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CIGRE 2012

Design Experience of 230/115/69kV Substation Refurbishment / Extension

Project in Philippine Grid Network
M.S. LEE, J.W. JUNG, S.Y.YEO, C.S.LEE, J.B.KIM
Hyosung Corporation
Republic of Korea
Rico Vega
National Grid Corporation of the Philippines

SUMMARY
Recently, for the purpose of power grid expansion, old equipment upgrade/updating and substation
refurbishment/extension project are increasing in the world. Even though, the portion of GIS
substation is increasing up to now, still conventional type AIS substation are main type substation in
the world due to issue of GIS maintenance time, spare component compatibility and project cost.
Therefore, many AIS substations are being maintained through refurbishment, upgrade and extension
of existing substation using AIS equipment. However for sites where land is scarce GIS is becoming
more and more popular for complete renewals of substations. Using GIS can make the renewable work
much easier thanks to the very small footprint of GIS. In addition the outage can be kept to a minimum
if the new GIS can be built, while keeping the old station in service. The only necessary outage would
then be when changing over the objects to the new GIS.
End of 2010, asset owner National Grid Corporation of Philippines (NGCP) issued the substation
refurbishment/extension project and Hyosung are now working with the construction. This paper
describes some issues considered during design of this project, such as transformer power capacity
growth, main equipment dismantling and new secondary system integration into existing system.
It can be expected that these kinds of projects will increase more and more in the world to achieve
the grid expansion as well as system maintenance. So careful consideration shall be given to minimize
the design error, and this contribution will be helpful to approach future similar projects. Furthermore,
more issues and experience during engineering design and execution will be shared for future project.

KEYWORDS
Substation, Air Insulated Switchgear, Turnkey Project

gabbamin@hyosung.com

1. Introduction
The demand of electric power is increasing due to rapid growth of economy in the world. Even
though there are issues about Euro zone economic crisis and political issues in the Middle East, it is
expected that the electric power demand will increase more than the increase of installed capacity.
The increase of electric power demand has influenced the generation, transmission and distribution
market, and the importance of substation part is increasing. Actually the numbers of new substation
projects are increasing with refurbishment, replacement and extension project of existing substation
due to the electric power demand growth and aged facility. AIS (Air Insulated Switchgear) is still the
main type of substation design, even though GIS (Gas Insulated Switchgear) was applied to the
substation about 40 years ago. The reason for this is limited GIS capability, compatibility problem of
spare part and long maintenance time. So, it can be expected that the number of AIS substations will
increase and it is emerging issue of engineering design considering interface with existing control,
protection system and limited shutdown schedule in the refurbishment / extension project.
From this back ground, the turn-key base contracts, where one contractor is responsible for
equipment procurement, design, engineering, transportation, erection to test & commissioning is
increasing in the Middle East region. The first major success factor of turn-key projects is low cost,
customizing and engineering to propose system interface. The second one is procurement ability
through partner-ship with skilled manufacturers. And the third one is risk management ability, within
the limited project budget and contract period, learned from various project experiences in the world.
Hyosung have delivered high voltage equipment to several hundred of substations in the world as a
manufacturer and executed AIS / GIS turn-key projects at the 15 countries.
In this paper, the following issues will be discussed, which are dealt with during project execution
like transformer power capacity growth, check point during main high voltage equipment dismantling,
transportation, test and system integration of existing secondary system into new system applying IEC
61850 protocol.
2. Project Outline
The following Luzon, San Esteban & Laoag and Bohol projects are turn-key contracts for substation
refurbishment, and extension including electrical, civil, structural, architectural and mechanical
portion task at the 9 sites in the Philippine Luzon and Visaya grid. Especially existing high voltage
equipment is planned to be dismantled from existing M substation located in Luzon grid and will be
transported to each site to execute the reinstallation, test & commissioning work together with new
delivered equipment. This means that, the design and engineering of the substations was done after
careful study of existing equipment and system.

Figure 1. Substation Location in Luzon and Visaya Grid

Luzon expansion project: Substation refurbishment and extension project for 7 sites in the
Luzon Grid
San Esteban Laoag project: Substation refurbishment and extension project for 3 sites in the
Luzon grid.
Bohol Backbone project: One new substation project and one extension project in the Visaya
grid.

The details of the project scope of work can be categorized as below.

1) Design, manufacturing, factory testing, supply, delivery, installation, field test & commissioning of
the Substation HV Equipment and Control & Protection equipment including Installation material.
2) Furnishing of labor, equipment, materials and tools for transporting from M S/S, re-installing, test
& commissioning of the existing substation equipment.
3) Furnishing of labor, equipment, materials and tools for the dismantling and re-installation, test &
commissioning of the existing substation equipment.
4) Manufacturing, supply, delivery, installation/erection of the 3 sets 230kV and 9 set 69kV
transmission line towers including installation material.
3. The Solution for main issue
3.1 Review and modification work caused from TR power capacity growth
The 100MVA transformer at the Cabanatuan substation under Luzon expansion project was
replaced with one of 300MVA capacity. The increase of capacity, lead to the following increase in
weight of transformer, foundation size and rated current.
Table 1. Existing and new transformer specification
Existing TR
New TR
Voltage
230/69/13.8 kV
230/69/13.8 kV
Capacity
100 MVA
300 MVA
Total Weight (pu)
1.0
1.46
Foundation Size
4000mm x 7000mm
5000mm x 8000mm
Rated Current (69kV Base)
837A
2510A
So, next two issues should be considered to complete the project and report as below. The existing
transformer foundation was decided not to utilize, so new foundation was designed and constructed.
3.1.1 Layout modification considering insulation clearance
Refer to Fig.2, the space for surge arrester installation on transformer high voltage side was reduced
due to increase in transformer size. In order to make enough clearance for transformer installation, we
reviewed installation of 3 phase surge arrester on the transformer main tank. But after simulation of
mechanical loading calculation, it was found that only B phase arrester could be installed on the
transformer tank since existing surge arrester had porcelain insulators and weighed 170kg per phase.
The arrester in phase A and C was thus kept in same position.

Table 2. NGCP insulation clearance criteria

Minimum Clearance
Phase to Ground
Phase to Phase
Phase to Phase
(Center Line)

Nominal Voltage
230kV
69kV
1850mm
800mm
3200mm
900mm
4000mm

2000mm

Figure 2. Section view of existing transformer

According to the NGCP insulation clearance [1] referring to Table.2, the standard require longer
distances than IEC 60071-1 standard [2, 3]. Considering this requirement, especially phase to phase
clearance, the location of transformer radiator can be in between phase A and phase C of surge arrester
to fulfilled NGCP clearance requirement. Mechanical loading calculation was done confirming the
safety when only B phase surge arrester was installed on the transformer main tank. Finally, the height
of surge arrester in phase A and C was matched with B phase through increasing the phase A and C
support height to 4.6 meters.

Figure 3. Section view of Transformer (A Phase) Figure 4. Section view of transformer (B Phase)

Figure 5. 300MVA Auto Transformer

3.1.2 Structural Analysis of Gantry Structure

The bus conductor of transformer secondary side was changed from 660mm2 single conductor to
660mm2 two bundle conductor due to growth of transformer capacity. It was necessary to guarantee
the safety of 69kV side gantry tower and beam connecting with two bundle conductor, so structural
analysis was executed using commercial software ANSYS. When the simulation was done, the short
circuit current was not considered, because it was same with before.
Table 3. Material property
Specification
Yield Strength
Angle L90x7
25.5 Kgf/

ITEM
Gantry Structure

Material
SS400

Tensile Strength
48 Kgf/

Conductor

AL Alloy

THAL 660

14.8 Kgf/

28 Kgf/

String Set

Steel

24kgf/

40Kgf/

First of all, to prove the re-use of existing gantry tower and beam, the structure was modeled as
below Fig.5 and value of displacement and stress was checked.

Figure 6. Modeling for gantry tower and beam

part

Figure 7. Maximum stress

Figure 8. Bus Conductor Connection

After simulation, the result is that maximum induced stress part is yoke consisting of the insulator
string set connecting with 69kV gantry beam. And the safety factor of 2.0 was confirmed referring to
the Table.4. And the simulation result of gantry structure which is purpose target was also confirmed,
so it is safe after checking the stress value as below Table. 4.

Location
Gantry Tower
Gantry Beam
String Set

Table 4. Result value of structure analysis

Stress
Criteria
Simulation
25.5kgf/
4.16kgf/
14.8kgf/
1.97kgf/
24kgf/
9.539kgf/

Displacement
2.08mm
0.411mm
-

3.2 Equipment dismantling, transportation and test process from M substation

It is essential to make the test according to Table.5 to confirm the condition of transformer, and
switchgear before dismantling from M substation. Unchanged test result values should be recorded
after dismantling, transportation and re-installation at another substation within a small tolerance. In
terms of turn-key base contract, there are two main contractors under this project, and the work of A
contractor is dismantling of the existing substation equipment and transporting to the designated area
inside the M substation. Subsequently, the work scope of B contractor is transportation of the packed
equipment, re-installation, test and commissioning. Hyosung are responsible for the B part of the
contract.
If the required test result could not be obtained as result of carelessness or accident during
dismantling, transportation and re-installation work, such defects and damages on the equipment shall
be repaired by the B contractor or replaced with new equipment. The dismantling and packing is
executed by A contractor, but the responsibility was put on B contractor. So, it was very important to
settle the coordination process with A contractor and supervision task for dismantling and packing.
Due to this reason, the major check list during equipment dismantling, transportation and testing items
before and after re-installation was defined as below.
3.2.1 Check list during dismantling and transportation of the equipment
In addition to transformer, various equipment dismantling was done, and several check point of
transformer and installation material was described considering the task complexity and importance.

Table 5. Major equipment site test schedule

1. Transformer

2. Circuit Breaker

1) insulation resistance test on each winding to

ground and between windings
2) Power factor test on each winding to ground
and between windings
3) Power factor tests on all bushings
4) Moisture content and electric strength of oil
5) Oil quality check (DGA, resistivity)

1) Measurement of insulation resistance

2) Tests of breaker timing at rated and minimum
auxiliary voltage
3) Tests on secondary wiring insulation
4) Tests of gas leakage and dew point
5) Tests of SF6 purity
6) Checking of SF6 pressure (tightness test)
7) Operation tests
4. Current / Voltage Transformer
1) Ratio test
2) Excitation test
3) Winding resistance test
4) Insulation (MEGGER) test
5) Burden measurement
6) Insulation power factor (10kV)
7) Polarity test (for current transformer only)

3. Disconnect switch
1) Testing of insulation resistance (2.5kV DC for
1 minute)
2) Tests of insulation resistance of motor
operation and auxiliary device control wiring
3) Measurements of contact resistance
4) Checking of operating mechanism
5) Anti condensation function

Table 6. Check List for Equipment Dismantling

No.

Check List

1.

Transformer main body insulation oil drain

1.1

Internal cleanliness check of oil drain tank or tanker before drain

1.2

Tank Body pressure Criteria: Below 0.3kg/cm2 / Dry Air: Below

dew point -50C

1.3

Prevention of oil leakage and moisture absorption

1.4

Re-use decision after insulation oil analysis

2.

Transformer internal winding dismantling

2.1

After manhole opening, site condition criteria: Humidity below 85%,

Oxygen above 19.5%.

2.2

Prevention of moisture at the opening hole.

2.3

Inspection of internal cleanliness and making the tool list before

internal work

Remark

Result

Remark

Transformer external accessories dismantling

3.1

Checking oil level as 0 through conservator oil level gauge

3.2

Prevention of external air into the conservator

3.3

Checking of oil leakage evidence and packing with cork wood

3.4

Prevention of moisture in to the bushing

3.5

Making the dismantled accessories list with quantity

Installation Material (Equipment Support, Hardware, Conductor)

4.1

Making the equipment list before dismantling (each type, substation)

4.2

Re-use decision after checking the wear and tear

4.3

Packing the material each type and substation

4.4

Checking size of anchor/mounting bolt and interval

4.5

Checking the HV equipment side terminal information (Type,

diameter, length, interval)

No.

Result

Table 7. Check list for transportation

Check List

1.

Route survey and eliminating obstacle prior to inland transportation.

2.

Prevention damage due to rolling and pitch during transportation

3.

Using the soft material between lashing wire and equipment

4.

Unloading inside the designated area (Minimizing the unloading)

5.

Installation of impact recorder: complying the standard value

3.2.3 Equipment Test Clause

Before and after re-installation, the following test should be performed as minimum. The test
clauses conducted to the power transformer, circuit breaker, disconnect switch, current transformer
and voltage transformer were described as below Table.5.
Before dismantling of each equipment, prior visual inspection was conducted and there was no issue
except for transformer. But some problem was discovered on the transformer operating at the M
substation. During the visual inspection, it was observed tank corrosion and oil leakage and
maintenance was not well conducted during the 25years of operation duration. As the original
manufacturer of transformer, Hyosung proposed the solution to re-use the transformer with the
following modifications.
Table No. 8 Solution for existing transformer
Item

Condition

Proposal

Radiator

Oil Leaks & Corrosion

Replacement of Radiator and connection pipes

Fan

Corrosion of power cable

Replacement of power cable

Bushing
LCP Cable

Oil leaks due to bushing Replacement of all bushings to recover the insulation
crack
level
Corrosion of Cable
Replacement of Cable to avoid short circuits

Main Body

Corrosion of Main body

Touch up painting and replacement of all gaskets

Apart from above transformer, overall appearance and oil condition was good to re-use, but it was
decided to need the oil re-filling and gasket replacement.
3.3. System upgrades to IEC 61850 protocol
The IEC 61850 protocol is being applied to NGCP system for the new substation automation
control system. The existing IED using IEC 60870-103 protocol is required to be integrated to the
automation system using IEC 61850 protocol system supplied through this project. So, overall system
was designed as below using protocol converter and separate gateway.
-

Protocol of existing substation IED: IEC 60870-103

Protocol of new IED: IEC 61850
Protocol of local area network inside the substation: IEC 61850

In addition to substation automation system, the protection management system (PMS) slave unit
was delivered under this project. It was connected PMS grid which NGCP is gradually establishing.
PMS is a separate system with substation automation system and fault/event recorder, but function is
similar. It will conduct the similar function as redundant concept, but the advantages are as below.
Collecting all the information from protection relay and fault/event recorder including event,
logical-linker, alarm, setting data, fault waveform files from relay & fault recorder. The substation
automation system and fault/event recorder can only collect part of above information, and they can
analyze certain part of information, while the PMS can get all the information and provide full data for
further analysis and advanced application.
It is possible to tele-control all the function of protection relay and fault recorder including remotely
modify the setting value, switch setting zone, logical-linker and generate the new waveform files of
fault recorder.
In the master unit, PMS could implement many advanced application in grid level including remote
centralized setting management, alarming when setting value changed, etc.

4. Conclusion
End of 2010, asset owner National Grid Corporation of the Philippines(NGCP) issued the substation
refurbishment / extension project and Hyosung are now in the construction phase. During the
engineering design and execution of these projects, some technical issues, such as transformer power
capacity growth, main equipment dismantling and new secondary system integration into existing
system, was considered and approved for the submitted report using analysis and calculation tools. We
also described the results of integration of substation existing and new automation system.
Now, NGCP is operating these systems in Philippines and Hyosung is executing another project
including 500kV substation.

BIBLIOGRAPHY
[1]

Standard Technical Specifications National Grid Corporation of Philippines.

[2]
[3]

IEC 60071-1 Insulation Co-ordination Part 1

Design guide for rural substations (RUS Bulletin 1724E-300)