector  400 A
Feeder pillar (FP)  400 A
 800 A
 1600 A
 P/E, 11 kV SSU and S/S Design 129

4.8.4. Civil Criteria

The following are guidelines of typical civil requirements to provide proper
working environment for the equipment and personnel working around the
pole-mounted substation with RMU. In general, the construction of this
substation should follow the guides presented in Subchapter 4.4 on outdoor
substation structures and Subchapter 4.7 on pole-mounted substations.

Table 4-19: Civil requirements of PAT with RMU

Item Minimum requirement
Size/dimension Land size : 4000 (L) x 3000 (W) mm
4
Support  2-pole structure:
structure - To support up to 100 kVA transformer
- 2 spun pole 10 m (5 kN cantilever strength)
- The transformer is mounted on 2 channel irons/U-
channel**
 4-pole structure:
- To support 300 kVA transformer
- 4 spun poles 10 m (5 kN cantilever strength)
- The transformer is mounted on 7 channel irons/ U-
channel**
 Pole to pole distance is 1800 mm
**size for channel iron:
- 11 kV : 2500 mm(L) x 100 mm (W) x 50 mm(H)
Switchgear area  Dimension : 3000 (L) x 3000 (W) mm
 Plinth able to support up to 5000 kg
 Roof type: Ardex corrugated sheets will be used
 Chain link fencing shall be built around the RMU and H-pole
structure
LV system  Buried LV underground cables are used as the outgoing cables
connection instead of LV overhead cable from the fuse-switch
disconnector to the first pole.
 This practice is to prevent animals like squirrels and monkeys
from reaching the pole-mounted substation via the LV
overhead cable.
Compound area  Civil criteria for outdoor substation for floor, plinth and roof
can be applied to the PAT with RMU construction as in
Subchapter 4.4.4.1.
Safety signage  Suitable and sufficient signage as mentioned in Subchapter
4.2.4.4.2 must be mounted on the PAT (below the
transformer channel iron base) or on the fencing of the
switchgear area.
 130 Substation Design Manual

Chapter 5: Design for Substations

with Special Requirements
This chapter presents general information concerning the design of the
Mobile Switching Station / Stesen Suis Utama Bergerak (Mobile SSU) and
mitigation methods for substations located in flood prone areas. It describes
configurations, illustrates typical layouts, and presents technical criteria of
these stations.

5.1. Mobile SSU

5
5.1.1. Overview
A mobile unit substation or mobile transformer is one in which all the
components are mounted on a highway trailer. These units may be readily
moved from one location to another by a prime mover.

The Mobile SSU provides a preconfigured, plug‐and‐play package that

minimizes installation time, effort and risk. It consists of a metal enclosure,
containing all the substation‐related elements, including the Medium Voltage
cubicles, low voltage distribution board, battery charger and other auxiliary
devices.

The Mobile SSU was introduced to perform the main functions as below:

(a) To provide temporary supply for new projects while a permanent

substation is being constructed.
(b) To assist in improving SAIDI as it is an alternative for quick supply
restoration by:
i. Diverting the network through the Mobile SSU to ensure continuity
of supply while a PPU undergoes rehabilitation/renovation works.
ii. Providing temporary supply by replacing whole or part of a PPU
which may be affected by any breakdown of the PPU equipment.
 Design for Substations with Special Requirements 131

The Mobile SSU enables TNB to fulfil its commitment for high network
reliability which in turn would enhance TNB’s service level.

The advantages of the Mobile SSU are:

 High mobility and fast connectivity to the distribution network.

 Minimises civil engineering work; fully assembled and tested in the
factory, ensuring an optimum level of quality and reliability.
 Requires a small area of 13 m x 3 m to station the container.

Figure 5-1: Two Mobile SSU units

33kV S/G 11kV S/G

3 2 1 1 2 3 4 5 6 7 8

Mobile SSU

On-Site Transformer
Figure 5-2: Mobile SSU connected to an on-site transformer
 132 Substation Design Manual

5.1.2. Layout
All equipment for the Mobile SSU is contained inside a standard intermodal
ISO container sized compartment, which is pulled on a trailer. Figure 5-3
below shows the dimension of the container.

12500 (41ft) Trailer Length

Landing Gear
Prime mover
5

2590 (8.5ft)

3940 (12.9ft)
General height

1350 (4.4ft)

1820 (6ft) Track

2500 (8.2ft)
Max width

Figure 5-3: Dimension of the container

 Design for Substations with Special Requirements 133

Figure 5-4 below shows the locations of major components inside the Mobile
SSU. A Mobile SSU typically consists of:

1. 3 units of 33 kV GIS switching panels:

(a) 1 incoming feeder
(b) 1 outgoing feeder
(c) 1 feeder to transformer
2. 2 units of air-conditioning
3. 7 units of 11 kV GIS switching panels:
(a) 1 incoming feeder (from 33/11 kV transformer); and
(b) 6 outgoing feeders
4. 1 unit of marshalling cubicle for 33/11 kV transformer
5. LVAC panel
6. 10 Control and Relay Panels (CRP) for 33 kV and 11 kV switching
5
panels
7. Battery and battery charger compartment – the battery is either of
sealed lead acid or compact dry and maintenance-free type.
8. Fire fighting equipment

(1) (2) (3) (4) (5) (6) (7) (8)

Figure 5-4: Plan layout of the Mobile SSU

All of the above components are installed in a standard 40 foot container

sized 12.192 L x 2.438 W x 2.591 H meters (40’ 0” L x 8’ 0” W x 8’ 6” H feet).
The container is also equipped with two air-conditioning units to ensure that
the equipment is at optimal operating temperature. Each air-conditioning unit
is operated alternately via auto-changeover switch to prolong their lifespan.
 134 Substation Design Manual

The following figures show some of the equipment inside the Mobile SSU.

Figure 5-5: 11 kV GIS switching panels

Figure 5-6: 33 kV and 11 kV Control Relay Panels (CRP)

 Design for Substations with Special Requirements 135

Figure 5-7: Low Voltage AC (LVAC) panel

Figure 5-8: Dry type battery cells in the battery compartment

 136 Substation Design Manual

(a) (b)

(c)

Figure 5-9: Cable entry point into the GIS switchgears underneath the
2 2 2
Mobile SSU, (a) 3C x 240 mm , (b) 3 x 1C x 500 mm , (c) 3 x 1C x 630 mm
 Design for Substations with Special Requirements 137

The Mobile SSU requires an external LV power source to provide supply to all
LV instruments including battery charger and air conditioning.

LV supply to the container is drawn from an external source and connected to

the plug point located at the bottom of the container as shown in Figure 5-10.

Figure 5-10: LV supply plug point

Four earthing points are available on a Mobile SSU.

 1 for 33 kV switchgears
 1 for 11 kV switchgears
 1 for CRP
 1 for other equipment such as battery charger and LVAC
 138 Substation Design Manual

These points shall be interconnected and then connected to a substation

earth rod using proper earthing cables. Earthing connection methods are
presented in Chapter 9.

Figure 5-11: Earthing Point

5.1.3. Electrical Criteria

Table 5-1 summarises the standard electrical ratings for equipment in a
Mobile SSU.

PPUs typically have 10 to 14 feeders. The Mobile SSU is designed to supply for
half-bus loads which is 7 feeders.

Table 5-1: Ratings of Mobile SSU

Item Rating
Voltage 33 kV & 11 kV single busbar
Busbar rating 2000 A
33 kV Circuit Breaker rating 1250 A (for the transformer and feeders)
11 kV Circuit Breaker rating 2000 A for the transformer and 1250 A for the feeders
Short Time Withstand Rating 25 kA, 3 seconds
Internal Arc Rating 25 kA, 1 second
 Design for Substations with Special Requirements 139

5.1.4. Operating Specifications

The Mobile SSU conforms to the following standards and operating
conditions: IEC 62271‐100, IEC 62271‐200 and IEC 62271‐102.

5.1.4.1. Normal Service Condition

 Operating temperature range
The ambient temperature shall be in the range of –5°C to +40°C and the
average value measured over a period of 24 hours must not exceed 35°C.

 Installation altitude
High‐voltage switchgear can be installed up to an altitude of 1000 meters.
At higher installation altitudes, the reduced voltage endurance must be
taken into account.
5
 Air pollution
The ambient air must be free of dust, smoke, corrosive or combustible
gases, steam and salts.

5.1.4.2. Prime Mover Type/Connection

Use of prime movers can be arranged through:

Pengurus Besar
Jabatan Perkhidmatan Logistik
Bahagian Perkhidmatan Korporat
Tenaga Nasional Berhad
129 Jalan Bangsar
50732 Kuala Lumpur

The container is suitable for prime mover class 4 x 2 for loads less than 35
tonnes. The prime mover should also have fifth wheel coupler.

The prime mover should have a 50.8 mm (2 inch) kingpin connection.

 140 Substation Design Manual

5.1.4.3. Equipment
The special tools/ test plug supplied with the Mobile SSU are:

 MMLB07 Multi Finger Test Plug


2
Pfisterer Socket Size 3, 36 kV Termination Kit, 630 mm XLPE
Aluminium Conductor

2
Pfisterer Socket Size 3, 36 kV Termination Kit, 500 mm XLPE
Aluminium Conductor
 Conductor Current Test Plug Size 2 with Dummy Plug
 Manual Charging Handle for Circuit Breaker Operating Mechanism
 Manual Operating Handle for Isolator
 Tif‐Xp‐1a SF6 Leak Detector
 Dummy Plug Size 3
5
Special tools for plugging in power cable termination and SF6 filling are not
supplied in the container. This service would be rendered by the site testing
and commissioning contractor.

5.1.4.4. Logistics and Operation

5.1.4.4.1. Ingress Protection

The IP class for the mobile SSU is IP55.

5.1.4.4.2. Level of Parking Area

o
The inclination of parking area should not exceed 10 while the mobile
substation is in operation.

5.1.4.4.3. Landing Gear

Two sets of landing gear supports are provided at the front and back side of
the container. The container will stand on these landing gears while in
operation.

5.1.4.4.4. Wedge for Tyres

During parking, the mobile SSU will be supported by the landing gears and
tyres. If wedges are to be used, the wedges suitable for 41 ft trailer are
recommended.
 Design for Substations with Special Requirements 141

Figure 5-12: Landing gears placed on solid and flat surface

5.1.4.4.5. Vehicle Insurance

The mobile container requires its own comprehensive first party vehicle
insurance, separate from the prime mover insurance.

5.1.4.4.6. Road Tax

The container requires a separate road tax from the prime mover. For road
tax renewal, the container should undergo road worthiness inspection
annually at PUSPAKOM.

5.1.4.4.7. Inspection Prior to Moving Vehicles

Prior to towing the container the followings inspection and actions should be
taken:

 Air brake is released

 Landing gear is raised
 Air conditioner cover for the condenser unit is securely installed.
 Tyre pressure is within 120 psi.
 All indicating and signal lights function properly.
 142 Substation Design Manual

5.1.4.4.8. Mobile SSU Transportation

The mobile container is subjected to road transport regulations with a

maximum speed of 90 km/hour.

5.1.4.4.9. Security

For the purpose of prevention of theft and unauthorized entry, pad locking
options are provided at each door.

Figure 5-13: Provision for padlocks at each door

5.1.5. Maintenance Specifications

5.1.5.1. Vehicle
 Landing Gear – The landing gear is suitable for weight of up to 30 tonnes.
 Axles – The container uses 2 axles with 60 tonnes combined capacity.
 Tyre – The container is equipped with 8 tyres installed on the axle with
one spare tyre. The typical tyre size is 11 R x 22.5 x 16. The recommended
tyre pressure is 120 psi.
 Design for Substations with Special Requirements 143

5.1.5.2. Equipment
The electrical installation shall be tested at each re‐location prior to start‐up,
or at intervals not exceeding 6 months, whichever comes first. The result of all
tests shall be recorded and retained.

The general tests required are listed as follows:

5.1.5.2.1. Visual Inspection

The Mobile SSU should be visually inspected for:

 Loose bolts and nuts
 Dust and foreign particles
 Dislocated parts
 Filing and chips
 Deformation, damage and wear 5
 Dislocated connectors and pins
 Loose switch terminals
 Rust
 Abnormal noise or smell
 Non working indicators

5.1.5.2.2. Impedance to Earth of the Common Earth Grid

It is essential that the common earth grid is tested in order to ensure that the
impedance to earth is not greater than the value required as calculated using
IEEE Std 80 as in Subchapter 9.3.

5.1.5.2.3. Insulation Resistance

The cable insulation resistance tests shall be carried out between phases and
earth, between phases, and between phases and neutral.
 144 Substation Design Manual

5.2. Flood Prone Areas

5.2.1. Overview
Generally, new substation sites should not be placed in flood prone areas.
Meanwhile for existing substations in flood prone areas, mitigation steps need
to be taken to prevent damage of substation equipment.

The objectives of substation equipment for this process are:

1. To minimize the risk of damage to TNB electrical installations during

flooding.
2. To ensure that the supply to the flooded area can be restored
immediately once the water recedes.
5 3. To maintain electricity supply to any unaffected area downstream even
though there is a flood at the upstream of the electrical network.

The following flood mitigation techniques are summarized from Pekeliling PBK
(Pengurusan Aset) Bil. A22/2012 – Kaedah Mitigasi Pencawang 11kV dan 22kV
di Kawasan yang Dilanda Banjir.

5.2.2. Methodology
The standard methodology for electrical installations flood mitigation is
outlined below:

1. Maximum Flood Level – Get historical and expected worst flood level
information from Jabatan Pengairan dan Saliran / Drainage and Irrigation
Department (DID). This information will be used to construct the
substation floor to a higher level than the worst flood level.
2. Mitigation Technique – Select the appropriate mitigation initiatives. In
general, the most suitable mitigation method shall comply to the
following:
(a) Safety issues when operating the equipment shall not be
compromised.
(b) The minimum clearance between tools/workers and the live parts
should be met.
 Design for Substations with Special Requirements 145

Initiatives for new and existing substations to reduce the effect of flooding
upon the distribution network are explained as follows:

5.2.2.2. New Substations

For new substations, the following should be implemented:

(a) Site selection – avoid flood plains altogether.

(b) Equipment selection – choose more flood resilient equipment.

5.2.2.3. Existing Substations

In the case of existing substations, the aim is to elevate the substations above
known flood levels and block water entry. Several mitigation options are
suggested below:

(a) Protection of individual equipment – raise plinth level for the equipment 5
or the floor of the substation.
(b) Protection of buildings – build a flood wall at the substation door
(indoor), block water entry through cable trench or install submersible
pump to pump out water from the substation.
(c) Convert to pole mounted substation.
(d) If the above mitigation options cannot be implemented, relocate the
substation.

Selection of mitigation techniques are based on the height of flood level and
type of substation involved. The mitigation techniques for the following types
of substations are further discussed in this chapter:

1. Pole mounted substation (PAT) with feeder pillar

2. Pole mounted substation (PAT) with RMU
3. Outdoor substation
4. Indoor substation
5. Compact substation
 146 Substation Design Manual

5.2.3. Mitigation for PAT with Feeder Pillar

For flood level of less than 3 feet:

 Raise feeder pillar plinth level to one foot above the flood level.

For flood level more than 3 feet:

 If the water level reaches the transformer, the substation must be

relocated.

This configuration will ensure that the MV feeder can still supply to other
unaffected areas.

Figure 5-14: Raised feeder pillar plinth

5.2.4. Mitigation for PAT with RMU

For flood level less than 3 feet:

 Raise RMU plinth level to one foot above the flood level; or
 Replace the RMU with load break switch (LBS).

For flood level more than 3 feet:

 If the water level does not reach the transformer, replace the RMU with
load break switch.
 If the water level reaches the transformer, PAT must be relocated.
 Design for Substations with Special Requirements 147

5.2.5. Mitigation for Outdoor Substation

For flood level less than 3 feet:

 Raise the RMU, transformer and feeder pillar plinths to one foot above
the flood level; or
 Raise the substation floor to one foot above the flood level.

For flood level more than 3 feet:

 Raise the substation floor to one foot above the flood level.
 If raising the floor is not possible, change the substation to pole-mounted
substation (PAT).
 If both are not practical, the substation has to be relocated.

Figure 5-15: RMU, transformer and feeder pillar plinths are raised higher
than the flood level

Figure 5-16: Pole-mounted substation (PAT) in a flooded area

 148 Substation Design Manual

Figure 5-17: Raised substation floor level under 3 feet

Figure 5-18: Raised substation floor for flood level of more than 3 feet
 Design for Substations with Special Requirements 149

5.2.6. Mitigation for Indoor Substation

For flood level less than 3 feet:

 Raise the RMU, transformer and feeder pillar plinths to one foot above
the flood level; or
 Raise substation floor to one foot above the flood level; or
 Construct a water barrier / flood wall at the substation door and install a
submersible water pump. Water entry through cable trenches should be
blocked to minimise the amount of water entering the substation.

For flood level more than 3 feet:

 Install flood walls and water pumps as above.

 If it is not practical to install flood walls at such height, the substation has
to be relocated. 5

Figure 5-19: Raised RMU, transformer and feeder pillar plinths

to above the flood level
 150 Substation Design Manual

Figure 5-20: Water barrier / flood wall constructed at the substation door

Figure 5-21: Higher flood walls may require staircase access to be built
 Design for Substations with Special Requirements 151

5.2.7. Mitigation for Compact Substation

For flood level less than 3 feet:

 Raise compact substation plinth to one foot above the flood level.

For flood level more than 3 feet:

 Raise compact substation plinth one foot above the flood level.
 If this is not practical, change to PAT or relocate the substation.

Figure 5-22: Raised compact substation plinth one foot above the flood level
 152 Substation Design Manual

5.2.8. Guideline for New Substations

For new substations, the planner should consider the following:

 All new substations should not be constructed in flood-prone areas.

 If this is unavoidable, the substation need to be built using the mitigation
techniques suggested previously in this chapter.
 TNB may also request the developer to build a custom-designed
substation building. An example is shown in the figure below.

Figure 5-23: Custom-designed substation building for flood-prone areas

 Primary Equipment 153

Chapter 6: Primary Equipment

6.1. Transformer

6.1.1. Overview
In “IEC Standard 60076 – Part 1: Power Transformers”, a transformer is
defined as a static piece of apparatus with two or more windings which, by
electromagnetic induction transforms a system of alternating voltage and
current in one winding into another system of alternating voltage and current
in one or more other windings, usually of different values and at the same
frequency for the purpose of transmitting electrical power.

An alternating voltage applied to one of the winding produces, by

electromagnetic induction, a corresponding electromotive force (EMF) in the
other windings. Thus energy can be transferred from the primary circuit to the
other circuits by means of the common magnetic flux. Thus, a transformer is a
6
device which transfers electric power from one circuit to another without
electric connection while maintaining the frequency of the power source as a
result of the transfer of energy.

Laminated Core

primary secondary

Figure 6-1: Magnetic circuit and windings of a transformer

 154 Substation Design Manual

6.1.2. Transformer Category

According to IEC 60076-1, windings in transformer can be classified into high
voltage (HV) or low voltage (LV) windings. HV winding is defined as the
winding having the highest voltage whilst LV winding is defined as the winding
having the lowest voltage. Referring to this definition, transformers in TNB
distribution system can be categorized into four categories:

 Category 1 – Free breathing power transformers with On-Load Tap

Changer (OLTC). This category of transformer has capacity above 5 MVA
up to 30 MVA.
 Category 2 – Free breathing power transformers with Off-Circuit Tap
Changer (OCTC). This category transformer has capacity of 3 MVA up to 5
MVA.
 Category 3 – Small power transformers with Off-Circuit Tap Changer
(OCTC). However, this category of transformers has capacity above 1
MVA but not larger than 3 MVA and can be either free breathing or
hermetically sealed transformers.
6
 Category 4 – Distribution transformer. It has primary and secondary
windings designed to operate at high and low voltage or vice versa
depending whether it is a step down or a step up transformer. This
category of transformer has capacity not larger than 1 MVA and can
either be a free breathing or hermetically sealed transformers.
 Primary Equipment 155

6.1.3. Transformer General Arrangement

6.1.3.1. Distribution Transformer

(9)
(8)
(10)

(11) (7)
(12)

(6)

(1)

6
(5)

(4)
(2) (3)

1. HV bushing 7. Pressure relief device (PRD)

2. Sampling/drain valve 8. Oil level gauge
3. Jacking pad 9. LV bushing flag
4. Corrugated fin wall 10. LV bimetal lug
5. Off circuit tap changer 11. LV bushing
6. HV bimetal lug 12. Top-mounted thermometer

Figure 6-2: Distribution transformer (external view)

 156 Substation Design Manual

(8)

(9) (7)
(10)
(11)
(6)

(1)

(2)

(3)
(5)
(4)

6
1. HV winding 7. Top clamping
2. LV winding 8. Neutral bar
3. Core (limb) 9. LV bar (red phase)
4. Insulation (press board) 10. LV bar (yellow phase)
5. Bottom clamping 11. LV bar (blue phase)
6. LV connection bar

Figure 6-3: Distribution transformer (internal view)

 Primary Equipment 157

Figure 6-4: A mock up construction of a distribution transformer showing the

internal parts
 158 Substation Design Manual

6.1.3.2. Power Transformer

(13) (12)
(11)

(14)
(16) (15)

(17) (10)
(18)

(19)
(20)
(9)
(21)

(8)

(7)
6
(6)
(1)

(2) (3) (4) (5)

1. Cooling radiator 12. Main conservator

2. Main tank 13. OLTC conservator
3. Motor drive unit (MDU) 14. Pressure relief device (PRD)
4. Lifting lug for complete unit 15. CT terminal box
5. HV cable box 16. Local control panel (LCP)
6. Oil level indicator 17. Inspection vent
7. Cable box breather 18. LV cable box
8. Buchholz relay 19. Lifting lug for cover
9. Cooling fan 20. On load tap changer (OLTC)
10. Core earth box 21. Top cover
11. Air leak detector

Figure 6-5: Power transformer (external view)

 Primary Equipment 159

(9)
(10)

(8)

(1)

(7)
(2)

(3) (6)

(4) (5)

1. Regulating winding 6. Support for winding

2. HV winding 7. Bottom clamping 6
3. LV winding 8. OLTC
4. Core (limb) 9. Top clamping
5. Foot 10. CT (for winding temperature)

Figure 6-6: Power transformer (internal view)

6.1.4. Transformer Design Characteristics

The transformers used in TNB distribution system are designed with specific
characteristics to suit the system requirement for safe operation under
normal service condition. By definition according to IEC 60076-1, normal
service conditions are at an altitude of not greater than 1000 m above sea
level, within an ambient temperature range of -25:C to +40:C, subjected to a
wave shape which is approximately sinusoidal, a three phase supply which is
approximately symmetrical and within an environment which does not
require special provision on account for pollution and is not exposed to
seismic disturbance. The basic design characteristics of distribution as well as
power transformers in TNB distribution system are briefly explained in the
following sub-chapters.
 160 Substation Design Manual

6.1.4.1. Rated Voltage

Rated voltage is the voltage in kV between line terminals at no-load of
untapped winding i.e. LV winding or of a tapped winding i.e. HV winding
connected on the principal (nominal) tap position.

6.1.4.2. Voltage Ratio

Voltage ratio is the ratio of the rated voltage of HV winding to the rated
voltage of LV winding. On the other hand, the voltage ratio notation for
identification is indicated as HV/LV e.g. 33/11 kV for a step down transformer
or LV/HV e.g. 11/33 kV for a step up transformer.

6.1.4.3. Rated Power

Rated power is a conventional value of apparent power indicating the capacity
6 of the transformer in kVA or MVA.

6.1.4.4. Rated Current

Rated current is the current flowing through a line terminal of a winding (line
current) which is derived from the rated power and rated voltage for the
winding. For a three phase transformer, the rated current iR in the winding
under consideration is given by:

Transformer Rated Power

𝑖𝑅 =
3 × Rated Voltage of the Winding

6.1.4.5. Rated Frequency

The rated frequency corresponds to the network frequency i.e. 50 Hz at which
the transformer is designed to operate.
 Primary Equipment 161

6.1.4.6. Short Circuit Impedance (Percentage Impedance)

Short circuit impedance of a transformer is the percentage voltage drop of the
no-load voltage at full load current due to the winding resistance and leakage
reactance. The impedance of a transformer has a major effect on system fault
levels. It determines the maximum value of current that will flow under fault
conditions. Thus, the percentage impedance of a transformer is designed to
balance between the effect of limiting the short circuit current and at the
same time maintaining the voltage drop within a permissible range.

By using the percentage impedance of the transformer, a symmetrical three

phase short circuit on the LV terminals will produce current if in Amps equal
to:

Transformer rated power kVA × 100

𝑖𝑓 =
3 × Rated voltage of LV winding kV × Percentage impedance

6.1.4.7. Winding Connection and Vector Group

The information on winding connection and vector group of a transformer is 6
very important to enable satisfactory operation of transformers in parallel.
The interphase connections of the HV and LV windings are indicated by the
capital and small letters respectively as shown in Table 6-1 . The winding
connection letter is immediately followed by its phase displacement clock
number. The letter symbols for the different windings are noted in descending
order. Figure 6-7 and Figure 6-8 shows some examples on the phasor
diagrams and clock number notations for typical transformer winding
connections.
Table 6-1: Winding connection designation
Winding Winding Connection Designation
HV winding Delta D
Star Y
Interconnected star
Z
(zigzag)
Neutral N
LV winding Delta d
Star y
Interconnected star
z
(zigzag)
Neutral n
 162 Substation Design Manual

HV Winding LV Winding

(a) 3-phase Delta-Star connection Dyn11

HV Winding LV Winding
6

(b) 3-phase Star-Delta connection YNd11

Figure 6-7: Phasor diagrams and clock number notation showing phase
displacement of +30⁰ for 3-phase transformers with connection symbols
Dyn11 and YNd11
 Primary Equipment 163

HV Winding LV Winding

(a) 3-phase Delta-Star connection Dyn1

HV Winding LV Winding
6

(b) 3-phase Star-Delta connection YNd1

Figure 6-8: Phasor diagrams and clock number notation showing phase
displacement of -30⁰ for 3-phase transformers with connection symbols
Dyn1 and YNd1
 164 Substation Design Manual

6.1.4.8. Losses and Efficiency

Losses of a transformer can be expressed in terms of no-load loss and load
loss. These quantities are determined by means of tests at rated voltage for
no-load test and at rated current for load loss.

When a transformer is energised, a magnetising current is required to excite

the core through the alternating cycles of a flux at a rate determined by the
system frequency. The energy dissipated in doing so is known as the no-load
loss, core loss or iron loss and it is present whenever the transformer is
energised. Hysteresis and eddy currents losses contribute to over 99% of the
no-load loss.

The load loss, also known as winding loss, copper loss or short circuit loss of a
transformer is generated by the flow of load current which varies as the
square of the load current. Load loss can be divided into three categories:


2
Resistive loss (I R) within the winding conductors and leads. This type of
6 loss dominates load loss.
 Eddy current loss in the winding conductors
 Stray loss due to leakage flux that intercepts the tanks and structural
steelwork which give rise to the eddy current flow

Other losses are due to effect known as magnetostriction where magnetic flux
in the core, causes it to physically expand and contract slightly with each cycle
of the magnetic field, produces the humming sound commonly associated
with transformers. This can cause losses due to frictional heating. In addition
to magnetostriction, mechanical loss due to fluctuating forces between the
primary and secondary windings as the result of the alternating magnetic
field. These incite vibrations within nearby metalwork, adding to the humming
noise and consuming a small amount of power.

The guaranteed no-load loss and load loss in kW of distribution and power
transformers are as shown in the tables that follow.
 Primary Equipment 165

Table 6-2: No-load loss and load loss in kW of a distribution transformer

6.6/0.433 kV 11/0.433 kV
kVA Load loss No-load Total loss Load loss No-load Total loss
(kW) loss (kW) (kW) (kW) loss (kW) (kW)
100 1.5 0.3 1.8 1.5 0.3 1.8
300 2.8 0.6 3.4 2.8 0.6 3.4
500 4.1 1.0 5.1 4.1 1.0 5.1
625* 4.7 1.3 6.0
750 1.2 1.2 7.2 6.0 1.2 7.2
1000 1.4 1.4 8.4 7.0 1.4 8.4
1250* 7.9 1.8 9.7
22/0.433 kV 33/0.433 kV
kVA No-load No-load
Load loss Total loss Load loss Total loss
loss loss
100 1.6 0.24 1.84 1.5 0.3 1.8
300 4.4 0.7 5.1 4.5 0.73 5.23
500 7.3 0.9 8.2 7.18 1.02 8.2
750 9.2 1.2 10.4 9.2 1.385 6.0
1000 11.7 1.5 13.2 11.85 1.665 7.0
6
*Note: Step up 0.415/11kV transformers

Table 6-3: No-load loss and load loss in kW of a power transformer

33/11 kV 11/33 KV
MVA No-load No-load
Load loss Total loss Load loss Total loss
loss loss
1.5 16.5 1.6 18.1 14.5 2.4 16.9
5 3.9 9 48
12.5 80 12 92
15 82 12 94 80 12 92
30 120 15 135
22/11 kV 22/6.6 kV
MVA No-load No-load
Load loss Total loss Load loss Total loss
loss loss
2 19.5 2.5 22
7.5 47 5 52 42 6 48
12.5 80 12 92 75 10 85
30 120 15 135
 166 Substation Design Manual

The energy efficiency of a transformer is given by the following formula:

Output
%Efficiency =
Output + Losses

P × kVA × p. f × 1000 × 100

=
P × kVA × p. f × 1000 + NL + LL × P 2 × T

Where,

P = per unit loading

NL = no-load loss in watts
LL = load loss in watts at full load, at 75˚C
T = temperature correction factor (T at 75˚C is 1.0)
p.f = power factor

Example of energy efficiencies at 0.9 lagging power factor for TNB distribution
transformers of various sizes calculated using the above formula are as
6 plotted in the graph of Figure 6-9.

The graph shows that distribution transformers are most efficient between
0.4 to 0.5 per unit loading. It also shows that bigger capacity transformers by
design, for example 1000 kVA, are more efficient as compared to the lower
capacity, for example 100 kVA.

Despite these facts, loading of a transformer and selection of transformer

capacity should not be based merely on losses or efficiency of the transformer
but should also consider for asset optimization. This is because the
transformer loaded at between 0.5 and 1.0 per unit loading has relatively
small difference in efficiency as compared to loading between 0.4 and 0.5 per
unit loading.
 Primary Equipment 167

Currently, energy efficiency of TNB distribution transformers are at par with

the current class 1 energy efficient transformers in the U.S. (NEMA TP-1) and
Europe (HD 428 C-C’), and they are comparable with future minimum energy
efficient standards in the U.S. (TSL2) and Europe (EN-50464-1:2007 Ao-Ak).

Figure 6-9: Energy efficiency of distribution transformers of different

capacities at various per unit loading
 168 Substation Design Manual

6.1.4.9. Noise Pressure Level

The average noise pressure level of a transformer is measured at 0.3 m from
the radiating surface, where the measurement should be performed
according to IEC 60076-10.

The maximum permissible sound level by receiving land as recommended by

the Department of Environment in its planning guideline for environmental
noise limits and controls are as follows:

Table 6-4: The Maximum Permissible Sound Level by Receiving Land

Receiving Land Use Day Time Night Time

Category 7.00 am - 10.00 pm 10.00 pm - 7.00 am

Noise Sensitive Areas,

Low Density Residential,
50 dBA 40 dBA
Institutional (School,
Hospital), Worship Areas.
Suburban Residential
6 (Medium Density) Areas,
55 dBA 45 dBA
Public Spaces, Parks,
Recreational Areas.
Urban Residential (High
Density) Areas, Designated
60 dBA 50 dBA
Mixed Development Areas
(Residential - Commercial).

Commercial Business Zones 65 dBA 55 dBA

Designated Industrial 70 dBA 60 dBA

As such, the design and construction of all types of substations should strictly
follow the requirement underlined by the latest revision of ESAH in order to
ensure the noise generated by a transformer is contained within the
substation so that the noise radiated outwards from the substation will not
exceed the specified limits above.
 Primary Equipment 169

6.1.4.10. Rated Insulation Level

Rated insulation level is a set of standard withstand voltages which
characterize the dielectric strength of the insulation used. The level is
identified by the highest voltage (rms) for equipment U m, associated with the
winding. The rules for coordination of transformer insulation with respect to
transient overvoltages are formulated differently depending on the value of
Um.

The rated insulation levels for standard dielectric insulation requirement,

i.e. lightning impulse withstand voltage, LI (peak) for the line terminals and
separate source AC withstand voltage (rms) for transformers in TNB
distribution network in accordance with IEC 60076-3 are as tabulated in
Table 6-5.

Table 6-5: Rated withstand voltages for transformer windings

Insulation Level
Highest Voltage Um of HV & LV Windings
AC LI
Winding with Um = 36 kV 70 kV 170 kV 6
Winding with Um = 24 kV 50 kV 125 kV
Winding with Um = 12 kV 28 kV 75 kV
Winding with Um  1.1 kV 3 kV -

6.1.4.11. Temperature Rise

Temperature rise is the difference between the temperature of the part under
consideration i.e. top oil or winding temperature and the ambient
(surrounding) temperature, when the transformer is loaded up to its
nameplate rating. A transformer with a lower temperature rise is more
efficient since it consumes less energy and generates less waste heat and
contributes to a longer life expectancy. On the other hand, lower temperature
rise will incur additional cost since more cooling medium or improved cooling
system is required.
 170 Substation Design Manual

6.1.4.12. Overloading
The normal design life expectancy of a transformer is based on continuous
duty under design ambient temperature and normal service or rated
operating conditions. However, the application of a load in excess of
nameplate rating and an ambient temperature higher than design ambient
temperature involves a degree of risk and accelerated ageing that reduces the
expected design life of the transformer.

Although the maximum loading capability of the transformer can be safely set
to 100% under normal condition of its capacity for a design ambient
temperature of 40:C, it is technically possible to overload the transformer
under the following conditions:

 Normal cyclic loading – loading of a transformer at higher ambient

temperature or a higher than rated load current during some part of the
24 hour cycle where the average loading is equivalent to the rated load at
normal ambient temperature.
6  Long time emergency loading – loading of a transformer at higher
ambient temperature or a higher than rated load current for a prolonged
part of the 24 hour cycle due to system outage that will not be
normalized before the transformer reaches a new and higher steady state
temperature.
 Short time emergency loading – unusually heavy loading of a transformer
of transient nature of less than 30 minutes due to the occurrence of one
or more unlikely events which seriously disturb normal system loading.

The risks or consequences of loading a transformer beyond its nameplate

rating are:

 Damage of the dielectric strength of the transformer insulation due to

development of gas bubbles as the result of hot-spot temperature
exceeding 140:C that could occur at the winding, leads or cleats.
 Eddy-current heating in metallic parts as the result of increased leakage
flux outside the core.
 Damage of bushings, tap changer, terminations and current transformer,
due to higher stresses beyond their design limits.
 Primary Equipment 171

Due consideration should also be given on the withstand capability of other

equipment in the system such as power and auxiliary cables, secondary
system and equipment as well as settings of protection relays before decision
to overload the transformer is made. Overloading of a transformer beyond its
nameplate rating shall therefore be performed strictly in accordance with IEC
60076-7 and TNB Distribution Planning Guideline.

6.1.4.13. Tap Changer and Tapping Range

Tap changer is a device used for changing the tapping connection of a winding
to regulate voltage level affected by load variations. There are two types of
tap changer used, the Off-Circuit Tap Changer (OCTC) and On-Load Tap
Changer (OLTC) which are explained further under Subchapter 6.1.5.6.

Tapping (regulating) range is the variation range of the tapping factor

expressed as a percentage of the rated nominal voltage of the tapped winding
i.e. HV winding. The typical tapping range of power and distribution 6
transformer tap changers is shown in Table 6-6 below.

Table 6-6: Tapping range according to transformer category

Tapping Nominal
Highest Lowest
Transformer per step Voltage
Transformer Tapping Range Voltage at Voltage
Voltage Ratio on HV on HV
Category (%) Lowest Tap at Highest
(kV) Winding Winding
(V) Tap (V)
(%) (V)
33/11,
+10% to -15% 1.67% 33000 36300 28050
33/22-11

11/33 +15% to -10% 1.67% 33000 37950 29700

Category 1

22/11 +10% to -15% 1.67% 22000 24200 18700

22/6.6 +9% to -16.5% 1.5% 22000 23980 18370

33/11,
+5% to -5% 2.5% 33000 34650 31350
33/0.433
Category 2, 22/11, 11/22,
+5% to -5% 2.5% 22000 23100 20900
3&4 22/0.433
11/0.433
+5% to -5% 2.5% 33000 11550 10450
0.415/11
 172 Substation Design Manual

Typical design characteristics for distribution and power transformers are

summarized in Table 6-7 and Table 6-8 respectively.

Table 6-7: Category 1 & 2 Transformer Basic Technical Parameters

Category Technical Parameter
Rated Voltage Ratio & Power 7.5 MVA, 15 MVA, 30
33/11 kV
 Power Transformer with MVA
OLTC (Category 1)
22/11 kV 12.5 MVA, 22.5 MVA

3.5 MVA, 7.5 MVA,

22/6.6 kV
12.5 MVA
33/22-11 kV
30 MVA
(Dual ratio)
7.5 MVA, 15 MVA,
33/11 kV
30 MVA

11/33 kV* 7.5 MVA, 15 MVA

 Power Transformer with

33/11 kV 5 MVA
6 OCTC (Category 2)

No. of phases & rated frequency 3-phase, 50 Hz

9 to 11% at reference temperature of

Short Circuit Impedance
75°C with tolerance of ±10%

Vector Group Dyn11, YNd1*, Ynd11*

Losses Refer to 6.1.4.8

Maximum Noise Pressure Level 55 dBA

Insulation Level Refer to 6.1.4.10

Temperature Rise 60°C (Top Oil), 65°C (Winding)

Tapping Range Refer to 6.1.4.13

*Step-up transformer
 Primary Equipment 173

Table 6-8: Category 3 & 4 Transformer Basic Technical Parameters

Category Technical Parameters

33/11 kV 1.5 MVA

Rated Voltage Ratio & Power
 Small Power Transformer 22/11 kV 2 MVA
(Category 3)
11/22 kV* 2 MVA

33/0.433 kV

22/0.433 kV
100, 300, 500, 750, 1000
 Distribution Transformer kVA
11/0.433 kV
(Category 4)
6.6/0.433 kV

0.415/11 kV* 300, 625, 1250 kVA

No. of phases & rated frequency 3-phase, 50 Hz

4.75% at reference temperature of 75°C

Short Circuit Impedance
with tolerance of ± 10% 6
Vector Group Dyn11, YNd1*, Ynd11*

Losses Refer to 6.1.4.8

Maximum Noise Pressure Level 60 dBA

Insulation Level Refer to 6.1.4.10

Temperature Rise 60°C (Top Oil), 65°C (Winding)

Tapping Range Refer to 6.1.4.13

*Step-up transformer
 174 Substation Design Manual

6.1.5. Transformer Construction

The main parts of a transformer are the core, the windings, transformer tank
to house the core and windings; bushing terminals for the external electric
circuit connection and the cooling arrangements to remove heat generated in
the core and winding for dissipation.

6.1.5.1. Core
The purpose of transformer core is to provide a low reluctance path for the
magnetic flux linking primary and secondary windings. The core is made up of
stacks of thin laminated magnetic sheet. Each lamination is insulated by a thin
non-conducting layer of insulation that increases resistivity of the material to
minimize the eddy current loss. The use of high permeability grain oriented
silicon steel is preferred due to its improved grain orientation to reduce
hysteresis loss.

The transformers used in TNB distribution system is of three-phase core with

three-limbs which are magnetically connected with each other at the upper
6
and the lower ends by yokes. In three-phase transformers, all the windings for
each phase are located at their own limb.

Figure 6-10: Distribution transformer three-limb core

 Primary Equipment 175

Figure 6-11: Core construction of power transformers

Figure 6-12: Complete core winding assembly

𝜙1 𝜙2 𝜙3

Window Yoke Limb

Figure 6-13: Three-limb transformer design that shows the flux

 176 Substation Design Manual

6.1.5.2. Winding
A winding is made up of conductors, coiled concentrically around the
magnetic circuit limbs to produce the desired number of turns in which will
determine the voltage of the winding. The conductor is usually made of
copper which is electrically insulated from each other with paper and in some
cases with enamel and paper to ensure that the current travels throughout
every turn.

The number of turn and the current in the winding primarily determine the
choice of winding type. The maximum current density in any winding is
2
designed usually not higher than 3 A/mm to reduce the dynamic effect
during short circuit.

Figure 6-14: Distribution transformer windings

Enamel coating

Conductor

Figure 6-15: Enamelled copper conductor

 Primary Equipment 177

Figure 6-16: Single strand with Kraft paper insulation

Figure 6-17: Continuous transposed cable (CTC) 6

Windings for transformers can be divided into four main types:

 Layer windings
 Foil windings
 Disc windings
 Helical windings

Distribution transformers are usually designed having layer winding on the HV

and foil winding on the LV, whilst power transformers have disc winding on
the HV and either disc or helical winding on the LV, depending on the value of
the rated current.

For layer type winding, the turns are arranged axially along the winding. The
consecutive turns are wound close to each other without any intermediate
space. The winding may be made as a single or multilayer winding.
 178 Substation Design Manual

Figure 6-18: Layer type windings

Foil windings are made of wide copper sheet, from some tenths of millimeter
up a few millimeters thick. It is usually used for windings with a small number
of turns but relatively high currents. The main technical advantage is that axial
mechanical forces acting on the windings in the transformer during short
circuit currents become insignificant.

Figure 6-19: Foil winding

 Primary Equipment 179

The disc winding concept is used for windings with a large number of turns
and relatively small currents. It is built up of a number of discs connected in
series. The major difference between a helical and a disc winding is the
number of turns per disc. In helical windings there is never more than one
turn per disc while disc windings have more than one turn per disc.

(a)

(b) (c)
Figure 6-20: Disc winding
 180 Substation Design Manual

The helical winding is suitable for high currents where the current is shared
between several parallel strands. The quantity of conducting material that can
be fitted inside a given volume is high compared to other types of winding.
Moreover it is mechanically robust and easy to manufacture, particularly
when continuously transposed cable is used.

(a)

(b) (c)
Figure 6-21: Helical winding
 Primary Equipment 181

Tapping (regulating) winding is usually wound at the outermost winding in a

power transformer for easy connection to the OLTC. Similar to the type of
windings mentioned above, tapping winding can either be made in layer,
helical or disc winding depending on the design requirement.

6.1.5.3. Transformer Insulation

Transformer main insulation can be divided into solid and liquid insulation.
Solid insulation in transformers consist mainly of oil impregnated paper and
pressboard. These are cellulose materials, which include Kraft, creped,
presspaper and diamond dotted paper (presspaper with partial resin coating).
Other type of cellulose materials are manila and rag paper as well as cotton
jute and linen fibres. Nowadays, thermal upgraded paper is preferred. It is a
normal cellulosic paper treated by the addition of stabilizers during
manufacture to provide better temperature stability and reduced thermal
degradation.

Mineral hydrocarbon oil has been the major liquid electrical insulation due to
its high dielectric strength to withstand the electric stresses imposed in 6
service. It also has sufficiently low viscosity to circulate and transfer heat, thus
it has been used as cooling medium in power transformers.

The combination of oil and cellulose material is one of the most satisfactory
insulant yet known and the electrical and thermal strength of this
combination is much higher than that of the individual materials used
separately. For example in terms of temperature rise, cellulose material alone
is of Class Y insulation with thermal withstand capability of up to 90:C.
However, with the impregnation of oil, the cellulose material has become
Class A type insulation with the maximum thermal withstand capability of up
to 105:C.
 182 Substation Design Manual

Figure 6-22: Samples of cellulose insulations used in transformers

 Primary Equipment 183

6.1.5.4. Tank and Preservation System

Tanks are designed to house the core and windings complete with oil so that
it can be lifted or moved by cranes, winch or jacks without over straining any
joints and without causing damage to the internal active parts and cause
subsequent leakage of oil. Some tanks are fitted with skid under bases
suitable for handling with roller bars. The skids are drilled to accommodate
axles and rollers when required.

In practice, there two types of transformer tank construction i.e. conventional

type tank with flat top cover mounted or belt type tank where the cover
junction or belting is near the bottom of the tank, dividing the complete tank
into top tank and bottom tank.

Figure 6-23: Conventional type tank

Figure 6-24: Belt type tank

 184 Substation Design Manual

Distribution transformers have corrugated tank design to function as cooling

fins. All distribution transformers in TNB distribution system used after the
year 1990 are of cover mounted tank type with hermetically sealed
preservation system. The tank, which does not require nitrogen or air
cushions, is completely filled with oil. The expansion and contraction of oil,
due to temperature fluctuations, is taken up by the expendable tank
corrugations.

Transformer tanks are designed to withstand an internal overpressure of

28 – 35 kPa (4 – 5 psi) in excess of that required to operate the pressure relief
device. The design of the tank is suitable for use as ground mounted or pole
mounted transformer. The tank is sealed in every opening point with sealant
and O-rings or flat type gaskets made of synthetic rubber bonded cork or hot
oil resistance synthetic rubber (Neoprene) that is of chemical and thermal
resistant for hot oil up to 120°C.

Figure 6-25: Hermetically sealed type transformer

 Primary Equipment 185

Another type is a free breathing conservator type transformer where the

expansion of oil due to temperature or pressure increase is taken up by the
conservator. The most importance feature and use of a conservator are:

(a) To allow for expansion and contraction of oil which is temperature

dependent.
(b) To reduce the surface area of the oil exposed to atmospheric air so that
contents of oxygen gas dissolved in the oil is reduced, thus reduces the
rate of oxidation of the oil which would otherwise tend to shorten
insulation life.
(c) To allow the main tank to be filled to the top cover, thus permitting oil-
filled bushing and the use of a gas actuated relay in the connection pipe
between the main tank and the conservator of a power transformer.

Figure 6-26: Conservator type distribution transformer

 186 Substation Design Manual

Figure 6-27: Conservator type power transformer

6 For distribution transformer, hermetically sealed type is more advantageous

compared with the conservator type transformer. The main advantage is that
the oil is not in contact with the atmosphere, thus avoiding absorption of
moisture and oxygen from the environment that can speed up the
degradation process of the insulation.

6.1.5.5. Cooling System

More than 85% of the heat generated in a transformer is caused by the
resistive loss in the winding and the remaining by the stray losses in the
structural metal parts of the transformer. Transformers utilize cooling systems
to transfer the heat produced to the surroundings and control the
temperature rise. This heat transfer mechanism helps to prevent the core,
windings, or any structural parts from reaching critical temperatures that
could deteriorate the insulation.
 Primary Equipment 187

The cooling designations for oil immersed transformers expressed in four-

letter code in accordance with IEC 60076-2 are described in Table 6-9. Typical
types of cooling systems used in TNB distribution system are ONAN and ONAF.

In ONAN type cooling system, heat is transferred from the windings, core and
structural metal parts to the oil. The heated oil circulates in the transformer
tank by the principle of natural convection and it is cooled by the natural air.
Cooling fins and radiators provide the means of increasing the area for heat
dissipation.

In ONAF type cooling system, fans mounted on the radiators, are used to
force an air blast on the radiators to increase the heat dissipation rate. The
fans are automatically switched on when the temperature of the oil and
windings increases above the permissible value. This happens during heavy
load condition and during higher ambient temperatures. Forced cooling can
increase the kVA rating of an oil immersed transformer by 15% to 30%.

Table 6-9: Cooling designation four letter code

First letter Internal cooling medium in contact with the windings
6
O Mineral oil or synthetic insulating liquid with fire point <
300:C
K Insulating liquid with fire point > 300:C
L Insulating liquid with no measurable fire point
Second
Circulation mechanism for internal cooling medium
letter
N Natural convection flow through cooling equipment and
windings
F Forced circulation through cooling medium, natural
convection in windings
D Forced circulation through cooling medium, with directed
flow through at least the main windings
Third letter External cooling medium
A Air
W water
Fourth letter Circulation mechanism for external cooling medium
N Natural convection
F Forced circulation (fans, pumps)
 188 Substation Design Manual

6.1.5.6. Tap Changer

6.1.5.6.1. Off-Circuit Tap Changer (OCTC)

Off-Circuit Tap Changer (OCTC) or sometimes called De-energised Tap
Changer (DETC) is a simple, cheapest but reliable device that can be used as a
mean of adjusting transformer voltage ratio by adding or removing tapping
turns. It is connected on the HV side and designed only to be operated when
the transformer is de-energised. Thus it is only applicable to installations in
which the loss of supply can be tolerated. In TNB distribution system it is
applicable for distribution and small power transformers up to 5 MVA 33/11
kV. Figure 6-28 shows the typical OCTC used in distribution transformers. The
OCTC connection types normally employed in the distribution transformers
are Linear and Single Bridging type as shown in Figure 6-29.

Figure 6-28: Off circuit tap changer

(a) (b)
Figure 6-29: Off circuit tap changer basic connection type
(a) Linear and (b) Single Bridging
 Primary Equipment 189

6.1.5.6.2. On-Load Tap Changer (OLTC)

The function of an OLTC is to switch from one winding tap to another without
interrupting the load current. OLTC can be installed inside the transformer (in-
tank) or in an externally mounted compartment which is welded or bolted to
the transformer tank. Figure 6-30 illustrates both of the OLTC installation
types.

Figure 6-30: Type of OLTC installation showing in-tank (left) and external
compartment (right)

There are two different designs of OLTC which are the diverter switch type
and the selector switch type OLTC. Figure 6-31 (a) shows diverter switch type
which has a tap selector and a diverter switch in a separate compartment; and
(b) the selector switch type also known as arcing type selector which
combines both functions of tap selector and diverter switch in one oil-filled
compartment.

The oil filled compartment is a free breathing tank connected via a pipe to a
conservator with the addition of a dehydrating breather to remove moisture
from the air that is in contact with the oil as shown in Figure 6-32. On the
other hand, there are two switching principles that have been used for the
load transfer operation during tapping transition i.e. by means of high speed
resistor or reactor.
 190 Substation Design Manual

Change-over
selector
Diverter
switch
Selector/Arching
switch
Transition
resistors
Tap
selector

(a) (b)

Figure 6-31: Two Different Types of OLTC (a) Diverter Switch Type OLTC,
(b) Selector Switch Type OLTC
6

1. OLTC Cover 6. Oil Conservator

2. Oil Compartment (Belly Tank) 7. Horizontal Drive Shaft
3. OLTC Insert 8. Vertical Drive Shaft
4. Motor Drive Unit 9. Bevel Gear
5. Oil Surge Relay
Figure 6-32: OLTC general arrangement showing oil filled compartment,
conservator and motor drive
 Primary Equipment 191

Majority of OLTC designs used in power transformers of TNB distribution

system is of in-tank selector switch type with oil immersed switching (arcing)
contacts and transition resistors for load transfer operation. The switching
arcs occur in oil due to the making and breaking of currents during normal tap
change operation. These arcs cause carbonization of oil that reduces the
dielectric strength of the insulating medium. They also cause heating of oil
that speed up its degradation process thus requires shorter maintenance
intervals of the OLTC. The new technology confines the current switching in
interrupted vacuum bottles where the switching contacts are no longer
immersed in the oil of the OLTC compartment. This new breed of OLTC known
as the Vacuum Switch OLTC helps to prevent contamination of oil due to
carbonization and hence lower the rate of oil degradation due to heating. As
the results, the OLTC has longer maintenance intervals up to 300,000
switching operations and thus reduces maintenance costs.

Change-over
6
selector

Roller type arcing switch

Transition
resistors

Figure 6-33: OLTC compartment and insert of oil Immersed switching

contacts
 192 Substation Design Manual

Vacuum switch

Figure 6-34: OLTC compartment and insert of vacuum switch OLTC

There are three different kinds of connecting schemes to which the OLTC can
be connected to the tapping winding (Figure 6-35) which are:

(a) linear,
(b) plus/minus; and
(c) coarse/fine.

Tapping winding in linear arrangement is commonly used for small tapping

ranges e.g. 10% of nominal voltage. The addition of the tapping winding
connected in series with the main winding results in the addition of voltage
across the tapping winding to the voltage across the main winding.
 Primary Equipment 193

6
Figure 6-35: Typical arrangements of tapping winding for OLTC connection

On the other hand, for larger tapping ranges, tapping winding in plus/minus or
coarse/fine arrangements can be used. In plus/minus arrangement, the
tapping winding is connected to the main winding via a change-over selector
that functions as plus minus switch. This switch provides an ability to add or
subtract the voltage of the tapping windings to or from the voltage of the
main winding allowing the tapping range to be doubled and at the same time
reduce the number of the tapping windings.

In a coarse/fine arrangement, the tapping winding is split into two groups,

coarse and fine windings. The coarse winding can be connected or
disconnected in series to the main winding to provide the larger addition or
subtraction of voltage whilst the fine winding is added or subtracted
sequentially with the smaller value of tapping step voltage.
 194 Substation Design Manual

 Oil Surge Relay

The oil surge relay is an oil-flow controlled relay installed between the OLTC
head and the conservator. Faults even at low-energy can lead to oil flow in the
OLTC oil compartment. The relay will trip when the specified oil flow speed
between the on-load tap-changer head and the oil conservator is exceeded.
However, any gases generated during OLTC switching will escape via a small
opening in the relay unobstructed to the oil conservator. The relay operates
according to the principle of a movable flap valve. When triggered, the flap
valve operates a reed switch and makes a signal available. Once it has been
triggered, the flap valve remains in its position and has to be reset manually.

Rupture disk Oil surge relay

Figure 6-36: Oil surge relay showing the internal components

 Primary Equipment 195

 Rupture Disk
The rupture disk is a pressure-relief device without signaling contact located
in the OLTC cover. Faults with large energy release can lead to strong pressure
waves with high pressure peaks, which can damage the on-load tap changer
oil compartment. An overpressure of more than 5 bar will rupture the disk
and enables the pressure to relieve immediately.

 Motor Drive Unit

Generally, on-load tap changers come with a motor to provide the drive to
allow the tap changer to operate. A typical OLTC with motor operating
mechanism connected to the tap changer is given below in Figure 6-37. The
Geneva gear principle is used to change a rotary motion into a stepping
motion. Drive is transmitted via a shaft system and bevel gears from the
motor-drive mechanism. A spring energy accumulator actuates the Geneva
gear. The Geneva gear operates the selector switch and the change over
selector. The Geneva gear is also used to lock the moving contact system into
position. 6

Figure 6-37: Typical motor operating mechanisms

 196 Substation Design Manual

6.1.5.7. Dimensions & Weight

The maximum dimension and weight for new distribution and power
transformers based on rated power is as shown in Table 6-10 and Table 6-11.

Table 6-10: Maximum dimension and weight for new distribution

transformers
11/0.433 kV 22/0.433 kV
Transformer
Rated Power Total Total
L x W x H (mm) L x W x H (mm)
Weight (kg) Weight (kg)
100 kVA 1000x700x1200 900 1100x750x1340 1100
300 kVA 1250x870x1370 1410 1350x900x1450 1800
500 kVA 1500x940x1500 2010 1760x1120x1550 2200
750 kVA 1700x930x1630 2460 1710x1040x1830 2500
1000 kVA 1750x950x1800 3200 1950x1200x2030 3800
(a)
Transformer 33/0.433 kV
Rated Power L x W x H (mm) Total Weight (kg)
6
100 kVA 1200x820x1570 1300
300 kVA 1450x920x1590 2050
500 kVA 1710x1020x1700 2400
750 kVA 1750x1020x1780 2900
1000 kVA 1880x1070x1820 3400
(b)

Table 6-11: Maximum dimension and weight for new power transformer
Complete Installation
Transport Arrangement
33/11 kV Arrangement
Transformer Total Total
L x W x H (mm) L x W x H (mm)
Weight (kg) Weight (kg)
1.5 MVA 2380x1400x2460 5500 2380x1400x2460 5500
5 MVA 3500x3300x3400 15000 3400x1480x2540 12000
7.5 MVA 5890x3140x3120 20000 3640x3020x3120 16550
15 MVA 6160x3730x3380 32300 3940x3730x3380 28750
30 MVA 7390x3900x4120 46800 4390x3900x3190 41900
30 MVA
7260x4950x4710 54350 4760x4950x3370 49300
(33/22-11 kV)
 Primary Equipment 197

6.1.5.8. Fittings and Accessories

Transformers are provided with the following standard fittings and
accessories:

6.1.5.8.1. Bushing Terminals

Distribution and power transformers are equipped with outdoor type oil-air
bushings made of solid porcelain on HV and LV sides for both phase and
neutral terminals. All conducting parts of the bushing are designed for rated
current of the transformers and capable to withstand overcurrent during
earth fault and cyclic overloading.

New distribution transformers come with cover-mounted open bushings

whilst most of power transformers have side mounted bushings in air filled
cable box.

For distribution and power transformers, crimping type terminal lugs are
provided where they are bolted onto the HV and LV bushing terminals. For
new LV bushing design, bushing flag is provided on the LV and neutral 6
terminals for the cable lug connection.

Table 6-12: Crimping type terminal lugs for distribution transformers

Transformer HV Terminals LV Terminals
Rating 6.6, 11, 22, 33 kV Phase Neutral
1 x bimetal lug for 1 x bimetal lug for 1 x bimetal lug for
100 kVA 2 2 2
70 mm Al cable 300 mm Al cable 300 mm Al cable
1 x bimetal lug for 1 x bimetal lug for 1 x bimetal lug for
300 kVA 2 2 2
70 mm Al cable 500 mm Al cable 500 mm Al cable
1 x bimetal lug for 2 x bimetal lug for 1 x bimetal lug for
500 kVA 2 2 2
70 mm Al cable 300 mm Al cable 300 mm Al cable
1 x bimetal lug for 2 x bimetal lug for 1 x bimetal lug for
625 kVA 2 2 2
70 mm Al cable 500 mm Al cable 500 mm Al cable
1 x bimetal lug for 2 x bimetal lug for 1 x bimetal lug for
750 kVA 2 2 2
70 mm Al cable 500 mm Al cable 500 mm Al cable
1 x bimetal lug for 2 x tinned copper lug 1 x bimetal lug for
1000 kVA 2 2 2
70 mm Al cable for 500 mm Cu cable 500 mm Cu cable
1 x bimetal lug for 2 x tinned copper lug 1 x bimetal lug for
1250 kVA 2 2 2
70 mm Al cable for 500 mm Cu cable 500 mm Cu cable
 198 Substation Design Manual

Table 6-13: Minimum size for crimping type terminal lugs for Power
Transformers
HV Terminals LV Terminals
Tx Rating Neutral
33 kV 11 kV
3 x tinned copper lug 9 x tinned copper lug 1 x tinned copper lug
30 MVA 2 2 2
for 400 mm Cu cable for 400 mm Cu cable for 400 mm Cu cable

3 x tinned copper lug 6 x tinned copper lug 1 x tinned copper lug

15 MVA 2 2 2
for 400 mm Cu cable for 300 mm Cu cable for 300 mm Cu cable

3 x tinned copper lug 3 x tinned copper lug 1 x tinned copper lug

7.5 MVA 2 2 2
for 400 mm Cu cable for 300 mm Cu cable for 300 mm Cu cable

3 x bimetal lug for 3 x bimetal lug for 1 x bimetal lug for

5 MVA 2 2 2
150 mm Al ABC 240 mm Al ABC 240 mm Al ABC

The minimum air clearances between bushing terminals of a transformers for

altitude 1000 meters and below, differs according to space constrains on the
6 transformer. When space is a constraint, air clearance particularly in a cable
box shall make reference to Surat Pekeliling Pengurus Besar Kanan
(Pengurusan Aset) Bil. A17-2011 and BS 6435 where the minimum air
clearance is specified according to the following conditions:

 Partially insulated cable box – cable cores only are fully shrouded for the
appropriate highest system.
 Fully insulated cable box – All live metal parts and cable cores are fully
shrouded for the appropriate highest system voltage.
 Primary Equipment 199

The minimum air clearance for open bushing terminals and bushing terminals
in cable box is tabulated in Table 6-14 below.

Table 6-14: The minimum requirement for air clearances

Open Bushing Cable Box
Nominal
Minimum Minimum
System Minimum Minimum
Clearance Clearance
Voltage Clearance Clearance Live
Phase-to- Live Metal-
Phase-to-Phase Metal-to-Earth
Phase to-Earth

415 V 77 58 - -

127 (partially 76 (partially

insulated) insulated)
11 kV 254 203
45 (fully 32 (fully
insulated) insulated)
242 (partially 140 (partially
insulated) insulated)
22 kV 330 279
100 (fully 75 (fully
insulated) insulated) 6
356 (partially 222 (partially
insulated) insulated)
33 kV 432 381
125 (fully 100 (fully
insulated) insulated)

The minimum creepage distance of the bushing insulator is in accordance with

IEC 60137 where the specific creepage distance is typically of pollution Level II
(20 mm/kV).

6.1.5.8.2. Gas actuated relay

Gas actuated relay is also known as Buchholz relay after its inventor. The gas
actuated relay is fitted in the connection pipe between the main tank and the
conservator. The relay has two functions:
 To collect free gas bubbles on their way up to the conservator from the
transformer tank.
 To detect abnormal oil flow to the conservator in the event of a serious
fault such as arcing within the transformer.
 200 Substation Design Manual

Figure 6-38: Gas actuated relay

Figure 6-39: Buchholz relay cross-section

At all times, the gas actuated relay should be filled with oil. When gas is
generated in the transformer due to incipient fault, the gas will displace the
oil in the relay and float will sink down. The protection is therefore arranged
in such a way that when a minor amount of a gas is collected in the gas
actuated relay an alarm signal is actuated. If an additional amount of gas is
collected tripping contact may be actuated.
 Primary Equipment 201

When a serious fault such as arcing occurs in the transformer, the gas
evolution will push a burst of oil up towards the conservator causes the lower
element to be deflected, actuating the contacts of the tripping circuit, thus
disconnecting the transformer from the supply.

6.1.5.8.3. Temperature indicator

HV WTI HV WTI OTI

6
Figure 6-40: Winding temperature indicators for power transformer (left) &
distribution transformer (right)

A new distribution transformer uses a top-mounted type thermometer fitted

on the transformer tank cover for direct measurement of top oil temperature.
For power transformer, the top oil temperature is measured using a sensor or
a bulb in the thermometer pocket on the top tank cover.

The measurement of winding temperature can be carried out in a direct or

indirect method. For a direct measurement, fibre optic sensors can be used to
measure the winding temperature. For indirect measurement, a thermal
image of the winding can be made to simulate the winding temperature of the
HV and LV windings. In this type of measurement, a current transformer on
the HV or LV winding supplies the output current to a heating element that
produces a temperature rise in addition to the oil temperature measured by
the sensing bulb in the thermometer pocket on the top tank cover. The
heating element is provided with an adjustable shunt or a calibration circuit so
that the precise thermal image can be set by shunting the CT output current.
In TNB distribution system, a single CT system is used where only one CT is
used on the HV and LV winding respectively.
 202 Substation Design Manual

Dedicated CT
Calibration
Calibration circuit
circuit
Temperature sensing bulb
Capillary tube
Dial gauge & switches

Figure 6-41: Winding temperature indicator schematic arrangement

The temperature of the winding depends on the transformer load and the
temperature of the cooling medium. These two parameters are measured and
6 made to interact in the temperature indicator. The winding temperature is
therefore measured by adding the temperature difference of the winding to
top oil temperature.

Fans are preferably activated as soon as the temperature hits the set value,
but it is not switched off again until the oil has truly cooled. There should be a
10 degree temperature difference in fan auto start and stop to avoid hunting.
The recommended temperature settings are:

1. Fan auto Start: 70:C

2. Fan auto Stop: 60:C
3. Top oil temperature alarm: 80:C
4. Top oil temperature trip: 90:C
5. Winding temperature alarm: 95:C
6. Winding temperature trip: 105:C
 Primary Equipment 203

6.1.5.8.4. Oil Level Gauge (OLG)

The new hermetically sealed distribution transformer design uses magnetic

type OLG, fitted on top of the transformer tank. The indication for maximum
and minimum is given by colour coding. The various brands of oil level gauge
have different colour coding. The maximum level indicated by the oil gauge
should correspond to the level of oil near the tip of HV bushings. For power
transformer, magnetic type OLG is used to gauge the level of oil in the
conservator for main tank and OLTC. Both magnetic types OLG for power and
distribution transformers have a float inside the main tank or conservator
tank where the position is transmitted magnetically through the tank walls to
the indicator installed on the tank surface.

Figure 6-42: Magnetic oil level gauge for (left) the conservator tank; and
(right) top cover of hermetically sealed distribution transformers

Pressure Relief Device

Oil Level Gauge
Figure 6-43: Conventional oil level gauge and pressure relief device at
distribution transformer
 204 Substation Design Manual

6.1.5.8.5. Pressure Relief Device (PRD)

PRD is used to release overpressure build up in the transformer tank so that

tank rupture can be prevented. It is a spring operated self-resealing PRD that
operate at absolute overpressure between 28 and 35 kPa (4 – 5 psi). PRD for
power transformers are equipped with a micro-switch. The operation of the
spring will in turn trigger the contacts of a micro-switch and trip the
transformer. It should be noted that PRD is not used for alarm indication.

Figure 6-44: Pressure relief device for power transformer

Figure 6-45: Pressure relief device for distribution transformer

 Primary Equipment 205

6.1.5.8.6. Dehydrating Breather

The dehydrating breather contains silica gel crystals. During expansion and
contraction of transformer oil due to change in temperature, the air passes
over the crystals which absorb any moisture in the air. Thus, allowing only dry
air goes inside the tank and reducing the amount of moisture absorbed in the
oil and winding insulation that can speed up degradation process. Due to
moisture absorption, the silica gel changes colour from blue to pink in the
course of time. On the other hand, new type of silica gel is cobalt chloride free
and is non-carcinogenic. It changes colour from orange when dry to green or
colourless when contains moisture.

The amount or mass of silica gel used is calculated based on among others the
mass of oil used, the maintenance interval and the average thermal cycle of
the transformer. Silica gel can be dried and restored to the original colour by
heating, though, proper health and safety cautions should be taken. The
dehydrating breathers are also provided with an oil trap, preventing
continuous contact between the moist air and the silica gel, thus allowing a
6
longer life and lower maintenance of the silica gel.

<10%

35%
50%

60%

90%
(a) (b) (c)

Figure 6-46: Dehydrating breather showing (a) conventional silica gel,

(b) new cobalt free silica gel that changes colour depending on the
percentage of moisture content, and (c) oil trap
 206 Substation Design Manual

Other standard fittings and accessories include:

Table 6-15: Standard fittings and accessories of a transformer

Standard Fittings Description
Drain/Sampling The valve is used for sampling and draining oil from the
valve tank. For conservator type transformers, the valve is in the
form of either gate, globe or ball type, and is provided at
the bottom of the main tank. However for hermetically
sealed transformers, the valve should not be operated
unless guided by an expert or the manufacturer.
Earthing Two earthing terminals on opposite long sides positioned
terminals closed to the bottom are provided for the tank. Both
terminals should be connected to earth at all times during
operation.
Top cover External earthing connections positioned diagonally on
earthing opposite top corners of the tank are provided for ensuring
connections earth continuity between top cover and main tank.
Core earth The core earth terminal box is provided for power
terminal transformer and located on top of the transformer main
tank cover to facilitate testing on transformer core. Only
6 single point bonding from core to the transformer body is
allowed to prevent circulating current in the core and metal
structure.

6.1.5.8.7. Valves

Figure 6-48 and Table 6-16 below shows typical schematic drawing for valves
arrangement and their functions respectively for power transformers.

(a) (b) (c)

Figure 6-47: Typical valve used for different functions on power
transformers. (a) Showing gate type valve with flanges, (b) Gate type valve
with sockets and (c) Plate or butterfly type valve
 Primary Equipment 207

Valve Legend

Open while transformer is in operation

Close while transformer is in operation 6

Figure 6-48: Schematic drawing showing typical valves arrangement and

positions

Table 6-16: Description of typical valves and types used for power
transformer
Item Description Size
1. Oil sampling/complete drain valve 50 mm gate type
2. Filter valve (top) 50 mm gate type
3. Shut off valve for HV disconnecting chamber 25 mm gate type
4. Buchholz relay shut off valve 80 mm gate type
5. Radiator shut off valve 80 mm plate type
6. OLTC conservator drain valve 25 mm socket type
7. Return valve for OLTC 25 mm gate type
8. Oil drain valve for HV disconnecting chamber 25 mm socket type
9. Oil surge relay shut off valve 25 mm gate type
10. Main conservator drain valve 25 mm socket type
11. Suction valve for OLTC 25 mm gate type
 208 Substation Design Manual

6.1.5.9. Terminal Markings

The terminal markings have been standardised for many years based on the
British Standard, BS 171 using the alphabets ABCN and abcn as the phase and
neutral symbols. For the 3-phase transformers used in TNB distribution
system, when facing the HV side, the position of the HV terminals from left to
right are in the order of ABC for delta connected winding or NABC for star
connected winding. When facing the LV side, the position of the LV terminals
from left to right are in the order of cban for star connected winding or cba
for delta connected winding.

n a b c a b c

A B C N A B C
6
Figure 6-49: Typical terminal markings for step-down (left) and
step-up (right) transformers

6.1.5.10. Rating Plate

Figure 6-50 and Figure 6-51 in the following pages show typical rating plates
for distribution and power transformers containing basic design data of the
transformers.
 Primary Equipment 209

Figure 6-50: Example of rating plate for distribution transformer

 210 Substation Design Manual

Figure 6-51: Example of rating plate for power transformer

 Primary Equipment 211

6.2. Switchgear

6.2.1. Overview
In “IEC 62271-1 Part 1: High-voltage Switchgear and Controlgear – Common
Specifications”, switchgear is defined as a general term covering switching
devices and their combination with associated control, measuring, protective
and regulating equipment, also assemblies of such devices and equipment
with associated interconnection, accessories, enclosures and supporting
structures.

The distribution system has predominantly indoor air insulated switchgear

(AIS) installations while the current trend is to employ gas insulated
switchgear (GIS) on the 33 kV network. Ring main units (RMU) are used in the
distribution network for the purpose of providing economical ring reticulation
systems. Sulphur hexafluoride (SF6) insulated RMUs are being used extensively
in the distribution network while existing oil RMUs in the system are gradually
being phased out. 6
Switchgears used in TNB distribution network are in the form of extensible
metal-enclosed switchboard and complying with IEC Standards such as IEC
62271-100, IEC 62271-200 and IEC 62271-1.

The switchgear used in TNB distribution system is designed with specific

characteristics to suit the system requirement for safe operation under
normal service condition.

By definition according to IEC 62271, normal indoor switchgear service

conditions are at an altitude of not greater than 1000 m above sea level,
within an ambient temperature range not exceeding 40:C, with no solar
radiation consideration. The ambient air is not significantly polluted by dust,
smoke, corrosive and/or flammable gases, vapours and salt. Also, the relative
humidity level shall not exceed 90% for duration of one month and a seismic
activity is also not considered as external vibration forces on the switchgear.
 212 Substation Design Manual

For outdoor switchgear, consideration would be taken into account of the

solar radiation, the ambient air may be polluted by dust, smoke, corrosive gas,
vapours or salt but does not exceed pollution level II (medium) according
Table 1 of IEC 60815.

6.2.1.1. Enclosure/Panel
Installations are designed so that their insulation capacity, degree of
protection, current carrying capacity, switching capacity and mechanical
functions conform to TNB requirements. These designs are tested against the
IEC standards to verify that the design could withstand and perform within
their designated rating.

6.2.1.2. Insulation Material

The rated value for the insulation level of a switchgear must be selected on
the basis of the requirements at site, e.g. on a 33 kV or 11 kV network.
Consideration is also made for the lightning and switching overvoltage
impulses and earthing/neutral configuration.
6
Switchgears used in TNB distribution network utilises these forms of
insulation within the switchgear enclosure:

 Atmospheric air
 Fluid form e.g. SF6 gas, oil

Solid insulation are utilised in the metal-enclosed switchgear to provide

support to the current carrying conductor within the metal enclosure.
Normally epoxy resins insulation is used and they must possess the necessary
creepage distance between live parts and earth, also would be able to
withstand electrodynamics stresses during short circuits.
 Primary Equipment 213

6.2.2. Air Insulated Switchgear (AIS)

Air insulated switchgears comprise of busbars, circuit breakers and cable
termination compartments insulated by air at atmospheric pressure. Busbars
are supported by specially designed resin bushing / insulator. Typical air
insulated switchgear is as shown in the figure below.

(3) (4)
(1) (2)

(5) 6
(12)
(6)

(7)
(8)

(11) (10) (9)

1. Metering Compartment 7. Multi Core Cable Box
2. Railing 8. Earth bar
3. Drawout VT Truck 9. Arc protection
4. Pressure Relief Flap 10. Heater
5. Busbar 11. Vacuum Circuit Breaker
6. Cable termination 12. Air Filter

Figure 6-52: Side View of AIS Switchgear

 214 Substation Design Manual

6.2.2.1. Enclosure/Panel
Metal-enclosed switchgear panels normally consist of:

1. Circuit breaker compartment

2. Busbar compartment
3. Cable compartment
4. LV compartment

6.2.2.1.1. Circuit Breaker Compartment

 To house the withdrawable circuit breaker and the facility to test the
circuit breaker in isolated position.
 A set of metal shutters is provided to cover each 3-phase group of
stationary isolating contacts. Each set is capable of being individually
operated and padlocked closed. The shutters shall open and close
automatically by a positive movement. When padlocked the shutters
shall prevent access to the fixed isolating contacts.

Figure 6-53: Withdrawable Circuit Breaker Truck

 Primary Equipment 215

Metal shutter

Earthing switch

Space heater

Figure 6-54: Circuit Breaker Compartment with safety shutters in closed 6

position (Double Busbar)

Reserve busbar
spout

Cable spout

Main busbar
spout

Figure 6-55: Circuit Breaker Compartment showing live electrical contacts

(Double Busbar)
 216 Substation Design Manual

6.2.2.1.2. Busbar Compartment

Busbar is an electrical conductor, adequately insulated at a specific voltage

level and capable of carrying a high current and normally a common
connection between several circuits in the system. The busbars and
connections is in accordance with IEC Recommendations and is continuously
rated for the site conditions and currents specified.

Any insulating material used as the busbar insulation is capable of

withstanding the heating effects of the rated short time current and rated
continuous current without permanent deformation or deterioration and
complies with IEC 60085 on thermal stability and IEC 60466 on flammability.

The busbars shall be adequately supported against short circuit forces and
provision shall be made to allow for thermal expansion of the conductors due
to normal and pulse load currents and short circuit current. The busbars shall
be contained in a separate compartment within the general casing of the
switchboard.
6

Figure 6-56: Busbar compartment in air (AIS)

 Primary Equipment 217

6.2.2.1.3. Cable Compartment

The cable compartment is designed to cater for the connection of the power
cables and the switchgear. This is to provide lasting and dependable
connection of cable conductors and the switchgear. The methods of
connection employed could be of the bolted or the plug in method.

In the case of air insulated switchgear panels, cable compartment would cater
for a 3-phase air insulated cable box suitable for dry type non thermal
termination system. The cable box shall be suitable for terminating the
maximum size of the following types of cables:
2
1. 33 kV, XLPE, single core, 630 mm , Aluminium
2
2. 11 kV, XLPE, single core, 500 mm , Aluminium, with M16 bolts
2
3. 11 kV, XLPE, three core, 240 mm , Aluminium, with M12 bolts

Cable bushings should be designed to terminate with the open palm to

accommodate bimetal termination lugs suitable for deep indentation crimping
in accordance to TNB Distribution Technical Specifications. Provisions shall be 6
made for earthing the body of each cable box. Adjustable cable clamps and
cable box base plate with approved cable entry seals that can accommodate
different cable sizes shall be provided. For single core cables, ferrous base plate
MUST NOT be used to prevent damaging heating effect to the cable due to
circulating current that flows on the ferrous plate

Figure 6-57: AIS Cable compartment

 218 Substation Design Manual

6.2.2.1.4. LV Compartment

Depending on type of installation, provision for the controlgear and protective

relays can be made at the top of the switchgear panels or in the Control Relay
Panel.

Figure 6-58: Control relay panel at the top of the switchgear

Figure 6-59: Control gear and protective device inside the control relay panel
 Primary Equipment 219

6.2.2.2. Circuit Breakers

Circuit breakers must be capable of making, conducting and breaking off
current under normal operational conditions. Furthermore, they have to trip /
open in accordance with a defined current / time characteristic under
overload and fault condition. This can be achieved with protection relays.

Circuit breakers used complies with the requirements of IEC 62271-100 and
meets the technical specification of TNB Distribution. All circuit breakers
having the same rating shall be identical in arrangement and shall be
interchangeable.

Operating mechanisms shall be operated electrically by DC Motor, and the

operating voltage of the DC motor shall correspond with the specified voltage
level at the substation. The operating mechanisms shall have a proven
operational endurance equivalent to the mechanical life of the circuit-
breaking unit and consistent with a low maintenance requirement.

The circuit breaker type is differentiated by its arc extinction medium for 6
example vacuum, SF6 gas and dielectric oil. The type of circuit breakers that
has been used in TNB Distribution system is as follows:

6.2.2.2.1. Bulk Oil/Minimum Oil Circuit Breaker

Bulk and minimum oil circuit breaker utilize transformer insulating oil for arc
extinction. In bulk oil circuit breakers, the contacts are separated inside a steel
tank filled with dielectric oil while in minimum oil circuit breaker, the three
phase contacts are mounted in separate insulated housing filled with
dielectric oil.

Bulk and minimum oil circuit breaker has been phased out due to
environmental and operational issues.
 220 Substation Design Manual

Figure 6-60: Example of bulk/minimum oil circuit breaker

6
6.2.2.2.2. Vacuum Circuit Breaker

In vacuum circuit breakers, the fixed and moving contacts are housed
permanently inside a sealed vacuumed ceramic bottle. The arc is quenched as
the contacts are separated in vacuum. In the MV switchgear range, vacuum is
the most predominant insulating medium for circuit breaking.

Figure 6-61: Example of vacuum circuit breaker

 Primary Equipment 221

6.2.2.2.3. Gas Circuit Breaker

Gas circuit breaker employs Sulphur Hexafluoride (SF6) gas for its arc
quenching medium. The three phase breaking contacts are individually
housed in gas filled insulated chambers at pressures of above 1 bar. The
pressure and gas flow for arc quenching is obtained by piston action.

Stationary
arc contact Stationary
contact

Nozzle

Moving
Moving
arc contact
contact
Piston rod
Cylinder
Piston
6
Opening Opening

Figure 6-62: Arc quenching mechanism for gas circuit breaker

Figure 6-63: Example of gas circuit breaker

 222 Substation Design Manual

6.2.2.3. Earth Switch

Earth switches are installed in switchgears primarily near the cable
termination end and in some cases, busbars. Every earthing switch must be
able of conducting its rated short-time current without damage.

TNB Distribution Division requires that the earth switch be provided to earth
the outgoing circuit. Circuit earthing shall be carried out by means of three
phase quick-acting fault-making earthing switches which forms an integral
part of the switch panel. The design utilised for earth switches is normally of
the manual charged spring operation.

Figure 6-64: Typical earth switch device used in AIS switchgear

6.2.2.4. Pressure Relief

For both air insulated and gas insulated switchgears, pressure relief facility is
provided to ensure that the any arc discharges that the operating personnel
may be exposed to, in the course of their duty e.g. operation of pressure relief
devices with arc discharges deflected in all directions, side and rear of panel
where operator may be working/ standing.

6.2.2.5. Indicators
Capacitive voltage indicator is provided for every feeder to give indication if
the every phase of the feeder is live or not. Mounted on the front fascia, the
indicator typically uses neon bulbs that light up or blink when the circuit is
energised.
 Primary Equipment 223

6.2.2.6. Ingress Protection

IEC 60529 defines the Ingress Protection (IP rating) and rates the degrees of
protection provided against the intrusion of solid objects (including body parts
like hands and fingers), dust, accidental contact and water in mechanical
casings and with electrical enclosures.

Ingress protection specified for Air Insulated Switchgears in the TNB

distribution network is as follows:

 IP42 externally & IP4X in-between compartments

6.2.2.7. Interlocks
All switchgears shall be provided with a comprehensive system of strong
mechanical interlocking device as well as electrical and software interlocks to
prevent any dangerous or undesirable operations.

The interlocks are to ensure safety to operators and correct sequence of

operation of all circuit breakers, load break switches, isolators, earthing 6
switches.

Examples of mechanical interlocking facilities in the TNB Switchgear are:

 Switching on the earth switch when the Circuit Breaker in CLOSED

position
 Racking in the CB when the Earth Switch is in CLOSED position

The complete interlock scheme shall be subjected to TNB Distribution Division

specification and requirement.
 224 Substation Design Manual

6.2.2.8. Typical Rating of AIS

Table 6-17: Ratings of air insulated switchgear
11 kV 22 kV 33 kV
AIS Parameter
Switchgear Switchgear Switchgear
1. Rated frequency 50 Hz 50 Hz 50 Hz
2. Rated voltage 12 kV rms 24 kV rms 36 kV rms
3. One minute power 28 kV rms 50 kV rms 70 kV rms
frequency withstand voltage
4. Impulse withstand voltage 75 kV peak 125 kV peak 170 kV peak
5. Rated short time current 20 kA rms 25 kA rms 25 kA rms
6. Rated duration of short 3 seconds 3 seconds 3 seconds
circuit
7. Rated 15 minutes DC 28 kV dc 50 kV dc 70 kV dc
withstand voltage of parts
directly connected to power
cables
6
8. Visible or audible corona None None None

6.2.2.9. Configuration for 11 kV Bulk Supply Switchgear

Table 6-18: Configuration of 11 kV Bulk Supply Switchgear
Requirements A1 A4 A5 A6
VCB=12 kV, 630 amps. Fault rating at 20kA, 3sec.
VCB Rating
Busbar = 800 amps
Areva
Differential Siemens Siemens
MICOM
Protection Relays 7SD610 Solkor N
P541

5P20 600/300/5 5P20 600/300/5 Amps for OCEF

Protection CTs
Amps for OCEF Class X 600/300/5 Amps

Metering CT Not Required

Voltage Transformer Not Required
Ammeter/Voltmeter Ammeter to be in built in Relay but voltmeter is required
Relay Test Automatic current shorting and isolating trip circuit to be
Terminal Block provided
Trip Circuit
To utilize relay in built functions
Supervision
 Primary Equipment 225

Table 6-19: Configuration of 11 kV Bulk Supply Switchgear (continue)

Requirements B2(A) B2(B) C1

VCB=12 kV, 630 amps. Fault rating at 20 kA, 3 sec.

VCB Rating
Busbar = 800 amps

Protection CTs 5P20 600/300/5 amps for OCEF

B2-50 = 50/5 CT
B2-200= 200/5 CT
B2 -75= 75/5 CT
Metering CT B2-300= 300/5 CT
B2-100= 100/5 CT
B2-400 = 400/5 CT
B2-150 = 150/5 CT
Not
Required

Voltage
11/0.11 kV(sq.rt 3)
Transformer
Ammeter/Volt Ammeter to be in built in Relay but voltmeter
meter is required 6
Relay Test Automatic current shorting and isolating trip
Terminal Block circuit to be provided
Trip Circuit To provide push
To utilize relay in built functions
Supervision buttons

Where,
A1 – Circuit Breaker with Overcurrent & Earth Fault Protection Relay
A4, A5, A6 – Circuit Breaker with OCEF, inclusive of Class X 600/300/5 CT’s with relays
for unit protection with specific relays
B2 (1) – Circuit Breaker with OCEF Protection Relay and VT &CT for metering (wound)
B2 (2) – Circuit Breaker with OCEF Protection Relay and VT & CT for metering (ring)
C1 – Bus Section
 226 Substation Design Manual

6.2.3. Gas Insulated Switchgear (GIS)

In Gas Insulated Switchgear (GIS), all live parts of the gas insulated switchgear
are enclosed in a compressed SF 6 gas system. SF6 gas with its good dielectric
strength provides the basic insulation medium for the switchgear. Currently,
GIS is mandatory for all new PPUs in the 33 kV and the 11 kV Class 1 systems.

(11)

(1)

(2)

(10)
(3)

(4)

(5)
6

(6) (9)
(8)
(7)

1. LV compartment 7. Current transformer

2. Relays 8. Cable termination
3. Gas density meter 9. Circuit breaker
4. Single line diagram / semaphore indication 10. Disconnectors/Isolators
5. CB operating mechanism 11. Busbar in SF6
6. Live indicator

Figure 6-65: Example of GIS Switchgear

 Primary Equipment 227

13
8
10

12

13 1

10 3
9
8 4

6
7
2
6

1. Three position disconnector

2. Multifunctional protection and control unit
3. Gas density sensor and filling valve
4. Vacuum circuit-breaker
5. Cable socket
6. Inner cone cable connector
7. Plug-in voltage transformer – feeder
8. Pressure relief disk
9. Current transformer or combined current and voltage sensor
10. Pressure relief duct
11. Measuring sockets for capacitive voltage indicator system
12. Busbars
13. Plug-in voltage transformer – busbar

Figure 6-66: Vacuum Interrupter in SF6 enclosure switchgear, with rated

three position disconnector (isolator)
 228 Substation Design Manual

6.2.3.1. Enclosure/Panel
The gas-insulated and metal-enclosed switchgear has been designed to
optimize availability and operator safety. The advantages of having gas-
insulated switchgear are as follows:

 Insensitive to environmental influences, such as humidity, dust and

aggressive gases.
 To provide high degree of personnel safety by having complete metal
enclosure for all live parts.

6.2.3.2. Cable Compartment

For Gas Insulated Switchgears, the type of termination kits to be supplied with
each panel shall be of the inner cone or outer cone system and shall be
designed for use on the various types of cables used by TNB. The termination
kits are type tested in accordance with the relevant IEC Standards.

Figure 6-67: Cable termination compartment with inner cone connectors

 Primary Equipment 229

Figure 6-68: Cable termination compartment with outer cone bushings

6.2.3.3. Vacuum Circuit Breaker

GIS only utilises vacuum circuit breakers (VCB) as the breaking mechanism. In
vacuum circuit breakers, the fixed and moving contacts are housed 6
permanently inside a sealed vacuumed ceramic bottle. The arc is quenched as
the contacts are separated in vacuum.

1. Circuit breaker compartment with front cover on

2. CB compartment with front cover removed

Figure 6-69: Typical fixed type circuit breaker used in GIS

 230 Substation Design Manual

Vacuum
Interrupter

Contact fingers
(fixed type)
6
Figure 6-70: Typical Fixed Type CB used in GIS

6.2.3.4. Pressure Relief

In the event of an internal fault, a pressure relief device operates before the
internal pressure exceed design pressure limit of the switchgear. The pressure
relief device should direct all the harmful gases and by products of the
internal fault away and safely from the operating personnel.

6.2.3.5. Indicators
Another important indicator is the SF 6 gas level gauge, also called manometer.
The manometer gives indication whether sufficient level of SF 6 is present
inside the tank especially prior to operation of the switches.
 Primary Equipment 231

6.2.3.6. Ingress Protection

Ingress protection specified for Gas Insulated Switchgears in the TNB
distribution network is as follows:

 IP42 externally and IP65 for gas enclosures

6.2.3.7. Interlocks
The interlocks are to ensure safety to operators and correct sequence of
operation of all circuit breakers, load break switches, isolators, earthing
switches.

For gas insulated switchgear, interlocks are enabled during operation of

isolators when the circuit breaker is in CLOSED Position.

6.2.3.8. Disconnector/Isolators with Earthing

Disconnectors are mechanical switching devices which provide an isolating
distance in the open position. They are capable to open or close a circuit if
either a negligible current is switched or there is no significant change in 6
voltage between the terminals of the poles. Currents can be carried for
specified times under normal operating conditions and under normal
conditions.

In gas-insulated switchgear, the earthing of the feeder is often achieved by

the earth-switch and completed by the closing of the circuit breaker

6.2.3.9. Typical Rating of GIS

Table 6-20: Rating of Switchgear Panels
Rating of Switchgear 33 kV and 22 kV Transformer Capacity
11 kV
Panels 90 MVA 45 MVA 30 MVA
a Feeder Panel 630 A 1250 A 1250 A 1250 A
b Transformer Panel 2000 A 2000 A 2000 A 2000 A
(LV Side)
c Transformer Panel N/A N/A N/A 1250A
(HV Side)
d Bus Section 2000 A 2000 A 2000 A 2000 A
e Bus Coupler N/A 2000 A 2000 A 2000 A
 232 Substation Design Manual

6.2.4. Ring Main Units (RMU)

6.2.4.1. Overview
In general, the Ring Main Unit (RMU) is a combination of two units of
switches, which are Load Break Switch (LBS) for the incoming and outgoing
feeders and switch-fuse or circuit breaker for the transformer T-off feeder. All
these switches are contained inside a tank filled with insulation.

To operate the switches inside the tank, operating mechanisms are mounted
externally on the tank and actuated manually using operating handles.

When SCADA function is required, motors connected with RTU for

communication and battery charger for dc supply are installed within the
operating mechanisms to enable switches to be operated remotely or via
supervisory.

In TNB, the RMU is the switching equipment used extensively in the 11 kV and
22 kV systems as it suits the system configuration and protection practice.
6
Additionally, the RMU offers the following advantages:

(a) Economical
(b) Ease of maintenance
(c) Space saving
(d) Suitable for indoor and outdoor use

The suitability of indoor and outdoor applications depends on the degree of

protection of the RMU (Ingress Protection (IP) rating). IP42 is suitable for
indoor while outdoor applications require a minimum of IP54. To achieve the
IP54 requirement, the RMU is clad with mild steel enclosure to cover the front
fascia. The definition of this IP is given in Appendix C.
 Primary Equipment 233

SF6 tank

Operating
mechanism

Figure 6-71: Example of operating mechanisms mounted on the tank in a

RMU (the front fascia of this RMU was removed) 6

Different types of RMU configuration (number of LBS and switch-fuse/circuit

breaker in the RMU unit) are used depending on the network requirement at
the substation. Typical configurations used in TNB are:

 2L + 1T or 2S+1F ( referring to 2 LBS and 1 switch-fuse/circuit breaker)

 2L + 2T or 2S+2F
 3L + 1T or 3S+1F
 3L + 2T or 3S+2F
 3L of 3S

For the insulation, RMU can either use mineral oil or Sulphur Hexafluoride
(SF6) gas. The insulation is responsible to clear the arc during operation. Other
than that, the insulation will also assist in cooling the bus-bar and the switch
blade inside the tank. In TNB, the RMU installed in the system is currently of
SF6 gas insulated.
 234 Substation Design Manual

(a) (b)
Figure 6-72: (a) Example of an outdoor RMU with front enclosure to achieve
IP54 requirement (b) When the enclosure is opened, the front fascia can be
6 accessed for operation and to observe indications.

Figure 6-73: An Example of Indoor RMU (Toprank Model TPM)

 Primary Equipment 235

The typical ratings for the RMU are given in the following table.

Table 6-21: Typical ratings for the RMU

Parameters 12 kV 24 kV
Continuous normal current 630 A 630 A
Short-time Withstand
 Load break switch 20 kA, 3 sec 20 kA, 3 sec
 Earthing switch 2.1 kA, 1 sec 2.1 kA, 1 sec
Making capacity
 Load break switch 50 kA peak 50 kA peak
 Earthing switch 5.4 kA peak 5.4 kA peak
Power frequency withstand Voltage
 Across earth and between poles 28 kV 50 kV
 Across isolating distance 32 kV 60 kV
Lightning impulse withstand Voltage
 Across earth and between poles 75 kV 125 kV
 Across isolating distance 85 kV 145 kV

Additionally, the RMU is internal arc tested to minimum 20 kA, 1 second for 6
the tank with accessibility Type A. Internal arc test is a type test used to verify
that the RMU is able to withstand the overpressure within the RMU due to
fault or flashover and hence to contain the arc internally without endangering
the authorised operators present near the RMU. Pressure relief valves are
installed on the tank usually at the bottom and are designed to rupture first
when there is overpressure inside the tank to release the arc away from the
authorised operators.

Tank

Pressure
relief device

Figure 6-74: Pressure relief device

 236 Substation Design Manual

6.2.4.2. Load Break Switch

Switches are mechanical switching devices, which not only make, carry and
interrupt current under normal conditions in the network but must also carry
for a specific time and possibly make currents under specified abnormal
conditions in the network.

A load break switch (LBS), as used in an RMU, can be used to make and break
a circuit under normal load current. However, it can only make but cannot
break the circuit during short circuit or fault conditions.

Due to this characteristic, the operating handle supplied with the RMU to
activate the operating mechanism of the LBS must have features to prevent
inadvertent breaking on fault to occur within 3 seconds after unintentional
closing on fault during operation. This requirement can be achieved for
example by the use of anti-reflex handle. The LBS is gang-operated to ensure
the 3 phases are operated simultaneously.

Figure 6-75: Internal view of LBS in Merlin Gerin RM6

 Primary Equipment 237

Figure 6-76: Internal view of LBS in Tamco GR1

Figure 6-77: Example of anti-reflex handle for LBS (Siemens 8DJ 20)
 238 Substation Design Manual

6.2.4.3. Switch-Fuse
The main function of this switch-fuse is to control the T-off circuit, which is
connected to the distribution transformer. Switch-fuse is essentially an LBS
connected in series with a fuse. Other than the closing and opening
operations, this switch is able to trip and isolate the supply automatically
during overload and fault conditions. In order to trip and isolate, a medium
voltage fuse is used to trigger the tripping mechanism. Alternatively, the
switch-fuse can also be replaced by a circuit breaker to control the
transformer T-off feeder. The tripping of this circuit breaker is controlled by a
time-lag fuse. The correct ratings of high voltage fuse and time-lag fuse must
be ensured for proper protection is achieved.

6.2.4.4. Interlocks
The RMU is equipped with mechanical interlocking facilities to ensure safety
to operators by principally preventing the following operations:

 Earthing the circuit while it is in live condition

6  Opening the testing access or the cable compartment and the fuse
compartment when the circuit is not earthed
 Switching ON of the circuit when the cable box compartment is opened

6.2.4.5. Indicators
Capacitive voltage indicator is provided for every feeder to give indication if
the every phase of the feeder is live or not. Mounted on the front fascia, the
indicator typically uses neon bulbs that light up or blink when the circuit is
energised. It is possible to conduct low voltage live phasing of the ring feeders
at the capacitive voltage indicator.

Another important indicator is the SF6 gas level gauge also called manometer.
The manometer gives indication whether sufficient level of SF 6 is present
inside the tank especially prior to operation of the switches.

6.2.4.6. Ingress Protection

IP42 for indoor application and IP54 for outdoor application
 Primary Equipment 239

6.3. Neutral Earthing System

6.3.1. Overview
TNB distribution practices an “effective system earthing” policy where the
source of supply at PMU and PPU must be earthed at the star point on the
secondary side of the transformer. This type of earthing system is known as
Neutral Earthing System where neutral is earthed by means of solid or
resistive earthing. Resistive earthing is achieved by the use of Neutral Earthing
Resistor (NER). The main purpose of the NER is to limit the single phase to
earth fault to a transformer rated full load current, thus protecting
installations, such as cables and transformers from damages due to extreme
heat generated by the fault current.

NEI

NER

Figure 6-78: Neutral earthing system showing NER & NEI

 240 Substation Design Manual

Figure 6-79 below shows a schematic diagram of a Neutral Earthing System

setup on the star side of power transformers which consists of NER, Neutral
Earthing Isolators (NEI) and associated earthing conductors and devices.

Busbar NEI Isolator

NEI
Close Open Close Open

Solid Earthing NER

Transformer 1 (T1) Transformer 2 (T2)

Figure 6-79: Neutral earthing system configuration

6
NER is installed at the star points of a large-capacity transformer that normally
exceeds 12.5 MVA. In most cases, transformers rated below 7.5 MVA do not
require NER. As such, only solid earthing is required.

Table 6-22 summarizes the normal rating of voltage, current and the size of
NER and NEI used.

Table 6-22: Standard ratings of voltage, current and the size of NER and NEI
Power Transformer NER NEI
NEI
Secondary Secondary Voltage Current Voltage Current
Voltage Capacity Resistance Busbar
voltage current rating rating Rating Rating
ratio (kV) (MVA) (Ohm) size
rating (V) rating (A) (V) (A) 2 (V) (A)
(mm )
33/22-11 30 22 787 16* 22 1600 10x100 36 1600
33/22-11 30 11 1575 4* 22 1600 10x100 36 1600
33/22 30 22 787 16 22 800 10x100 36 1600
33/11 30 11 1575 4 11 1600 10x100 12 1600
11/33 15 33 262 24 33 800 10x100 36 1600
33/11 15 11 787 8 11 800 10x100 12 1600
22/11 12.5 11 656 16 11 800 10x100 12 1600
22/6.6 12.5 6.6 1093 4 11 1600 10x100 12 1600
*Note: NER dual rating specific for connection of star point transformer dual ratio 33/22-11 kV
 Primary Equipment 241

6.3.2. Design and Construction

6.3.2.1. Neutral Earthing Resistor (NER)
There are two types of NER i.e. liquid and dry metallic type. Liquid type NER
requires frequent maintenance to ensure the electrolyte solution is kept
topped up and at the correct ionic strength where the bulk resistance value of
the electrolyte must be accurately calibrated so that the value will not
increase significantly with the increase in surrounding temperature.
Furthermore, dry metallic type NER does not suffer from evaporation, freezing
and leakage. For this reason, dry metallic NER is preferred and it has been
used as early as 1990 to replace the liquid type NER in PMU and PPU.

Dry metallic type NER, comprises of non-corroding heavy duty metallic

resistor elements, enclosed in a ventilated cubicle made of stainless mild steel
or galvanised steel, suitable for outdoor installation on concrete flooring.

Figure 6-80: Dry metallic type NER showing the metallic resistor elements
(grid)
 242 Substation Design Manual

6.3.2.1.1. Voltage

NER is often described by the system or line voltage of the supply, e.g. 11 kV
NER. The maximum voltage that NER actually experiences in service is the line
to neutral or phase voltage. The available voltage ratings of the NER in TNB
distribution network is as shown in Table 6-22.

6.3.2.1.2. Continuous Current & Ohmic Resistance

NER is rated by current at phase voltage and it is usually chosen to be equal to

or lower than the rated current of the transformer on the star side as shown
by the formula below.

MVA
Ifull load =
3 × Vline

System impedances are ignored. This implicitly specifies the ohmic resistance
value of the NER as follow.

6 Vphase
NER =
Ifull load

By Ohms Law, the ohmic resistance value of the NER can also be calculated
by:

V 2 line
NER =
MVA

Example: For 30 MVA 33/11 kV Transformer,

30
Ifull load = = 1574 A
3 × 11

The ohmic resistance value for the transformer is thus,

112
NER = =4Ω
30

Table 6-22 provides a comprehensive list of the current ratings and ohmic
resistance values according to the transformer capacity.
 Primary Equipment 243

6.3.2.1.3. Time

Resistors are generally rated to carry their current for a time of 10

seconds. The current will actually flow for a much shorter time than this. The
10 second time is chosen to allow for the occurrence of multiple events. This
can happen when auto-reclosers are used. It also allows for the operation of
an upstream backup protection device, if the protection relay fails.

6.3.2.1.4. Insulation Levels

NER never experience voltages in excess of phase voltage. However,

insulation level is designed based on the line voltage. This has minimal impact
on size, weight and cost of the NER designed for medium voltages.

6.3.2.1.5. Temperature Rise

Temperature rise is limited to 760°C maximum, in strict accordance to
ANSI/IEEE 32, 1972. This was based on the resistor alloy and insulation
technology available in 1972. Current technology may allow for a rise of
1000°C, maximum. The specification of a 1000°C design may significantly 6
reduce size, weight and cost.

6.3.2.1.6. Temperature Coefficient of Resistance (TCR)

Metallic resistors have a positive temperature coefficient of resistance (TCR).

This means that the current flowing will not exceed the rated value. Current
reduces as the NER warms up. In general the TCR is limited to 3.5% per 100°C
rise.

6.3.2.1.7. Termination

NER has three main terminals or connection points. The first terminal
connects one end of the resistor to the neutral of the transformer. The second
terminal connects the remaining end of the resistor to earth. The third
terminal provides enclosure earth bonding.

The enclosure earth terminal and resistor earth terminal is separated to

facilitate for testing on site.
 244 Substation Design Manual

The resistor neutral terminal is typically in the form of a porcelain bushing

rated for the line voltage. The resistor earth terminal is typically in the form of
a bushing rated for 1.2 kV. The enclosure earth terminal is usually in the form
of a M12 stud.

6.3.2.1.8. Ingress Protection (IP) Rating

The NER in TNB distribution network is typically designed to have the degree
of ingress protection for the enclosure of at least IP23 in accordance with IEC
60529. The materials used within a NER typically include resistive alloys,
stainless steels, ceramics, galvanised steel and copper. All of these materials
are durable in harsh environments. Hence the need for stringent
environmental protection is low.

Higher IP ratings of the NER in excess of IP54 can significantly restrict the
escape of heat from the resistor. High IP requirement thus can significantly
increase size and weight of the NER to cater for effective heat dissipation. This
will result in higher cost.
6
NER is hot during and after operation. The IP rating does not infer that it is
safe to touch the NER.

6.3.2.1.9. Enclosure

The enclosure is made of stainless mild steel or galvanised steel for free
maintenance.

6.3.2.1.10. Neutral Earthing Interlock

The NER is normally provided with interlocking mechanism so that it can be

interlocked (electrical or mechanical) with the 33/11 kV transformer incoming
circuit breaker. The interlock works in such a way that it is not possible to
close the transformer 11 kV incoming circuit breaker if its respective earthing
link is open.
 Primary Equipment 245

6.3.2.2. Neutral Earthing Isolator (NEI)

NEI is a simple switching mechanism to provide isolation of the NER for
maintenance of any section of the substation. The NEI is designed for outdoor
operation, complete with supporting steelwork with minimum safety
clearances in accordance with IEC 60071.

The Isolators are typically single pole double air break, centre rotating post
type with minimum 50 degree blade opening and is of wall mounted type.
Neutral busbars is made of tinned copper. The isolator blade is made of
copper where its tip is coated with silver for good electrical contact.

The neutral earth switch is normally provided with vertical drive rod and
mechanism box. The adjustable drive rod is made of galvanised steel pipe with
length and diameter suitable for easy operation. Adjustable rod clamp is also
provided to allow for on-site adjustment of the vertical drive rod.

Neutral cable connections to the NEI shall be insulated with non-thermal

termination kit. 6
The typical ratings of NEI use in TNB distribution network was tabulated in
Table 6-22 and Figure 6-81 shows typical arrangement of NEI for 11 kV 1600 A
ratings.

6.3.2.2.1. Ratings

The ratings of the NEI namely, voltage, impulse withstand voltage continuous
current and time are designed to be at least equal to the ratings of the NER.
The minimum short circuit current rating of the NEI is shown in Figure 6-22
below.

Table 6-23: Minimum short circuit current rating of the NEI

NEI Rated Voltage Short Circuit Current
11 kV 20 kA, 3 secs
22 kV 20 kA, 3 secs
33 kV 25 kA, 3 secs

However, most of the NEI used in the system is often rated at 25 kA, 3 secs.
 246 Substation Design Manual

NEI busbar
50˚ blade opening

Adjustable drive rod

Disconnectors
Vertical drive rod
Non-thermal
termination
Adjustable
drive clamp

Mechanical
switch assembly

Connection from Connection from

transformer 1 transformer 2

Figure 6-81: Typical arrangement of NEI rated at 11 kV 1600 A

6.3.2.2.2. Size of Conductors

6
The conductors are sized so that they are capable of carrying the continuous
current rating of the NER. The typical size of the main busbar conductors was
summarized in Table 6-22.

6.3.2.2.3. Clearance

The air gap between terminals of the same pole with the isolator open is
designed to be of a length to withstand a minimum impulse voltage wave of at
least 115 percent of the specified impulse insulation rating to earth. The
typical distance of the gap between the terminals of the same pole for NEI
rated at 33 kV is 500 mm.

6.3.2.2.4. Ancillary Equipment

NEI installations should be equipped with the following accessories:

i. 2 units of outdoor ring current transformer (CT) of Class X and frequency

50 Hz for REF protection. The knee point voltage V KP and CT resistance RCT
are to be determined based on the relaying scheme.
ii. 2 units of outdoor ring CT of Class 5P20, frequency 50 Hz and burden
15 VA for SBEF protection.
 Primary Equipment 247

Sample calculation to determine REF and SBEF CT ratios for 30 MVA 33/22 kV
transformers neutral earthing system is as follows.

NER 
22,0002  16
30,000,000

IFL = 524.9A ≈ 600A INER = IEF = IFL ≈ 800A

CTSBEF = 800/5A

33
30 MVA 800/5 A 900/1 A
CTREF  600  / 1  900 / 1A
33/22 kV 22
3

3
SBEF REF

22 kV
IFL = 787.3A ≈ 800A
NER 800 A
16 Ω

6
Sample calculation to determine REF and SBEF CT ratios for 30 MVA 33/11 kV
transformers neutral earthing system is as follows.

NER 
11,0002  4
30,000,000
IFL = 524.9A ≈ 600A INER = IEF = IFL ≈ 1600A

CTSBEF = 1600/5A

33
30 MVA 1600/5 A 1800/1 A CTREF  600  / 1  1800 / 1A
33/11 kV 11
3

SBEF REF

11 kV
IFL = 1574.6A ≈ 1600A
NER 1600 A
4Ω
 248 Substation Design Manual

In practice, a dual ratio CT is mostly used to cater for upgrading of transformer

capacity in the PMU and PPU. Table 6-24 lists the typical CT ratios used
according to the transformer ratings.

Table 6-24: CT ratios for REF and SBEF protection

Power Transformer NER CT Ratio
Secondary
Voltage ratio Capacity Resistance REF SBEF
voltage
(kV) (MVA) (A) (A) (A)
rating (V)
33/22-11 30 22 16* 1800/900/1 1600/800/5
33/22-11 30 11 4* 1800/900/1 1600/800/5
33/22 30 22 16 1800/900/1 1600/800/5
33/11 30 11 4 1800/900/1 1600/800/5
33/11 15 11 8 1800/900/1 1600/800/5
11/33 15 33 24 600/300/1 600/300/5
22/11 12.5 11 16 800/1 800/5
22/6.6 12.5 6.6 4 800/1 1200/5

CT 1

CT 2

Figure 6-82: Installation of CT 1 and CT 2 for REF and SBEF protection

respectively
 Primary Equipment 249

iii. Neutral Switch Auxiliary Contacts enclosed in stainless steel cubicle for
each isolator connecting to Transformers 1 and 2, NER and direct earth
connection and is rated for 110 VDC with eight numbers (8 Nos.) of
Normally Open and eight numbers (8 Nos.) Normally Close contacts.

Figure 6-83: Neutral Switch Auxiliary Contacts cubicle for indication of the
isolator’s open-close operation

6
6.3.3. Safety
During single line fault to ground, fault current will flow through NER, copper
conductor connecting NER to NEI, copper busbar on the NEI and back to the
transformer star point via the neutral cable as depicted by Figure 6-84.

Red Phase

Star Point

VNER NER Yellow Phase

Blue Phase

If Fault

Earthed Sheath Cable

Figure 6-84: Fault current flowing If due to phase short circuit to earth
 250 Substation Design Manual

The fault current flowing through the NER will instantaneously produce a
voltage across it approximately equal to the value of the phase voltage or
VL/√3. For example, the voltage across the NER connected on the star point of
a 33/11 kV transformer during single line to ground fault is approximately
6.35 kV. This proves that NER and NEI including all neutral earthing
conductors are High Voltage equipment as defined in TNB Safety Rules since
during single line to ground fault the equipment will experience phase-to-
earth voltage of more than 600 V. As such, NER, NEI and all neutral earthing
conductors shall be treated strictly in accordance with TNB Safety Rules.

In the event where NER is isolated and transformer star point is connected
directly via solid earthing, fault current will flow directly to earth. This will
produce a voltage approaching the earth potential or 0 V. However, the value
of the fault current will rise as no NER is connected to limit the fault current.

Hence, when working with NER, NEI and all neutral earthing conductors, the
procedures stipulated in Subchapter 6.3.4 shall be strictly observed.
6
6.3.4. Procedures When Working with NER, NEI and Neutral
Earthing Conductors
6.3.4.1. General Procedures:
(a) The NER Bay shall be locked at all time to prevent anyone from entering
the area without the permission from TNB authorized personnel.

(b) All TNB personnel or contractors must wear safety shoes provided or
approved by TNB when entering the high voltage zone including the NER
Bay.

(c) All TNB personnel must wear the personal protective equipment (PPE)
when operating the high voltage equipment during shutdown and
normalization of supply.
(d) Only TNB approved wooden ladder shall be used when working in the
high voltage zone including the NER Bay.
 Primary Equipment 251

6.3.4.2. Procedures When Working with NER or Conductors Directly

Connected to NER for Maintenance, Repair or Replacement Work
Prior to commencement of work on the NER or any parts of the conductors
directly connected to the NER, a shutdown of the power transformers
connected to the common neutral earthing system must be performed in
accordance with Seksyen 3, Aturan Keselamatan Elektrik, Bahagian
Pembahagian TNB, where the transformers shall amongst others be made
dead, isolated, proven dead and earthed at all points of isolation of supply to
the transformers including points of isolation from the neutral earthing
equipment.

6.3.4.3. Procedure When Working with Exposed Neutral Earthing

Conductors on Neutral Bushing and Neutral Cable of the
Transformer, NEI Busbar or Conductors Directly Connected to the
NEI and Transformer Star Point
When work requires direct contact on the exposed metal parts of the Neutral 6
Earthing Conductors on the neutral bushing and neutral cable of the
transformer, NEI busbar or conductors directly connected to the NEI and
transformer star point, a shutdown of the power transformers connected to
the common neutral earthing system must be performed in accordance with
Seksyen 3, Aturan Keselamatan Elektrik, Bahagian Pembahagian TNB, where
the transformers shall amongst others be made dead, isolated, proven dead
and earthed at all points of isolation of supply to the transformers including
points of isolation from the neutral earthing equipment.

6.3.4.4. Procedure When Working with Solid Earthing Conductor

When work requires direct contact on the exposed metal parts of the solid
earthing conductor, the respective isolator or disconnector for the solid
earthing on the NEI must be made open and any parts of the solid earthing
conductor shall be inspected to ensure all connection to the NEI busbar and to
any one of the transformer star point is safely disconnected before allowing
permission to work.
 252 Substation Design Manual

6.3.4.5. Prohibitions
(a) Any work performed on the NER, NEI and neutral earthing conductors
that are directly connected to NER, NEI Busbar and star point of any
energised transformer is totally PROHIBITED. This is to avoid danger to
the personnel resulting from the high voltage produced in the event of
single line to earth fault.

(b) Bypassing the NER by means of connecting the solid earthing to the
neutral earthing system at any time is totally PROHIBITED. This is to
protect the respective apparatus such as cables and transformers from
damage due to infinitely high fault current due to the absence of the NER.

(c) Concealing the neutral earthing conductors underneath the surface of the
substation wall is PROHIBITED. The fault current will leak through the
wall surface under wet condition and can cause electrical shock to
personnel touching the wet wall. Additionally, heat caused by the fault
current will cause surface crack and degradation of the wall.
6

6.4. Medium Voltage Fuse

Medium voltage (MV) fuses are used in the switch-fuse of RMU to provide fast
isolation of circuit when there is fault in the distribution transformer or
transformer tail on the HV and/or LV side. A fuse interrupts excessive current
(or termed as blows) so that further damage to the equipment protected is
prevented.

MV fuses used in RMU in TNB system are of high rupture capacity (HRC) and
back-up current limiting type. A HRC fuse is a fuse that is filled with silica sand
surrounding the fuse link. It is used on applications where the fault current
needs to be suppressed fast and with no flash over. On a fault current a
tremendous amount of heat is created within the fuse. That heat melts the
silica sand into glass, and glass being an insulator, suppresses the arc over and
breaks the circuit instantaneously.
 Primary Equipment 253

MV fuses used in RMU in TNB system are also fitted a striker mechanism. This
would provide the user with a visual indication that the fuse link has operated.
Striker mechanisms are driven by explosive charges or compressed springs
and both are triggered by a thin fuse in parallel with the elements that when a
current flows through it, the elements would melt. The current would then
heats up the wire and detonates the explosive charge or melt the wire and
releases the spring, pushing the striker pin out of the fuse link’s end cap. A
suitable mechanism is used to prevent from the pin being pushed back into
the fuse body.

End cap Star core Moisture tight seal

Porcelain barrel

6
Granular Quartz
Fuse elements Striker coil Expelled striker
Figure 6-85: Front view of MV fuse

Silver ceramic
point contact
Star core
Striker coil

Granular
Quartz

Fuse elements
Porcelain barrel

Figure 6-86: Cross-section of MV fuse

 254 Substation Design Manual

Another type of fuse used for transformer protection in RMU utilising circuit
breaker is the time lag fuse. This type of fuse, also known as anti-surge, or
slow-blow is designed to allow a current which is above the rated value of the
fuse to flow for a short period of time without the fuse blowing. This situation
normally arises in magnetising inrush current of transformers which can draw
larger than normal currents for up to several seconds when first energised.

Figure 6-87: Time Lag Fuse

6.4.1.1. Dimension and Design of Fuse Contact

MV fuses are available in different dimensions and designs of the fuse
contacts which are selected according to the types of RMU where the fuses
will be used (refer to Table 6-25). For SF6 gas insulated RMU, the MV fuse shall
comply with dimension as specified in DIN 43625. Often, this fuse is referred
to as MV DIN fuse.
 Primary Equipment 255

Table 6-25: Type of fuses in different RMUs

No. Type of RMU Features
1. SF6 – gas insulated Based on DIN 43625 standard
Example: RMU Tamco GR1, RMU
Indkom, RMU Merin Gerin RM6

442 mm
22 kV

11 kV

292 mm

2. Oil insulated with in-air fuse Based on IEC 60282-1 Type III
compartment with type D tags
Example: HFU Tamco, HFU
Cutler-Hammer

6
Side view

Top view

3. Oil insulated with the fuse Based on IEC 60282-1 Type II

compartment immersed in oil
Example: RMU ABB (oil type),
RMU Long and Crawford, RMU
EPE Rokks
 256 Substation Design Manual

6.4.1.2. Fuse Rating

The rating of the MV fuse to be used depends on the capacity of the
distribution transformer connected to the switch-fuse feeder and is
determined based on the following characteristics:

(a) Shall provide 3-phase protection against short-circuit current that occurs
in the HV or LV side of the transformer
(b) Able to withstand transformer inrush magnetising current which is
typically 12 x full load current transformers for 100 ms
(c) Able to withstand the usual periodic overcurrent up to 150% of
transformer full load current
(d) Giving discriminatory grading with low voltage (LV) fuses for the highest
rating used in the LV system which is 250 A. This is to ensure that the LV
fuses operate properly when there is fault in the LV system.

Referring to the time-current characteristics for MV fuse, the ratings in

Table 6-26 should be observed for 11 kV and 22 kV SF6 gas insulated RMU.
6
Table 6-26: The fuse rating must be suitable with the transformer ratings
System Transformer capacity
Fuse rating (A)
voltage (kVA)
100 16
300 31.5
11 kV 500 50
750 80
1000 100
100 6.3
300 16
22 kV 500 25
750 40
1000 50
 Primary Equipment 257

6.5. Feeder Pillar

6.5.1. DIN-Type Feeder Pillar

Feeder pillars (FP) are used as an LV distribution point from the substation
transformer outgoing feeder to the customers. In TNB, feeder pillars used are
designed based on standards developed by the German Institute for
Standardization or Deutches Institut fur Normung (DIN). Previously, the
feeder pillars installed in the system were of the British Standards (BS) design.

The design and technology of the DIN-type feeder pillar has been used by TNB
for feeder pillar rated at 400 Amps (also known as mini feeder pillar) since
1999. Based on the experience of using DIN-type feeder pillar 400 Amps, TNB
has started to migrate to DIN-type feeder pillar for rating 1600 A since 2010,
and since 2012 for 800 A rating.

Figure 6-88: DIN-type feeder pillar rated at 400 Amps (or mini feeder pillar)
 258 Substation Design Manual

Figure 6-89: Example of a BS Type 1600 A feeder pillar

6.5.2. Rational for Using the DIN-Type LV Feeder Pillar

There are several advantages of using DIN-type feeder pillar compared to BS
6 type feeder pillar. The features of DIN type feeder pillar are:

1) 30% reduction of size from the existing BS type feeder pillar

2) Operational safety due to the fully shrouded concept
3) The design which can minimize the risk of vandalism and theft:
 Red phase, Yellow phase and Blue phase busbars are not easily
accessible as the incoming and outgoing units are installed onto the
busbars very close to one another with gaps of less than 10 mm
between the units.
 Neutral busbar is also not easily accessible as it is mounted behind
the front plate.
 All bolts and nuts securing the busbars to the feeder pillar frame are
applied with special chemical called thread locker to prevent these
bolts and nuts from being opened by spanner.
 No link and fuse carriers are present in the DIN-type feeder pillar as
in the BS type. These link and fuse carriers contain copper and are
very prone to theft. In the DIN-type feeder pillar, all copper contacts
are embedded within the incoming and outgoing unit bodies and are
hence difficult to be stolen.
 Primary Equipment 259

Copper contacts

Figure 6-90: Copper contacts on fuse carrier of BS-type feeder pillar

Copper contacts

Figure 6-91: Copper contacts embedded within the disconnector body of

DIN-type feeder pillar
 260 Substation Design Manual

6.5.3. Design and Construction of Feeder Pillar

The design for the 1600 A, 800 A and 400 A feeder pillars (FP) are essentially
similar in terms components and functions. The differences lie in the size of
current-carrying components used to suit the required ratings, the number of
incoming and outgoing units to suit network requirement as well as methods
of cable termination.

(1) Instrument panel

(2) (4)
Disconnector unit Fuse-switch
(Incoming) disconnector
(Outgoing)

(3) Cable termination

Figure 6-92: DIN-type 1600 A LV feeder pillar

In general, feeder pillars consist of four main components as shown in Figure

6-92 and provide the functions as follows:

1. Instrument panel
 Instrument panel is only available in FP 1600 A and 800 A. It is front-
mounted and is equipped with ammeter with maximum demand
indicator and 13 A, 3 pin switched socket outlet.
 Additionally, the instrument panel is fitted with 60 A cartridge type fuse
wired to the blue phase busbar and one neutral link wired to the
neutral busbar to facilitate the connection of auxiliary single phase
loads such as substation lighting, portable tools, etc.
 Primary Equipment 261

Figure 6-93: Close up of the instrument panel

2. Incoming disconnector unit

 Rating: 2 x 1000 A (for FP 1600 A and 800 A)
 Contains copper solid link rated 1000 A or size NH3
 Single-pole operated
 For FP 400 A, the incoming consists of direct terminations of
incoming cables onto the busbars.
 Function: Provide means to isolate the FP from the source/supply 6

3. Cable termination
 Cable cores of the incoming and outgoing cables for Red, Yellow and
Blue phases are terminated via bolted connection in the termination
area provided at the bottom of the respective incoming disconnector
and outgoing fuse-switch disconnector units (for FP 1600 A and 800
A).

Figure 6-94: Close up of cable termination for one feeder

 262 Substation Design Manual

 For FP 400 A, the incoming cables are directly terminated via bolted
connection onto the busbars. The outgoing cables are connected to
the termination area provided at the bottom of the outgoing fuse rail
units via core clamps.
 All neutral cores are terminated directly via bolted connection onto
the neutral busbar.

4. Outgoing fuse-switch disconnector

 Rating: 8 x 400 A (for FP 1600 A), 5 x 400 A (for FP 800 A) and
6 x 160 A ( for FP 400 A)
 Contains LV DIN fuse blade contact type of size NH2 (for FP 1600 A
and 800 A) and size NH 00/000 (for FP 400 A).
 Depending on the operation requirement the available fuse ratings
are as follow:
o 125 A, 160 A, 200 A and 250 A for NH2
o 50 A, 80 A and 100 A for NH 00/000
 Function:
6
o Provide fast isolation through interruption by fuse when
fault occurs at outgoing feeders
o Provide means to isolate the outgoing feeders from
source/supply

Figure 6-95: LV DIN fuse blade contact type of size NH2 used in the outgoing
unit
 Primary Equipment 263

5. Busbar
 The phase busbar system is designed to carry the rated continuous
current
 Made of tinned copper with the following minimum copper
equivalent dimension:
o 80 mm x 10 mm (for FP 1600 A)
o 38 mm x 10 mm (for FP 800 A)
o 6 mm x 40 mm (for FP 400 A)
 The neutral busbar has similar material and dimension to the phase
busbar. The neutral busbar is connected to the earth bar through
braided copper wire.

6. Feeder pillar enclosure

 The enclosure is made of electro galvanised steel. Sufficient
ventilation is provided to permit natural circulation of air.
 The doors are equipped with camlock for locking of the doors. The
camlock is opened using the Allen Key provided by manufacturer
6
with every feeder pillar. As such, standard padlocks are no longer
required to lock the doors. The padlocking facility provided on the
door is to enable Authorised Persons to use non-standard lock during
shutdown or breakdown as per safety requirement.

Camlock

Handle

Padlocking facility

Camlock

Figure 6-96: Camlock with Allen key

 264 Substation Design Manual

6.6. Current Transformer (CT)

A current transformer (CT) is a device for sensing current flowing through a
power system and sending current signal to a protective relay system. The
functions of current transformer are:

(a) To reduce power system current to lower value for measurement

(b) To insulate secondary circuits from the primary
(c) To permit the use of standard current ratings for secondary equipment

The differences between current transformers (CT) for metering and

protection are shown in Table 6-27.

Table 6-27: Difference between CT for metering and protection

Metering Protection
1 Used for instrumentation such as  Used for operation of protective
ammeter, energy meters, transducer devices such as relays in CBs and
etc. reclosers.
6  Can be connected is series with
ammeter

2 Accuracy is paramount  Reliability and stability during

operation up to accuracy limit
current

3 Specified in accuracy class e.g. 0.2  Specified in accuracy and

and 0.5 accuracy limit factor (ALF)
e.g. 5 P 10, 5 P 20, cl X, S etc.

4  Operate at rated accuracy class  Accurate from rated primary to

between 100%-120% current accuracy limit (ALF) current
ratings.
 Normal operating range is 20%-
100%.
 Beyond 120%, CT saturates so no
further increase in secondary
current with further primary
current rise
 Primary Equipment 265

The protective current transformer must be capable of providing an adequate

output over a wide range of fault conditions, from a fraction of full load to
many times full load. The CT standards are governed by IEC 185:1987,
IEC 44-6:1992, BS 3938: 1973, and BS 7626.

Characteristics and specifications of the current transformer include:

 Current transformer is normally of the dry type design using epoxy resin
as insulation and tested to IEC 60044-1.
 The CT shall be capable of carrying rated primary current for one minute
with the secondary winding open. Where open circuit secondary voltage
would exceed 3.5 kV, suitable protection shall be provided at the
secondary terminals to limit the voltage.
 The CT is installed on the circuit side of the circuit breaker except on
busbar sectionalising and coupling equipment as may be required.

(a) Ring type

(b) Wound type

Figure 6-97: MV current transformer

 266 Substation Design Manual

Protection CTs

Metering CTs

Figure 6-98: CT for protection and metering inside switchgear

6

6.6.1. Protection Current Transformer (CT)

The protection CT has the following characteristics:

1. The output of each protection CT is 15 VA with an accuracy limit factor of

20. The adequacy of these figures can be confirmed by calculation. The
CT Class is typically 5P20 for protection.
2. For high impedance unit protection where specified in the specification,
class X CT is used. The knee point voltage is confirmed by calculation.
3. The classification of CT for protection is normally written as 5P10 or 5P20;
5 are 5% composite error at 10 or 20 times of the rated current, while P
denotes protection CT.
 Primary Equipment 267

6.6.2. Metering Current Transformer (CT)

One of the characteristics for metering CT is the accuracy class that is typically
0.2 and 0.5. This means that the errors have to be within the limits specified in
the standards for that particular accuracy class.

Specifications of metering CTs for consumers taking 415 V are:

 Ratio : Is 5A
*where Is is the primary ratio of the metering CT
 Class : 0.2
 Burden : 7.5 VA
 Unit : 3 Nos. (One for each feeder)
 Standards : IEC 60044-1 (1996)

Specifications of metering CTs for consumers taking 6.6 kV, 11 kV, 22 kV and
33 kV (indoor breaker) are:

 Ratio : Is 5A
6
*where Is is the primary ratio of the metering CT
 Class : 0.2
 Burden : 15 VA
 Unit : 3 Nos. (One for each feeder)
 Standards : IEC 60044-1 (1996)

Table 6-28: Current Transformer (CT) sizes

100/5, 150/5, 200/5, 300/5,
LV CT ratio 400/5, 500/5, 600/5, 800/5,
1000/5, 1200/5, 1600/5

50/5, 75/5,
MV CT ratio 100/5, 150/5, 200/5,
300/5, 400/5

An example of metering Current Transformers (CT) installed for each phase is

shown in Figure 6-99.
 268 Substation Design Manual

Figure 6-99: Example of Metering Current Transformer (CT)

Example: Current Transformers (CT) Size Calculation

To determine CT size, the following calculation should be done:

𝑃= 3 × 𝑉𝑝−𝑝 × 𝐼 × cos 𝜃
6
𝑃
𝐼=
3 × 𝑉𝑝−𝑝 × cos 𝜃

cos 𝜃 = 0.85

Where:-
P = Apparent power
Vp-p = Line voltage system
I = Line current ampere
cos θ = Power factor

For example:
500 𝑘𝑊
I=
3 × 0.415 𝑘𝑉 × 0.85
I = 818.36 𝐴

Thus, the suitable CT size is 1000/5 A.

Note: Metering CT size should be higher than the calculated value.

 Primary Equipment 269

Figure 6-100: Armoured cable is used to connect the CT and PT to the meters

6
Table 6-29: Armoured Cable Configuration
Cable No. Cable configuration
1 S1 terminal red phase current transformer
2 S2 terminal red phase current transformer
3 S1 terminal yellow phase current transformer
4 S2 terminal yellow phase current transformer
5 S1 terminal blue phase current transformer
6 S2 terminal blue phase current transformer
7 Red phase voltage
8 Yellow phase voltage
9 Blue phase voltage
10 Neutral
11&12 Earthing
 270 Substation Design Manual

6.7. Potential Transformer (PT)

Potential Transformers (PT) are used to step down the voltage for
measurement, protection and control. TNB Distribution Division only uses
electromagnetic type potential transformers. The functions of the PT are for:

(a) Measurement/metering
(b) Automatic Voltage Regulation (AVR)
(c) Protection for directional OCEF relay

 The PT is normally of the cast resin filled type and it is complies with
IEC 60044-2 with a class of 0.5.
 The rated output of the PT is normally specified at 50 VA per phase but
alternatively adequacy can be determined by calculation of the burden.
 The normal ratio of PT is normally to the rating of 33 kV, 22 kV, and
11kV/110V (3 single phase star-connected and neutral earthed).
 The PT should be able to be isolated from the circuit during testing by
6 means of isolatable links or withdrawable mechanism.

Figure 6-101 below shows an example of an electromechanical PT and

Figure 6-102 shows the location for the PT inside a switchgear compartment.

Figure 6-101: Electromechanical PT

 Primary Equipment 271

Potential Transformer

Figure 6-102: Potential Transformers inside the switchgear compartment

6
Specifications of potential transformers are:

 Ratio :
Vs 3
110 3
*Where Vs is the supply voltage given to the consumer

 Class : 0.5
 Burden : 50 VA minimum.
Sharing between protections and metering PT can be
allowed provided that separate fusing is provided and the
burden of the shared load does not exceed 10 VA. If the
burden of the shared load is more than 10 VA, then 100 VA
PT should be used.

 Unit : 3 Nos. (one for each feeder)

 Standards : IEC 60044-2 (1997)
 272 Substation Design Manual

Figure 6-103: Potential Transformer Fuse

Each PT is equipped with PT fuse normally rated at 3.15 A. This fuse will
isolate the PT from the system in the event of fault at the PT i.e. internal
winding, secondary bushing. Therefore, the system will not trip or de-
energize.

However, the fuse will not blow if the fault is at the secondary circuit because
6
the fault current equivalent at the primary side is too small to blow the fuse.
Normal practice is to place fuse or MCB at the secondary side to protect the
circuit, but they are prone to tampering and nuisance tripping causing
incorrect energy consumption recorded by the meter.

For the future, TNB will replace these fuses with copper links to avoid PT fuse
blow issue and solely depends on OCEF protection to trip if there is any fault
caused by the PT.
 Secondary Equipment 273

Chapter 7: Secondary Equipment

7.1. Overview
Secondary equipment is needed to ensure reliable operation of the primary
equipment. They cover the functions of protection, monitoring, control,
automation and communication.

7.2. Protection/Protective Relaying

7.2.1. Protection System

Protection System is a branch of electrical power engineering concerned with
design and operation of primary equipment. It detects abnormal power
system conditions to rapidly remove and selectively isolate such conditions
from service in order to return affected power system to its normal state.

There are 3 main functions of Protection System:

1. To safeguard the entire system to maintain continuity of supply

7
2. To minimize damage and repair costs where it senses fault

3. To ensure safety of personnel.

7.2.1.1. Components of Fault Isolating System

Fault isolation system consists of:

1. Protection Relay / Equipment

2. Current Transformer (CT) & Potential Transformer (PT)

3. Circuit Breaker

4. DC System

Each component above is explained further in the following subchapters. The

relationship among these components is as shown in Figure 7-1.
 274 Substation Design Manual

Protection System

Circuit Breaker
CT
Protection Trip CB
Equipment Coil Mechanism
/ Relay
PT

CT – Current Transformer
PT – Potential Transformer
DC System CB – Circuit Breaker

Figure 7-1: Fault Isolation System

7.2.1.2. Protection Relay

A protection relay is a device that monitors power system parameters such as
current, voltage and frequency input. It triggers alarm or initiate trip to the
circuit breaker if the input measured is outside its preset range.
7
Protection relays respond to abnormal system conditions such as short-circuit,
open-circuit, overloading, and reverse power flow.

Particularly for transformer, it responds to the oil and winding temperature as

well as gas pressure.

There are 3 types of relays used in TNB Distribution Division system:

1. Electromechanical relay

2. Electronics/static relay

3. Numerical Intelligent Electronic Device (IED)

 Secondary Equipment 275

7.2.1.2.1. Electromechanical Relay

Electromechanical relays are constructed with electrical, magnetic and

mechanical components, have an operating coil and various contacts and are
very robust and reliable.

Time dial sets the stop position of the

disk and therefore sets the contact
travel distance

Upper poles

Metal disk

Moving
contact
Damping contact

Fixed
contact
Direction of torque produced
on disk
Current
Restraining force of spring;
Spring normally holds disk at rest 7
against mechanical stop
Lower pole Shaft
Pickup point adjusted by
selecting current tap

Figure 7-2: Basic principle of electromechanical relay

Although this type of relay has been in operation for many years, there are
several limitations such as:

(a) Demagnetizing problem due to ageing

(b) Limited functionality as compared to numerical relays

 276 Substation Design Manual

The figure below shows an example of CDG 36 type electromechanical relay.

Figure 7-3: Electromechanical relays (CDG 36)

7.2.1.2.2. Static Relay

7
Static relays with no or few moving parts became practical with the
introduction of the transistor. Static relays offer the advantage of higher
sensitivity than purely electromechanical relays, because power to operate
output contacts is derived from a separate supply, not from the signal circuits.
Static relays eliminate or reduce contact bounce, and could provide fast
operation, long life and low maintenance.

Limitation for this relay is mainly on the expected lifespan which is

approximately based on TNB Distribution Division maintenance policy. An
example of a static relay that is used in TNB Distribution Division is shown in
Figure 7-4.
 Secondary Equipment 277

Figure 7-4: Examples of static relay (MCGG52)

7.2.1.2.3. Numerical Intelligent Electronic Devices (IED)

Numerical Intelligent Electronic Devices (IED) is a relay that converts voltage

and current to digital form and processes the resulting measurements using a
microprocessor. The digital relay can emulate functions of many discrete 7
electromechanical relays in one device, simplifying protection design and
maintenance.

A typical IED contains protection functions, control functions controlling

separate devices, an auto-reclose function, self monitoring function,
communication functions etc. IEDs receive data from sensors and power
equipment, and can issue control commands, such as tripping circuit breakers
if they sense voltage, current, or frequency anomalies, or raise/lower voltage
levels in order to maintain the desired level.
 278 Substation Design Manual

Among the features available in a numerical relay include:

(a) Facility for local and remote relay setting

(b) Event recording
(c) Group setting features
(d) Password protected
(e) Fault disturbance waveform

One of the advantages of the IED relay is that size is significantly reduced
compared to the electromechanical type. Examples of IED relays used in TNB
Distribution Division are shown in Figure 7-5.

(a) SIEMENS SIPROTEC 7SD61 (b) MICOM P123

Figure 7-5: Examples of Numerical IED relays

7.2.1.2.4. List of Accepted Relays

TNB implements stringent standard procedure for product acceptance for

procurement of relays. The list of the TNB accepted relays is kept and updated
by Transmission Protection.
 Secondary Equipment 279

7.2.1.3. Current Transformer (CT) & Potential Transformer (PT)

The Current Transformer and Potential Transformer are part of the
components in the switchgear as discussed in Subchapter 6.6 and Subchapter
6.7.

7.2.1.4. Circuit Breaker

Circuit breaker is primary equipment that isolates faults. The device is as
discussed in Subchapter 6.2.

Generally, under fault condition, protection relay receives and analyzes

information and closes its contacts. This will energize the trip coil inside the
CB and operate its opening mechanism to isolate the faulty circuit from the
power system.

7.2.1.5. DC System
Protection system requires uninterrupted and independent power source.
Typically, DC supply is preferred over AC supply due to its reliability and
immunity to disturbance and surges.

DC system is required to power up the relays and CB auxiliaries. It will be

further elaborated in Subchapter 7.4
7
7.2.2. Protection Scheme
Physically, protection relays are connected to other components such as CT,
PT, time-delay relays, auxiliary relays, secondary circuits, trip circuits, auxiliary
wiring, fascia, and tripping relays to make up for a protection scheme.

This protection scheme is designed to safe guard primary equipment from

various type of fault. The design of such scheme varies depending on the:

 Type and rating of the primary equipment to be protected

 Size and the complexity of the substation

Examples of protection schemes are overcurrent earth fault scheme, pilot

wire protection scheme, current differential scheme, transformer differential
scheme, etc.
 280 Substation Design Manual

7.2.2.1. Protection Schemes for PPU

Figure 7-6 shows general protection schemes for PPU.

 Solkor
RF/Current
Differential
 OC/EF
33 kV

33 kV Outgoing
1HO 2HO
 Tx Differential
 Tx Differential
 Tx Guard
 Tx Guard
 OC/EF
Tx2  OC/EF
Tx1

NER

 OC/EF  OC/EF
 REF  REF
31 Bus Section 32

 SBEF Tx1
11 kV Outgoing
7  SBEF Tx2

 OC/EF
 Translay

Figure 7-6: Protection schemes for PPU

 Secondary Equipment 281

7.2.2.1.1. Underground Feeder

Protection schemes implemented are:

 Over Current Earth Fault (OCEF)

 Current Differential (CD) using fibre optic or Pilot Wire Protection
 Directional OCEF
 Other alternatives subject to the network configuration.

7.2.2.1.2. Overhead Feeder

Protection schemes implemented are:

 OCEF
 Auto reclose
 Other alternatives subject to the network configuration.

7.2.2.1.3. Transformer Feeder HV

Protection schemes implemented are:

 Transformer Differential
7
 OCEF
 Transformer mechanical protection – refer to Subchapter 6.1.5.8
o Gas activated relay (Buchholz)
o Winding and oil temperature
o Pressure Relief Device (PRD)
 Other alternatives subject to the network configuration.

7.2.2.1.4. Transformer Feeder LV

 Restricted Earth Fault

 Standby Earth Fault
 OCEF
 282 Substation Design Manual

7.2.2.1.5. Busbar

Protection schemes implemented are:

 Busbar separation scheme (BSS) - The scheme is to separate the busbar

when outgoing feeder fails during fault.
 Busbar/switchgear protection scheme - TNB Distribution Division employs
arc protection technique as the busbar protection scheme. It comprises
of:
o Master relays installed at independent arc protection panel for
transformer LV incomers and feeder incomers.
o Slave relays located in switchgear, and
o Sensors in switchgear and busbar compartments.

Current input to the scheme is taken from the LV incomer. The scheme is such
that outgoing feeder breaker will trip for downstream fault in the switchgear
and the scheme will trip LV incomers for busbar fault. In case of a transformer
breaker failure or delays to open, an intertrip to HV transformer feeder will
take place.

7 Master
VAMP 220 (Master) Master
VAMP 220 (Master)

Ib>

T2 T2
VX010
VX010 (Slave)
(Slave)

CB1 T1 CB2 T1

CB3

X1 X2

Sensors

Figure 7-7: Example of Arc Protection Scheme

 Secondary Equipment 283

7.2.2.2. Protection Schemes for 11 kV Stations

7.2.2.2.1. Underground Feeder

Schemes implemented for underground feeder protection are:

 Over Current Earth Fault (OCEF)

 Current Differential (CD) using fibre optic or pilot wire protection
(Translay)
 Directional OCEF
 Other alternatives subject to the network configuration.

7.2.2.2.2. Overhead Feeder

Schemes implemented for overhead feeder protection are:

 OCEF
 Other alternatives subject to the network configuration.

7.2.2.2.3. 11kV/0.4kV Distribution Transformer Feeder

Scheme implemented for 11kV/0.4kV distribution transformer feeder

protection is: 7
 OCEF
 284 Substation Design Manual

7.3. Control
Control hierarchy is designed in TNB equipment to ensure safety to personnel
in the field by restricting the permission to control the equipment. It
comprises:

1. Local Control (Highest Priority)

2. Remote Control (Second Priority)
3. Supervisory (Least Priority)

This priority determines how the internal wiring will be designed. Descriptions
of the controls are as follows:

1. Local Control
Personnel are required to do switching at the equipment or
switchgear. This facility is to facilitate maintenance, inspection and
emergency operation.

2. Remote Control
In this mode, personnel are required to do switching activities from
the control room.

7 Permission for switching from supervisory is determined here.

3. Supervisory Control
Switching activities are done from Regional Control Centre (RCC),
where principal items of substation are controlled and monitored via
SCADA system. The SCADA is covered in Chapter 8.
 Secondary Equipment 285

7.3.1. Control Hierarchy for PPU

For PPU, the control hierarchy is achieved by using the Control and Relay
Panels (CRP). CRP facilitates centralized control, monitoring and status of
primary equipment in that particular substation.

The control panel incorporates:

(a) Protection relays

(b) Alarms fascia
- Alarm handling facilities for operational personnel
(c) Switches
- Inclusive of control switches (discrepancy switch),
remote/supervisory switch
(d) Analogue meter (Ammeter and Voltmeter)
- Indicating actual current and voltage reading.
(e) Auto/Manual trip counter for circuit breaker
- Auto is for cumulative number of CB tripping while manual is for
cumulative number of CB opening.
(f) Auxiliary relays
(g) Interposing transformers
- An instrument installed in overcurrent circuit to protect
7
transducer, ammeter.
(h) Fuses
(i) Links
(j) MCBs
(k) Test terminal blocks
- Facilities for secondary testing.
(l) Transducer
- An equipment to provide remote on line system parameters.
(m) Semaphore
- Visual indication of the status or position of its primary equipment.
(n) Mimic and labels
- A representation of the primary equipment and its voltage rating.
- In the mimic diagram, the breakers are systematically
numbered/coded.
 286 Substation Design Manual

The colour coding for the mimic as practiced in TNB are as follows:

Table 7-1: Colour coding for the mimic

Colour Voltage
Yellow 11 kV
Blue 22 kV
Red 33 kV
Green 132 kV
Brown 275 kV
Black Neutral/Ground

Metering

Windows
Alarm Fascia

Protection
Relay

7 Mimic Diagram &

Control

Figure 7-8: An example of Control and Relay Panels

In the mimic diagram, each circuit breaker is uniquely numbered for ease of
identification. These numbers are always referred to during operation. The
standard numbers are as explained in Subchapter 3.3.1.
 Secondary Equipment 287

7.3.1.1. Interlock
Mechanical and electrical interlocks are included on mechanisms and in the
control circuits of apparatus installed in substations as a measure of
protection against an incorrect sequence of manoeuvres by operating
personnel.

The common interlocks are:

1. Opening & closing of NER

2. Opening & closing of transformer isolator
3. Insertion of PT
4. Transformer HV and LV opening and closing interlock
5. Busbar live transfer
6. Earthing interlock

7.3.2. Control Hierarchy for 11 kV Stations

Generally, for 11 kV stations only the local control mode is available.

If the station is equipped with Remote Control Box (RCB) the three levels of
control hierarchy can be achieved.
7
The Remote Control Box (RCB) can be incorporated into existing 11 kV circuit
breaker / RMU to provide control and indication of the circuit breaker / LBS
(RMU). The control panel incorporates:

(a) Two different coloured lamps to show the status of the circuit
breaker/LBS (RMU):
i. Green lamp : “OFF” condition of circuit breaker/LBS (RMU)
ii. Red lamp : “ON” condition of circuit breaker/LBS (RMU)
(b) Feeder signal
(c) Station alarm
(d) Switches
i. Supervisory remote switches
ii. Open/close switch
iii. Earth switch
 288 Substation Design Manual

The RCB indicators are shown in Figure 7-9.

Figure 7-9: RCB indicators

The RCB is SCADA ready for future interconnection with RTU. The signal must
include:

 Supervisory Open Command: signal from RTU to trip circuit breaker

 Supervisory Close Command: signal from RTU to close circuit breaker
 Supervisory Indicator: signal to be sent to RTU to indicate the selector switch
7
selected to supervisory mode
 Remote Indicator: signal to be sent to RTU to indicate the selector switch
selected to remote mode
 CB Open Indicator: signal to be sent to RTU to indicate the circuit breaker
“OFF” condition
 CB Close Indicator: signal to be sent to RTU to indicate the circuit breaker
“ON” condition

Each RCB box can control up to 4 feeders. Where space is a constraint, RCB can
be mounted outside the substation’s wall as shown in the Figure 7-10.
 Secondary Equipment 289

RCB

Figure 7-10: Remote Control Block (RCB) for P/E

7.4. DC & AC Auxiliary Systems

7.4.1. DC System
In a substation, Direct Current (DC) system is used to provide power to all
auxiliaries such as:

(a) Protective devices 7

(b) Tele-control equipment such as Remote Terminal Unit (RTU)
(c) Circuit breaker auxiliaries

7.4.1.1. DC System for PPU and SSU

The DC system for PPU and SSU is rated at 110 V DC; comprising chargers,
battery banks (86-88 cells) and DC distribution board. The DC system is of dual
parallel redundant chargers with interlocking system and operating in parallel
with battery banks.
 290 Substation Design Manual

Battery charger

DC distribution
board Battery bank

Figure 7-11: DC system in the battery room

7.4.1.1.1. Charger

7 A charger is an equipment that rectifies AC supply into DC. It is used as the

main DC source to supply station DC auxiliaries and at the same time to
charge the standby battery bank during normal operation.

Charger 1 Charger 2 DC distribution

board

Figure 7-12: Dual battery charger panel and DC distribution board (110 V)
 Secondary Equipment 291

7.4.1.1.2. Battery Bank

Battery bank is used as backup to supply station auxiliaries whenever station

AC supply fails. It is designed to cater for 5 hours during any station AC supply
blackout.

It also serves as an extra DC source whenever the station DC load requires

supply more than what can be delivered by the charger.

Battery banks and battery chargers must be well maintained to ensure that
the protection system functions properly.

Figure 7-13: A dual battery bank

7.4.1.1.3. DC Distribution Board

The DC distribution board distributes the 110 V DC supply to the required

apparatus, for example CBs trip coil, protection relays and annunciators. The
DC distribution board can be seen in Figure 7-12.
 292 Substation Design Manual

7.4.1.2. DC System for P/E with VCB Switchgear

The DC system for P/E with VCB switchgear is rated at 30 V DC. The system
comprises charger, battery bank (25 cells) and terminal blocks that are
incorporated in a single cubicle as shown in Figure 7-14.

Figure 7-14: A typical single cubicle battery charger (30 V DC)

in an 11 kV substation
 Secondary Equipment 293

7.4.2. AC System
AC System is required to supply all substation AC auxiliaries such as:

 OLTC driving mechanism

 Remote Tap Changer Control Panel
 Each Battery Charger
 Control and Relay Panel – Heater & Lighting
 Switchgears – Heaters

The AC supply can be derived from:

 Local transformer LV Distribution Board (DB) in the case of PPU; or

 LV distribution transformer or LV mains from SAVR; or
 Customer AC supply

Figure 7-15 shows an example of an LVAC Switchboard.

Figure 7-15: LVAC Switchboard

 294 Substation Design Manual

7.5. Heater

7.5.1. Heater for 33 kV Switchgears

For 33 kV switchgears, heaters are installed at 3 locations in the switchgear:

1. Breaker compartment
2. Cable compartment
3. CT compartment

All the heaters are installed in parallel. The power capacity and the number of
heaters are dependent on the type/model of the switchgear. The typical
ratings for the heaters are given in Table 7-2.

Table 7-2: Heater rating 33 kV switchgear

Heater Location Power Rating
Breaker compartment 120 W
Cable compartment 80 W
CT compartment 80 W

7 ON/OFF
Switch Thermostat
Fuse
L
Heater 3
Heater 1

Heater 2

Link
N

Figure 7-16: Circuit for heater installation inside 33 kV switchgears

 Secondary Equipment 295

7.5.2. Heater for 11 kV Switchgears

7.5.2.1. Heater for 11 kV Switchgears at PPU and SSU
For 11 kV switchgears at PPU and SSU, heaters are installed at 2 locations of
the switchgear:

1. Breaker compartment
2. Cable compartment

Both heaters are installed in parallel. The power capacity and the number of
heaters are dependent on the type/model of the switchgear. The typical
ratings for the heaters are given in Table 7-3.

Table 7-3: Heater rating 11 kV switchgear

Heater Location Power Rating
Breaker compartment 80 W
Cable compartment 80 W

ON/OFF
Switch Thermostat
Fuse
L
7
Heater 1

Heater 2

Link
N

Figure 7-17: Circuit for heater installation inside 11 kV switchgears

 296 Substation Design Manual

7.5.2.2. Heater for 11 kV Switchgears at P/E

For 11 kV switchgears at P/E, heaters are generally installed at the breaker
compartment and cable compartment. However, sometimes a breaker is
installed only at the breaker compartment. The power capacity and the
number of heaters are dependent on the type/model of the switchgear. These
heaters are typically rated at 80 W and 100 W.

7.6. Secondary Wiring

7.6.1. DC Wiring
 DC wiring is the nerve for the control and the protection of station
auxiliaries.

2
Wires of multistrand 2.5 mm grey insulated coloured are used as
standard DC wiring.
 Special tagging is required for tripping circuits whereby the wires should
be labelled with red coloured TRIP tagging.

7.6.2. AC Wiring
 AC wiring is the nerve for all the AC station auxiliaries.
7 
2
Black coloured 2.5 mm wiring 1000 V grade is used for AC circuitries.
 AC wiring should be segregated from DC wiring for fear that induced AC
will be present in the DC system.
 Special attention should be given to CT wiring as it is required to be
colour coded as per the phase that it carries namely RYB and the size of
2
the conductor shall be 4.0 mm . All circuitries are to be numbered for its
usage as per BS 158.
 Secondary Equipment 297

Wiring for measurement

Wiring for tripping circuit

Figure 7-18: Secondary wiring

7.7. Metering
The purpose of metering in the substation is as follows:

1. MV metering 7
(a) For customer taking bulk supply 6.6 kV, 11 kV, 22 kV, 33 kV,
66 kV, 132 kV, 275 kV.
(b) For PMU between transmission and distribution
(c) For PPU between primary distribution medium voltage (33 kV &
275 kV) and secondary medium voltage (22 kV and 11 kV)
(d) For P/E between neighbouring area or ‘Kawasan’
2. LV metering
(a) For customer taking bulk supply more than 100 A
(b) for recording substation use or free units

For metering installations up to 33 kV, CTs and VTs shall be provided and
installed by TNB at TNB's outgoing switchgear. A floor mounted metering
cubicle shall be provided by the consumer in the specified metering room for
the installation of TNB meters.
 298 Substation Design Manual

For LV metering and supply scheme with substation, the meter panel/cubicle
is installed inside TNB substation perimeters (refer ESAH).

Figure 7-19: Typical LV meter wall-mounted in a substation

Table 7-4 shows the comparison between MV metering and LV metering.

Table 7-4: Comparison between MV metering and LV metering.

7 Parameter MV LV

CT operated With PT Without PT

Phase to phase 110 V 415 V

Voltage
Phase to neutral 63.5 V 240 V
5 A (10 A)
Current (max) 5 A (10 A)
1 A (2 A)

Example of MV metering wiring configuration is shown in Figure 7-20.

 Secondary Equipment 299

Metering Panel

Main meter Check meter

kWh/kVARh kWh/kVARh

Voltage
Isolators

Potential Transformer

110 V (Line)

11 kV (Line)
Test
Terminal PT Fuse (PT)
Block

Figure 7-20: MV wiring 7

The main and check meters are located at the front panel of the metering
compartment as shown in Figure 7-21. Main meter is on the left side and
check meter is on the right side.

Feeder Feeder
main meter check meter

Figure 7-21: Typical MV metering panel with main and check meter
 300 Substation Design Manual

7.7.1. Test Terminal Block (TTB)

The Test Terminal Block (TTB) is located inside the Meter Test Box (MTB) in
the metering panel. It is used to isolate the meter from the current source to
perform maintenance works on the meters. The number of TTBs required
depends on the number of feeder, i.e. 1 TTB per feeder.

(a) TTB connections label

7

(b) Installation with wiring inside MTB

Figure 7-22: Test Terminal Block (TTB)

 Secondary Equipment 301

7.7.2. Voltage Isolators

The function of the voltage isolators is to replace fuse to overcome the latter’s
disadvantage in terms of possibility to blow. It is used to isolate the meter
from the current source to perform maintenance works on the meters. The
number of voltage isolators required depends on the number of feeder,
i.e. 6 voltage isolators per feeder.

Figure 7-23: Voltage isolators

7.7.3. Meter Test Box (MTB)

The main function for Meter Test Box (MTB) is to cover and protect the
installation of voltage isolators and the Test Terminal Block (TTB). This Meter
Test Box (MTB) is installed inside the meter panel.
7
The external view of the Meter Test Box (MTB) is shown in Figure 7-24
whereas the internal view is shown in Figure 7-25.

Figure 7-24: Meter Test Box (external view)

 302 Substation Design Manual

Voltage
isolators

Test Terminal
Block (TTB)

Figure 7-25: TTB and voltage isolators inside MTB (internal view)

7.8. Communications
Two types of communication cables exist in TNB, i.e. fibre optics and pilot
7 cables. They are both used for Supervisory Control and Data Acquisition
(SCADA), communication and protection system. Currently, TNB only use fibre
optics for new installation.

Figure 7-26: Cross-sectional view of armoured pilot cable (left) and

an optical fibre cable (right)
 Secondary Equipment 303

7.8.1. Pilot Cable

Typical number of pilot cable pairs currently being used according to
distribution network needs are summarised in Table 7-5.

Table 7-5: Typical no. of pilot cable pairs used in the distribution system
No. of pair used
Voltage No. of pair used for SCADA
No. of pairs for unit
(kV) to RCC
protection
1-2 pairs per
12 pairs
communication loop
11 1 pair
8 pairs for telecontrol &
37 pairs
telecoms
17 pairs for telecontrol
33 37 pairs 1 pair
10 pairs for telecoms

Table 7-6 below shows the diameter resistance and elongation of conductor
in completed cable.

Table 7-6: Diameter resistance and elongation of conductor in completed

cable
Resistance of Overall Diameter
Diameter Conductor/km at Elongation of Insulated
0 7
20 C Conductor
Nominal Max Min Max Min Nominal
mm mm Ω Ω % mm
0.918 0.920 25.32 27.04 18 2.00

Table 7-7 shows the maximum mutual capacitance and capacitance unbalance
with the conductor size.

Table 7-7: Mutual capacitance and capacitance unbalance

Maximum Mutual Maximum Capacitance
Conductor Size
Capacitance Unbalance
mm µF/km pF/161m
0.914 60 200
 304 Substation Design Manual

Table 7-8 shows the core identification for the pilot cable.

Table 7-8: Core identification

Core Core Core
Size Colour Colour Colour
No. No. No.
12 1 Black/Red 2 Black/Blue 3 Black/White
Pairs
4 Black/Green 5 Black/Yellow 6 Black/Brown
7 Black/Grey 8 Black/Orange 9 Black/Violet
10 Red/Blue 11 Red/White 12 Red/Green
37 1 Black/Red 2 Black/Blue 3 Black/White
Pairs
4 Black/Green 5 Black/Yellow 6 Black/Brown
7 Black/Grey 8 Black/Orange 9 Black/Violet
10 Red/Blue 11 Red/White 12 Red/Green
13 Red/Yellow 14 Red/Brown 15 Red/Grey
16 Red/Orange 17 Red/Violet 18 Blue/White
19 Blue/Green 20 Blue/Yellow 21 Blue/Brown
22 Blue/Grey 23 Blue/Orange 24 Blue/Violet
25 White/Green 26 White/Yellow 27 White/Brown
28 White/Grey 29 White/Orange 30 White/Violet
31 Green/Yellow 32 Green/Brown 33 Green/Grey
7
34 Green/Orange 35 Green/Violet 36 Green/Brown
37 Yellow/Grey

7.8.2. Optical Fibre

There are two types of fibre optic used in TNB Distribution Division:

1. Slotted
2. Loose tube

The loose tube type is more preferable as it is easier to do splicing whereas

the slotted type requires a special splicing machine.
 Secondary Equipment 305

Fibre optic cables provide better performance compared to pilot cables. The
reasons behind the use of optical fibre cable as against pilot cables are:

(a) No signal degradation

(b) Immune to electromagnetic interference
(c) No electrical interferences
(d) Higher speed and longer distance coverage
(e) Support more RTUs in a communication loop
(f) Less repeater needed to boost signal for long distance
(g) Better dependability and security
(h) Lower capital costs

Table 7-9 and Table 7-10 show the underground fibre optic cable
specifications and underground fibre optic characteristics.

Table 7-9: Underground fibre optic cable specifications

Particulars Details
Cable sheath material 1. UV resistant
2. Fungus resistant
3. Black colour
Construction 1. Slotted tube or loose tube construction
2. 24 single mode fibres compliant to ITU-T
5 7
G.652.C
3. Resistant to water penetration
4. Non-armoured and non metallic
Cable marking Adequate cable identification and marking
Mechanical properties 1. Proof test (whole length) is 1.0% strain during
≥ 1.0sec
2. Stress corrosion factor (n) is ≥ 18
3. Weibull modulus (calculated from 60% of the
fractures) is ≥ 40
Optical properties Compliant to ITU-T G.652.C

5
Refers to the fibre optic cable that fulfils the needed criteria to support applications
up to capacity of STM-16, and permits the transmission of extended wavelength
between the range of 1360nm to 1530nm.
 306 Substation Design Manual

Table 7-10: Underground fibre optic characteristics

Description Details

Fibre type Silica/Silica doped, Single Mode

 0.40 dB/km at 1310 nm

Maximum attenuation
 0.25 dB/km at 1550 nm
 ≤ 0.35 dB/km at 1310 nm
Average attenuation
 ≤ 0.23 dB/km at 1550 nm

Mode field diameter Peterman II (8.6 µm – 9.5 µm) ± 0.6 µm @ 1310 nm

 1150 nm – 1330 nm (fibre)

Cut-off wavelength
 ≤1260 nm (cable)

Zero dispersion wavelength 1300 nm – 1324 nm

 ≤ 3.5 ps/(nm*km) at 1310 nm

Maximum dispersion/chromatic
 ≤ 18 ps/(nm*km) at 1550 nm
2
Maximum zero dispersion slope 0.092 ps/(nm *km)

125 ± 1 µm
Cladding diameter

Attenuation at bending of fibre

7  Attenuation at 1310nm  ≤ 0.05 dB
for 100 turns, ø40mm
 Attenuation at 1550nm  ≤ 0.05 dB
for 100 turns, ø60mm

7.8.2.1. Cable Sheath

The supplied fibre optic cable is black track resistance high-density
polyethylene. The typical value of the dielectric strength is in accordance to
IEC 60243 test method. Outer sheath surface is smooth with no irregularities.
 Secondary Equipment 307

7.8.2.2. Colour Coding

The fibre cores are colour-coded using ANSI/TIA/EIA-598-A standard colour
codes for ease of identification, as listed in the following table.

Table 7-11: Fibre colour coding

Fibre/Tube no. Colour
1 Blue
2 Orange
3 Green
4 Brown
5 Slate / Grey
6 White
7 Red
8 Black
9 Yellow
10 Violet
11 Rose / Pink
12 Aqua / Turquoise

The fibre core groups for the slotted type cable need to be easily identified by
slot Identification markings.
7
7.8.2.3. Fibre Optics Boundary of Responsibility
TNB Distribution Division has developed fibre optic infrastructure in power
system to replace the pilot cable as a telecommunication medium. In order to
ensure efficient management of the fibre optic infrastructure, TNB
Distribution Division has agreed to hand over the fibre optic infrastructure to
ICT Division (Fibre Optic Distribution Management Charter between ICT
6
Division and Distribution Division, June 2012) . The ICT – Distribution
Operational Boundary is shown in Figure 7-27.

6
Fibre Optic Distribution Management Charter between ICT Division and Distribution
Division, June 2012
 308 Substation Design Manual

Patch panel & Telecommunication

patch tray equipment
Underground
Fibre Optic Cable 110/24 VDC
Power Supply (PPU) MDF/DDF

RTU
Communication Box
RTU Multi-core/
Control Cable
RTU/SCS Equipment 1 Equipment 2

Legend
Distribution
ICT

Figure 7-27: ICT – Distribution operational boundary

7.9. Other Secondary Equipment

7
7.9.1. Earth Fault Indicator
Earth Fault Indicators (EFI) was introduced in the 11 kV underground systems
since 1990 (Arahan Ketua Jurutera Pembahagian 25/90 & 25/90A). The key
objective of the EFI installations is to reduce the restoration time through
identifying the faulty section in the network. Optimal use right placements
and correct installations of the EFI are one of the factors that could contribute
towards achieving the targeted key performance index measured by System
Average Interruption Duration Index (SAIDI). Typical earth fault indicators are
shown in Figure 7-28 and Figure 7-29.
 Secondary Equipment 309

A complete unit of EFI consists of:

 A split-core current transformer – to detect fault current in cable core

 Indicator unit – for indicator unit, they have two functions:
i. Controller box
(a) Consist of DIP switch for EFI setting
(b) Function as a brain of the EFI where the indicator will blink
during fault
ii. LED Lens
(a) Show indications during fault

(a) Soule Bardin (b) Cabletroll 7

CT Ring
EFI Controller box

LED Indicator

(c) Endau

Figure 7-28: Earth Fault Indicator

 310 Substation Design Manual

Figure 7-29: Components inside Earth Fault Indicator

7.9.1.1. Working Principle of EFI

The EFI used in TNB Distribution Division system is designed to operate in a
normally open-ring system with non-automatic feeder switches at all the
distribution substations. It basically consists of two components, a core
balance current transformer and an indication facility.
7
Its current transformer is attached at the outer sheath of the 3-phase
11 kV cable in each installation either at the incoming feeder cable
termination or outgoing feeder cable termination of the substation.

Transformer Controller Box

(EFI)
Switch

Incoming Outgoing

CT

Figure 7-30: Layout location for earth fault indicator (EFI)

 Secondary Equipment 311

7.9.1.1.1. EFI Current Sensor

The EFI current sensor is in the form of a CT ring for the detection unit is an
encapsulated split – core design suitable for embracing the sheath of:


2
3 core cables of conductor section of up to 300 mm
(maximum diameter – 90 mm)

2
3 single core cables of conductor section of up to 500 mm
(maximum diameter – 300 mm)

The current transformer needs to be suitable for use in outdoor installations.

7.9.1.1.2. Detection Unit

The fault passage indicator is required to detect earth fault currents down to a
value of at least 40 A.

The detection relay provides for multiple, discrete user settable earth fault
current pick up values with a minimum range of 40 A to 240 A. It provides for
user settable operation delay time with a minimum range 50 ms to 150 ms.

The detection unit is mountable on the inside or outside wall of an indoor

type substation or on a compact substation. The enclosure should be at least
of protection index IP54 to IEC 529. 7

7.9.1.1.3. Signalling Device

The indicator may be a separate unit in itself or form an integral part of the
whole device.

Indication (light indicator) of the passage of fault current which operates,

remains in operated position until reset. The indicator may be mounted on
the outside wall of an indoor type 11 kV distribution substation or on some
support for an outdoor substation remote from the detection relay.
 312 Substation Design Manual

CT Ring

Figure 7-31: Location of CT ring

7
EFI Controller Box

Figure 7-32: EFI controller box inside P/E

 Secondary Equipment 313

7.9.1.2. EFI Placement

The placement of EFI is recommended to be placed at outgoing feeder of
substations.

7.9.1.3. EFI Installation

The correct installation of EFI current transformer (CT) is shown as follows in
Figure 7-33 and Figure 7-34.

Switchgear body
BADAN PERKAKASUIS
DISEMAK
DILUKIS
TAJUK

Gasket
GASKET
Screw
SKRU
EFI
WILAYAH PAHANG

CLAMP DI KEKALKAN DAN

DISAMBUNG KE BUSBAR
BUMI MELALUI PVC
COPPER 19/064 (35mmp)
Cable Box
CABLE BOX

KE BAWAH MASUK DALAM

CT EFI
DM
S. MOGANADAS

CABLE BOX-4

Socket 200A
TENAGA NASIONAL BERHAD

SOCKET 200A

P/EBUSBAR
earth
BUMIbar
P/E

Socket 200A
SOCKET 200A

GAMBAR 4
Socket 200A
SOKET 200A Cable Gland
CABLE GLAND

BUAH PLUMB ATAS

Through the
DI DALAM CT EFI

CT ring Sheath
SHEATH
TN/
NO. FAIL

CTCT ring
EFI

7
DAERAH TEMERLOH

Conductor from
PENGALIR DARI CT KE EFI

CT to EFI
BUAH PLUMB BAWAH

jumper pvc copper

19/064 (35MMP)

PILC Cable
CABLE Armouring
PERKARA

AMOURING PILC

MOHAN MANON

Figure 7-33: Installation of EFI for PILC cable

 314 Substation Design Manual

Switchgear Body
BADAN PERKAKASUIS
DILUKIS
TAJUK

Gasket
GASKET

Screw
SKRU
WILAYAH PAHANG

P/E earth bar connected

to cable
KE CABLEbox
BUSBAR BUMI P/E DISAMBUNG
TERUS BOX
Cable Box
CABLE BOX
S. MOGANADAS

CABLE BOX-8

Location
LOKASI A A
TENAGA NASIONAL BERHAD

Socket 200A
SOKET 200A
Raychem
RAYCHEM

GAMBAR 8
Location
LOKASI B B

JUMPER PVC COPPER

Braided copper
19/064 (35mmp) ATAU EFI
EFI
NO. FAIL

"BRAIDED COPPER WIRE"

wire
DAERAH TEMERLOH

XLPE cable
KABEL PILC ATAU XLPE

Location
LOKASI C C
PERKARA

MOHAN MANON

Figure 7-34: Installation of EFI for XLPE cable

7.9.1.4. EFI Settings

To ensure that the EFI perform according to its desired function, due care
7 must be given when selecting the right settings for current trip level to avoid
any form of mal-operations i.e. unnecessary/false indication OR no operation.
To avoid these conditions, the following criterion for setting the EFI current
trip level is to be adhered:

𝐼𝐸𝐹 > 𝐼𝑇𝑟𝑖𝑝 > 𝐼𝑇𝐶𝑎𝑝

Where:
IEF = Prospective Earth Fault Current of feeder (minimum case)
ITrip = EFI current trip level setting
ITCap = Downstream capacitive current

ITCap can be determined by multiplying the charging current (IC) of the various
size of cables with the total length of the cables involved downstream from
the location of the EFI.
 Secondary Equipment 315

Table 7-12 shows the values of charging current (A/km) of various sizes of
XLPE and PILC cables as given by manufacturer.

Table 7-12: Charging current per unit length of 11 kV XLPE and PILC cables
(Ic – Data from manufacturer)
XLPE PILC
Charging Charging
2 2
Size (mm ) Rating (A) Current Size (mm ) Rating (A) Current
(A/km) (A/km)
150 280 0.7587 25 80 0.82

240 350 0.9359 70 140 0.9399

500 550 1.2695 120 200 1.1614

185 250 1.3849

300 330 1.6982

7.9.2. Automatic Transfer Scheme (ATS)

A transfer scheme is an electrical switch that reconnects electric power source
from its main source to a backup source. Switches may be manually or
automatically operated. In the TNB distribution MV network, an Automatic 7
Transfer Scheme (ATS) is often installed at SSU with two different sources
which cannot be paralleled but need to be restored within 10 seconds
whenever the main incomer fails.
 316 Substation Design Manual

(a) ATS scheme installed at switchgear

PPU 1 PPU 2
CB 18 CB 1
Multiple
st
P/Es
1 Leg
Main Backup
CB 16675 CB 16678
(PT new installation) (PT new installation)
7
CB 16676 CB 16677 P/E
(PT-existing)

Consumer
(b) Single line diagram

Figure 7-35: Automatic Transfer Scheme without bus section

 Secondary Equipment 317

(a) ATS scheme installed at switchgear

PPU 1 PPU 2

st st
1 Leg 1 Leg

Main Main
CB 14976 Bus section CB 18622
(PT-new installation) open (PT-new installation)

CB 14980 CB 14978 CB 14981 7

NOP CB 14977 CB 14979 NOP
(PT existing) P/E (PT existing)

Consumer substation
(b) Single line diagram

Figure 7-36: Automatic Transfer Scheme with bus section

 318 Substation Design Manual

7.9.3. Supervisory/SCADA Interposing Panel (SIP)

The Supervisory/SCADA Interface Panel (SIP) interfaces the signal from the
Control and Relay Panel (CRP) and switchgear to the RTU in order to enable
supervisory control point explained in Subchapter 7.3 from the remote control
point. The SCADA Interface Panel (SIP) can be either floor standing or wall-
mounted.

RTU

SIP

Figure 7-37: SIP and RTU

 Secondary Equipment 319

(1) (2) (3) (4)

(5)

(6) (7)

(8)

(9) (10)
Description
1 Thermostat
2 Miniature circuit breaker – AC power supply
3 Cubicle illumination lamp
4 Door switch
5 Heater ON/OFF switch
6 Terminal block
7 Terminal block
8 Terminal block (AC bus wiring)
9 Heater
10 Earth bar
Figure 7-38: Supervisory Interface Panel (SIP)
 320 Substation Design Manual

Chapter 8: SCADA System

8.1. Overview
Supervisory Control and Data Acquisition (SCADA) is a concept used to
describe a system that enables control and monitoring of devices or
equipment remotely. In TNB Distribution Division, SCADA systems are used to
assist the operation and management of transmission and distribution of
electricity. The advantages of using SCADA system are optimization of plant
processes, and provide operations that are more efficient, reliable and safer.

The basic overview of a SCADA system is depicted in Figure 8-1. It consists of

three (3) main components:

1. Master System
2. Communication System
3. Remote Terminal Units (RTUs)

A SCADA system consists of a number of Remote Terminal Units (RTUs)

collecting field data and sending data back to a Master System via a
communication system. The Master System displays the acquired data and
also allows the operator to perform remote control tasks.

Master Systems are located in Regional Control Centres (RCC). At present

8 there are four RCCs in Distribution, namely, the Metro and Southern Regional
Control Centres (MSRCC), located in Kuala Lumpur and the Northern and
Eastern Regional Control Centres (NERCC) in Seberang Jaya.
 SCADA System 321

Data
Communication
Communications RTU
system
System

RTU

RTU
Master System Communication System
Remote Terminal Units
(RCC)
Figure 8-1: Overview of SCADA system

Figure 8-2: Metro Regional Control Centre 8

 322 Substation Design Manual

8.2. Master System

The Master System is essentially a network of computer subsystems with
various functions to support the operation of the SCADA based control centre,
as shown in the Figure 8-3. The Master System consists of basic SCADA
functionalities such as data acquisition from Remote Terminal Units (RTUs),
processing of acquired data, supervisory control, user interface functionality
or Human Machine Interface (HMI), historical data processing, trending,
communication with the communication gateway, etc.

Front end
Data

Servers/Back end

Human
Machine
Interface
Printer
Operator’s workstation Operator’s workstation

Figure 8-3: The basic layout of the Master System

8 Functionally, the Master System consists of three (3) main subsystems:

1. Front-end Subsystem
2. Server/Back-end Subsystem
3. Human Machine Interface (HMI) Subsystem
 SCADA System 323

8.2.1. Front-end Subsystem

The functions of the front end subsystem are as follows:

 Manages communication with the Remote Terminal Units

 Responsible for the transmission and reception of raw data to/from the
Remote Terminal Units
 Receives data from Remote Terminal Units, pre-process them and send to
Server/Back-end Subsystem
 Receives control requests from Server/Back-end Subsystem and sends to
Remote Terminal Units

8.2.2. Server/Back-end Subsystem

The Server/Back-end Subsystem contains main SCADA applications and
databases which holds information of all points. It processes control
commands received from the Human Machine Interface (HMI), packages it
and sends to Front-end. It also processes data received from the Front-end
and sends to HMI.

8.2.3. Human Machine Interface Subsystem

The Human Machine Interface (HMI) allows the controller to interface with
SCADA System. It processes controller commands and send to Server/Back-
end Subsystem. It also receives information from Server/Back-end Subsystem
and presents it to the controller either visually on monitors or printers. It also
8
receives alarms and alerts the controller visually and audibly.

Figure 8-4: Human Machine Interface

 324 Substation Design Manual

Additionally, two Distribution Management Systems (DMS) are also

implemented into the Master Systems:

 The first DMS function covers activities and tasks such as Distribution
Operation Analysis, Safety Documents, Operational Document
Management and Operational Planning.
 The second DMS function is the Forced Outage Management Functions,
which include Fault Location, Isolation, and Service Restoration function,
estimation of customer interruption, and Network Normalization
Management.

8.3. Communication System

The SCADA communication system facilitates transfer of data between Master
System (RCC) and Remote Terminal Units (RTU). The communication mediums
are as below:

i. Fibre optic
ii. Pilot cable
iii. Leased lines
iv. GPRS
v. Radio
vi. Microwave
The network topology consists of:

i. Point-to-point
8 ii. Multi-drop
iii. Loop configuration
While the communication schemes are:

i. Polling
ii. Unsolicited reporting

The telecontrol protocols currently implemented are:

i. IEC 60870-5-101
ii. DNP 3.0
iii. Extended WISP+
iv. Harris H6000
 SCADA System 325

The Extended WISP+ and Harris H6000 are required for legacy systems to
support existing RTUs. Whereas the IEC 60870-5-101 protocol is mainly used
to communicate with the newer RTUs installed in TNB’s network.

The Inter-Control Centre Protocol (ICCP) is also implemented as control centre

to control centre communication protocol.

8.4. Remote Terminal Unit (RTU)

A substation installed with a Remote Terminal Unit (RTU) is considered a
remote station. The SCADA equipment in a remote station consists of the RTU
and communication equipment. The RTU collects data from the remote
station, processes and executes control commands from the Master System.

An RTU is a microprocessor-controlled electronic device that interfaces

objects in the physical world to a distributed control system or SCADA by
transmitting telemetry data to the system, and by using messages from the
supervisory system to control connected objects. An RTU monitors the digital
and analogue field parameters and transmits data to the Master System. An
RTU can be interfaced with the Master System with different communication
media and it can support standard protocols.

In TNB substations, the RTU can be classified into two types:

1. Primary RTU for PMU/PPU/SSU 33 kV

8
- RTU cubicle is Floor-Standing type
- DC supply is 110 VDC
- Generally located in Control Room beside Supervisory Interface Panel
(SIP)

2. Secondary RTU for PE/SSU 11 kV

- RTU cubicle is Wall-mounted type
- DC supply is 30 VDC
- Located in the Switchgear Room beside Wall-mounted SIP
 326 Substation Design Manual

Master System

Supervisory Remote
Control and Relay Panel
Interface Panel Terminal Unit

SIP RTU

Figure 8-5: Connection of Control Panels, Relay Panels, SIP and RTU

8.4.1. RTU Requirements

 RTU must have a valid Product Certification / “Sijil Guna Pakai” by TNB.
 RTU and communication module (modem and fibre converter) must
derive its power from the substation’s:
o 110 VDC supply and expected to operate between the range of 95
VDC to 130 VDC for PMU, PPU and 33 kV SSU.
o 30 VDC supply and expected to operate between the ranges of 25 V
8 dc to 40 VDC for 11 kV substations.
 RTU must be equipped with DC power supply surge protector.
 RTU must also be equipped with another surge protector to protect line
communication module (modem & fibre converter) from electrical surge.
 RTU shall be able to support all communication protocols listed below:
- IEC60870-5-101 (balanced and unbalanced mode)
- IEC60870-5-103
- IEC60870-5-104
- DNP3.0
 SCADA System 327

8.4.2. I/O Interface Card

Data and control signals from/to the plant equipment are relayed to/from the
Control Centre via the RTU’s input/output interface card module. The RTU
input/output interface cards can be configurable and modular to suit different
input/output interfaces with various sizes.

The RTU input/output interface cards comprise of three (3) main items as
described below:

1. Digital input is typically a voltage-free normally-open contact at the

plant side. The opening or closing of the contact will indicate a new
status of the plant, e.g. circuit breaker open or close status, link open
or close status, protection relay operation alarms and supervisory or
local switch status & substation DC system alarms.

2. Analog input is typically dc current (4-20 mA) that is usable to the

RTU. The source is normally transformed value of the CT and/or PT
secondary output, converted by transducers. Modern electronic
relays may provide the DC current as well e.g. feeder & transformer
loadings/amps, PT voltages, tap changer positions and temperature.
This analog input may not be available and/or required in some
plants.

3. Digital Output is normally an open contact of interposing relay at the

plant side. The momentary closing of the contact, which energizes
the closing coil of the interposing relay, simulates the operation of a
8
switch. Energizing the voltage of the coil is normally given by the
RTU, from the substation DC voltage supply. Heavy Duty Interposing
Relay is normally used to manage high switching current at the plant
side.
 328 Substation Design Manual

RTU Cabinet
Cabinet Indicators
Lamp
Power Distribution and
Interport Link Module
HX RTC
Module

RTU Input/Output
Module

8 Grounding
Bar

Figure 8-6: Example of an RTU in a Primary Substation

(RTU type: Viscon Dua)
 SCADA System 329

8.5. SCADA-ready Substations

A substation is said to be equipped with SCADA-ready facilities if the plant
equipment has facilities for data acquisition of power system parameters
(derived from plant transducers), breaker status (On/Off), protection relays,
alarms and control of various power system devices (breaker Trip/Close,
motor operated switches Trip/Close and relay reset).

Switchgears, Control Panels, Transformers, Earth Fault Indicators (EFIs), Line

Fault Indicators (LFIs) and their related components such as indication
devices, protection relays and CT/PT outputs are referred to as Plant
Equipment. A SCADA system provides monitoring and control facilities for this
plant equipment from the Control Centre.

A SCADA-ready substation has these facilities wired to an Input/Output

Termination Box at the plant side and the connection from the Input/Output
Termination Box to the RTU via a Supervisory Interface Panel (SIP) or Remote
Control Box (RCB) is known as Plant Interfacing Work.

Generally, in the TNB Distribution Division SCADA system, 11 kV substations

(including P/E, SS and SSU) are referred to as Secondary Stations whereas
33 kV substations (including PMU, PPU & SSU) are referred as Primary
Stations.

Plant equipment in Primary Stations are equipped with SCADA-ready facilities.

However, most of the plant equipment in Secondary Stations are not.
8
 330 Substation Design Manual

Chapter 9: Earthing

9.1. Overview
Earthing may be described as a system of electrical connections to the general
mass of earth.

An earthing system consists of two elements, the earth conductors and the
earth electrodes.

 The earth conductor is a conductor of low impedance which provides an

electrical connection between a given point in equipment (an installation
or system) and an earth electrode.
 The earth electrode is a conductor or group of conductors in intimate
contact with and providing an electrical connection to earth.

9.1.1. Design objectives

In general, there are 3 types of earthing systems:

1. Safety or equipment earthing i.e. to protect human life against excessive

hazardous voltages (touch and step voltages).
2. Power system earthing i.e. to earth the neutral of a system and provide
zero reference voltage.
3. Lightning protection system for effective operation of lightning protection
devices.

The substation earthing system shall meet two main purposes which are:
9 1. To provide means to carry electric currents into the earth under normal
and fault conditions without exceeding operating and equipment limits or
adversely affecting continuity of service.
2. To assure that a person in the vicinity of earthed installations is not
exposed to the danger of critical electric shock.
 Earthing 331

To meet the design objectives and requirements, the design for earthing of all
equipment and the provision of earthing systems and connections shall be in
accordance with the recommendations in the following standards:

 BS 7430 – British Standard Code of Practice for Earthing

 IEEE Std. 80 – IEEE Guide for Safety in AC Substation Grounding
 IEEE Std. 81 – IEEE Guide for Measuring Earth Resistivity, Ground
Impedance, and Earth Surface Potentials of a Ground System

9.1.2. Step and Touch Voltage

When fault current or lightning strikes current flows in the earthing system, a
voltage drop or potential difference is created between the earth electrode
and radiating points from the electrode as shown in Figure 9-1.

As can be seen in the example shown in Figure 9-2, the voltage drops V1, V2,
and V3 etc (known as surface potential) vary according to earth resistance and
the earth current at particular instant of flow.

/ lightning

Figure 9-1: Fault current path to earth and its induced potential gradient
 332 Substation Design Manual

Surface of
earth

Top view of
energised
electrode

V1
V4

V3 V2

Figure 9-2: Top view of surface earthing potential differences

Due to the existence of this potential gradient, two critical potential

differences can be defined:

 Touch voltage – The potential difference between the earth surface on

which a person may stand and the surface of an earthed facility the
person is touching.
 Step voltage – The difference in surface potential experienced by a
person bridging the distance of 1 metre with the feet without contacting
any grounded object.

9
 Earthing 333

Figure 9-3: Critical shock situations

Earthing systems shall have an overall voltage rise, touch voltage and step
voltage that are uniformly distributed and within the allowed tolerances.

The detailed step-by-step calculations to determine the allowable step and

touch voltages can be found in IEEE Std. 80.

9.1.3. Tolerable Current in the Human Body

 The magnitude and duration of a current conducted through the human
body at 50 Hz should be less than the value that can cause ventricular
fibrillation of the heart.
 Ventricular fibrillation is a heart condition that results in immediate arrest
9
of blood circulation.
 Fibrillation current is assumed to be a function of duration of the current
and individual body weight.
 The safety of a person depends on preventing the shock energy from
exceeding the fibrillation threshold before the fault is cleared.
 334 Substation Design Manual

9.2. Earth Connections Above-Ground

Above-ground earthing connections involve the earthing conductors and all
intermediate connections made from a given point in the equipment to an
earth electrode.

Besides using suitable conductor types, the connection method is also

important to ensure proper earthing requirements are met.

The following are the approved types of earthing conductors and connection
methods, followed by above-ground earthing layout for different substations.

9.2.1. Earth Conductors

Earth conductors are used as circuit protective and bonding conductors:

1. Circuit protective conductor:

 The conductors that connect each circuit to ensure that the earth
fault current will return to its source separately.
 Includes conductors that connect the supply neutral to the earth
electrode.
 E.g. metallic sheath of a cable, tin-plated copper braid, copper strips.

2. Bonding conductor:
 These ensure that exposed metallic parts such as metal enclosures of
equipment and other items of conductive material are bonded
together and remain at approximately the same potential during
electrical fault conditions.
 E.g. copper strip.
9
The criteria for selecting the material and sizing of earth conductors are:

(a) Compatibility with material of earth electrode to minimise galvanic

corrosion.
(b) Resistant to corrosion.
(c) Sufficient cross-sectional area to carry maximum earth fault current for a
short time.
 Earthing 335

The following equation is used to calculate the minimum cross-sectional area,

Ac, of an earth conductor. It is in accordance to IEEE Std.80.

Equation (minimum cross-sectional area, Ac)

𝐼
𝐴𝐶 =
𝑇𝐶𝐴𝑃 ∙ 10−4 𝐾 + 𝑇𝑚
∙ ln 𝑜
𝑡𝑐 ∙ 𝛼𝑟 ∙ ρ𝑟 𝐾𝑜 + 𝑇𝑎

Where,

I is the rms current (kA)

2
Ac is the conductor cross section in mm
o
Tm is the maximum allowable temperature in C
o
Ta is the ambient temperature in C
o
Tr is the reference temperature for material constants in C

Ko is the 1 𝛼0 or 1 𝛼𝑟 − 𝑇𝑟 in C
o

αr is the thermal coefficient of resistivity at reference temperature Tr in 1/

o
C

ρr is the resistivity of the earth conductor at reference temperature Tr in

𝜇Ω-cm

tc is the duration of current in seconds

TCAP is the thermal capacity per unit volume from Table 1, pg 42 IEEE
3 o
Std.80, in J/(cm · C)

Alternatively, equation from BS7430 can also be used to determine the

minimum cross-sectional area, S of earth conductor. 9

𝐼 𝑡
𝑆=
𝑘

Where,
I is the average fault current, in Amperes (rms)
t is the fault current duration, in seconds
 336 Substation Design Manual

The rms current density, k, is derived from:

𝑇2 + 𝛽
𝑘 = 𝐾 𝑙𝑜𝑔𝑒
𝑇1 + 𝛽

Where,
o
T1 is the initial temperature, in C
o
T2 is the final temperature, in C

And values of K and β for typical conductor materials are shown in Table 9-1.

Table 9-1: Values of K and β

K β
Metal 2 o
A/mm (rms) C
Copper 226 254
Aluminium 148 228
Steel 78 202

Based on the criteria and calculations for selecting earth conductors, the types
of earth conductors used in TNB are copper strips and tin-plated copper braid.

9
 Earthing 337

9.2.1.1. Copper Strip

 For P/E 11 kV, SSU 11 kV and 11 kV switching room in PMU/PPU:
2
o 70 mm Cu equivalent. e.g. 25 mm x 3 mm
 For P/E 22 kV, SSU 22 kV and 22 kV switching room in PMU/PPU:
2
o 120 mm Cu equivalent
 For SSU 33 kV , 33 kV switching room in PMU/PPU:
2
o 300 mm Cu equivalent e.g. 50 mm x 6 mm

Figure 9-4: Copper strips connecting the supply neutral to earth

(circuit protective conductor)

Figure 9-5: Copper strip for earthing of equipment

(bonding conductor)
 338 Substation Design Manual

9.2.1.2. Tin-plated Copper Braid

 Tin-plated copper braid with minimum cross-sectional area of minimum
2
16 mm

Switchgear body
Gasket
Screw

P/E earth bar

connected to cable box

Lug socket
Heat shrink
Back to PMU
(star point)
Earth
fault
Braided copper wire flow
PILC or
XLPE cable

Earth fault occurring

downstream

Figure 9-6: Braided copper wire connecting cable sheath to earth

Figure 9-7: Copper braid (circuit protective conductor)

 Earthing 339

9.2.2. Connection Methods

 All connections made in an earthing system shall meet the same general
requirements for the conductors used in terms of electrical conductivity
and current carrying capacity.
 The connections shall be strong enough to withstand the mechanical
forces caused by the electromagnetic forces of the maximum expected
fault currents and be able to resist corrosion for the intended life of the
installation.
 Correct connection technique will ensure minimal contact resistance.
 Connection methods to be used for above-ground applications are:
o Brazing
o Bolt and nut

9.2.2.1. Brazing
 Connection is made by heating a piece of Silver Copper Phosphorus
(SilFos) in between two copper plates.
 This method gives a solid electrical and mechanical connection.

Silver SilFos
9

Copper plate

Figure 9-8: Brazing

 340 Substation Design Manual

9.2.2.2. Bolt and Nut

 The copper plate is first drilled to the required size of the bolt, the plate is
then pre-tinned in order to provide a better electrical connection and to
avoid oxidation of the copper before connection is made.
 Brass bolts and nuts are used.
 The bolts and nuts must be tied firmly to give a solid connection
 In order to avoid loose connection over a period of time, jam nuts are
used.

Brass bolt
Brass nut
Lock nut

Pre-tinned copper plate 50 mm

Figure 9-9: Bolt and nut

Jam nut

Figure 9-10: Jam nut

 Earthing 341

9.2.3. Earthing Conductor Layout in Substations

The above ground earthing conductor layouts in substations are designed to
achieve the following:

1) All exposed metallic parts such as metal enclosures of equipment and

other installations of conductive material in the substations are
interconnected
2) Continuity of the earth conductors to the earth electrode so that earth
fault current flow to earth is ensured

9.2.3.1. Earthing at PPU

For complete protection of the equipment and personnel working in a PPU,
earthing conductors must be connected to the following:

(a) Lightning arrestors

(b) Installations:
i. Switchgears
ii. Transformers
iii. Cable sheath of the power cables
iv. Neutral Earth Resistor (NER) and Neutral Earth Isolators (NEI)
v. NER Junction Box
vi. Remote Tap Changer Cubicle (RTCC)
vii. Control and Relay Panel (CRP)
viii. Supervisory/SCADA Interfacing Panel (SIP)
ix. Remote Terminal Unit (RTU)
x. LV AC board
xi. Battery charger

The earthing for lightning arrestors must have dedicated earth electrodes. The
9
lightning earthing electrodes and system earthing electrodes must be bonded
together.
 342 Substation Design Manual

2
All metal parts shall be bonded together using copper strip of 300 mm Cu
equivalent and connected at some points to the earth electrodes. All
connections of earth conductors shall be brazed. The design of the earth
electrodes (i.e. earthing layout below-ground) shall refer to Subchapter 9.3 in
accordance to IEEE Std. 80.

Common earthing layout of a typical one and a half storey PPU is shown in
Figure 9-11 and Figure 9-12 for each floor.

50 x 6 mm
copper tape
to be
concealed
on the floor

50 x 6 mm 50 x 6 mm
copper tape to copper tape to
be buried be buried
9 under ground under ground

Figure 9-11: Earth connection of PPU (Ground floor and cable cellar)
 Earthing 343

Copper tape rise

from floor below

EF-2

EF-3

Copper tape rise

from floor below

Figure 9-12: Earth connection of PPU (First floor)

 344 Substation Design Manual

Table 9-2: Legend for PPU earth connection figures

Symbol Description

1 Copper tape to be buried inside concrete for all doors

2 Earth chamber including earth rod and connector

3 Jointing to the outside

4 Copper tape to be exposed ( 1 ft from finish stone chipping level)

5 Individual chamber not connected to be grid

TC Test clamp

50 mm x 6 mm copper tape to be concealed on the floor

Individual earth chamber

50 mm x 4 mm
copper tape
50 mm x 4 mm copper tape 4 mm DIA. HEX NUT

4 mm DIA. BOLT SEALED

IN WALL O.2 PCD
EQUALLY SPACE
50 mm φPVC CONDUIT/DUCT
5 mm THK. M.S

9 Figure 9-13: Test clamp detail

 Earthing 345

Square Tape Clamp

PVC cover copper

Square Tape Clamp tape from first
floor
Copper Tape to be
450

Ground Level encased on the floor

level

450
Ground Level

Figure 9-14: Square tape clamp

9.2.3.2. Earthing for Indoor Substations

The earthing layout for indoor P/E is shown in Figure 9-15 and Figure 9-16.
Earth conductors shall connect LV neutral bushing, transformer body, RMU
body, feeder pillar body and cable sheaths at termination to the earth rods.
The connections of the earth conductors use either bolted connection or
brazing. All earth rods are connected in parallel with separation of L to 2L,
where L is the length of the earth rod. To achieve the required earth
resistance value of less than 3 ohms, more earth rods can be added in parallel.
The details of earthing layout for indoor P/E are included in the Substation
Design Booklet (Buku Panduan Piawai Baru Rekabentuk Pencawang Elektrik
(Jenis Bangunan) Bahagian Pembahagian, TNB).

9
 346 Substation Design Manual

Feeder pillar Transformer

Switchgear Earthing
point

Doors Earth Chamber

Figure 9-15: Earth Connection of Standalone Indoor Substation – Double

Chamber

Metering room Transformer Switchgear

Earthing
point

Feeder
pillar

9
Entrance Earth chamber

Figure 9-16: Earth Connection of Attached Indoor Substation – Double

Chamber with Metering Room
 Earthing 347

9.2.3.3. Earthing for Outdoor Substation

For outdoor P/E, the earthing layout is shown in Figure 9-17. Earth conductors
shall connect LV neutral bushing, transformer body, RMU body, feeder pillar
body and cable sheaths at termination to the earth rods. The connections of
the earth conductors use either bolted connection or brazing.

Earthing point

Transformer

Switchgear

Feeder
pillar

Earth chamber Door

Figure 9-17: Earth Connection of an Outdoor Substation

9
 348 Substation Design Manual

9.2.3.4. Earthing for Compact Substation

For compact substation, the earthing layout is shown in Figure 9-18. Within
the enclosure, LV neutral bushing, all metallic bodies of the equipment and
cable sheaths at termination are bonded using earth conductors. Typically,
the enclosure is connected to the earth rods via two earthing points, one from
the LV compartment and the other from the RMU compartment. The
connections of the earth conductors use either bolted connection or brazing.

LV
Transformer RMU
Feeder
Pillar

Doors

Earth chamber

Figure 9-18: Earth Connection of Compact Substation

9
 Earthing 349

9.2.3.5. Earthing for SSU

The earthing layout for SSU is shown in Figure 9-19. Earth conductors shall
connect LV neutral bushing, all metallic bodies of the equipment and cable
sheaths at termination to the earth rods. The connections of the earth
conductors use either bolted connection or brazing.

Earthing point

Earth chamber

Figure 9-19: Earth Connection of SSU

9.2.3.6. Earthing for Pole Mounted (PAT) Substation

For PAT, the earthing layout is shown in Figure 9-20. The lightning arrestors
must have dedicated or separate earth electrode or download and connected
to a dedicated earth electrode. Meanwhile, earth conductors shall connect LV
neutral bushing, transformer body and cable sheaths at termination to the 9
system earth electrode. The lightning earthing electrode and system earthing
electrodes must be bonded together.
 350 Substation Design Manual

Lightning arrester

LV neutral

Copper braid
from cable Transformer
termination body

Copper strip

Add more earth

rods in parallel as
and when required
to improve earth
resistance

Earth chamber

9 Earth rod

Figure 9-20: Earth Connection of Pole Mounted Substation (PAT)

 Earthing 351

9.2.3.7. Earthing for Pole Mounted (PAT) Substation with RMU

The earthing layout for PAT with RMU is shown in Figure 9-21 and
Figure 9-22. Earth conductors shall connect LV neutral bushing, transformer
body, RMU body, feeder pillar body and cable sheaths at termination to the
earth electrodes.

LV neutral

Transformer
Copper braid body
from cable
termination

Copper strip

Earth chamber

Add more earth

rods in parallel as 9
and when required
to improve earth
resistance
Earth rod

Figure 9-21: Earth Connection of Pole Mounted Substation (PAT) with RMU
(front view)
 352 Substation Design Manual

Copper braid
from cable
termination
Add more earth Add more earth rods as
rods as and when and when required to
required to improve earth
improve earth resistance
resistance

Copper strip

RMU
Feeder pillar

Earth Chamber

Figure 9-22: Earth Connection of Pole Mounted Substation (PAT) with RMU
(top view)

9
 Earthing 353

9.3. Earth Connections Below-Ground

9.3.1. Earth Electrode

Earth connection below-ground is a system of connected conductors buried in
the earth used for collecting ground current from or dissipating ground
current into the earth. Criteria of earth electrodes:

 Sufficient cross-sectional area to carry the maximum expected fault

current for a short time.
 Good electrical conductivity.
 Corrosion-resistant in soil:
– examples of materials are copper, galvanised steel and cast iron.
 Aluminium is not suitable as earth electrode as it is susceptible to
accelerated corrosion the oxide layer formed is non-conductive.

Typically components for the earth electrode are:

1. Earth rods
2. Earth plates
3. Horizontal conductors

Earth rods must have rigid cores for easy driving-in. The earth electrode used
in TNB is copper-clad steel. Copper-clad steel is used as it has high tensile
strength, copper plating for better conductivity. They are able to reach into
deeper, low resistivity soil with limited excavation and backfilling.
Additionally, they are easy and cheap to install.

Minimum size requirement for the earth rod is:

9
 16 mm diameter x 1.5 m (5 ft) long

Earth rods are protected inside earth chambers as shown in Figure 9-24. The
earth chamber is specified as:

 30 cm x 30 cm (12” x 12”) in size

 Made of concrete
 To allow access to earth rod for inspection and testing
 354 Substation Design Manual

Driving head

Coupler

Earth rod

Coupler

Earth rod

Figure 9-23: Earth rod parts

Figure 9-24: Earth rod chamber and cover

 Earthing 355

9.3.2. Connection Methods

For below-ground, connection method used to connect earth electrodes is the
brazing technique. Bolted connections are not allowed for below-ground
connections.

Exothermic or heat-releasing welding techniques can also be used for below-

ground connections. An example of exothermic welding is the Cadweld®
technique. This connection method provides strong connections, is corrosion-
resistant, and is long-lasting even when exposed to harsh environments.

9
Figure 9-25: Cadweld mould (left) and completed connection (right)

The connection to each earth rod inside the earth chamber is considered as an
above-ground connection. Hence, bolted connections are allowed between
earth conductor and earth rod inside the earth chamber.
 356 Substation Design Manual

9.3.3. PPU Earthing Design

Design must be based on IEEE Std 80 following the following design process:

 acquiring data on the proposed substation and site characteristics

 developing a preliminary design
 calculating the various hazardous voltages at many locations within and
outside the substation to determine the relative safety of the design
 modifying the design as necessary
 recalculating the hazardous voltages to insure the design meets the
objectives
 the process may have to be worked through many times before the
objectives are achieved

Case study calculations of the Bukit Gambir Containerised PPU can be found in
Appendix B. The executive summary and case study results are as follows.

The design of the earthing system for the newly proposed Bukit Gambir CPPU
has been carried out. Preliminary calculations have been performed using the
IEEE Std.80 routines and the final design has been checked using the
specialized earthing software package which is Current Distribution,
Electromagnetic Fields, Grounding and Soil Structure Analysis (CDEGS). The
main parameters and findings are shown in Table 9-3.

Table 9-3: Bukit Gambir CPPU site earthing study findings

Earth resistance 2.51 Ω
Net single-phase-to-earth fault current 1600 A
Earth potential rise (EPR) 4.02 kV
Maximum touch potential within allowable limit yes
9
Maximum step potential within allowable limit yes
 Earthing 357

9.3.4. SSU/PE/PAT/CSU Earthing Design

Typically, the basic layout uses 4 earth rods connected in parallel using copper
strip installed at the corners of the substation. The separations between these
earth rods are in the range of L to 2L, where L is the total length of the earth
rod.

The earth resistance value of the earthing must be less than 3 ohms.

9.3.5. Earth Resistance Measurement

Earth resistance, RE , is the resistance of the earth electrode with respect to
remote/true earth of zero resistance. RE is measured to verify the adequacy of
a new earthing system, detect changes in an existing earthing system,
determine hazardous step and touch voltages and determine the Earth
Potential Rise (EPR).

Legend:
1 – Electrode resistance
2 – Contact resistance
3 – Earth resistance
I – Current

I I 9

Figure 9-26: Earth resistance

Measurement method used in TNB to determine RE is called the fall-of-

potential (FOP) technique.
 358 Substation Design Manual

V
Current
E P electrode C
Potential Current
electrode electrode
x

Electrode
d
being tested

Figure 9-27: Fall-of-Potential (FOP) technique

The FOP involves measurement of voltage and current by using potential and
current probes driven into the earth. RE is calculated from the measured
voltage and current (R = V/I) as a function of distance between the potential
probe and the earth electrode under test, x. This is achieved by moving the
potential probe at a certain distance from current probe which remains fixed.

A typical FOP test result is as shown in Figure 9-28.

Earth Auxiliary Effective

electrode potential resistance areas
under test electrode do not overlap

9
62% of D 38% of D
Auxiliary
Resistance

current
Resistance of auxiliary
current electrode electrode

Resistance of earth electrode

Distance from Y to earth electrode

Figure 9-28: FOP test result

 Earthing 359

According to IEEE Std. 81, the apparent RE value is the resistance at the 61.8%
of the distance between the earth electrode under test and the current probe,
D. This 61.8% rule is credible provided the following are met:

 Adequate probe distances

 Homogeneous soil resistivity
 Identical electrodes

According to IEEE Std. 81, the spacing between the current electrode and the
electrode/earth system being tested, D, shall be minimum 6 to 10 times the
diagonal size of the earthing system of the substation, d (Figure 9-29).

Diagonal distance
Substation
earthing
system

Figure 9-29: Diagonal size of the earthing system of the substation

This may require the use of extended leads for the current and potential
probes as the standard lead’s length provided with earth resistance test
equipment is typically 100 m only. The spacing is required to obtain more
accurate RE as adequate separation will ensure the return current and voltage
measuring points are effectively outside the influence of the earth system to
be tested. If separation is not adequate and effective resistance areas 9
overlap, the test result in Figure 9-30 is obtained leading to inaccurate RE.

Another source of measurement error in FOP is when the return current and
voltage measuring points are within metallic objects inherent of the site such
as buried pipes. In this case, the test equipment will read RE value that is not
the true apparent value. Therefore, the measurement area must keep away
from metallic objects and must minimize their interferences.
 360 Substation Design Manual

Auxiliary Auxiliary
Ground
potential current
electrode
electrode electrode
under test

Overlapping effective
resistance areas
Resistance

Distance from Y to ground

Figure 9-30: FOP test result

9.3.6. Improving Earth Resistance

 Earth resistance of earth electrode must be lower than allowable design
value to achieve effective earthing
 Factors affecting RE:
– Soil resistivity
– Size and type of arrangement of individual earth rods

9.3.6.1. Soil Resistivity

9
 Soil resistivity varies from one soil spot to another depending on:
– Moisture content
– Chemical composition
– Concentration of salt dissolved in contained water
– Grain size and distribution
– Closeness of packing of soil grain

 Low soil resistivity is desirable to achieve low RE

 Earthing 361

 Soil treatment to lower resistivity includes:

– Salt treatment (possible leaching, must be renewed periodically)
– Bentonite (2.5 Ω·m at 300% moisture, not suitable for very dry
environment)
– Chemical-type electrodes (copper tube with salt)
– Ground enhancement materials placed around rod in-hole or around
grounding conductors in trench (e.g. SanEarth, GEM)

 A site with low soil resistivity should be chosen when possible

Figure 9-31: Soil treatment around earth rod to lower soil resistivity
 362 Substation Design Manual

9.3.6.2. Size & Type of Arrangement of Individual Earth Rods

 RE can be reduced by:
– Increasing the length of buried rod (using coupler to connect
additional rod). However this is only effective for soil profile with low
resistivity at the bottom layer.
– Increasing number of rods connected in parallel. Separation of rods
shall be from L to 2L (L is length of rod).

80
Percent resistance of one electrode

Two rod electrodes

3 m long x 15.9 mm diameter
70

60

50

40
0 5 10 15 20 25 30
Electrode spacing, m 0
Figure 9-32: Effect of inter-electrode spacing on combined resistance

9
 Fire Fighting System 363

Chapter 10: Fire Fighting System

10.1. Overview
In case of fire occurring in a substation, a properly designed fire fighting
system is important to mitigate and contain the fire. This chapter aims to
introduce the basic concepts and requirements for TNB Distribution
Substations. Table 10-1 shows requirements for substation fire protection.

Table 10-1: Fire Protection Requirements

Parameters Fire Protection Requirements
Running 24 x 7 1. Collateral Damage IS NOT ALLOWED
2. NO Clean Up Required
Electrical Equipment Extinguishing Agent Shall Be Electrically
NON-CONDUCTIVE
Safety To Human Safety To Personnel:
1. NO Oxygen Deficiency
2. NO Fatality (Lethal)
Extinguishing Agent 1. Immediately Vaporize Upon Discharge
2. Leaves NO RESIDUES
3. Do Not Cause Significant Condensation
Fire Performance 1. Extinguish All Type Classes of Fires (Class A, B
and C) with NO RE-IGNITION
2. Very Fast To Extinguish Fires (Fast Fire Knock
Down)
Operational Issues Capable to Be Refilled On Side to:
1. Minimize Down Time (Post Accidental Agent
Discharged or Post Fire Agent Discharged)
2. Maintain the level of availability of protection at
highest level possible.
Environmental Minimal Impacts On Environment, ODP = 0, GWP
Impacts and ALT are acceptable defined by AHJ (Authority
Having Jurisdiction), DOE (Department Of
Environment) or EPA (Environmental Protection 10
Agency) - USA
 364 Substation Design Manual

10.2. Fire System Requirements for TNB Substations

10.2.1. System Performance Requirements

A system installed within TNB substations must meet specific performance
requirements. TNB fire suppression system performance requirements
include, but are not limited to:

(a) Performance Based Design must be used based on the design fire
scenario for substation fires applied for each particular enclosure, i.e.,
control room, switchgear room and indoors transformer room.

(b) For halogenated agent, the maximum HF by products shall be LESS than
500 ppm. Engineering correlation may be used to estimate the maximum
allowable fire size.

(c) Discharge time shall be as short as possible to extinguish fire efficiently

and to limit further fire damage on protected equipment.

(d) The under/over pressurization in the enclosure due to agent discharge

shall be as low as possible to maintain the integrity of the enclosure
boundaries (minor building modification is permitted).

(e) Pressure relieving vents, located near the finished ceiling, may be
necessary to regulate rapid pressure changes during discharge. Comply
with the manufacturer’s recommended procedures relative to enclosure
venting.

(f) System Design Approval - Prior to installation of a fire extinguishing

system, the system must be certified or approved as compliant to all
TNB’s PSI requirements (ENGR-750-54, ENGR-5202-PSI and ENGR-5203-
PSI)

Table 10-2 and Table 10-3 highlight the extinguishing system performance
parameters and minimum standard requirements for detection system.
10
 Fire Fighting System 365

Table 10-2: Extinguishing Agent System Performance

Parameter Minimum Standard Requirement
Extinguishing Extinguish all fires without re-flash (re-ignition)
Agent  8 AWG, XLPE Cable Fires – 350 Amp Current
 Flammable Liquid Spilled Fire (Pool Fire)
 Fast to Ultra Fast Fire Growth
Agent Less than NOAEL concentration level or Not to exceed
Concentration Maximum PBPK Concentration for 5 minutes
exposure time.
Enclosure Over Less than Lung Damage: 80 kPa (11.6 psi)
Pressure
Acid Gases (HF +  Potential impact for Equipment: Less than 500
CF2O) by-products ppm peak.
 Potential impact for Human: Less than 200 ppm
for 5 minute exposure to human.
Oxygen Level Not below 16% for 5 seconds average
Skin Burns Less than second-degree skin burns:
o 2
< 1316 C-s over 10 seconds or heat flux < 160 kJ/m
o 2
(<2400 F-s over 10 seconds or heat flux < 3.9 cal/cm )
2
Discharge Forces Not to exceed 78 m/s (8g) over 30 ms
Discharge Noise Not to exceed hearing protection level
 With hearing protection: 162 dB
 Without hearing protection: 140 dB
Agent Accidental Not cause collateral damage (Leaves No Residues).
Discharge (No Fire The protected equipments are in good running
Discharged) condition 24 x 7, without any personnel intervention.
Agent Fire  Not cause collateral damage (Leaves No Residues).
Discharged (Post  The un-damage equipments are still in good
Fire Capability) condition and may run (work) 24 x 7.
 Minimal down time to replace the damage
equipment due to fire.
Enclosure Venting Minimal Venting Based On:
and Integrity  500 Pa Structural Strength
 80% Minimum Protected Height During 10 10
Minutes Holding Time.
 366 Substation Design Manual

Table 10-3: Detection System Performance

Parameter Minimum Standard Requirement
Smouldering Fires Cross Zoning Detection Systems
 Photoelectric Smoke Detector with 10 C Rate
o
o
of Rise of Temperature and greater than 40 C
 Ionization Smoke Detector with 10 C Rate of
o
o
Rise of Temperature and greater than 40 C
Flaming Fires Cross Zoning Detection Systems
 Photoelectric Smoke Detector with 10 C Rate
o
o
of Rise of Temperature and greater than 40 C
 Ionization Smoke Detector with 10 C Rate of
o
o
Rise of Temperature and greater than 40 C
Sensitivity Adjustable with minimum 0.5%/ft
Detection Activation  Capability to be activated at range of fire size
from 100 kW to 200 kW, with onset cable
damage at 400 kW fire size.
Maintenance Easy to maintain:
 Intelligent, self diagnostic
 Built-in Drift Compensation
 Field Replaceable Optical Chamber
 Visual indication when time to clean
 False Alarm Immunity

10.2.2. System Design Approval

The certification/approval plan defines the approval requirements for a
system and should provide sufficient overall system detail and description so
that all certification requirements can be adequately assessed and agreed to.
The certification plan includes, but is not limited to, a functional hazard
assessment (FHA), a detailed system description and operation, identification
and means of compliance to each applicable regulatory requirement,
minimum dispatch configuration, certification documentation, and a schedule.

10 ENGR-5202-PSI
ENGR-5206-PSI ENGR-5207-PSI INSTALLATION
ENGR-5203-PSI
 Fire Fighting System 367

A summary of contents from the PSI requirements that are required for
system design approval are as follows.

10.2.2.1.1. ENGR-5202-PSI - Proposed Fire Extinguishing System Design

1. Design Brief
2. Site Survey Report
3. Performance Based Design Analysis
4. Hydraulic Flow Calculation
5. Battery Load Calculation
6. Design Drawing (Shop Drawing)
 Plan Layout Drawing
 Fire Alarm And Detection Systems Layout
 Schematic Diagram - Fire Extinguishing System
 Schematic Diagram – Releasing Agent Control Panel
 Fire Suppression Piping Layout
 Fire Suppression Isometric Diagram
 Cylinder Arrangement and Demarcation Lines
7. Manufacturer Type Endorsement Certificate for Design Analysis

10.2.2.1.2. ENGR-5203-PSI – Materials Specifications

1. Technical Specification of the materials (components) used in the

proposed design conforming to the SGP material list.

10.2.2.1.3. ENGR-5210-PSI – Delivery Quality Assurance and Installation

Quality Control

1. Product Delivery Quality Assurance Certificate issued by third party

appointed by TNB
2. Installation Quality Control Certificate issued by third party
appointed by TNB
3. Testing Commissioning and Acceptance
10
 368 Substation Design Manual

10.2.3. Component Design Requirements

All component used shall be approved (listed) under the following
internationally accredited bodies:

1. Underwriter Laboratories (UL)

2. Factory Mutual (FM)
3. Loss Prevention Certification Boards (LPCB)
4. Vertrauen durch Sicherheit (VdS), German fire protection institute
5. ASME B16.3 (2006) Malleable Iron Threaded Fittings, Classes 150 and 300
6. ASME B16.39 (2009) Standard for Malleable Iron, Threaded Pipe Unions;
Classes 150, 250, and 300
7. ASTM A106/A106M (2010) Standard Specification for Seamless Carbon
Steel Pipe for High-Temperature Service
8. ASTM A53/A53M (2010) Standard Specification for Pipe, Steel, Black and
Hot-Dipped, Zinc-Coated, Welded and Seamless

Defence-In-Depth (DID) philosophy and concept shall be applied:

(a) Minimizing the probability of control panel damage and accidental

discharge due to lightning strike.


220 – 240 VAC
Solenoid Actuator
POWER LINE
LIGHTNING
ARRESTOR SIGNAL LINE
LIGHTNING
ARRESTOR

RELEASING AGENT CONTROL PANEL

BACKUP BATTERIES

The use of Power Line and Signal Line Lightning Surge Arrestor have the
following benefits:
1. Damaging the control panel system components
10 2. Maintain the expected backup batteries life and avoiding the
premature damage.
3. Minimizing the accidental (voluntary) discharge due to lightning
strike
 Fire Fighting System 369

(b) In the case of control panel power loss during fire event, the
extinguishing agent shall be capable to be discharged manually
(redundancy system).

AUTOMATIC INITIATING DEVICES MECHANICAL

MANUAL
DISCHARGE
ACTUATOR

ELECTRIC
SOLENOID
MANUAL INITIATING DEVICES DISCHARGE
ACTUATOR

CYLINDER VALVE

RELEASING AGENT CONTROL PANEL

AC POWER

BACKUP BATTERIES

The discharge system actuation of extinguishing agent shall have two actuation
systems, i.e., electrically and manually. Electrical actuation can be triggered
automatically by system detectors or manually by manual release station
through control panel. The manual mechanical actuation will be the last
survival of the system to enable to discharge the extinguishing agent in the
case of electrical power loss during fire event.

Any proposed system which has no manual mechanical actuation on the

system cylinder will not be considered.

10
 370 Substation Design Manual

10.2.4. Testing Requirements

(a) Blow Off Testing - To ensure that there will be no residual solid
particles inside the discharge piping distribution, which may cause
damage to the protected equipment.

(b) Extinguishing Agent Integrity Testing - To ensure that all

extinguishing agent dispersed and mixed within the enclosure
through discharge nozzle, in order to efficiently extinguish the fire.

(c) System Component Functionally Testing – To ensure the component

functionality as per specification.

(d) Functional System Integrity Testing – To ensure the operation

sequence of the systems as designed.

(e) Room Integrity Testing - To Meet 10 Minutes Minimum Holding Time

to ensure No Re-Ignition.

10.2.5. Guarantee Requirements

The guarantee is for a period of 5 years with an option for another 5 years
subject to the following conditions:

(a) Installations and revisions are done by panel contractor (installer)

possessing the DITCM (Design-Installation-Testing-Commissioning-
Maintenance) Approval from manufacturer having SGP from TNB.

(b) Installations shall be done according to the Installation and Manual

Operation from Manufacturer.

(c) The guaranteed of the goods shall be for an initial period of 1 year,
subject to an annual revision done by the panel contractor and
annually renewed once every revision is done, with maximum
guarantee of 5 years.

10
 Fire Fighting System 371

Within the guarantee period in force, the manufacturer shall warrant the
following conditions:

(a) The extinguishing agent discharge shall be clean, non corrosive and
will not damage to the machinery and equipment, non toxic and will
not harm to human. Under technical advice from manufacturer,
panel contractor (installer) shall be responsible for cleaning, repair
work or replace or pay the damages claimed by TNB on TNB’s assets
which are directly damaged by the voluntary discharge of
extinguishing agent.

(b) The system components supplied shall be genuine, new and

complete system and function within the warranty period. Panel
contractor (installer) shall be responsible for the damages or pay
damages claimed by TNB on TNB’s assets which are directly damaged
from the failure of the system to function during fire.

(c) Within the warranty period, the systems shall not have false
discharge due to the system manufacturing and/or design defect.
Panel contractor (installer) shall be responsible for rectification work
on the system supplied and gas refill due to the false discharge.

10.2.6. Sijil Guna Pakai (SGP)

All fire fighting systems must utilize products that have obtained the
certificate of Sijil Guna Pakai (SGP) from approved panel companies (syarikat
panel).

Products with the SGP are to be installed, commissioned and maintained by

the supplying panel companies for five years after commissioning.

A list of presently approved products with SGP can be found in the Circular
Surat Pekeliling Pengurus Besar Kanan (Pengurusan Aset) Bil. A14/2012
Menggunapakai Khidmat Syarikat Panel dan Produk Sistem Pemadam
10
Kebakaran untuk Bahagian Pembahagian.
 372 Substation Design Manual

10.3. System Components

The fire extinguishing system must be designed, tested and installed to be
compatible with the existing building and substation. Typical fixed fire
extinguishing system consists of:

1. Fire Suppression System Components

2. Fire Alarm and Detection System Components

10.3.1. Fire Suppression System Components

The set of components for the fire suppression system include the
Extinguishing Agent, Master/Pilot Cylinder, Storage Cylinders, Piping Network
including Manifold, Valve Opening Actuation Hoses, Manual Pneumatic
Discharge Lever, Pneumatic Cones, Pressure Gauge, Safety Burst Disk,
Discharge Hoses, Check Valve (Retention Valve), Pressure Switch, Solenoid
Actuator and Discharge Nozzle(s).

10

Figure 10-1: Typical system components and arrangement

 Fire Fighting System 373

7
6

TO PIPE 5
DISTRIBUTION 3
AND NOZZLE(S) 4

2 2 2 1

1. Master cylinder
2. Slave cylinder
3. Solenoid actuator
4. Opening valve connection hose
5. Discharge hoses
6. Manifold
7. Restrictor (pressure reducer only for systems using inert gasses)

Figure 10-2: Arrangement of storage cylinder components

10
 374 Substation Design Manual

10.3.2. Fire Alarm and Detection System Component

The main detection system component is the Releasing Agent Control Panel.
It receives signals from fire detectors and engages the fire suppression
system.

Other components of the fire detection system are Secondary Power Backup
Batteries, Automatic Initiating Devices (Fires Detectors), Manual Initiating
Devices (Manual Release and Abort Stations), Alarm Bell, Sounder
(Horn/Siren) and Strobe (Beacon), Evacuate Sign, Agent Discharge Sign, LED
Beacon.

PENGESAN
KEBAKARAN
ALARM
AUTOMATIC BELL
INITIATING RELEASING AGENT CONTROL PANEL
DEVICE
(ZONE-01) LED
BEACON

ALARM SYSTEM DEVICES

DETECTION SYSTEM DEVICES

HORN
STROBE

AUTOMATIC EVACUATION
INITIATING SIGNAL
DEVICE
(ZONE-02)
PANEL KAWALAN
EVACUATE

MANUAL INITIATING
AC POWER 12VDC BACKUP BATTERY SOLENOID ACTUATOR
DEVICES

BEKALAN ELEKTRIK

Figure 10-3: Releasing agent control panel connections

10
 New Technology 375

Chapter 11: New Technology

11.1. Mobile Equipment

11.1.1. Mobile Power Transformer 15 MVA 33/11 kV

11.1.1.1. Overview
Transformer is the heart of any substation. It provides the power source to
serve vast areas and consumer population including domestic, commercial,
industrial, hospitals, governmental administrative centres and other critical
areas.

During its service life, the transformer needs to be maintained as to prolong

its life and to prevent catastrophic failures. Often the case, shutting down a
33/11 kV transformer for maintenance or repair is almost impossible
especially for areas where supply availability is most critical, for example
administrative, commercial or industrial areas with high loading and limited or
no injection points, islanded system or single transformer substations with no
n-1 capability.

Unexpected failures of the transformer as the result of internal failure, natural

disaster, sabotage or act of terrorism are also possible resulting in system
outage in the surrounding territory. If such failure occurs in the critical areas
described above, then complete restoration of supply to such areas may take
days, resulting in loss of income and serious damage to TNB reputation.

For the reasons mentioned above, many utilities in the world have utilized
mobile transformer simply for its main advantage of fast and rapid
deployment capability. In short, mobile transformer can be used to ensure
supply availability and reliability for the following purposes and conditions:

 Planned maintenance
 Forced outage for transformer repair
 Supply restoration due to transformer failure
 Temporary supply before completion of PPU 11
 376 Substation Design Manual

11.1.1.2. Design

11.1.1.2.1. General Concept

The design of the mobile power transformer is based on the following
concepts:

 Mechanically Robust – To cater for mechanical vibration as the result of

frequent movement along various kinds of terrain profiles and road
conditions.
 Higher Thermal Withstand Capability – To suit for the thermal effect due
to various load condition at different sites.
 Installation Flexibility – To be able to connect, terminate or dismantle
from system easily and fast. Use of more superior or advance technology
for ease of cable laying and connections such as plug-in bushings is being
considered.
 Prolonged Life – To have better or improved design characteristics so
that the transformer can be utilized when needed without failing.
 Environmentally Green – To minimize risk due to pollution of soils and
environment with the consideration of the use of green technology i.e.
synthetic bio-degradable oil for insulation and cooling.
 Ease of Installation & Operation – To possess ability for plug-and-play for
ease of installation, operation and dismantling.
 Safety of Operators – To prevent any potential hazards to the operators
by taking into consideration security and practicality of the design.

11.1.1.2.2. Basic Configuration

The mobile power transformer consists of the following main components

mounted on a trailer:

 15 MVA 33/11 kV Power Transformer

 11/0.415 kV 100 kVA Auxiliary Transformer
 Neutral Earthing Resistor (NER),
 Remote Tap Changer Control (RTCC) Panel

In addition, the mobile power transformer will be fully equipped with a Prime
11 Mover suitable for the application.
 New Technology 377

11.1.1.2.3. Basic Parameters

The basic specification of the power transformer is as shown in Table 11-1.

Table 11-1: Basic technical specification of the Power Transformer

Category Technical Parameter
No. of phases & rated frequency 3-phase, 50 Hz
Short Circuit Impedance 10% at reference temperature of 75°C
Vector Group Dyn11
No-Load Losses at Nominal Voltage 8.5 kW ± 10%
Load Loss at Nominal Voltage Tap 75 kW ± 10%
Maximum Noise Pressure Level 55 dBA
Core Maximum Flux Density 1.6 Tesla
2
Winding Maximum Current Density 2.5 A/mm
Temperature Rise 50°C (Top Oil), 55°C (Winding)
+10% to -15% at 1.67% per step on HV
Tapping Range
winding
Type of Oil Insulation Synthetic Ester Bio-degradable Oil
Type of Cooling ONAN/ONAF
Type of Bushing HV & LV Plug-in Type
Maximum Dimensions 17 x 4 x 5 meters
(incl. Trailer & Prime Mover) (L x W x H)

Similar to the power transformer, the auxiliary transformer will also be using
synthetic ester bio-degradable oil. All other technical parameters are similar
to the specification of a normal distribution transformer.

The NER ratings will follow the basic parameters as listed in Table 6-22
Chapter (NER).

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 378 Substation Design Manual

RTCC

Figure 11-1: Illustration of the proposed mobile power transformer

arrangement showing the main components

11.1.2. Mobile Step-Up Transformer 625 kVA 0.415/11 kV

11.1.2.1. Overview
When power interruption occurs due to power system breakdown or failure
of power equipment, system operators are obliged to restore supply as soon
as possible to ensure SAIDI is below targeted level. In the process, some
operators tend to feed supply into 11 kV network using the existing step down
transformer in order to reduce the number of mobile generators used until
supply is normalized and fully restored. In the case where breakdown
occurred in the rural area, a 500 kW mobile generator may be sufficient to
step up supply to feed a number of substations.

However, the above practice to step up supply using a normally step down
transformer is strictly prohibited by TNB with the issue of the Vice President
Directive No. A14-2008. This is because under normal load flow and normal
voltage regulation condition, use of step down transformer as step up will
work and supply can be fed without any problem. However, problem usually
occurs during line-to-earth fault condition in the 11 kV (delta) side. This is
11
because step down transformer with Dyn11 vector group has no star point on
 New Technology 379

the 11 kV side and therefore the system protection could not detect the earth
fault current to trip the protection device. Under this condition, the faulty
phase will normally approach zero volts but the voltage of the un-faulty
phases will rise by 3 times their phase voltage and give rise to safety
hazards.

11.1.2.2. Use of a Permanently Installed Step-Up Transformer

To solve the issue on using step down transformer for stepping up supply, the
Senior General Manager (Engineering) has issued a circular No. A17-2009 to
give guidelines on the use of permanently installed step-up transformer. The
technical requirement set-up in the circular that need to be complied is as
follow:

i. The vector groups for the step-up transformer shall either be YNd11
or YNd1 or YNyn0. For standardization purposes, the use of YNyn0
vector group is not recommended for new project.
ii. Voltage ratio shall be 0.415/11 kV.
iii. Installation of the step-up transformer shall be at substation on a
spur feeder.
iv. The selected substation shall be installed with added RMU T-off
Transformer Circuit or a VCB.
v. The RMU T-off Transformer Circuit shall be fitted with appropriate
fuses whilst the VCB shall be fitted with appropriate relays.
vi. LV distribution board or feeder pillar may be installed when
necessary.
vii. The capacity of the step-up transformer shall be equal or more than
the capacity of the mobile generator. For example 625 kVA
transformer for 500 kW generator.
viii. The step-up transformer shall be tested and proven healthy for use.

The substation selected for the permanent installation may be at the upper
stream, middle or downstream of the spur feeder depending on the rating
and size of 11 kV cables, logistic and installation suitability, operation and
customer requirement as illustrated in the diagram below:

11
 380 Substation Design Manual

Step up transformer
0.415/11 kV Distribution Board
YNd1 or YNd11 (DB) or Feeder Pillar Mobile
generator set

To LV
customer
Step down transformer
Distribution Board
11/0.415 kV (DB) or Feeder Pillar
Dyn11
To the other
substation

To the other
substation

PE 11/0.415 kV

Figure 11-2: Schematic Diagram of 11 kV network showing substation with

permanently installed step-up transformer

11.1.2.3. Use of a Mobile Step-Up Transformer

11.1.2.3.1. General Concept

Based on the Senior General Manager (Engineering) Circular No. 17-2009

described in Paragraph 3 above, the proposed mobile step-up transformer will
consist of a step-up transformer 625 kVA 0.415/11 kV securely mounted on a
mobile truck or drawbar trailer. Appendix 1 shows the basic layout drawing
for the proposed design.

For the proposed mobile step-up transformer unit, RMU T-off Transformer
Circuit or VCB shall be permanently installed at the selected substation and
will not be part of the mobile step-up transformer unit.

11
 New Technology 381

11.1.2.3.2. Design Concept

The proposed concepts for the design of the mobile step-up transformer are:

 Mechanically Robust – To cater for mechanical vibration as the result of

frequent movement along various kinds of terrain profiles and road
conditions.
 Higher Thermal Withstand Capability – To suit for the thermal effect due
to various load condition at different sites.
 Installation Flexibility – To be able to connect, terminate or dismantle
from system easily and fast. Use of more superior or advance technology
for ease of cable laying and connections such as plug-in bushings may be
considered.
 Prolonged Life – To have better or improved design characteristics so
that the step-up transformer can be utilized when needed without failing.
 Environmentally Green – To minimize risk due to pollution of soils and
environment with the consideration of the use of green technology such
as synthetic bio-degradable oil for insulation and cooling.
 Ease of Operation – To ease in particular, monitoring of the load so that it
shall not exceed the capacity of the step-up transformer or the mobile
generator.
 Safety of Operators – To prevent any potential hazards to the operators
by taking into consideration security and practicality of the design.

11.1.2.3.3. Application

It should be noted that the substation or feeder fed by the mobile generator
through the step-up transformer shall be operated in islanded operation and
isolated from other system or other source of supply.

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 382 Substation Design Manual

11.1.2.4. Rationale for the Use of Mobile Step-Up Transformer and the
Advantages over Permanent Installation
The rationales and advantages for the use of mobile step-up transformer are
as follow:

 The step-up transformer if permanently installed will only be utilized

when major power interruption occurs. Hence, the use of mobile step-up
transformer is practical for effective asset utilization.
 The use of the mobile step-up transformer will give more flexibility for
selection of the substations (indoor or outdoor). This is because the
selected substation for stepping up voltage into the 11 kV network will
only require added installation of either a RMU T-off Transformer Circuit
or a VCB and will therefore solve the issue of space constrain.

Figure 11-3: Illustration the proposed arrangement of the mobile step-up

transformer

11
 New Technology 383

11.1.3. Mobile Compact Sub

The Mobile Compact Substation is basically a compact substation unit (CSU)
that is mounted on a mobile platform. It is designed for the following
purposes:

 Temporary replacement in the event of substation failure due to

transformer or switchgear failure.
 Used for the immediate need of power supply especially for fast track
projects while permanent substations are being constructed.
 Used to fulfil temporary power supply application which require high 3-
phase load.

The capacity of the transformer of CSU is 1000 kVA and further details are the
same as in Chapter 4.6.

Figure 11-4: Mobile compact substation

11
 384 Substation Design Manual

11.2. Energy Efficient Distribution Transformers

11.2.1. Overview
Transformers operate 24 hours a day, seven days a week during which time
they undergo constant losses of 1 to 2% of the electricity that passes through
them. Energy efficient transformers can help to minimize these losses. In
Malaysia, more than 80% of electricity generation is by fossil fuel that
contributed to the CO2 emission. In financial year 2010/11, a total of 0.54
metric tons of CO2 emission was estimated per MWh of electricity produced
by TNB. Thus, by reducing transformer losses, CO 2 emission can directly be
reduced to minimize the global green house effect.

In TNB distribution network, distribution transformers are the third largest

loss-making component after LV and 11 kV overhead and underground cables.
The total losses contributed by distribution transformers throughout the
distribution network are as shown in Figure 11-5.

33kV OH & UG
Distribution cables 0.29%
22kV OH & UG
Transformer
cables 0.10%
1.21%

11kV OH & UG
cables 1.61%
Power
Transformer
0.41%

6.6kV OH & UG
cables 0.06%
LV OH & UG
cables 1.67%
Figure 11-5: Technical losses by components in TNB distribution system

11
 New Technology 385

In order to reduce transformer losses and to achieve overall reduction in

technical losses, TNB had acknowledged the following transformer
technologies. However, the adoption of these technologies will commence
once they are cost effective where the total ownership costs of these
transformers are at least equal to the total ownership cost of the conventional
silicon steel core transformers.

11.2.2. Amorphous Wound Core Transformer

Silicon steel has been used over the years as transformer core material. Silicon
steel like most metals, have a crystalline structure. This means that the atoms
in the structure arrange themselves in an ordered manner. On the other hand,
the atoms in an amorphous metal are not arranged in any ordered structure;
rather they have a tightly-packed, but random arrangement. Amorphous
metal are formed by cooling the liquid material quickly enough to prevent
crystallization; the atoms do not have time to arrange themselves into an
ordered structure. Figure 11-6 shows the structure of crystalline,
polycrystalline and amorphous materials.

Figure 11-6: Structures of crystalline, polycrystalline and amorphous

materials

Amorphous metal contains ferromagnetic elements such as iron, or cobalt

alloyed with a glass former such as of boron, silicon, or phosphorus. These
materials have high magnetic susceptibility, with low coercivity and high
electrical resistance. The high resistance leads to low losses by eddy currents
when subjected to alternating magnetic fields, a property particularly useful in 11
 386 Substation Design Manual

transformers. Typically, core loss can be 70–80% less than with traditional
crystalline materials.

Figure 11-7: Flat wound core and coil assembly of amorphous core
transformer

As explained in Chapter 6.1.5.1, most distribution and power transformers

core construction are typically of stack core type. However, because of the
specific characteristics of amorphous metal i.e. brittleness, sensitivity to
pressure, low saturation, wafer thickness at only 0.025 mm, etc., the
amorphous core is suitable only for wound core and the transformer core
design has to be modified; instead of a three legged core, a three phase
amorphous transformer needs four cores to form a five legged core as shown
in Figure 11-7.

Figure 11-8: Fully assembled oil immersed amorphous core transformer

11
 New Technology 387

11.2.3. Tri-Dimensional Wound Core Transformer

The improvement in the transformer design has led to the introduction of the
tri-dimensional triangular wound core which has changed the existing
configuration of the core and coil assembly of the transformer. The tri-
dimensional wound core comprises of three separate cores which are exactly
the same, allowing symmetrical and identical magnetic circuit in each core.
Each single core of this tri-dimensional core is wound with several trapezoid
shaped grain oriented silicon steel strips continuously in order, avoiding air
gap that cause high resistance due to laminating joints. The cross sectional
area at any point of the core frame is almost a semicircle and with rounded
corners as well as shorter yoke length, high flux density can still be achieved
with less utilization of core material.

Figure 11-9: Structure of tri-dimensional wound core

When fully assembled, the joined sections of the laminated cores form three
identical columns or limbs which are almost perfectly round in shape with
cross sectional filling factor reaching 99%, avoiding magnetic flux distortion at
joined sections. All the above factors contribute to the reduction of no-load
loss by 15 ~ 20% and noise level improvement by 5 ~ 10 dB for the same
silicon steel grade. In addition, for the same cross sectional area of the limb,
the average length of the winding can be reduced by 2 ~ 3% as compared to
the conventional stack core due to the more circular cross sectional area of
the limb as shown in Figure 11-10.

11
 388 Substation Design Manual

Figure 11-10: Cross sectional area of a tri-dimensional core limb (left) and
conventional stack core limb (right)

Figure 11-11: Complete assembly of oil immersed tri-dimensional wound

core transformer showing before tanking (left) and after tanking (right)

11
 New Technology 389

11.2.4. Performance Comparison between Amorphous

Wound Core and Tri-Dimensional Wound Core
Transformers
 The Amorphous Wound Core Transformer has higher energy efficiency
followed by the 3-D Wound Core Transformer as compared to
Conventional Transformer for all loading profiles and sectors as shown in
Figure 11-12.
 The higher energy efficiency of the Amorphous Core Transformer is
mainly due to its very low no-load loss even though its load loss is slightly
higher than the 3-D Wound Core and the Conventional Transformers as
indicated in Table 11-2.
 The results shows that generally the transformers reach their maximum
energy efficiency at 30-50% of their loading capacity.
 The 3-D Wound Core Transformer has relatively lower material utilization
as indicated by its weight for low load loss and noise level performance.
 The Amorphous Wound Core Transformer demonstrated the highest
energy efficiency and reduction for total energy loss and CO 2 emission
followed by the 3-D Wound Core Transformer.

Table 11-2: Main Features of 11/0.433 kV Amorphous Core and Tri-

Dimensional Core Transformers 300 kVA as compared to Conventional
Silicon Steel Core
No-Load Load Noise
Weight
No Transformer Loss Loss Level
(kg)
(watts) (watts) (dBA)
TNB Specified Maximum
- 600 2800 60.0 -
Limit
Conventional Silicon Steel
1 547 2662 58.6 1650
Stack Core
2 Amorphous Wound core 111 2719 44.7 1270
Tri-Dimensional Silicon
3 480 2655 42.0 1124
Steel Wound Core

11
 390 Substation Design Manual

Figure 11-12: All-day efficiency of Amorphous Core and Tri-Dimensional Core

Transformers as compared to Conventional Transformer for all loading
profiles and tariff sectors

11.3. Cast Resin and Synthetic Ester Bio-Degradable

Oil Immersed Transformers

11.3.1. Overview
TNB has been using oil filled transformers in its system. However there are
issues such as fire (flammability) environmental concerns (low
biodegradability), leakage and maintenance associated with these
transformers. These concerns are magnified for those transformers located in
the densely populated areas, public areas, shopping centres, especially when
the substations are attached to the building. Hence, the use of cast resin
transformers and synthetic ester bio-degradable oil immersed transformers
have been approved for use in indoor and outdoor (including pole mounted
and mobile) distribution substations respectively for less flammable and more
11 environmental friendly insulation materials.
 New Technology 391

11.3.2. Cast Resin Transformer

The use of cast resin transformer is recommended in location where the fire
risk associated with the use of mineral oil is considered to be unacceptable,
for example in substation buildings attached to shopping complexes, offices,
apartment buildings, hospitals and the like.

The metal parts of a cast resin transformer account for around 90% of its total
weight. The insulation materials amount to only about 10%. Of this, less than
half can be considered flammable because typically about two-thirds of the
resin compound is silicon dioxide filler (quartz powder) and much of the
insulation material of the LV winding is glass based. Hence not more than 5-
6% of the total weight of the transformer comprises of flammable substances.
In addition, the resin used has typical self ignition temperature of 450 ⁰C at
which the material will start to ignite. Some main features of cast resin
transformer are as follow:

 Uses epoxy resin reinforced with glass fibre which prevents cracking of
epoxy compound even under overload conditions.
 Epoxy resin has excellent electrical properties, low shrinkage, good
adhesion to many metals and resistance to moisture, thermal and
mechanical shock.
 By molding process.

Figure 11-13: Typical Cast Resin Transformers

11
 392 Substation Design Manual

Table 11-3: Main Difference in Construction and Manufacturing Techniques

of Cast Resin Transformers
Parts Main Features Construction/Manufacturing Methods
 Cu or Al round or rectangular shape
Type of Conductor with or without enamel coating
 Cu or Al foil
 Glass fleece layer
 Non-layer glass mat on inner and
Type of Insulation
outer surface
Layer
 Very thin layer or turn insulation
HV Winding Mylar foil
 Vacuum cast quartz powder filled
resin
 Epoxy glass vacuum
Type Embedding
 Epoxy quartz + Al(OH)3
Techniques
 Vacuum cast glass fibre laminated
 Epoxy no vacuum (high risk of
bubbles formation)
Type of Conductor  Cu or Al foil
 Layer insulation pre-impregnated
Type of Insulation
(pre-preg); polyester foil with glass
LV Winding Layer
resin coating
Type of Embedding
 Polymerized by heat treatment
Technique
Note: Cu – Copper
Al - Aluminium

11
 New Technology 393

Table 11-4: Technical Comparison between Cast Resin Transformer and

Hermetically Sealed Oil Immersed Transformer
Hermetically Seal Oil
Criteria Cast Resin Transformer
Immersed Transformer
Yes (mineral oil leakage
Environmental Effect Not polluting
which is not biodegradable)

Temperature Rise
100 K 60 K
Limit

Flash Ignition Temp = Flash point = 150˚C

310˚C (Temperature at which (Lowest temperature at
Flash Ignition Temp/
gases evolve from the which it can vaporize to
Flash point (Liquid)
material can be ignited by a form an ignitable mixture in
spark) air)

Self Ignition Temp/

Fire point = 170˚C
Fire Point (Liquid) Self Ignition Temp
The fire point is the
(Insulating liquid 450˚C (Epoxy Resin)
temperature at which
below ≤ 300°C is = temp at which the material
lubricant combustion will be
considered flammable will spontaneously ignite
sustained
liquid)

Typical Dimension
1590 x 900 x 1750
(L x W x H) 1700 x 950 x 1525
(without enclosure)
mm

Weight 3100 kg (Cu); 3400 kg (Al) 3190 kg (Cu)

The current TNB substation

Ventilation ventilation is sufficient based Normal ventilation.
on CFD study

The replacement of a
The replacement of a winding
Repair winding can only be done in
can be done on site
the factory

Maintenance CBM CBM

11
 394 Substation Design Manual

11.3.3. Synthetic Ester Bio-Degradable Oil Immersed

Transformer
Synthetic ester oils have been used in distribution transformers since 1970s in
the Europe with no reported problems. For power transformer, the synthetic
ester oil has been used in 238 kV power transformer located in Sweden.
Synthetic ester oil being completely biodegradable makes it more
environmentally friendly and thus harmless to marine life. It is typically
manufactured from compounds which are largely sourced from vegetables
and it has proved to be of very low toxicity. In certain cases it has been shown
to be many times less toxic than highly refined petroleum oil. It has a very
high flash point of 310°C and an auto-ignition temperature of 435°C, makes it
less flammable and suitable for use in fire hazards environment.

The dielectric strength of synthetic ester oil is less affected by moisture than
mineral oil. Under normal transformer loading, synthetic ester oil can retain
higher moister content as compared to mineral oil and therefore allow more
migration of moisture from paper insulation into the oil. This “drying”
property can contribute to preserve cellulose life. Furthermore, synthetic
ester is highly stable towards oxidation and the by-products as the result of
aging of synthetic ester oils are less aggressive than mineral oil and hence less
harmful to paper insulation. This property of synthetic ester oils makes it
suitable for use in a free breathing transformer.

However, the synthetic ester oil has slightly higher viscosity as compared to
the mineral oil. This is a disadvantage for efficient cooling and during
impregnation process. In addition, the dielectric strength of synthetic ester
impregnated paper against rms and impulse breakdown voltage is relatively
lower compared to the mineral oil. However, these disadvantages can be
remedied through improved design clearance and modification on the cooling
fins as well as through longer impregnation under vacuum during
manufacturing. DGA can be still used as a condition assessment tool for
synthetic ester oil, but the diagnosis criteria and interpretation need to be
adjusted.

11
 New Technology 395

Table 11-5: Technical Comparison between Synthetic Ester with Other Fluids

Fluids/ Criteria Mineral Oil Silicone Oil Synthetic Ester Natural Ester

BDV (kV)
55 50 70 70
Typical Value
Viscosity (Typical
9.24 40 28 33
Value)
Needs
Design, Needs
modification Prone to
Manufacturing - modification
on cooling Ageing.
and Operational on cooling fins
fins
Safety & Fire
O K3 K3 K2
Classification
Non-Bio Non-Bio Biodegradable Biodegradable
Environmental &
Effect to Effect to No Effect To No Effect To
Health
Health Health Health Health

11.4. RMU CB

11.4.1. Overview
The ring main unit with circuit breaker (RMU CB) is RMU with circuit breaker
function installed at the outgoing feeders. This tripping of the circuit breaker
is controlled by self powered relay. As in a conventional RMU, the incoming
feeder still uses load break switch (LBS) and the transformer T-off feeder still
uses switch-fuse combination with MV DIN fuse.

Features:

 Incomer – Load Break Switch

 Transformer – Switch-Fuse
 Outgoing – Circuit Breaker
 Protection – Self Powered Relay

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 396 Substation Design Manual

RMU CB

Figure 11-14: Single Line of RMU CB

Figure 11-15: Example of RMU CB (Indkom)

11
 New Technology 397

Figure 11-16: Example of RMU CB (Siemens)

Currently, some RMUs used in TNB have circuit breaker function but only for
the transformer T-off feeders. Its tripping function is controlled using time lag
fuse. This kind of circuit breaker is usually of the rotating arc type which has
very limited number of switching operation at rated short circuit breaking
current i.e. 20 kA. Additionally, the integral earth switch in series with this
circuit breaker has rated short time withstand current of 2.1 kA, 1 second.
Therefore, by design this kind circuit breaker cannot be used for outgoing
feeders whereby circuit breaker with more superior performance such as
vacuum circuit breaker is required.

11
 398 Substation Design Manual

Figure 11-17: Example of RMU with CB for transformer feeder (Clockwise

from top: Lucy Sabre VRN2a, Merlin Gerin RN2, Tamco GR1)
11
 New Technology 399

11.4.2. Self Powered Relay

Self powered relay used in the RMU CB is a numerical relay that has three
phase non-directional overcurrent and non directional earth fault protection
with selectable inverse time (IDMT) or definite time for low-set and high-set
stage. It does not require any auxiliary voltage supply and consequently it can
also be used for switchgear without external batteries. It takes its power
supply energy from the CT circuits and provides the tripping pulse energy to
the circuit breaker.

The CTs are installed/mounted on bushings in the cable compartment with

fixed mounting brackets. The electrical clearance and voltage stress
management are ensured to avoid any partial discharge in the CT and bushing
vicinity.

The relay is buffered by a battery for feeding the liquid crystal display as well
as for memorising fault values and reset of the trip relay. Failure of the
battery has no effect on the protective functions of the relay. The battery has
a typical service life of more than 10 years.

The front portion of the relay is protected by a transparent cover and meets
IP54 requirement and hence is suitable for outdoor application.

Figure 11-18: Example of self powered relay (Woodward WIP1)

11.4.3. Configuration of RMU CB

As with conventional RMUs, RMU CBs are non-extensible and are available in
several configurations to suit network requirement. The notation for the
configuration of RMU CB in TNB is given by 3 numerals; first numeral refers to
the number of incoming with LBS, second numeral refers to the number of
switch-fuse/circuit breaker for transformer T-off feeder and third numeral 11
 400 Substation Design Manual

refers to the number of outgoing feeders with circuit breaker controlled by

self powered relay. Examples of typical configurations used in TNB are as
follow:

 RMU CB 101: 1 load break switch + 1 circuit breaker outgoing feeder

 RMU CB 101M: 1 load break switch + 1 circuit breaker outgoing
feeder with energy meter (for border metering)
 RMU CB 111: 1 load break switch + 1 switch-fuse/circuit breaker + 1
circuit breaker outgoing feeder
 RMU CB 121: 1 load break switch + 2 switch-fuse/circuit breaker + 1
circuit breaker outgoing feeder
 RMU CB 112: 1 load break switch + 1 switch-fuse/circuit breaker + 2
circuit breaker outgoing feeder
 RMU CB 102: 1 load break switch + 2 circuit breaker outgoing feeder
 RMU CB 122: 1 load break switch + 2 switch-fuse/circuit breaker + 2
circuit breaker outgoing feeder

11.4.4. Advantages of Using RMU CB

a) Improved fault sectionalising capability
 Reduce the time to find the failures and expedite the restoration of
supply
 Reduce the number of effected customers in tripping especially on
long feeder and worse performance feeder (WPF). This is because
faults occurring downstream of RMU CB will be cleared by the RMU
CB instead of the by the CB at the PPU or SSU further upstream.
 Hence, SAIDI will be improved.
Sebelum

SSU
PMU

Figure 11-19: Single Line Diagram before using RMU CB

11
 New Technology 401

Selepas RMU-CB

PMU

SSU

Figure 11-20: Single Line Diagram after using RMU CB

b) Does not require substation building

 RMU CB can be installed in outdoor P/E substation such as existing
outdoor conventional RMU as it has degree of protection IP54.
 Does not require external LV supply because it uses self-powered
relay and hence battery and battery charger are not required
 Economical due the cost of RMU CB installation is lower than SSU
construction complete with VCB panels, battery and battery charger
 However, SSU construction is more relevant for certain cases. In
cases when SCADA facility is required, external voltage supply is
required for battery and battery charger (DC system) needed for the
motorisation devices, RTU etc.
 To ensure protection coordination is achieved, selection of
substation/placement of RMU CB has to be planned together with
State Protection Unit.

Figure 11-21: RMU CB installed in Outdoor Substation

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 402 Substation Design Manual

11.5. Containerised PPU

11.5.1. Overview
The containerised PPU uses GIS-type for both 33 kV and 11 kV switchgears.
The advantages of this containerised PPU include:

 Suitable for limited land size

 Components are readily installed at the factory, therefore shortening the
construction period as compared to conventional PPU. The typical
duration for commissioning of conventional PPU is 12 months whereas
the duration for the containerised PPU is 6 months.

However, there are several disadvantages such as:

 Space limitation for extension

 Cabin lifespan is shorter than conventional PPU building
 Aesthetically inferior than conventional PPU building

Figure 11-22: Containerised PPU

11
 New Technology 403

Each Containerised Primary Distribution Substation (CPPU) 33/11 kV

7
2 x 30 MVA consists of:

(a) 1 x Pre-fabricated container unit complete with external

walkway/platform housing of about 17 panels of metal-clad 2000 A 25 kA
3 s 11 kV Single Bus-bar GIS with non-withdrawal circuit breaker.

(b) 1 x Pre-fabricated container unit complete with external

walkway/platform housing of about 7 panels of metal-clad 2000 A 25 kA 3
s 33 kV Single Bus-bar GIS with non-withdrawal circuit breaker.

(c) 1 x Pre-fabricated container unit complete with external

walkway/platform housing 11 kV and 33 kV Relay, Control Panels, Charger
and 110 volt DC Battery Banks. The DC Battery Banks are located in a
separate room with proper ventilation to eliminate the risk of vaporised
battery chemicals which may cause corrosion to the equipment.

(d) 1 x Compact substation rated at 11/0.433 kV 500 kVA.

(e) 1 x 11 kV 1600A 50 Hz 4 Ohm Neutral Earthing Resistor (NER) complying

with ANSI/IEEE Std 32-1972 (Reaffirmed 1990)

11.5.2. Engineering Specification

The following engineering specifications are for a conventional and standard
Switchgear & Control Room. However, designs incorporating tried and tested
alternative space saving technology with equivalent or superior performance
and reliability compared to conventional designs are encouraged and
preferred.

8
The CPPU shall have the following features:

7
Design, fabricate, supply, install and commission containerised primary distribution
substation (CPPU) at PPU Jalan Bukit Gambir, for TNB Distribution Pulau Pinang 11
(Volume i)-Part 1: Instruction To Tenderers (ITT)
 404 Substation Design Manual

(a) 33 kV switchgear container

 All 33 kV metal-clad switchgears shall be of Single Bus-bar (SBB) GIS
and non-withdrawal type. These switchgears shall be housed
separately from the 11 kV panels.
 The total number of panels shall be 7:4 feeder panels, 2 transformer
incomer panels, and 1 bus-section panel.
 The feeder earth shall be integrated into the feeder panels.
 Bus-bar earth (LHS & RHS) shall be integrated into the bus-section
panel.

(b) 11 kV switchgear container

 All 11 kV metal-clad switchgears shall be of Single Bus-bar (SBB) GIS
and non-withdrawal type.
 The total number of panels shall be 17:2 transformer incomer panels,
1 bus-section panel and 14 feeder panels.
 The feeder earth shall be integrated into the feeder panels.
 Bus-bar earth (LHS & RHS) shall be integrated into the bus-section
panel.

(c) Insulation compartment

 It is mandatory that all busbars, circuit breaker and the cable
termination be in gas compartments.
 It is also mandatory that the main bus bar and the circuit breaker
compartments be segregated. However, the circuit breaker and cable
termination compartment can be constructed as one.
 It is preferred that the CT and PT are installed in air.

8
Design, fabricate, supply, install and commission containerised primary distribution
11 substation (CPPU) at PPU Jalan Bukit Gambir, for TNB Distribution Pulau pinang
(Volume i)-Part 2c: Technical Specifications (CPPU)
 New Technology 405

(d) Circuit breaker rating is as per the following table.

Table 11-6: Circuit breaker rating for containerised PPU

Type 33 kV 25 kA 3 s 11 kV 25 kA 3 s

1. Feeder 1250 A 630 A

2. Incomer from transformer 1250 A 2000 A

3. Bus section 2000 A 2000 A

(e) Switchgear main bus-bar rating is as per the following table.

Table 11-7: Switchgear main bus-bar rating for containerised PPU

Type 33 kV 25 kA 3 s 11 kV 25 kA 3 s

1. Feeder 2000 A 2000 A

2. Incomer from transformer 2000 A 2000 A

3. Bus section 2000 A 2000 A

11
406 Substation Design Manual

Appendix

Appendix A: Metering Calculations

The resistance of a conductor (with a constant cross-sectional area) can be
calculated from the equation:

𝑅 = 𝜌×𝑙 𝐴 (1)
o
Where, 𝜌 = resistivity of the conductor material (given typically at +20 C)
𝑙 = length of the conductor
𝐴 = cross-sectional area

Table A-1: Resistivity and temperature coefficient for copper (Cu)

o o
Material Resistivity 𝝆 (+20 C) Resistivity 𝝆 (+75 C) Temp. Coefficient 𝜶
–1
Copper 0.0178 μΩ·m 0.0216 μΩ·m 0.0039 K

o
Table A-2: Resistance per one meter cable length (+75 C) for copper
2 2 2
Material 2.5 mm 4 mm 6 mm
Copper 0.00865 Ω/m 0.00541 Ω/m 0.00360 Ω/m

Using the MV wiring connection in Figure 7-20, the worst case scenario is with
o
resistance per cable length at +75 C, maximum secondary current 5 Amps
flowing in the circuit, CT burden is given as 15 VA, while main and check meter
burdens are 1 VA each. The conductor is laid from CT (S1 pin) to the main
meter, then through the check meter, and back to CT (S2 pin). Thus the total
conductor length is 2 x L, where L is the distance from the meter to the CT.
2
With this information, the maximum allowable distance, L, for a 2.5 mm
copper cable can be calculated as follows:

Cable burden = 𝑆 = 𝐼 2 𝑅
Total CT burden − meter burden = 𝐼 2 × 𝜌 × 𝑙 𝐴
15VA − 2 × 1VA = (5 Amps)2 × 0.0216 μΩ ∙ m × 1m/2.5mm2 × 2𝐿
13 = 0.432 × 𝐿
𝐿 = 13/0.432
𝐿 = 30.09 m
 Appendix 407

Appendix B: CPPU Bukit Gambir Earthing Calculations

B.1 Introduction
The Bukit Gambir Containerised Primary Distribution Substation (CPPU) has
been proposed to be constructed next to the existing P/E Bukit Gambir 2.
A consultant has been engaged to design the earthing system for the
substation. This earthing design report is concerned with the following work:

1. Soil resistivity measurements and the derivation of the electrical soil

model.
2. Calculation of the current carrying capability of the proposed earth
electrode.
3. Calculations of the tolerable touch and step potentials.
4. The calculations of earth resistance touch and step potentials based on
IEEE Std.80-2000 routines.
5. Presentation of the proposed earthing design.
6. Validation of the earthing design using a specialist earthing software
package.

Calculations carried out are earth resistance, touch and step profiles for the
whole substation and the surface potential profile of the surrounding area of
the substation.
408 Substation Design Manual

B.2 Site Resistivity

B.2.1 Introduction
The soil resistivity measurements were carried out using the Wenner method.
The measurements were taken on the actual substation site on 1 December
2010. Two measurements traverses were conducted, as shown in Figure B-1.

The traverses were chosen based on the best available land area in order to
maximize the spacing and minimize the likely interference from buried
metallic objects. Both traverses R1 and R2 were conducted using Wenner
spacing of up to 13.5 metres.

R1
R2

Figure B-1: Measurement traverse at substation site

 Appendix 409

B.2.2 Soil Resistivity Measurement Procedure

Soil resistivity testing is the process of measuring a volume of soil to
determine the conductivity of the soil. The resulting soil resistivity is
expressed in ohm-metre (Ω·m) or ohm-centimetre (Ω·cm).

The Wenner 4-point Method is by far the most used test method to measure
the resistivity of soil. Other methods do exist, such as the General and
Schlumberger methods, however they are infrequently used for earthing
design applications and vary only slightly in how the probes are spaced when
compared to the Wenner Method.

A four-terminal earth tester is required, equipped with four short test rods
and connecting leads. The test leads should be checked for continuity and
condition prior to use.

Before carrying out any testing, checks should be made from cable records or
by using above-ground detection equipment, for the location of any buried
cables, earth conductors or metal pipe work. These would adversely affect the
accuracy of the readings taken, particularly if they are parallel to the
measurement traverse. Clearly this will not be an issue at most rural locations.

The traverse locations chosen should be preferably be free of long buried

metal pipes etc., but if this is not possible the measurement traverse should
be as near perpendicular to them as possible. The route chosen should not be
close and parallel to the overhead line support or route. As the line supports
are earthed, then their close presence and the counterpoise will adversely
affect the readings. If the soil resistivity measurement leads are long and in
parallel with an overhead line, then an induced voltage may occur in the leads
should fault current flow through the overhead line. To avoid this,
measurement routes should preferably be at right angles to overhead lines. If
they must be in parallel, then a separation of 20 metres or more from the line
is preferable and the route oriented such as to be at as near rectangular to
the line as possible.

Figure B-2 shows the general measurement arrangement. The four earth rods
should be driven into the ground in a straight line, at distance “a” metres
apart and driven to a depth of “d” metres.
410 Substation Design Manual

Array Centre
X

3a a
a2 2
a a a

Soil Surface
d

Probe

C1 P1 P2 C2

EARTH TESTER

Figure B-2: The Wenner Soil Resistivity Measurement Array

The four earth rods should be connected to the tester, with the outer rods
connected to the C-1 and C-2 terminals, and the inner rods to the P-1 and P-2
terminals.

When the instrument is switched on, there will be an apparent resistance

reading on the meter, which is “R” ohm. The meter should be left on to allow
the build in filters to operate and the value after about 30 seconds should be
fairly constant. The apparent soil resistivity (ρ) is then given by 2πaR Ω·m. If
the value is varying significantly, this may be due to interference, high contact
resistance at the test rods, a damaged test lead or the reading being at the
lower limit of the instruments measuring capability. If, after investigating the
above, the reading is still changing by more than 5%, record a series of ten
consecutive readings over an interval of few minutes, calculate the average
and then proceed with the rest of the measurements.

At least two series of measurements, via traverses perpendicular to one

another should be taken, to allow interference and small local variation
effects to be balanced out. If any readings were unstable, then additional
traverses will be necessary, possibly further away from the site.
 Appendix 411

If the surface soil is very dry, the high contact resistance with the rod will
restrict the flow of test current. To overcome this it is recommended that a
short steel rod, having a smaller radius than the test rod, is driven into the soil
to a depth of 150 mm and removed. A weak solution of saline water is poured
into the hole and the test rod driven in. If this does not provide a satisfactory
reading, the rod may be driven in a little deeper.

A better arrangement is a cluster of three to five rods positioned 250 mm

apart and connected together. Rod clusters like this are normally only
required at long test (“a”) spacings and would introduce an error if used at
small spacings. It is very unusual to require rod depth of more than 0.3 metres
and precautions will be required to ensure that third party equipment or
cables are not damaged if rods are driven to more than 0.2 metres depth.
Their installed depth should never exceed one twentieth of “a”.

Software programs are available for carrying out detailed calculations, based
upon data from the above readings, to provide a “best-fit”, representative soil
model for the area, consisting of a number of vertical and horizontal layers
having different resistivity values.

B.2.3 Results
The result of the measurements taken and their corresponding apparent
resistivities are shown in Table B-3.

Table B-3: Soil resistivity measurement data

Spacing (m) R1 (Ω) ρ(Ω) R2 (m) ρ(Ω·m)
1 21.1 132.59 20 125.68
1.5 14.43 136.02 13.96 131.59
2 10.96 137.75 10.07 126.56
3 6.52 122.92 7.27 137.05
4.5 4.55 128.66 4.59 129.80
6 3.370 127.06 3.4 128.19
9 2.480 140.26 2.3 130.08
13.5 1.609 136.50 1.593 135.14
412 Substation Design Manual

The plot of apparent resistivity of each traverse against inter-electrode

spacing is shown in Figure B-3.

Figure B-3: Plot of apparent resistivity against measurements spacing

A specialist earthing software packaging is used to derive the electrical soil

model for the measurements data acquired. The plot of the measurements
data and the derived electrical soil model is shown in Figure B-4 and the
derived multilayer electrical soil resistivity model and its uniform equivalent
are shown in Table B-4.
 Appendix 413

Legend

Measured result curve 1

Compared result curve 2
Soil model curve 3

RESAP<Bukit Gambir>

Figure B-4: Plot of the soil resistivity measurements data and the derived
electrical soil model

Table B-4: Derived electrical soil model and its uniform equivalent
Layer Resistivity (Ω·m) Thickness (m)
Top 130.6 13.4
Bottom 146.0 ∞
Uniform equivalent 132.8 ∞

B.3 Conductor Sizing

The earth electrodes will have to be able to conduct a current of 25 kA
magnitude for 3 seconds. The following routine, from IEEE Std.80-2000, is
used to calculate the minimum electrode size for the given requirement.
414 Substation Design Manual

B.3.1 Input Parameters

I = 25 RMS Current (kA)

Tm = 450 Maximum Allowable Temperature (Degree Celsius)

Ta = 40 Ambient Temperature (Degree Celsius)

Ko = 242 Ko Factor (Table 1, pg42 IEEE Std.80)

αr = 0.00381 Thermal Coefficient of Resistivity at Reference

Temperature (Table 1, pg42 IEEE Std.80)

ρr = 1.7774 The Resistivity of the Earth Conductor at Reference

Temperature (Ω·m) (Table 1, pg42 IEEE Std.80)

tc = 3 Time of Current Flow (s)

TCAP = 3.422 Thermal Capacity Factor (Table 1, pg42 IEEE Std.80)

Equation (minimum cross-sectional area, Ac)

I
𝐴𝐶 ∶=
𝑇𝐶𝐴𝑃 ∙ 10 −4 𝐾 + 𝑇𝑚
∙ ln 𝑜
𝑡𝑐 ∙ 𝛼𝑟 ∙ ρ𝑟 𝐾𝑜 + 𝑇𝑎

B.3.2 Results
The minimum allowable conductor cross-sectional area is calculated to be
2
203.31 mm . In the present work, the dimension of the earth electrode to be
2
used in 50 mm x 6 mm (cross-sectional area of 300 mm )

B.4 Tolerable Touch and Step Voltages

The tolerable touch and step voltages are calculated using the IEEE Std.80-
2000 routines.

B.4.1 Input Parameters

ts = 0.5 Duration of shock in seconds

ρ = 132.8 Soil resistivity in Ω·m

ρs = 3000.0 Surface layer resistivity in Ω·m (Crushed rock)

hs = 0.15 Surface layer thickness in m (Crushed rock)

 Appendix 415

B.4.2 Results
Surface layer resistivity derating factor,

ρ
0.09 1 −
ρ𝑠
𝐶𝑠 ∶= 1 −
2 ∙ 𝑕𝑠 + 0.09
(Eq 27 pg 23 IEEE Std.80)
𝐶𝑠 = 0.78

Tolerable touch voltage for human with 50 kg body weight in V (no footwear),

0.116
𝐸𝑡𝑜𝑢𝑐 𝑕50 ∶= 1000 + 1.5𝐶𝑠 ∙ ρ𝑠
𝑡𝑠
(Eq 32 pg 27 IEEE Std.80)
𝐸𝑡𝑜𝑢𝑐 𝑕50 = 739.45 V

Tolerable step voltage for human with 50 kg body weight in V (no footwear),

0.116
𝐸𝑠𝑡𝑒𝑝 50 ∶= 1000 + 6𝐶𝑠 ∙ ρ𝑠
𝑡𝑠
(Eq 29 pg27 IEEE Std.80)
𝐸𝑠𝑡𝑒𝑝 50 = 2466.0 V

B.5 Earthing Design

The proposed substation earthing design is shown in the Conclusions and
Recommendations (Section B.10). The earthing system is designed to control
the touch and step potentials, and to link the earth electrodes to the above-
ground metallic equipment and any lighting protection system employed. The
fence of the substation is designed to be separately earthed from the main
earthing system of the substation. For a separately earthed fence, any
equipment earthed to the main substation earth will need to have a minimum
of 2 metre separation distance to the fence (and any metallic object
connected to the fence earth). Also, to protect against touch and step
potential hazards, the entire substation will need to be covered with an
insulation layer; the minimum being crushed rock.
416 Substation Design Manual

The main parameters of the design are shown on Table B-5 below.

Table B-5: Earthing design parameters

2
Substation earthing area 448.2 m
2
Size of earth electrode 50 x 6 mm (300 mm )
Diameter of rod 16 mm
Length of earth electrode 209.3 m
Length of each rod 5.4 m (3 x 1.8 m)
Number of rods 17
Total lengths of rods 91.8 m
Total buried lengths of rods and electrodes 301.1 m
Depth of buried electrodes 0.3 m
Thickness of crushed rock layer 0.15 m

B.6 Earth Resistance Calculations

The earth resistance of the substation is calculated based on the IEEE Std.80-
2000 routine.

B.6.1 Input Parameters

ρ = 132.8 Soil resistivity (average value taken from measurement)
in Ω·m
Lc = 301.1 Total length of all connected grid conductors in m
d1 = 0.036 Diameter of grid conductor in m
b = 0.016 Diameter of earthing rod in m
nR = 17 Number of earth rods placed in area A
Lr = 5.4 Average length of a earth rod in m
h = 0.3 Depth of grid burial in m
a' = (𝑑1 ∙ 𝑕) sqrt(a·2h) for conductors buried at depth h, where a is the
conductor radius
A = 448.2 Area covered by grid
k1 = 1.10 Constant related to the geometry of the system
k2 = 4.8 Constant related to the geometry of the system
 Appendix 417

B.6.2 Results
Resistance of grid conductors,

ρ 2𝐿𝑐 𝑘1 ∙ 𝐿𝑐
𝑅1 ∶= In ′
+ − 𝑘2
𝜋𝐿𝑐 𝑎 𝐴
(Eq 54 pg 66 IEEE Std.80)
𝑅1 = 2.739 Ω

Resistance of all earth rods,

ρ 4𝐿𝑟 2𝑘1 ∙ 𝐿𝑟 2
𝑅2 ∶= In −1+ 𝑛𝑅 − 1
2𝜋. 𝑛𝑅 . 𝐿𝑟 𝑏 𝐴
(Eq 55 pg 66 IEEE Std.80)
𝑅2 = 2.689 Ω

Mutual resistance between the group of grid conductors and group of earth
rods,

ρ 2𝐿𝑐 𝑘1 ∙ 𝐿𝑐
𝑅𝑚 ∶= In + − 𝑘2 + 1
𝜋𝐿𝑐 𝐿𝑟 𝐴
(Eq 56 pg 66 IEEE Std.80)
𝑅𝑚 = 2.325 Ω

Total grid resistance,

2
𝑅1 𝑅2 − 𝑅𝑚
𝑅𝑔 ∶=
𝑅1 + 𝑅2 − 2𝑅𝑚
(Eq 53 pg 66 IEEE Std.80)
𝑅𝑔 = 2.519 Ω
418 Substation Design Manual

B.7 Calculated Touch (Mesh) Voltage for the Earthing Design

The touch (mesh) voltage is calculated based on the IEEE Std.80-2000 method.

B.7.1 Input Parameters

H = 0.3 Depth of grid burial in m

D=6 Spacing between parallel conductors in m

d = 0.036 Diameter of grid conductor in m

ρ = 132.8 Soil resistivity encountered by grid conductors buried in

depth h in Ω·m

n=3 Number of parallel conductors in one direction

Lc = 209.3 Total length of horizontal electrode in m

LR = 91.8 Total length of rods in m

IG = 1600 Net fault current in A

LM = 301.1 Effective buried length, where LM := Lc + LR

B.7.1 Results
Corrective weighting factor that adjust the effect of inner conductors on the
corner mesh:

1
𝐾′𝑖𝑖 ∶= 2
2∙𝑛 𝑛

(Eq 82 pg 93 IEEE Std.80)

𝐾′𝑖𝑖 = 0.303

𝐾𝑖𝑖 = 1

Note: For grids with earth rods along the perimeter, or for grids with earth
rods in the grid corners, as well as both along the perimeter and throughout
the grid area, Kii = 1
 Appendix 419

Corrective factor for grid geometry:

𝐾𝑖 ∶= 0.644 + 0.148 ∙ 𝑛
(Eq 89 pg 94 IEEE Std.80)
𝐾𝑖 = 1.088

Corrective weighing factor that emphasises the effects of the grid depth:

𝑕
𝐾𝑕 ∶= 1 +
𝑕𝑜
𝑕𝑜 = 1 m (grid reference depth)
(Eq 83 pg 93 IEEE Std.80)
𝐾𝑕 = 1.14

Spacing factor for mesh voltage:

1 𝐷2 𝐷 + 2𝑕 2
𝑕 𝐾𝑖𝑖 8
𝐾𝑚 ∶= · In + − + + In
2𝜋 16𝑕 ∙ 𝐷 8𝑑 ∙ 𝐷 4𝑑 𝐾𝑕 𝜋 2𝑛 − 1
(Eq 81 pg 93 IEEE Std.80)
𝐾𝑚 = 0.54

Mesh voltage at the centre of the corner mesh, V:

ρ ∙ 𝐾𝑚 ∙ 𝐾𝑖 ∙ 𝐼𝐺
𝐸𝑚 ∶=
𝐿𝑀
(Eq 80 pg 91 IEEE Std.80)
𝐸𝑚 = 415.0 V

The mesh voltage is calculated to be lower than the allowable touch voltage
limit calculated in Section B.4.2, which is 739.45 V.
420 Substation Design Manual

B.8 Calculated Step Voltage for the Earthing Design

The step voltage is calculated based on the IEEE Std.80-2000 method.

B.8.1 Input Parameters

H = 0.3 Depth of grid buried in m

D=6 Spacing between parallel conductors in m

ρ = 132.8 Soil resistivity encountered by grid conductors buried in

depth h in Ω·m

n=3 Number of parallel conductors in one direction

IG = 1600 Net fault current in A

Lc = 209.3 Total length of horizontal electrode in m

LR = 91.8 Total length of rod in m

B.8.2 Results
The effective buried length of conductors:

𝐿𝑠 ∶= 0.75 · 𝐿𝑐 + 0.85 · 𝐿𝑅
(Eq 93 pg 94 IEEE Std.80)

Spacing factor for step voltage:

1 1 1 1
𝐾𝑠 ∶= + + 1 − 0.5𝑛−2
𝜋 2·𝑕 𝐷+𝑕 𝐷
(Eq 94 pg 94 IEEE Std.80)
𝐾𝑠 = 0.608

Corrective factor for grid geometry:

𝐾𝑖 ∶= 0.644 + 0.148 · 𝑛
(Eq 89 pg 94 IEEE Std.80)
𝐾𝑖 = 1.088
 Appendix 421

Step voltage between a point above the outer corner of the grid and a point 1
metre diagonally outside the grid:

ρ · 𝐾𝑠 · 𝐾𝑖 · 𝐼𝐺
𝐸𝑠 ∶=
𝐿𝑠
(Eq 92 pg 94 IEEE Std.80)
𝐸𝑠 = 597.67 V

The step voltage is calculated to be lower than the allowable limit, 2466 V, as
calculated in Section B.4.2.

B.9 Computer Simulations

The designed earthing system is simulated in a specialist earthing software
package to calculate and verify the design parameters. The layout of the
modelled earth grid is shown in Figure B-5.

Figure B-5: Earth grid layout for CPPU Bukit Gambir

422 Substation Design Manual

B.9.1 Earth Resistant Calculation

The earth resistance of the modelled earth grid has been calculated by the
software to be 2.5126 Ω. This value is close to that calculated using the IEEE
Std.80-2000 routine shown in Section B.5. The main reason for the slight
difference in the results is that the software takes into account the multi-
layered electrical soil model, whilst the calculations in Section B.5 only utilise
the uniform equivalent soil model. The calculations by the software also show
that the earth resistance is lower than 5 Ω, which complies with TNB’s
requirement.

B.9.2 Touch Potential Calculation

The touch potentials are calculated for the whole substation, assuming a net
single-phase-to-earth fault current of 1600 A. The touch potential plot is
shown in Figure B-6. The minimum touch potential threshold is set at
739.45 V, which is the calculated allowable touch potential limit.

Figure B-6: Touch potential plot for CPPU Bukit Gambir

Figure B-6 shows that the touch potentials in the areas where the equipment
will be placed do not exceed the allowable limit.
 Appendix 423

For the purpose of calculating touch potentials for different EPR magnitudes,
the touch potential plot with respect to the percentage of EPR is produced
and is shown in Figure B-7.

Figure B-7: Touch potential plot for CPPU Bukit Gambir (% of EPR)
424 Substation Design Manual

B.9.3 Step Potential Calculations

The step potentials are calculated for the whole substation. The step potential
plot is shown in Figure B-8, which shows the step potential in the substation
as percentages to the substation’s EPR.

Figure B-8: Step potential plot for CPPU Bukit Gambir (% of EPR)

As shown in Figure B-8, the maximum step potential that can be experienced
in and around the substation is 16.61% of the substation’s EPR. Assuming a
net single-phase-to-earth fault current of 1600 A and an EPR of 4020.16 V, the
maximum step voltage which can be experienced in and around the
substation is therefore 667.75 V, which is smaller than the calculated
allowable limit of 2466 V (Section B.4.2). The substation is therefore safe
against step potential hazards.

B.9.4 Surface Potential Calculations

The surface potentials in and around the substation are calculated as a
percentage of the EPR. The resulting contour plot is shown in Figure B-9.
 Appendix 425

SINGLE-ELECTRODE/SCALAR POTENTIALS [ID: BUKIT GAMBIR 3]

LEGEND

MAXIMUM VALUE: 98.28767

150 MINIMUM VALUE: 7.980539

100

LEVEL 3 (60,000)

50
Y AXIS (METERS)

0
LEVEL 2 (25,000)

-50

LEVEL 1 (15,000)
-100
-50 0 50 100
X AXIS (METERS)
Potential Profile (% reference PR)
Figure B-9: Surface potential profile for CPPU Bukit Gambir (% of EPR)

Figure B-9 shows that surface potentials of up to 15% of the EPR can be
experienced up to a distance of 50 m from the edge of the substation earth
grid, as shown by contour Level 1. For an EPR of 4020.16 V, the surface
potential at this distance is 603.0 V.

B.10 Conclusions and Recommendations

B.10.1 Conclusions
The earthing design for CPPU Bukit Gambir has been produced. The earthing
resistance of the substation is calculated to be lower than 5 Ω and the
simulations have shown that the design is adequate for handling touch and
step potentials for a net single-phase-to-earth fault current of 1600 A.
426 Substation Design Manual

Conservative assumptions have been used in the design, where the

calculations have not considered the parallel paths of the fault current. During
a single-phase-to-earth fault a significant portion of the fault current will flow
back to the source via the cable sheath, thus reducing the fault current
flowing to earth. This will result in the substation attaining a lower EPR, touch
and step potentials than that calculated.

B.10.2 Recommendations
1. Install the earthing system as shown in Figure B-10.

2. Cover the whole substation area with insulating material, e.g. crushed
rock.

3. The fence has been designed to be separately earthed from the

substation. It is therefore very important to maintain a minimum
separation distance of 2 m between metallic objects connected to main
substation earth and the fence. These may be in the form of metallic
lamp posts and control panels.

4. The substation has a large prospective EPR which exceeds the ITU limit of
430 V. Precautions will need to be taken against services coming in and
going out of the substation, e.g. water rains, LV supplies and
telecommunication lines.

5. For an EPR of 4020.16 V, sufficient potentials up to 603 V can be expected

up to 50 m from the substation earth grid. The impact of this high
magnitude surface potential in the surrounding areas of the substation
will need to be assessed by TNB.

6. TNB to investigate the suitability of bonding the earthing of CPPU Bukit

Gambir to the earthing system of the adjoining P/E Bukit Gambir 2. This
will result in a reduction of the overall earth resistance and EPR, but other
issues like the possibility of transferred potentials via distribution cable
sheaths will need to be considered.
 Appendix 427

Notes:
1. Conductor for earth Grid is 50 mm x 6 mm copper tape, to be buried at
300 mm below surface level.
2. Base of structures and equipment to be connected to earth grid using
50 mm x 6 mm copper tapes.
3. Connection between copper tapes is by brazing.
4. Earth rod diameter is 16 mm, 3 x 1.8 m long.
5. Connection between electrodes and rods to be carried out in earth pits.
6. Substation area to be covered with crushed rock, 150 mm thick.
7. Minimum 2 m separation required between fence and any earthed
equipment.

Figure B-10: Earth grid layout for CPPU Bukit Gambir

428 Substation Design Manual

Appendix C: IP – Ingress Protection Ratings

Ingress Protection (IP) ratings are developed by the European Committee for
Electro Technical Standardization (CENELEC) (NEMA IEC 60529 Degrees of
Protection Provided by Enclosures – IP Code), specifying the environmental
protection the enclosure provides.

The IP rating normally has two numbers:

1. Protection from solid objects or materials

2. Protection from liquids (water)

IP 3 5

Code Letters
First Characteristic numeral
Second Characteristic numeral

Example – IP35
With the IP rating IP35:

 3 – describes the level of protection from solid objects; in this rating,

enclosure protects from solid objects of 2.5 mm diameter – e.g. a tool
such as a screwdriver.
 5 – describes the level of protection from liquids; in this rating, enclosure
protects against low pressure jets of water from all directions.

An "X" can use for one of the digits if there is only one class of protection, i.e.
IPX1 which addresses protection against vertically falling drops of water e.g.
condensation.
 Appendix 429

First characteristic numeral

Protection against solid foreign objects Degree of protection for
people against access to
I.P Example Tests hazardous parts with:
Protection unspecified
X (untested)

0 Non protection Non-protected

Full penetration of 50 mm
diameter of sphere not
1 allowed. Contact with
Back of hand
hazardous parts not permitted
Full penetration of 12.5 mm
diameter of sphere not
2 allowed. The jointed test finger Finger
shall have adequate clearance
from hazardous parts
The access probe
of 2.5 mm
3 diameter shall
Tool
not penetrate

The access probe of

4 1 mm diameter Wire
shall not penetrate

Limited ingress of dust

Dust
5 permitted (no harmful
protected
deposit)
Wire

6 No ingress of dust Dust tight

430 Substation Design Manual

Second characteristic numeral

Protection against harmful ingress of water Degree of protection
I.P Example Tests from water
Protection unspecified
X -
(untested)
-

0 Non protection Non-protected

Protected against vertically

1 falling drops of water
Vertically dripping

Protected against vertically

falling drops of water with Dripping up to 15˚ form
2 enclosure tilted 15˚ from the vertical
the vertical.

Protected against sprays to

3 60˚ from the vertical.
Limited spraying

Protected against water

Splashing from all
4 splashed from all directions
directions
– limited ingress permitted

Protected against low

pressure jets of water from Hosing jets from all
5 all directions – limited directions
ingress permitted

Protected against strong

jets of water e.g. for use on Strong hosing jets from
6 ship decks – limited ingress all directions
permitted

Protected against the

7 effects of immersion Temporary immersion
between 150 mm and 1 m

Protected against
8 continuous submersion at a Continuous immersion
specified depth.
 Appendix 431

List of Abbreviations
ABC Aerial bundled cables
AC Alternating Current
AHJ Authority Having Jurisdiction
AIS Air Insulated Switchgear
Al Aluminium
ALF Accuracy Limit Factor
ASME American Society of Mechanical Engineers
ASTM American Society for Testing and Materials
ATS Automatic Transfer Switch
AVR Automatic Voltage Regulator
AWG American Wire Gauge
BS British Standards
CB Circuit Breaker
CDG Circular Disk Gear
CPPU Containerised Primary Distribution Substation
CRP Control & Relay Panels
CSU Compact Substation Units
CT Current Transformer
CTC Continuous Transposed Cable
Cu Cuprum
DC Direct Current
DID Drainage and Irrigation Department
DIN German Institute for Standardization /Deutches Institut fur
Normung
DITCM Design-Installation-Testing-Commissioning-Maintenance
DMS Distribution Management Systems
DNP Distributed Network Protocol
DOE Department Of Environment
DPC Damp-Proof Course
EDO Expulsion Drop-Out
EFI Earth Fault Indicator
432 Substation Design Manual

ELCB Earth Leakage Circuit Breaker

EMF Electromagnetic Field
ENGR Engineering
EPA Environmental Protection Agency
EPR Earth Potential Rise
ESAH Electricity Supply Application Handbook
FHA Functional Hazard Assessment
FM Factory Mutual
FOP Fall-of-Potential
FP Feeder Pillar
G.I Pipe Galvanized Iron Pipe
GIS Gas Insulated Switchgear
GPRS General Packet Radio Service
GWP Global Warming Potential
HDPE High Density Polyethylene
HFU Housing Fuse Unit
HMI Human Machine Interface
H-Pole Pole Mounted Substations
HRC High Rupture Capacity
HV High Voltage
HX RTC HX Remote Terminal Controller
ICCP Inter-Control Centre Protocol
IEC International Electrotechnical Commission
IED Intelligent Electronic Device
IEEE Institute of Electrical and Electronic Engineers
IOM Interconnection Operation Manual
IP Ingress Protection
ISO International Organization for Standardization
LBS Load Break Switch
LCP Local control panel
LFI Line Fault Indicator
LHS Left Hand Side
LILO Loop-in, loop-out
LPDC Loss Prevention Certification Boards
 Appendix 433

LV Low Voltage
LVAC Low Voltage AC
M&E Management and Engineering
MCB Miniature Circuit Breaker
MDPE Medium Density Polyethylene
MDU Motor Drive Unit
MSB Main Switch Board
MTB Meter Test Box
MV Medium Voltage
NER Neutral Earth Resistance
NOAEL No Observable Adverse Effect Level
NTL Non-Transferable Load
OCEF Over Current Earth Fault
OCTC Off-Circuit Tap Changer
ODP Ozone depletion potential
OLG Oil Level Gauge
OLTC On-Load Tap Changer
PAT Pencawang Atas Tiang / Pole Mounted Substation
PBPK Physiologically-based Pharmacokinetic
PE Pencawang Elektrik / Distribution Substation
PECU Photoelectric Control Unit
PF Power Factor
PMU Pencawang Masuk Utama / Main Intake Substation
PN6 Pressure Nominal 6 – max pressure 6 bar
PPU Pencawang Pembahagian Utama / Primary Distribution
Substation
PRD Pressure Relief Device
PSI Process System Improvement
PT Potential Transformer
PVC Polyvinyl Chloride
RC Reinforced Concrete
RCB Remote Control Box
RCC Regional Control Centre
REF Restricted Earth Fault
RHS Right Hand Side
434 Substation Design Manual

RMU Ring Main Unit

RMU CB Ring Main Unit with Circuit Breaker
RTCC Remote Transformer Control Cubicle
RTU Remote Terminal Units
S/S Stesen Suis / Switching Station
SAIDI System Average Interruption Duration Index
SAVR Sesalur Atas Voltan Rendah
SBB Single Bus-Bar
SBEF Stand by Earth Fault
SCADA Supervisory Control And Data Acquisition
SF6 Sulphur hexafluoride
SGP Sijil Guna Pakai
SILFOS Silver Copper Phosphorus
SIP SCADA Interface Panel
SPCC Spill Prevention Control and Countermeasures
SSU Stesen Suis Utama / Primary Switching Station
SWA Steel Wire Armoured
SWG Standard Wire Gauge
TTB Test Terminal Block
UL Underwriter Laboratories
uPVC Unplasticised Polyvinyl Chloride
VA Volt-Ampere
VAR Volt-Ampere Reactive
VCB Vacuum Circuit Breaker
VDC Voltage Direct Current
VdS German fire protection institute/Vertrauen durch Sicherheit
VT Voltage Transformer
WISP+ Wireless Internet Service Provider
XLPE Cross-link Polyethylene
 Appendix 435

Glossary
Annunciators An indicator showing remotely whether each of several
items is in the required position or state or not, e.g. door
signal with automatic doors or lamp indicating any of
several abnormal conditions
Bio-degradable Biodegradation or biotic degradation or biotic
decomposition is the chemical dissolution of materials
by bacteria or other biological means
Busbar Low-impedance conductor to which several electric
circuits can be connected at separate points
Bushing Device that enables one or several conductors to pass
through a partition such as a wall or a tank, and insulate
the conductors from it.
Carcinogenic Any substance, radionuclide, or radiation that is an agent
directly involved in causing cancer
Clearance Shortest distance in air between two conductive parts
Creepage distance Shortest distance along the surface of a solid insulating
material between two conductive parts
Discrepancy Switch A switched indicator, with an acknowledgement facility,
which shows any discrepancy between the actual and
indicated state of the equipment being monitored
Double Busbar Substation A substation in which the lines and transformers are
connected via two busbars by means of selectors
Earth Resistance The resistance existing between the electrically
accessible part of a buried electrode and another point
of the earth, which is far away
Heat Shrink Mechanically expanded extruded plastic tube ordinarily
made of nylon or polyolefin, which shrinks when heated
in an effort to return to the relaxed diameter it originally
had when extruded
Incoming Feeder In a substation a feeder bay which is normally used to
receive power from the system
Interlock A device used to help prevent a machine from harming
its operator or damaging itself by stopping the machine
when tripped
Internal Arc The result of a rapid release of energy due to an arcing
fault between phases, neutral or a ground
Magnetostriction Reversible deformation of a body due to magnetization
arising from an applied magnetic field
436 Substation Design Manual

Main Busbar In a double busbar substation, any busbar which is used

under normal conditions
Mimic Diagram An arrangement of symbols representing the current
state of switchgear and lines of a substation (network)
and which may be updateable and may have control
functions
Outgoing Feeder In a substation a feeder bay which is normally used to
transmit power to the system
Photoelectric Applies to electrical phenomena caused by absorption of
photons
Plinth a usually square block serving as a base; broadly: any of
various bases or lower parts
Pole-mounted Substation An outdoor distribution substation mounted on one or
more poles
Premix Something that is mixed or blended from two or more
ingredients or elements before being marketed, used, or
mixed further
Relay Relating to, or having the characteristics of, an auxiliary
apparatus put into action by a feeble force but itself
capable of exerting greater force, used to control a
comparatively powerful machine or appliance
Reserve Busbar In a double busbar substation, any busbar which is used
under abnormal conditions. It is generally less well
equipped than a main busbar
Ring Substation A single busbar substation in which the busbar is formed
as a closed loop with only disconnectors in series within
the loop
Semaphore Indication of 'Close' and 'Open' position of circuit
breakers, isolators and earth switches shall be
incorporated in the mimic diagram
Short Circuit A low-resistance connection established by accident or
intention between two points in an electric circuit. The
current tends to flow through the area of low resistance,
bypassing the rest of the circuit.
Silmalec Aluminium alloys containing magnesium and silicon, the
two latter ingredients acting as hardeners and can be
heat-treated.
Single Busbar Substation A substation in which the lines and transformers are
connected to one busbar only
Soil Resistivity Function of soil moisture and the concentrations of ionic
soluble salts and is considered to be most
comprehensive indicator of a soil’s corrosivity
 Appendix 437

Spur Connection Feeder to which subscriber's taps or looped system

outlets are connected
Step-down Substation A transformer substation in which the outgoing power
from the transformers is at a lower voltage than the
incoming power
Step-up Substation A transformer substation in which the outgoing power
from the transformers is at a higher voltage than the
incoming power
Substation The part of a power system, concentrated in a given
place, including mainly the terminations of transmission
or distribution lines switchgear and housing and which
may also include transformers. It generally includes
facilities necessary for system security and control (e.g.
the protective devices)
Switching Substation A substation which includes switchgear and usually
busbars, but no power transformers
Switchyard Typically found in AIS PMU and Outdoor PPU, it contains
the air insulated switching installations
Tracking The progressive degradation of the surface of a solid
insulating material by local discharges to form
conducting or partially conducting paths
Transducer A device capable of being actuated by one or more input
quantities and of supplying output quantities related to
the input quantities, but of different physical nature
Vector Group Indicates the phase difference between the primary and
secondary sides, introduced due to that particular
configuration of transformer windings connection
Ventricular Fibrillation Heart rhythm problem that occurs when the heart beats
with rapid, erratic electrical impulses
Viscosity A measure of the resistance of a fluid which is being
deformed by either shear stress or tensile stress.